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SUPPLEMENT
Bose® Model 1801/1800 Power Amplifier
Q4, part number 102428 and Q5, part number 102429 are no longer available with the lead length needed for soldering to the PCB. Use the part numbers listed below when ordering these transistors. Make a note in your Model 1801/1800 power amplifier service manual, part number 192527.
Reference Designator Q4 Q5
Description SIM, 2N2219 SIM, 2N5415
Part Number 102428-1K 102429-1K
Note 1 2
NOTE: The part numbers listed are kits. They include the following parts: 1. Q4 kit: 1 102428 transistor 3 264371 extension pins 1 192527-S1 supplement. 2. Q5 kit: 1 102429 transistor 3 264371 extension pins 1 192527-S1 supplement.
2001 Bose Corporation 10/2001
©
Supplement
Part Number 192527-S1
Contents
Specifications ................................................................................................................................... 2 Safety Information ............................................................................................................................ 3 Electrostatic Discharge Sensitive (ESDS) Device Handling ........................................................ 4 Disassembly/Assembly Procedures ........................................................................................... 5-8 Test Procedures ............................................................................................................................... 9 Figure 1. 1801 Component Location .............................................................................................. 10 Figure 2. 1801 Side View ............................................................................................................... 10 Figure 3. 1800 Front Panel ............................................................................................................ 11 Figure 4. 1800 Rear View of Front Panel ....................................................................................... 11 Figure 5. 1801 Rear View of Front Panel ....................................................................................... 11 Figure 6. 1800 Rear Panel ............................................................................................................. 12 Figure 7. 1801 Rear Panel ............................................................................................................. 12 Part List Notes ................................................................................................................................ 13 Figure 8. 1801 Front Panel ............................................................................................................ 13 Part List ...................................................................................................................................... 14-17 Figure 9. 1801/1800 Block Diagram ............................................................................................... 18 Figure 10. LED PCB Layout ........................................................................................................... 19 Figure 11. LED PCB Schematic Diagram ...................................................................................... 20 Figure 12. Amplifier Schematic Diagram ........................................................................................ 21 Figure 13. Amplifier PCB Layout .................................................................................................... 22 Troubleshooting Guide .................................................................................................................. 23 Voltage Conversion Instructions .................................................................................................. 24 Service Bulletin ......................................................................................................................... 25-28
PROPRIETARY INFORMATION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF BOSE® CORPORATION WHICH IS BEING FURNISHED ONLY FOR THE PURPOSE OF SERVICING THE IDENTIFIED BOSE PRODUCT BY AN AUTHORIZED BOSE SERVICE CENTER OR OWNER OF THE BOSE PRODUCT, AND SHALL NOT BE REPRODUCED OR USED FOR ANY OTHER PURPOSE.
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SPECIFICATIONS
Mechanical Dimensions:
1801 1800
7 3/16" H x 18" W x 18 1/2" D (Including Knobs) 81/4"H x 19"W x 15"D (not including handles) 82 95 80 91 lbs lbs (shipping) lbs lbs (shipping)
Weight:
1801 1800
Power Requirements Voltage: Frequency: Power Consumption:
105-125 AC USA, 210-250 AC EUR 50-60 Hz Minimum 60 watts Normal 1000 watts Maximum 1960 watts
Integral DesignTM Amplifier Output : (both channels operating ) Harmonic Distortion: (THD) @ 250 watts IM Distortion: (4:1 60-7kHz) 150 watts Frequency Response:
250/250 watts @8 ohms 400/400 watts @4 ohms Less Than .15% (20Hz-5kHz) Less Than .5% (5kHz-10kHz) Less Than .15% 20Hz-10kHz ±.25dB 10kHz-15kHz ±.7dB 15kHz-20kHz ±1dB -100dB .5mV across 8 at zero volume 4 ohms or higher 1.5 Vrms for 250 watts output into 8 ohms 50,000 ohms or higher
Signal to Noise Ratio: (unweighted) Load Impedance: Input Sensitivity: Input Impedance:
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SAFETY INFORMATION
