Classe Audio Delta Series User manual

Classé Audio Inc
5070 Francois Cusson
Lachine, Quebec, Canada
H8T 1B3
Tel: [phone]
Fax: [phone]
www.classeaudio.com
Service Manual v1.4
___________________________________________
Delta-Series Amplifiers:
CA 2100 Stereo Amplifier
CAP 2100 Integrated Stereo Amplifier
___________________________________________
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 1 of 50

Contents
PCB LIST.......................................................................................................................................... 5
TESTING PROCEDURES .................................................................................................................................. 6
PRODUCTION TESTING: .................................................................................................................... 6
START-UP TESTING (COMPLETE AMPLIFIER): .................................................................................. 6
FINAL TESTING: ...............................................................................................................................7
PROGRAMMING PROCEDURES ...................................................................................................................... 8
PRODUCTION: .................................................................................................................................. 8
AUX POWER SUPPLIES AND CAPACITOR BOARDS ........................................................................................ 9
CA2100:......................................................................................................................................................... 9
TESTING THE AUX POWER SUPPLY BOARD (B3A5XR02) ............................................................. 9
TESTING CAPACITOR BOARD (B3A1XR00).................................................................................... 9
CAP2100: .................................................................................................................................................... 10
TESTING THE INPUT BOARD (B3F1XR04) .................................................................................... 10
TESTING THE AUX POWER SUPPLY BOARD (B3F2XR04) ............................................................ 10
TESTING CAPACITOR BOARD (B3F3XR00)................................................................................... 11
SENSOR /CONTROL BOARD......................................................................................................................... 12
CALIBRATING THE SENSOR /CONTROL BOARD (PCB B3B1XR04) ............................................. 12
TESTING THE SENSOR /CONTROL BOARD (PCB B3B1XR04) ...................................................... 12
AC BOARDS.................................................................................................................................................. 13
TESTING THE AC-SENSOR BOARD (PCB B3A7XR00) .................................................................. 13
TESTING AND CALIBRATING THE AC-CONTROL BOARD (PCB B3B3XR02) ................................ 13
TESTING THE COMPLETE CONTROL ASSEMBLY.......................................................................................... 14
RS-232 SETUP:...............................................................................................................................14
FACTORY DATA: ............................................................................................................................ 14
AC POWER CHECK: ........................................................................................................................ 15
SENSOR/CONTROL MODULE CHECK 1: .......................................................................................... 16
POWER-UP SEQUENCE CHECK:....................................................................................................... 16
FRONT PANEL CHECK: ................................................................................................................... 16
INPUT TYPE SELECTION: ................................................................................................................ 17
AMP-NUMBER SELECTION: ............................................................................................................ 17
MUTE FUNCTION:........................................................................................................................... 17
TIMER FUNCTION:.......................................................................................................................... 17
FAULT LOGGING FUNCTION:.......................................................................................................... 17
SENSOR/CONTROL MODULE CHECK 2: .......................................................................................... 18
DC-PROTECTION CHECK:............................................................................................................... 18
TRIGGER FUNCTION CHECK: .......................................................................................................... 18
IR FUNCTION CHECK:..................................................................................................................... 18
TESTING THE MAIN AMP PLUG-IN BOARD ................................................................................................... 19
B3B6XR04 (MODIFIED FOR CA2100/CAP2100) .......................................................................... 19
TESTING THE HEATSINK ............................................................................................................................. 20
PRELIMINARY BIAS ADJUSTMENT.................................................................................................. 20
OUTPUT DC OFFSETS..................................................................................................................... 20
SIGNAL PASS-THROUGH AND OSCILLATION CHECK....................................................................... 21
BIAS RE-TRIM AFTER WARM-UP..................................................................................................... 21
HEATSINK BURN-IN AND BIAS RE-ADJUSTMENT............................................................................ 21
BIAS CONFIRMATION AFTER BURN-IN ........................................................................................... 21
START-UP TESTING (COMPLETE AMPLIFIER) ............................................................................................. 22
CHECKLIST: ................................................................................................................................... 22
BASIC CHECKS............................................................................................................................... 22
50/100 OHM CHECK........................................................................................................................ 23
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CA2100 AUX POWER SUPPLY ...................................................................................................... 24
CAP2100 AUX POWER SUPPLY.................................................................................................... 25
CURRENT SENSOR ZERO CALIBRATION CHECK.............................................................................. 25
MAIN AND MOSFET POWER SUPPLIES ......................................................................................... 25
MAIN PLUG-IN BOARD RAILS ......................................................................................................... 26
BIAS CHECK ................................................................................................................................... 26
OUTPUT DC OFFSETS..................................................................................................................... 26
SOFT-START AND BIAS RELAYS CHECK ......................................................................................... 26
SIGNAL AND MUTE CHECK............................................................................................................. 26
FULL POWER &OSCILLATION CHECK ............................................................................................ 27
CURRENT SENSOR CALIBRATION CHECK 2 .................................................................................... 27
CAP2100: PHONO BOARD DETECTION AND GAIN TEST................................................................. 28
LISTENING FOR NOISE .................................................................................................................... 28
POPS AND WHISTLES CHECK .......................................................................................................... 28
CA2100: RS-232 FUNCTION TEST ................................................................................................. 28
CAP2100: RS-232 FUNCTION TEST ............................................................................................... 29
CA2100: DIM LEVELS TEST .......................................................................................................... 29
CAP2100: DISPLAY BRIGHTNESS LEVELS TEST ............................................................................ 29
BUTTON FUNCTION TEST ............................................................................................................... 30
TRIGGER FUNCTION TEST .............................................................................................................. 30
IR FUNCTION TEST ......................................................................................................................... 30
CA2100 DC PROTECTION TEST ..................................................................................................... 31
CAP2100 DC PROTECTION TEST ................................................................................................... 32
SHORT-CIRCUIT PROTECTION TEST................................................................................................ 32
CA2100 CAN-BUS FUNCTION TEST ............................................................................................. 32
CAP2100 CAN-BUS FUNCTION TEST ........................................................................................... 33
AUDIO PRECISION TESTING ........................................................................................................... 33
APPENDIX A: FUSES..................................................................................................................................... 36
INTERNAL: ..................................................................................................................................... 36
EXTERNAL: .................................................................................................................................... 36
APPENDIX B: CA2100 RS-232 INTERFACE................................................................................................. 37
COMMANDS AVAILABLE AT ALL TIMES......................................................................................... 37
COMMANDS AVAILABLE WHEN THE AMP IS ON............................................................................ 38
COMMANDS AVAILABLE WHEN THE AMP IS OFF .......................................................................... 38
FACTORY COMMANDS AVAILABLE ONLY WITH A PASSWORD ...................................................... 39
MODEL CHART .......................................................................................................................... 39
APPENDIX B2: CAP2100 RS-232 INTERFACE ............................................................................................ 40
REV 1.0 ................................................................................... ERROR!BOOKMARK NOT DEFINED.
DATA FORMAT ........................................................................ ERROR!BOOKMARK NOT DEFINED.
COMMAND STRUCTURE .......................................................... ERROR!BOOKMARK NOT DEFINED.
COMMAND STRINGS................................................................ ERROR!BOOKMARK NOT DEFINED.
REPLIES AND STATUS ............................................................. ERROR!BOOKMARK NOT DEFINED.
REV 1.6 (5 APRIL 2004) ......................................................... ERROR!BOOKMARK NOT DEFINED.
DATA FORMAT ........................................................................ ERROR!BOOKMARK NOT DEFINED.
COMMAND STRUCTURE .......................................................... ERROR!BOOKMARK NOT DEFINED.
COMMAND STRINGS................................................................ ERROR!BOOKMARK NOT DEFINED.
REPLIES AND STATUS ............................................................. ERROR!BOOKMARK NOT DEFINED.
REV 1.91 (19 APRIL 2004).......................................................................................................... 40
DATA FORMAT ............................................................................................................................... 40
COMMAND STRUCTURE ................................................................................................................. 40
COMMAND STRINGS....................................................................................................................... 40
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 3 of 50

REPLIES AND STATUS .................................................................................................................... 41
APPENDIX D: TYPICAL SPECIFICATIONS .................................................................................................... 43
APPENDIX E: POWER-ON SEQUENCE .......................................................................................................... 44
APPENDIX F: MODIFICATIONS CHECKLIST ................................................................................................ 45
CA2100: ........................................................................................................................................ 45
CAP2100: ...................................................................................................................................... 46
APPENDIX G: TROUBLESHOOTING ............................................................................................................. 49
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 4 of 50

PCB list
PCB Description CA2100 CAP2100
B3A1XR02 Capacitor board 1
B3A2XR02 Left output board 1 1
B3A3XR00 Right output board 1 1
B3A5XR03 Aux power supply 1
B3A7XR03 AC-sensor board 1 1
B3A8XR01 Front Panel 1
B3B1XR04 Sensor & Control plug-in board 2 2
B3B3XR04 AC-control board 1 1
B3B6XR04 (modified) Voltage amplifier (“main”) plug-in board 2 2
B3B9XR04 Communications board 1
B507XR01 IR-Trigger board 1
B3BCXR02 AC-input board 1
B3F1XR06 Preamp (input) board 1
B3F2XR05 Aux power supply 1
B3F3XR01 Capacitor board 1
B3F4XR01 Voltage Selector board 1
B3F5XR01 Communications board 1
B403XR04 IR-Trigger board 1
B3BDXR01 “Neutral” filter board 1 1
B42BXR04 GUI board 1
Touch-screen (TFT) 1
B42CXR02 Front panel IR board 1
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 5 of 50