1. Parts that have special safety characteristics are identified by the symbol on schematics or by special notes on the parts list. Use only replacement parts that have critical characteristics recommended by the manufacturer. 2. Make leakage current or resistance measurements to determine that exposed parts are acceptably insulated from the supply circuit before returning the unit to the customer. Use the following checks to perform these measurements: A. Leakage Current Hot Check-With the unit completely reassembled, plug the AC line cord directly into a 120V AC outlet. (Do not use an isolation transformer during this test.) Use a leakage current tester or a metering system that complies with American National Standards Institute (ANSI) C101.1 "Leakage Current for Appliances" and Underwriters Laboratories (UL) 1492 (71). With the unit AC switch first in the ON position, then in the OFF position, measure from a known earth ground (metal water pipe, conduit, etc.) to all exposed metal parts of the unit (antennas, handle bracket, metal cabinet, screwheads, metallic overlays, control shafts, etc.), especially any exposed metal parts that offer an electrical return path to the chassis. Any current measured must not exceed 0.5 milliamp. Reverse the unit power cord plug in the outlet and repeat test. ANY MEASUREMENTS NOT WITHIN THE LIMITS SPECIFIED HEREIN INDICATE A POTENTIAL SHOCK HAZARD THAT MUST BE ELIMINATED BEFORE RETURNING THE UNIT TO THE CUSTOMER. B. Insulation Resistance Test Cold Check-(1) Unplug the power supply and connect a jumper wire between the two prongs of the plug. (2) Turn on the power switch of the unit. (3) Measure the resistance with an ohmmeter between the jumpered AC plug and each exposed metallic cabinet part on the unit. When the exposed metallic part has a return path to the chassis, the reading should be between 1 and 5.2 Megohms. When there is no return path to the chassis, the reading must be "infinite". If it is not within the limits specified, there is the possibility of a shock hazard, and the unit must be repaired and rechecked before it is returned to the customer.
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ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) DEVICE HANDLING
This unit contains ESDS devices. We recommend the following precautions when repairing, replacing or transporting ESDS devices: · Perform work at an electrically grounded work station. · Wear wrist straps that connect to the station or heel straps that connect to conductive floor mats. · Avoid touching the leads or contacts of ESDS devices or PC boards even if properly grounded. Handle boards by the edges only. · Transport or store ESDS devices in ESD protective bags, bins, or totes. Do not insert unprotected devices into materials such as plastic, polystyrene foam, clear plastic bags, bubble wrap or plastic trays.
General Description
The 1801 and 1800 are Integral DesignTM Power Amplifiers with all Silicon Solid-State Circuitry using 14 power transistors per channel. Capable of complete stability with all loudspeaker loads regardless of capacitive or inductive character. They employ fast acting electronic protection circuits for current limiting. They use computer grade capacitors throughout the power supply, along with a 2.0kW power transformer and 1300 sq. inches of heat sink area. They also have a power monitor display using a light emitting diode array and in the case of the 1801 signal meters as well.
CAUTION: THE BOSE® 1801/1800 POWER AMPLIFIERS CONTAIN NO USER-SERVICEABLE PARTS. TO PREVENT WARRANTY INFRACTIONS, REFER SERVICE TO WARRANTY SERVICE STATIONS OR FACTORY SERVICE.
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DISASSEMBLY/ASSEMBLY PROCEDURES
1801 Power Amplifier
Note: Refer to Figure 1 for the following procedures. 1. Top Cover Removal 1.1 Remove the two screws that secure the top cover at the rear of the unit. Loosen the two screws located on each side of the unit towards the front. 1.2 Slide the top cover towards the rear of the unit and lift the cover off the unit. 2. Top Cover Replacement 2.1 Slide the top cover onto the unit while making sure the screws on the side of the unit are lining up with the slots in the top cover. 2.2 Secure the top cover to the unit. 3. Amplifier PCB Removal 3.1 Perform procedure 1. 3.2 Disconnect the wire harness, the two wires connected to the thermal cutout, and the input cable going to the PCB. 3.3 Remove the six screws (2B) located on the side of the unit between the heat sink fins (see Figure 2). 3.4 Carefully pry the PCB inward towards the power transformer (the PCB is stuck to the chassis by the heat sinking compound) and lift the board out of the unit. 4. Amplifier PCB Replacement 4.1 Slide the PCB into place. Be sure there is sufficient heat sink compound on the PCB's heat sink. 4.2 Align the six screws that secure the PCB into place and secure the PCB to the chassis. 4.3 Connect the wire harness, thermal cutout wires, and the input cable to the PCB. 5. Front Panel Removal 5.1 Perform procedure 1. 5.2 Remove the nut securing the top of the front panel. The nut is located on the inside of the front chassis beside the thermal cutout indicator. 5.3 Remove the knobs on the controls and remove the two shaft nuts holding the front panel in place. 6. Front Panel Replacement 6.1 Align the front panel over the controls and secure it in place. 6.2 Secure the top of the front panel and replace the knobs. 6.3 Perform procedure 2. 7. Front Chassis Assembly Removal 7.1 Perform procedure 5. 7.2 Locate and remove the four screws that secure the front assembly to the chassis. 7.3 Push down on the top of the front assembly to release the bottom of the assembly and pull the assembly towards you. 8. Front Chassis Assembly Replacement 8.1 While pushing down on the front assembly slide the assembly in towards the unit. 8.2 Pull up on the front assembly to align the screw holes with the unit and secure the assembly in place. 8.3 Perform procedure 6.
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DISASSEMBLY/ASSEMBLY PROCEDURES
1801 Power Amplifier
Note: Refer to Figure 5 for the following procedures. 9. LED PCB Removal 9.1 Perform procedure 7. 9.2 Unsolder the wires to the LED PCB and make a note of the wiring configuration. 9.3 Remove the center nut located on each side on the LED lamp housing. 9.4 Lift the LED assembly out from the front chassis. 9.5 Disassemble the LED assembly to gain access to the PCB. Note: Remember how the lamp housing spacers are placed. 10. LED PCB Replacement 10.1 After reassembling the LED assembly, place it onto the front panel assembly and secure it in place. 10.2 Resolder the wires to the PCB. 10.3 Perform procedure 8. 11. Meter Assembly Removal 11.1 Perform procedure 7. 11.2 Remove the three nuts holding the meter lamp housing assembly to the front panel assembly. 11.3 Remove the two nuts holding the wires to the meter you want to replace and remove the meter. 12. Meter Assembly Replacement 12.1 Place the new meter on to the front assembly. Connect the wires going to the meter. 12.2 Place the meter lamp housing over the meters and secure it to the front assembly. 12.3 Perform procedure 8. 13. Front Panel Controls Removal 13.1 Perform procedure 7. 13.2 Locate the control or switch you want to replace and unsolder the wires and components on that control or switch. 13.3 Remove the shaft nut holding the control or switch to the front assembly and remove it. 14. Front Panel Controls Replacement 14.1 Place the new control or switch into the front assembly and secure it in place. 14.2 Resolder the wires and/ or components to the control or switch. 14.3 Perform procedure 8. 15. Lamp Removal 15.1 Perform procedure 7. 15.2 Using a flat blade screwdriver, pry under the edge of the socket and lift the socket out. 16. Lamp Replacement 16.1 Replace the defective lamp. 16.2 Place the lamp socket back into the lamp housing. 16.3 Perform procedure 8. Note: It may be necessary to remove the LED PCB Assembly to replace the lamps see procedure 9.
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DISASSEMBLY/ASSEMBLY PROCEDURES
1800 Power Amplifier
Note: Refer to Figure 1 for the following procedures. 1. Top Cover Removal 1.1 Remove the four screws that secure the top cover to the unit. 1.2 Slide the top cover towards the back of the unit and lift it off. 2. Top Cover Replacement 2.1 Place the top cover on to the unit and slide it under the front panel lip. 2.2 Secure the top cover to the unit. 3. Amplifier PCB Removal 3.1 Perform procedure 1. 3.2 Disconnect the wire harness, input cable, and the two wires going to the thermal cutout. 3.3 Remove the six screws (2B) located on the side of the unit between the heat sink fins (see Figure 2). 3.4 Carefully pry the PCB inward towards the power transformer (the PCB is stuck to the chassis by the heat sinking compound) and lift the board out of the unit. 4. Amplifier PCB Replacement 4.1 Slide the PCB into place. Be sure there is sufficient heat sinking compound on the PCB's heat sink. 4.2 Align the six screws that secure the PCB into place and secure the PCB to the chassis. 4.3 Connect the wire harness, thermal cutout wires, and the input cable to the PCB. 6.2 Align the holes in the front panel with the chassis, place the screws into their location by hand and then tighten with a screwdriver. Note: While tightening the screws lift up on the top lip of the panel to provide enough room to slide the top cover under the lip. 7. LED PCB Removal 7.1 Perform procedure 5. 7.2 Remove the two screws that secure the PCB to the front panel. 7.3 Unsolder the wires at the LED PCB, make a note of the wiring configuration, and remove the board from the unit. 8. LED PCB Replacement 8.1 Place the LED PCB into place on the front panel. 8.2 Secure the PCB to the front panel. 8.3 Resolder the wires to the LED PCB. 5. Front Panel Removal 5.1 Perform procedure 1. 5.2 Locate and remove the eight screws holding the front panel to the chassis. Four of the screws are located just inside the two handles and the other four are the larger screws on the front panel. 5.3 Using the handles pull the front panel away from the chassis enough to access the gain controls and LED PCB. 6. Front Panel Replacement 6.1 Slide the front panel into place. Be careful not to pinch the wiring harness at the bottom of the front panel between it and the chassis.