Testing Procedures
Production testing:
Individual testing for the following boards:
oAUX power supplies
oCapacitor boards
oNeutral Filter boards
oAC-sensor boards
oMain (plug-in amp) boards
oHeatsink boards
Calibration and testing for the following boards:
oSensor/control boards
oAC-control boards
“Group” testing of the following board assembly:
oAC-sensor boards
oAC-control boards
oSensor/control boards
oFront panel boards
oCommunications boards
oTrigger/IR boards
Start-up testing (complete amplifier):
Visual inspection (EVERYTHING !) and basic checks (modifications etc)
50 ohms check
Software version check
AC-control calibration check
AUX Power Supply voltages
Current sensor zero calibration check
Main power supply and MOSFET rail voltages
Main plug-in board rails
Bias check on heatsinks
Output DC offsets
Soft-start and bias relays check
Signal and mute check (both balanced and single-ended, ALL channels)
Full power + oscillation check (with load)
Current sensor calibration check 2
Noise (listening with AND WITHOUT terminated inputs)
Power-up pop (cold start and warm-start)
Power-down whistling
RS-232 functions (including calibration checks, parameter settings, etc)
DIM levels check
All button functions
Trigger function
Remote control and IR functions
DC protection
Polarity
Short-circuit protection
CAN-bus communication
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Audio Precision measurements (results logged in computer database)
Final testing:
Final Test Part 1 (open unit):
Visual inspection (everything !) & modifications check
Final bias adjustment (at 120V)
Software versions check
AC-control calibration check
AUX power supply voltages
Current sensor zero calibration check
Main power supply and MOSFET rail voltages
Main plug-in board rails
Bias verification
Output DC offsets
Soft-start and bias relays check
Signal through (both balanced and single-ended, all channels)
Full power + oscillation check (with load)
Current sensor calibration 2
Noise (listening with terminated and unterminated inputs, BAL and SE)
Trigger function
Remote control and IR functions
DC protection
Short-circuit protection
CAN-bus communication
Voltage Selection (final)
Internal fuses change (if needed)
Final Test Part 2 (closed unit)
Visual inspection (everything !)
Full power + oscillation check (with load)
Noise (listening with terminated and unterminated inputs, BAL and SE)
RS-232 functions (including calibration checks, parameter settings)
DIM levels test
All button functions
Audio Precision final testing (both balanced and single-ended, all channels)
Main fuse change (new)
Shipping (unit packed)
Last Test (Vladimir)
Power-up and power-down noises check
Listening (both BAL and SE, + Mute check)
Function test (buttons only)
LED level check
Final data lo
gg
in
g
(
via RS-232
)
and printout
Burn-in 2
(
music & load
,
3 ni
g
hts at final AC
)
Close unit
(
shi
pp
in
g
g
u
y
s install wra
p
and to
p
cover
)
Burn-in 1
(
o
p
en unit on idle
,
2 ni
g
hts at 120Vac
)
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 7 of 50

Programming Procedures
Production:
The processors on the following boards need to be programmed:
AC-control (PIC16F819)
Sensor/control (PIC16F819)
Front panel (PIC18F258)
Please see Appendix F for the latest software revisions.
The Front Panel board needs to be defaulted (its memory cleared completely) immediately after its FIRST
programming (during the “group” testing of the control board assembly). Please see Appendix B.
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 8 of 50