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DISASSEMBLY/ASSEMBLY PROCEDURES
1800 Power Amplifier
Note: Refer to Figures 3, and 4 for the following procedures. 9. Gain Control Removal 9.1 Perform procedure 5. 9.2 Remove the gain control knobs. 9.3 Unsolder the capacitor lead and wires from the control. 9.4 Remove the nut that secures the control to the front panel and remove the control. 10. Gain Control Replacement 14.1 Align the rear panel with the chassis. 10.1 Place the new control into the front panel and secure it into place. 10.2 Resolder the capacitor lead and the wires to the terminals on the gain control. 10.3 Perform procedure 6. 11. Power Switch Removal 11.1 Perform procedure 5. 11.2 Remove the wires on the rear of the power switch. 11.3 Remove the nut securing the switch to the front panel and remove the switch. 12. Power Switch Replacement 12.1 Place the new power switch into the front panel and secure it in place. 12.2 Reconnect the wires on the rear of the switch. 12.3 Perform procedure 6. 14.2 Secure the rear panel to the chassis. Be sure to use the rear panel bracket on the bottom of the panel. 14.3 Secure the ground wires to the chassis. 14.4 Perform procedure 2. Note: Refer to Figure 6 for the following procedures. 13. Rear Panel Removal 13.1 Perform procedure 1. 13.2 Locate and remove the four screws securing the rear panel and the rear panel bracket to the unit. Note: One of the screws holds the ground wires to the chassis. Take care not to lose the nuts that secure this screw and the wires. 14. Rear Panel Replacement
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TEST PROCEDURES
1. Bias Adjustment Setup and Procedure 1.1 Locate the -85V negative terminal found on the capacitor (C4). See Figure 1 for the location of C4. Note: The 1801 and very early 1800's had two lugs on the caps. One with two or three wires and one single wire. The later production 1800 had three lugs on the capacitor. Either way the lug with the two or three wires is the lug to disconnect from the capacitor. All other lugs remain. 1.2 Remove the lug with two or three wires connected to it. 1.3 Connect a 0-200mA meter between the disconnected lug and the - terminal on the capacitor C4. 1.4 Disconnect the PCB that is not being tested by unplugging the multiple pin connector. 1.5 Turn the amplifier on with no input signal applied and adjust the bias pot (R13) for 90mA with the board cold. Note: The PCB must be removed from the chassis for the bias to be adjusted. 2. Frequency Response Procedure 2.1 Apply a 1Vrms, 1kHz signal to the input. 2.2 Reference a dB meter to the output. 2.3 Check the response from 20Hz to 20kHz. The response should not exceed ±1 dB. Refer to the response specification on page 2. 3. DC Offset Procedure 3.1 With no signal applied measure the DC offset at the output. It should measure 250mV or less. 4. Power Output Procedure 4.1 Connect an 8 ohm, 250 Watt load to the output. 4.2 Apply a 1.75Vrms, 1kHz signal to the input. 4.3 Turn the gain controls up to the point where the clipping LED's just begin to light up and check the output for 250 watts. 4.4 Repeat the steps above for a 4 ohm load. The output measurement should be 400 watts. 5. Harmonic Distortion Procedure 5.1 With the unit connected as in procedure 3, turn the gains up to just before clipping and check the distortion at the frequencies of 20Hz, 5kHz, and 10kHz. 5.2 The distortion limits are .15% from 20Hz to 5kHz and .5% from 5kHz to 10kHz. 6. Thermal Cutoff Procedure 6.1 Apply a signal to the unit with the outputs loaded ( 8 or 4 ohms ). Short one channel at a time until the unit goes into thermal cutoff. The thermal indicator should turn on and the output of the unit should be off. 6.2 Disconnect the short from the output. Wait until the unit comes out of thermal cutoff. You can speed this process by cooling the PCB with a fan. 6.3 Once the unit is cooled apply a signal to the channel you had shorted to check to see if its operational. 6.4 Apply a signal to the other channel and short the output. Wait for the thermal indicator to come on then remove the short and cool the PCB.
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Figure 1. 1801 Component Location
Figure 2. 1801 Side View 10
Figure 3. 1800 Front Panel
Figure 4. 1800 Rear View of Front Panel
Figure 5. 1801 Rear View of Front Panel 11
Figure 6. 1800 Rear Panel
Figure 7. 1801 Rear Panel 12
PART LIST NOTES
1. This part is not normally available from Customer Service. Approval from the Field Service Manager is required before ordering. 2. The reference designators in bold are located on the LED PCB. 3. This part is not located on the PCB'S. 4. The reference designators marked with a symbol are located on the Front Panel. 5. The part numbers listed with SIM are selected components and may not be directly interchangeable with standard available parts. 6. This part is located on the amplifier PCB. 7. This part is used on the 1801 Power Amplifier. 8. This part is used on the 1800 Power Amplifier. 9. Items marked with a ¥ symbol are not shown in the exploded views.
Figure 8. 1801 Front Panel 13
PART LIST
Main Part List (per figures 1-7) Item Number A1 RT-1, RT-2 ¥ Q10-23 Q10-23 Q10-23 Q10-23 Q4, 5 ¥ ¥ ¥ ¥ ¥ S1 S1 S2 S3 J3, 4 (J5, 6 1801 ) R5, 6 R5, 6 1 2 3 4 5 5 M1, 2 B1-4 B5, 6, 7 B8 K1 6 7 T1 T1 T1 Description Preload Network Thermal Cut-Out RCA Jack Screw, 6/32 x 1/2 Stainless Steel Washer Plastic Insulator Nut, Brass, 6/32 x 5/16 x 1/8 Heat Sink Assy Top Wiring Harness Bottom Wiring Harness Top Wiring Harness Bottom Wiring Harness Audio Cable Toggle Switch, ON/OFF Switch, ON/OFF Input Switch Speaker Switch Phone Jack Gain Control, 100k Gain Control, 100k Indicator Lens, White Indicator Lens, Red Lens Housing Front Handle Knob Knob VU Meters Meter Lamps L.E.D / Bose® Logo Lamp 1847 Thermal Cutout Indicator Start-up Relay Accy Outlet Line Cord Transformer Transformer (110v) Transformer (220v) Part Number 102666 102440 102784 106348 103032 102901 103016 102571 102929-1 103281-1 103365 103366 102838 103291 102740 102576 103400 102704 102406 103260 103479-1 103479-0 103478 121914 128907 121911 102570 103063 102580 102582 102818 107558 103441 102434 110185 112669 Note 6 6 6, 9 6 6 6 6 6 1, 7, 9 1, 7, 9 1, 8, 9 1, 8, 9 9 8 7 7 7 7 8
8 7 8 7 7 7 7
1, 7 1 1
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PART LIST
Main Part List (per figures 1-7) Item Number 8 F1 F1 F1 ¥ ¥ 9 10 11¥ 12 13 14 15 16 17 18 19 ¥ ¥ 20 21 22 23 24 25 Part Number Rubber Foot 121929 Fuse (110v)15A, 1 1/4 x 1/4Slo-Blo 103608 Fuse (220v) 8A, 5 x 20mm 108190-800 Fuse (220v) 7A, 1 1/4 x 1/4Slo-Blo 103609 Fuse Cap for 1 1/4 x 1/4 109484 Fuse Cap for 5 x 20mm 109493 Front Panel Assy 103380 Front Panel Assy 121910 Rear Panel Assy 103282 Rear Panel Assy 103266 Amp PCB Complete 102735-1 L.E.D Board Complete 102751 Carton and Fillers 103268 Heat Sink Side 102536 Heat Sink Corner 102474 Top Cover 102544 Top Cover 121930 Screw Heat Sink 103041 Accessory Kit 102745 Accessory Kit 103361 Black Binding Post 109068-0 Red Binding Post 109068-2 Blue Binding Post 109068-6 Black Binding Post Base 109069-0 Fuse Holder 109485 Strain Relief 102708