Aux Power Supplies and Capacitor Boards
CA2100:
Testing the AUX Power supply Board (B3A5XR02)
Perform a detailed visual inspection of the Aux Power Supply. Check all capacitor directions (polarity). Check if all
capacitors are standing up properly. Verify (measure if necessary) that the Voltage Selector (CON1) resistors are:
0 ohms for the 100Vac setting,
75 ohms for the 120Vac setting,
182 ohms for the 230Vac setting,
511 ohms for the 240Vac setting.
Use your multimeter on its diode setting to verify that all four voltage-select LEDs as well as the “bad_power” LED are
installed with the correct polarity and are working (each LED should light-up). You will have to move the voltage-select
jumper to all four positions to check this.
Verify jumper setting for 120V AC. Apply 120V AC between LIN2 and N.
Verify voltage before regulator (on C104) around 20Vdc and after regulator (on C105) around 12Vdc.
Change jumper setting to 240V AC. Apply 240V AC between LIN2 and N.
Verify voltage before regulator (on C104) around 20Vdc and after regulator (on C105) around 12Vdc.
Change jumper setting back to 120V AC.
For the following tests use a “bypassed” power-supply jig powered from a variac.
Install Temporary jumper under the relay K101 and K201 (short the relay).
Connect the secondary winding of the transformer to AC101 and AC103 and the Center Tap to AC102.
Bring up the AC gradually (in 15V steps) while measuring the MOSFET supplies at +M101 and –M101 relative to
ground at AC104. Keep a close eye on the circuits, listen for frying or popping noises, and feel the variac for
vibration caused by excess current. If you hear a capacitor pop, mark the board and replace it. Raise the variac
voltage until you measure +/-66Vdc on the DC voltage rails (about 70Vac on the variac, depending on the
transformer on the jig).
Now do the same way on other side of board as follows.
Connect the secondary winding of the transformer to AC201 and AC203 and the Center Tap to AC202.
Bring up the AC gradually (in 15V steps) while measuring the MOSFET supplies at +M201 and –M201 relative to
ground at AC204. Keep a close eye on the circuits, listen for frying or popping noises, and feel the variac for
vibration caused by excess current. If you hear a capacitor pop, mark the board and replace it. Raise the variac
voltage until you measure +/-66Vdc on the DC voltage rails (about 70Vac on the variac, depending on the
transformer on the jig).
Disconnect the capacitor board and discharge the capacitors on both sides.
Also remove the temporary jumper from relays K101 and K201 and re-solder relay pins properly.
Testing Capacitor Board (B3A1XR00)
For the following tests use a “bypassed” power-supply jig powered from a variac.
Connect the secondary of transformer to AC2 and AC4 and Center Tap at AC6.
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Bring up the AC gradually (in 15V steps) while measuring the main DC rails at +V201 and –V201 relative to ground
at GND201. Keep a close eye on the circuits, listen for frying or popping noises, and feel the variac for vibration
caused by excess current. If you hear a capacitor pop, mark the board and replace it. Raise the variac voltage until
you measure +/-66Vdc on the DC voltage rails (about 70Vac on the variac, depending on the transformer on the
jig).
Now do the same thing to other side of the board.
Connect the secondary of transformer to AC1 and AC3 and Center Tap at AC5.
Bring up the AC gradually (in 15V steps) while measuring the main DC rails at +V101 and –V101 relative to ground
at GND101. Keep a close eye on the circuits, listen for frying or popping noises, and feel the variac for vibration
caused by excess current. If you hear a capacitor pop, mark the board and replace it. Raise the variac voltage until
you measure +/-66Vdc on the DC voltage rails (about 70Vac on the variac, depending on the transformer on the
jig).
Disconnect the capacitor board and discharge the capacitors.
CAP2100:
Testing the Input Board (B3F1XR04)
Perform a detailed visual inspection of the board. Check all capacitor directions (polarity). Verify that all the
modifications have been implemented (see Appendix F).
Connect the Input board to the test jig and verify the following voltages:
Before regulator Q101 (one side of diode D101): about 17Vdc
After regulator Q101 (other side of diode D101): 12Vdc
Before regulator Q102 (pin3): 12Vdc
After regulator Q102 (pin1): 5.8Vdc
Set the volume to 86 (unity gain). Pass a 1Vpeak, 1kHz signal (sine-wave, then square wave) through ALL the inputs
(both left and right: BAL, LIN1, LIN2, LIN3, and TAPE-IN) and check that it appears on ALL the outputs (both left and
right: LINout and TAPEout). In each case repeat with 10Hz and 10kHz signals and make sure the output levels are the
same as the input level and the same for all frequencies. Verify that the square wave signal shows no signs of ringing,
oscillation, or other deformation.
With the volume still at 86 confirm that the DC offsets on the Line and Tape outputs do not exceed +/-4mV.
Testing the AUX Power supply Board (B3F2XR04)
Perform a detailed visual inspection of the Aux Power Supply. Check all capacitor directions (polarity).
Connect AUX transformer (TC0600-0040) to U101.
Verify the following voltages:
Before regulator Q201 (right side of diode D201) about 17.5Vdc
After regulator Q201 (left side of diode D201) 12Vdc.
Before regulator Q101 (right side of diode D101) about 17.5Vdc
After regulator Q101 (left side of diode D101) 12Vdc.
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Before regulator Q301 (left side of diode D301) about 20Vdc
After regulator Q301 (right side of diode D301) 12Vdc.
Before regulator Q302 (right side of diode D302) about -20Vdc
After regulator Q302 (left side of diode D302) -12Vdc.
Before regulator Q401 (pin 1) 12Vdc
After regulator Q401 (pin 3) 5Vdc.
Testing Capacitor Board (B3F3XR00)
For the following tests use a “bypassed” power-supply jig powered from a variac.
Connect the secondary of transformer to AC2 and AC4 and Center Tap at AC6.
Bring up the AC gradually (in 15V steps) while measuring the main DC rails at +V201 and –V201 relative to ground
at GND201. Keep a close eye on the circuits, listen for frying or popping noises, and feel the variac for vibration
caused by excess current. If you hear a capacitor pop, mark the board and replace it. Raise the variac voltage until
you measure +/-66Vdc on the DC voltage rails (about 70Vac on the variac, depending on the transformer on the
jig).
Now do the same thing to other side of the board.
Connect the secondary of transformer to AC1 and AC3 and Center Tap at AC5.
Bring up the AC gradually (in 15V steps) while measuring the main DC rails at +V101 and –V101 relative to ground
at GND101. Keep a close eye on the circuits, listen for frying or popping noises, and feel the variac for vibration
caused by excess current. If you hear a capacitor pop, mark the board and replace it. Raise the variac voltage until
you measure +/-66Vdc on the DC voltage rails (about 70Vac on the variac, depending on the transformer on the
jig).
Disconnect the capacitor board and discharge the capacitors.
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 11 of 50