blue, 103362-6 black, 103362-0
Description
Note
9 9 1, 7 1, 8 1, 7, 9 1, 8 1 1 1 1 1, 7 1, 8 1, 7, 9 1, 8, 9
Plug, double banana red, 103362-2
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PART LIST
Resistors Reference Designator R1-4 R2 R3 R9, 17 R11 R12, 51, 53 R13 R18, 20, 48 R25, 26 R31-36, 41-46 R37-39 R47 R50 R52, 54 R55, 57 R56 R1,3,101,103 R2,4,10,13,16,19 102,104,107,110 113,116,119 R5,105 R6,9,106,109 R8,108 R11,111 R12,15,18,112, 115,118 R14,114 R17,117 R20,120 R21,121 R22,122 Description 1M, 1/2W, 10% 8.2k, 1/2W, 10% 3k, 2W, 10% 6.19, 1/4W, 1% 1.5k, 1/4W, 1% 340, 1/4W, 1% 100, Bias Pot 23.7k, 1/4W, 1% 182, 1/4W, 1% 0.8, Wirewound, 3W, 5% 0.4, Wirewound, 6W, 5% 4.7, 2W, 5% 470, 1/2W, 5% 10k, 1/4W, 1% 100k, 1/4W, 1% 680, 1/2W, 5% 5.1k, 1W, 5% 150 1/2W, 5% 3.6k, 1W, 5% 2k, 1/2W, 5% 8.2k, 1W, 5% 12k, 1/2W, 5% 1k, 1/2W, 5% 24k, 1/2W, 5% 43k, 1/2W, 5% 15k, 1/2W, 5% 120, 1/2W, 5% 18k, 1/2W, 5% Part Note Number 102944-105 3 104064-822 108676-302 104095-6191 104095-1501 104095-3400 102832 104095-2372 104095-1820 102394 102395 102393 102942-471 104095-1002 104095-1003 102942-681 104064-512 2 102942-151 2 104064-362 102942-202 104064-822 102942-123 102942-102 102942-243 102942-433 102942-153 102942-121 102942-183 2 2 2 2 2 2 2 2 2 2
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PART LIST
Capacitors Reference Designator C1, 2 C1, 14, 15 C1,101 C2, 3 C3, 4 C5 C5, 16 C6, 7, 10, 11 C8 C9 C12, 13, 17 Description 1uF, Mylar, 50v, 10% .1uF, Electrolytic, 100v, 10%, NP 100uF Electrolytic, 3v 30uF Electrolytic, 100v 14,000uF, Electrolytic, 100v 18,000uF, Electrolytic, 10v 27pF, Ceramic Disc, 25v, 10% .01uF, Ceramic Disc, 25v, 10% 200pF, Ceramic Disc, 200v, 10% 300pF, Ceramic Disc, 200v, 10% 1000pF, Ceramic Disc, 200v, 10% Diodes and Transistors Reference Designator D1-4 D5-8 CR1-4, 7, 16, 17 CR10-17,110-117 CR1-9,101-109 CR5, 18, 19 CR6, 15 CR8-14, 20, 21 Q1 Q2, 8 Q2,102 Q3 Q4 Q5 Q6 Q7, 24, 25 Q1,3-10,101,103110 Q9 Q10-23 U1 Description Bridge Rectifier Diodes Diode 1N4148 L.E.D Diode Diode SIM 1N3070 Diode 1N5425, Zener, 15V, 1/2w Diode SIM 1N4003 SIM MM-4001 SIM 2N3906 SIM SIM SIM SIM SIM 2N6175 2N2219 2N5415 2N3584 2N3904 Part Number 102578 102422 116997 106864 102411 102423 102422 102425 102426 102427 102428 102429 102430 102432 102431 117579 102409 Note Part Number 102751 102403 102836 102405 102438 104229 102397 102399 102400 102396 102453 Note 4 2 3 3
2 2
5 5 2 5 5 5 5 5 2 5
SIM 2N6211 MJ15011 Integrated Circuit, MC1556G
17
Bridge Rectifier
Turn On Relay Figure 9. 1801/1800 Block Diagram 18
Figure 10. LED PCB Layout 19
Figure 11. LED PCB Schematic Diagram 20
Notes: 1. See Bias Adjustment Procedure. 2. U1 input (pin 2) virtual ground, output test point 8 (pin 6) 275mV. 3. Early production units replace R28 with capacitor C15 (0.1uF) found in either side of the pc board. 4. All resistors are 1/2 watt 5% unless otherwise specified. 5. All capacitor in uF unless otherwise specified.
Figure 12. Amplifier Schematic Diagram
21
Figure 13. Amplifier PCB Layout 22
TROUBLESHOOTING GUIDE
SYMPTOM 1. DC Offset: 2v 2v Defective U1 Defective Q1 Defective U1 Defective CR1, 2, 6, 15 Open ground at the RCA input jack Defective Q1-8, Q24 Defective CR16, 17 Short between transistor and heat coupler Shorted driver or output transistor Test point "A" polarity the same as DC offset (see Figure 11) Test point "A" polarity opposite to the DC offset (see Figure 11) Trouble shoot (by removing collector screws) in this sequence. Negative: Q9, 11, 23, 21, 22, 19, 20, 18 Positive: Q6, 10, 17, 16, 14, 13, 12, 15 3. Oscillation: Unloaded Defective C5 Defective Q6, Q9 Defective CR8 Open C4, 5, 9, 11 Defective R24, 29, 30, 51, 52 Defective U1, Q1 Defective R57, 58 Defective Q4, 6, 7, 9 Open R11, 12, 13 Defective C5, C8 Shorted Mica Insulator Q3 POSSIBLE CAUSE
2. High Current:
Loaded
4. Excessive Noise: 5. No Bias Adjustment: 6. Incorrect Frequency Response:
7. Excessive Distortion: Defective Q7, Q8, Q25 Defective CR18, 19 Defective CR5 ( at full output only)
23
VOLTAGE CONVERSION INSTRUCTIONS
1. Perform Top Cover removal procedures for the model amplifier your going to convert. 2. Refer to the figures below for the voltage conversion being performed. 3. On the 1801 when converting to 110 volts remove the in-line resistor found wired to the thermal cutoff indicator. Connect the wire directly. For 220 voltage conversion connect a 56k ohm 1/2 Watt resistor directly to the thermal cutoff indicator terminal. 4. Use an MDL 10 amp fuse for 110 volt operation. 5. Use an MDL 5 amp fuse for 220 volt operation.
NOTE: FOR 220 VOLT AC USERS ONLY For 110 volt operation of the accessory outlet, move the wire labeled "TO RECEPTACLE" from transformer connector #4 to connector #2. The amplifier will operate on 220 volts and provide 110 volts to the accessory outlet (up to a maximum of 3 amps).
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SERVICE BULLETIN
Subject: Interchangeability of repaired amplifier PCB. Torroidal Power Transformer. 1800 Amplifier used with a TC-18 Transit Case. Date: 09/19/1977 Bulletin #13
Remarks: The 1801 power amplifier board ( part # 102735 ) will no longer be shipped as a standard repair part. Instead, a universal replacement board ( part # 102735-1 ) with a special thermostatic clip connection allowing the use of this board in the 1801 and early production 1800 wire harness assembly. In the case of the 1801, amplifier boards may be intermixed with no difficulty, using the clip connection. In the case of the 1800, amplifier boards may be intermixed below serial #750. However, for serial numbers above 750, use of the larger heat sink version (102735-1) is required. When replacing amplifier boards in either unit, be certain to use additional thermal grease and to tighten the screws holding the board to the chassis. The 1800/1801 amplifiers are now using a torroidal power transformer that reduces the unit's overall weight by 20 Lbs. The new transformer, ( P/N 107968 ) is found in 1800 amplifiers ( S/N 1630 and above ) and in 1801 amplifiers ( S/N 6838 and above ). Connections for the transformer are the same as indicated in the Service Manual for both units. The 1800 power amplifier, when used with the TC-18 transit case, should be inspected periodically for dirt and dust accumulation on the heat sink surfaces. Any accumulation should be removed as this significantly reduces the amplifier's ability to dissipate heat and increases the likelihood of thermal overload.