Sensor / Control Board
Before you begin, perform a detailed visual inspection of the board. Check for missing components, missing
solder or accidental solder bridges (especially under surface-mount ICs). Check direction of all ICs, capacitors,
and diodes, and other visible problems.
Calibrating the Sensor / Control Board (PCB B3B1XR04)
Check all components.
Turn trimpots R3, R4, R15 and R16 CCW to end (minimum).
Short (with a jumper) the two rightmost pins (looking from the top) on connector TO-OP.
Connect a tested PROGRAMMER ADAPTER to connector TO-MAIN-CTR on the control board.
Power-up.
Use local ground on test-point T2 (on the control/sensor board)
Verify local supply voltage: 5.0 Vdc on tab of regulator Q3, and 12Vdc on the left pin of the same
Adjust current zero reference:
oProbe test point T1 and trim R15 CW until voltage on T1 rises to 250mVdc.
oProbe test point T3 and trim R3 CW until voltage on T3 rises to 250mVdc.
Adjust current max reference:
Connect a variac AC power supply to the control board test fixture. Tweak the variac down to minimum, connect
the resistor load to the test fixture and power it on. While monitoring the DC output of the fixture increase the
variac supply until the output reaches 80Vdc across the load (with the load connected). Disconnect the load,
place the control board on the calibration fixture (with mechanical extension to match the new sensor spacing),
and reconnect the load. Power up the test fixture and:
oProbe test point T1 and trim R16 CCW until voltage on T1 rises to 500mVdc.
oProbe test point T3 and trim R4 CCW until voltage on T3 rises to 500mVdc.
Power-off the load and re-adjust current zero reference (re-trim T1 and T3 to 250mVdc). Re-adjust current
max reference (re-trim T1 and T3 to 500mVdc). Repeat if necessary.
Testing the Sensor / Control Board (PCB B3B1XR04)
After calibration (see above) use the same setup to check the following:
Use local ground on test-point T2 (on the control/sensor board)
Verify local supply voltage: 5.0 Vdc on tab of regulator Q3, and 12Vdc on the left pin of the same
Verify the dc-protection reference voltage: 1.84Vdc on test-point T4
Verify the floating output voltage: 1.72Vdc on test-point T5
Verify the output of the optocoupler (pin 3 on Q6). It should be high (5Vdc)
Connect a 10k (code 1002) resistor from ground to the top middle pin of connector TO-OP. The voltage on
test-point T5 should change to 0.92Vdc.
Connect a 10k (code 1002) resistor from the 5V supply to the top middle pin of connector TO-OP. The
voltage at the output of the optocoupler (pin 3 of Q6) should go low (under 0.5Vdc)
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 12 of 50

AC Boards
Before you begin, perform a detailed visual inspection of the AC-sensor and AC-control boards. Check for
missing components, missing solder or accidental solder bridges (especially under surface-mount ICs). Check
direction of all ICs, capacitors, and diodes, and other visible problems.
Testing the AC-Sensor board (PCB B3A7XR00)
Check all components.
Connect a tested mini-toroid transformer (ToroidTech TR0005-0015) to CON1 (primary) and CON2
(secondaries)
Insert 400mA fuse at F1
Connect Earth from AC plug to MH1
Connect 120Vac between N4 (neutral) and N5 (line)
Power-up
Verify that the voltage on pin 3 of the voltage regulator is 5.0Vdc
Verify that the first secondary of the mini-toroid (on BR1) measures 11.5Vac
Verify that the second secondary of the mini-toroid (on BR2) measures 3.3Vac
Use your oscilloscope to look at the voltage on pin6 of IC1. It should be a 60Hz square wave with 5V peaks.
Use your oscilloscope to look at the voltage on pin6 of IC2. It should be 5Vdc.
Testing and calibrating the AC-Control board (PCB B3B3XR02)
Check all components.
Turn trimpot R7 CCW to end (minimum).
Connect the AC-Control board to a tested AC-Sensor board with mini-toroid transformer (see above)
Power-up the assembly and adjust your variac to precisely 120Vac
Connect your voltmeter’s ground probe to pin5 of IC2 on the AC-Sensor board
Probe test point T1 on the AC-Control board
Turn trimpot R7 CW until the voltage on T1 rises to 1.43Vdc
To test the digital portion of the circuitry on this board, refer to the following section.
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 13 of 50

Testing the complete control assembly
Assemble the following boards: AC-Sensor (with mini-toroid), AC-control, AUX power supply, Front Panel (for your
amp model), Sensor/Control boards (as many as required for your amp model), Communications board, Trigger
& IR board.
Interconnect as follows:
Mount the AC-control board on the AC-Sensor board
Plug the mini-toroid connectors into the AC-Sensor board
Connect a 10-pin cable from the AC-control board to FROM_AC_CTR on the AUX power supply
Connect a 10-pin cable from the Trigger & IR board to TO_IR on the Communications board
Connect a 10-pin cable from TO_FRONT on the Com board to FROM_COMM on the Front Panel
Connect a 10-pin cable from FROM_AUX on the Front Panel to TO_FRONT on the AUX PS
Connect 10-pin cables from each Sensor/Control board to the AUX power supply
Insert a shorting plug between pins 1 and 2 of connector TO_OP on each Sensor/Control board
Connect a blue line from terminal N on the AC-Sensor board to terminal N on the AUX power supply
Connect a brown line from terminal L2 on the AC-Sensor board to terminal LIN2 on the AUX power supply
Connect Earth to post MH1 on the AC-Sensor board
Connect 120Vac between terminals N4 (neutral) and N5 (live) on the AC-Sensor board
RS-232 setup:
Connect an RS-232 cable from the serial port of a computer to your Delta series amplifier.
Start HyperTerminal on the computer and configure the serial port to which you connected as follows:
Baud rate: 9600 bits per second
Data bits: 8
Parity: none
Stop bits: 1
Flow control: hardware
Please refer to Appendix B for a complete description of the available RS-232 command set.
Factory data:
Before you begin, the Front Panel board needs to be defaulted (its memory cleared completely).
While the assembly is in standby mode, type in “fac” (followed by the Enter key.) The system will display the
factory data. For example:
D-AMP Ver: 1.0 Copyright (c) 2003 Classe Audio
Model: CAM400, Amp# 1
OK
AC Control: 2E, Heatsink 1: L1, Heatsink 2: L1,
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 14 of 50

Verify the version of software loaded into the front-panel board and the control/sensor modules (see Appendix
F for latest software versions). If these are not up-to-date, you should load the latest software versions using
the MPLAB ICD 2 “hockey-puck” programmer.
Set the model number of the amplifier according to which front panel you are testing (see Appendix B).
AC power check:
Type in “sdp” (followed by the Enter key). You will get a response detailing the AC power parameters. For
example:
AC Setting = 120
Line V = 122 V
Current = 0.0 A
Line Freq. = 61 Hz
Internal Temp. = 25 C
Ground is OK.
Line Phase is OK.
OK
Verify that all the readings are correct (especially the AC line voltage and the temperature).
If your AC voltage from your variac does not agree with the setting of the Voltage Selector jumper (CON 1)
on the AUX power supply, the “bad power” LED (D404) on the AUX PS will go on. The AUX PS transformer
will NOT power up (so the front panel and RS-232 will NOT work) until this condition is cleared. You should
test this function by unplugging the system and switching the voltage select jumper (ONLY) to 240V. The “bad
power” LED will be on and the Standby LED on the Front Panel will be off (no power to the AUX PS). Switch
the voltage selector jumper back to 120V when you’re done.
The acceptable voltage ranges are:
240VAC setting: accept over 185Vac an under 260Vac
230VAC setting: accept over 185Vac an under 260Vac
120VAC setting: accept over 95Vac and under 135Vac
100VAC setting: accept over 90Vac and under 110Vac
If the voltage is out of the specified range, the unit will NOT turn on.
If the voltage goes out of range while the unit is ON then:
If the voltage is OVER for more than 10 seconds the unit will shutdown, an AC fault will be recorded
in the fault log, and the Standby LED will flash fast (2 blue flashes per second).
If the voltage is UNDER the unit will remain on (keep playing) but the Standby LED will flash fast (2
blue flashes per second).
Unplug the AC and remove the Earth pin. Reconnect the AC (without the Earth pin) and repeat the “sdp”
command. You should see an error message indicating this fault.
Unplug the AC, reconnect the Earth terminal, but reverse the line and neutral terminals. Again, when you do
an “sdp” you should see an error message indicating this fault.
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 15 of 50

Sensor/Control module check 1:
Type in “LPI” (list programmable items). You will get the following type of response depending on the amplifier
model and the number of sensor/control boards attached:
INP1 = B | RTP1 = 6 | RTN1 = 6 | TTP1 = 90
FBI1 = 90 | RFT1 = 30 | LFE1 = 0
INP2 = B | RTP2 = 6 | RTN2 = 6 | TTP2 = 90
FBI2 = 90 | RFT2 = 30 | LFE2 = 0
OK
The above reply indicates that there are two sensor/control boards recognized by the system and the specific
parameters of each are listed. The meaning of each of these is as follows:
INPx = B (B=balanced, S=single-ended)
RTPx = 6 slow-blow positive rail current trip point (2 digit from 05 to 75)
RTNx = 6 slow-blow negative rail current trip point (2 digit from 05 to 75)
RFTx = 30 fast-blow trip delay in ms (3 digit from 10 to 255)
TTPx = 90 temperature trip point in degrees Celsius (2 digit from 25 to 99)
FBIx = 90 fast-blow current trip point (3 digit from 090 to 190)
LFEx = 0 DC-protection tripping delay (each unit equals 5ms, Limits 0 to 99)
For now, all you need to check is that all the sensor/control boards respond and they return a reasonable list
of values (no zeros or weird values anywhere). These parameters will be reprogrammed before shipping.
Power-up sequence check:
Type in “PWR” (followed by the Enter key) to power up the system. You will get the following response:
Power up in process.
When the power-up is complete, it will display:
Amplifier now ON.
Type in “PWR” again to power down and then repeat the power-up sequence. Make sure that the system
powers up properly. Follow the timing diagram (see Appendix D) and listen for the relay clicks at the right
times (ignore the front panel LEDs).
Front Panel check:
Verify that the front panel you are testing corresponds to the amplifier model where it will be used (see
Appendix F for a listing of the various versions of this board).
Check that the “Standby” LED is solid blue (and NOT red) when the system is in Standby mode. All other LEDs
should be off at this time. Press button S4 (immediately above the Standby button). This reverses the logic state
of all the channel LEDs so they should all glow pink (both blue and red at the same time). If any LEDs are not
pink they will need to be repaired or replaced.
Repeat the power-up sequence as above and observe the Front Panel LEDs. As the system powers up the LEDs
corresponding to each of the “channels” will flash blue and then turn solid blue. The upper row LEDs are
active if the corresponding channel is in Balanced mode while the lower row LEDs are active if the
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 16 of 50