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SERVICE BULLETIN
Subject: Resistor Failure Date: 09/19/1977 Bulletin #13A Remarks: We have found that the resistor R3 on the 1801/1800 amplifier PCB's have shown a higher failure rate than normal. Studies reveal that the resistor normally runs at about 150-170°F. The etch layout at R3 is not sufficient to provide adequate heat sink for this component, and the resistor eventually changes value due to the heat. This changing value causes the resistor, capacitor C2, and the zener diode CR15, to fail. The symmetrical circuit, R2, C2, and CR6 all have sufficient heat sinking capability on the etch layout and does not cause failures. To improve the reliability of the boards, R3 should be changed from a carbon resistor to a ceramic resistor of the same value. The ceramic resistor should be elevated slightly above the PCB surface to provide adequate air ventilation for self cooling purposes. The new ceramic resistor P/N is 108676-302. In addition, R2 should also be changed to a new value. The resistor will be changed from 3k to 8.2k, P/N 104064-822. This resistor is carbon, and due to the etch layout, need not be elevated. This modification must be preformed on all PCB's brought in for repair, regardless of the actual failure.
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SERVICE BULLETIN
Subject: Thermal Improvement Date 10/05/1979 Bulletin #17 Remarks: I'm pleased to inform you that we have developed a method for improving the thermal stability of the 1800 amplifier, which may have been a problem to you during the last several months. This problem was caused by a change we were forced to make when RCA discontinued the manufacture of the transistor we had been using as Q3 on the 1800 PCB's. The following change should be made on 1800 PCB,s which have the new Q3 ( MMPS U10 ). 1. Change R13, the bias pot (P/N 102832), to a new one which has not been sealed with glyptol. This will allow you to adjust the bias current later. 2. Change R11 (P/N 102977-1501) from 1.5k to 1.8k (P/N 107170-182). 3. Apply a piece of Mylar insulating tape over the small (3/4" x 1/4") vertical surface of the heat coupler bracket that is immediately above and parallel to C12. 4. Apply a small blob of thermal grease to the Mylar tape. 5. Obtain a 10k thermistor (P/N 111153) and place insulating tubing over the leads, leaving them about 1 inch long. 6. Solder the thermistor across (in parallel) the new R11. 7. Place the body of the thermistor against the blob of thermal grease applied in step 4. 8. Obtain a thin piece of polypropylene or other springy plastic and cut it to about 3/8" x 3/4". Punch a small hole in one end of it and fasten it to the heat bracket using the screw that mounts Q3 to the bracket. The tension of the bent piece of plastic will keep the thermistor pressed into the thermal grease. 9. Adjust the bias current to 90ma according to the service manual. NOTE: This change will be made on all future production units of the 1800 amplifier.
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SERVICE BULLETIN
Subject: Output Transistors Date: 10/13/1980 Bulletin # Pro-81-001 Remarks: Due to supply demands, Bose® Corporation has changed the output transistors on the PM-2 and the 1800 amplifier boards currently being produced. The transistors have been change from Bose P/N 102433 (2N5840) to P/N 117579 ( Motorola MJ15011). The new output transistors are not compatible with the original 102433 transistors. If you service an 1800 power amplifier or PM-2 mixer, check the serial numbers on the printed circuit board and the P/N on the output transistors to see which output device is being used. Below is a list of the approximate serial number break for the newer P/N 117579 transistors. PM-2 Boards: 1800 Boards: PM-1 Boards: 1801 Boards: Approximately 30800 and above Approximately 30800 and above All have P/N 102433 All have P/N 102433
When replacing output transistors, you must use the correct replacement device. Older units with P/N 102433 on the output transistors must be replaced with 102433 (2N5840) transistors. Units with output transistors with P/N 117579 must be replaced with 117579 (MJ15011) transistors.
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® ®
Bose Model 1801/1800 Power Amplifiers
©
1997 Bose Corporation
Service Manual
Part Number 192527 REV 01
SPECIFICATIONS AND FEATURES SUBJECT TO CHANGE WITHOUT NOTICE
® ®
Bose Corporation The Mountain Framingham Massachusetts USA 01701
P/N 192527 REV. 01 06/97 FOR TECHNICAL ASSISTANCE OR PART ORDERS, CALL 1-800-367-4008