corresponding channel is in Single-ended mode. For each channel, only one of the two LEDs should be active
(upper of lower, depending on the selected mode for that channel). A red LED indicates a fault condition.
Note that the timing of these LEDs does NOT correspond to the timing of the relays. When the system is
powered-up, all channel LEDs (either upper OR lower) should be solid blue.
With the boards powered up (LEDs on) verify the dimming of the front-panel LEDs using the DIM command
via RS-232 (check ALL LEDs, both balanced and single ended mode).
Input type selection:
To program the input type (Balanced or Single-ended) for each channel, briefly press the SELECT button while
the unit is in Standby. The channel LEDs will light up in blue to display the current configuration (upper LED
ON means Balanced, lower LED ON means Single-ended). The LED for channel 1 will be flashing to indicate
that you can modify the input type for this channel. You may switch the input type by pressing the MODE
button (this will also change the blinking LED). You may move on to the next channel by pressing SELECT
again. To finish the input configuration press SELECT until the LEDs are all off (after channel 5).
Amp-number selection:
The AMP-number is a unique ID (from 1 to 15) assigned to each amplifier in a multi-amplifier system. This
number is also equal to the delay (in seconds) the amplifier waits (from the time you press the Standby button)
before it starts powering-up. This delay ensures that multiple amplifiers do start powering up at the same time.
To change the AMP-number press and hold the MODE button while the unit is in Standby. After about 3
seconds the channel LEDs will ALL go ON at the same time. If you let go the MODE button (without pressing
anything else), the LEDs will go off briefly and then blink (all together) to indicate the currently programmed
AMP-number. The number of times the LEDs flash ON is the current AMP-number. To change the AMP-
number, press and hold the MODE button. After 3 seconds, when the unit turns ON all the channel LEDs,
press the SELECT button as many times as the wanted AMP-number (while still holding the MODE button).
When you are done, let go the MODE button. The unit will flash the LEDs as many times as the new AMP-
number to confirm your entry.
Mute function:
The amplifier can be muted via RS-232 or remote control. All channels are muted together (see Appendix B).
When the unit is in mute mode, the corresponding active channel LEDs (either balanced OR single-ended for
each channel) flash blue.
Timer function:
A global timer keeps track of the time the unit has operated since shipping. This timer is activated every time
the unit is powered up (from Standby), and it stops when the unit is powered down (back to Standby). It is
updated every hour to prevent missed counts due to power failures etc. This timer can be read (and cleared
with the proper password) via RS-232 (see Appendix B).
Fault logging function:
The amplifier keeps a log of the faults (protection conditions) that have occurred since shipping. This log is
updated every time an amp module reports a fault to the front panel. This log can be read (and cleared with
the proper password) via RS-232 (see Appendix B). 128 entries are kept in the log. When the log is full the
oldest entry is deleted.
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Sensor/Control module check 2:
Once the system is powered on, type in “sda” (follower by the Enter key). The sensor/control modules will
return a real-time snapshot of current and temperature values as follows:
AMP1: POS 0A | NEG 0A | TEMP 10C
AMP2: POS 0A | NEG 0A | TEMP 6C
OK
Ignore the temperature readouts at this point – they are incorrect because the sensors are on the heatsinks
which are not present. The thing to check here is that there are no error messages (DC protects etc.) To
trigger a DC fault you can simply pull off the jumper between pins 1 and 2 on connector TO_OP on one of
the sensor/control modules.
DC-protection check:
Repeat the following procedure on each of the sensor/control modules:
Use a 10k ohm resistor to jumper a variable DC voltage to pin 5 of connector TO_OP. Raise the DC voltage
slowly from zero to 2.5Vdc. The DC protection should trigger when you exceed +2Vdc. When the module
enters protection mode, the corresponding channel LED should flash red AND the module should NOT restart
until the AC has been unplugged (or an “rff” command has been issued via the RS-232 port).
Repeat as above but lower the DC from zero to –2.5Vdc. The DC protection should trigger when you exceed -
2Vdc. Again, the corresponding channel LED should flash red AND the module should NOT restart.
Trigger function check:
Connect a switched +5Vdc signal to the trigger-in input on the Trigger/IR board. When this signal pulses
positive, the output of optocoupler U101 (pin 3) will pulse positive also (it is normally low). If the amp was on
Standby it should respond by powering up. If the amp was already ON, the trigger will be ignored. When you
switch the trigger signal off, the amp will power-down (back to Standby).
The trigger-out signal is just a loop-through of the trigger-in signal. Measure it to verify that it is the same as
the trigger-in (actually about 0.2 Volts lower).
IR function check:
Check all the IR functions. To do this, connect the IR-out from an IR receiver (IR/Trigger test jig) to the IR-in of
the amplifier and use the amplifier remote to control the amp. Verify that all IR commands work as expected.
When external IR-in signal is plugged in (as above), the IR-out is a loop-through of this signal. Verify that there
is signal present on this output when a button is pressed on the remote control. Note that this line is normally
“high” (close to 5V) and it pulses “low” when a signal is present.
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 18 of 50

Testing the main amp plug-in board
B3B6XR04 (modified for CA2100/CAP2100)
Perform a detailed visual inspection of the main amp plug-in board. Verify that the board has been updated
as listed in Appendix F.
Check the types and orientations of the transistors, the polarity of the caps, and the values of the resistors. The
orientation of the little red LEDs cannot be checked after installation but will become obvious when the board
is powered up (all LEDs should be ON).
Connect the board to the test jig. Gradually bring up the variac AC powering the board (in 15 Volt steps). In
each case monitor the voltage on both sides of resistors R140 and R141 (relative to ground). Verify that these
voltages are always the same (if you have 10V on the left side of R140 you should also see 10V on the left
side of R141). When you reach full power you should see 54Vdc on the left side of R140 (and the left side of
R141) and 66Vdc on the right side of R140 (and the right side of R141). Check that all the LEDs are ON.
Verify the following voltages:
Voltage on TP10 (relative to ground) should be +54Vdc (when the main rails are at 66Vdc)
Voltage on TP9 (relative to ground) should be -54Vdc (when the main rails are at 66Vdc)
Voltage on TP4 (relative to GND) should be 8.64Vdc
Voltage on TP3 (relative to GND) should be 8.61Vdc
Voltage on TP1 (relative to +54Vdc rail) should be 0.361Vdc
Voltage on TP6 (relative to +54Vdc rail) should be 2.00Vdc
Voltage on TP8 (relative to +54Vdc rail) should be 1.335Vdc
Voltage on TP11 (relative to +54Vdc rail) should be 1.548Vdc
Voltage on TP2 (relative to -54Vdc rail) should be 0.362Vdc
Voltage on TP5 (relative to -54Vdc rail) should be 2.02Vdc
Voltage on TP7 (relative to -54Vdc rail) should be 1.342Vdc
Voltage on TP12 (relative to -54Vdc rail) should be 1.550Vdc
Measure output DC offset: it should be less than +/-8mVdc
Make sure that a test signal passes to the output with a gain of 29dB.
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 19 of 50

Testing the Heatsink
Before you begin, turn trimpot RV101 (or RV201 depending on the orientation of the board) on the heatsink
board all the way CCW. This will bring the biases on the output transistors to zero.
Perform a detailed visual inspection of the heatsink board. Verify that the board revision is up-to-date (the
board number can be found on the bottom side of the board just beside the break-away portion and can only
be seen with a mirror). Check the types of the MOSFETs: they should be (2S)K216 on the positive output side
of each board and (2S)J79 on the negative output side, and the types of the bipolar transistors: they should
be (2S)C3263 on the positive output side of each board and (2S)A1294 on the negative output side. Verify
that R114 is 4.7 ohms and that it doesn’t touch the relay next to it. Also verify that all the relays are 12V type
(and NOT 5V type). Finally, verify that the temperature compensation transistor (Q101 or Q201) is well glued
to the heatsink.
DO NOT power-up the heatsink without a tested main amp plug-in board. Make sure that the main
amp plug-in board is seated properly on the heat-sink board connectors.
For the following tests use a “bypassed” power-supply jig powered from a variac. Make sure that the
capacitors on the supply are discharged before you connect the heatsink to the jig.
Bring up the AC gradually (in 15V steps) while measuring the main DC rails (on the big brass binding posts)
and the MOSFET supplies (+V202 and –V202) relative to ground (GND or GND201). The MOSFET supplies
should be at the same voltage as the respective DC rails. Keep a close eye on the circuits, listen for frying or
popping noises, and feel the variac for vibration caused by excess current. If you hear a capacitor pop, mark
the board and replace it. Raise the variac voltage until you measure +/-66Vdc on the DC voltage rails.
Check the biases on the output transistors. They should still be zero. If not, trim them down to zero and if that
doesn’t work then power off immediately.
While the heatsink is on, verify that the Zener supplies for the DC-protect circuit are +/-12Vdc (measure the
voltages on the accessible ends or resistors R201 and R203 under the main board, relative to ground). Verify
that these resistors are 3kohms. Verify also that resistor R119 is 10k ohms (RN55D1002). If the code is not
visible then measure it.
Finally, with the heatsink off and disconnected from power, check for shorts between the chassis of the
heatsink and digital ground (on the tab of temperature sensor Q8).
Preliminary bias adjustment
If everything went well you can now proceed to a preliminary adjustment of the bias. Re-adjust the variac until
you have exactly 66.0Vdc on the DC-rails. Connect the ground probe of your voltmeter to the middle point
between resistors R108 and R113 (output) and probe the other end of either resistor. Trim RV101 CW until
the bias rises to 7mV. This should eventually bring the bias to 10mV which is the desired final value.
Output DC offsets
Measure the DC offset voltage on the output of the heatsink board (relative to ground) and verify that it does
NOT exceed +/-10mVdc.
CA(P)2100 AMP Service Manual v1.4 inc voltage change info .doc Page 20 of 50