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Infinity Kappa 202a User manual

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Kappa 202a
Automotive Amplifier
SERVICE MANUAL
Infinity Systems Incorporated
250 Crossways Park Dr.
Woodbury, New York 11797
Rev0 10/2004
- CONTENTS -
SPECIFICATIONS ……..…………………………………………………………..2
FEATURES ..……………………………….……………….……………….…...…3
APPLICATIONS (SET-UP GUIDE) ………………..……..……………………….4
PRECAUTION AND NOTES..…..………………….….…………………………..6
INSTALLATION ….………..…………..…………….……………………………..7
TROUBLESHOOTING ….………..………………….……………………………..9
BLOCK DIAGRAMS………...……………….……………….…………..….…….10
ELECTRICAL PARTS LIST ..……………….……………….…………..….…….11
PCB DRAWINGS ….………..……………………………………………………..16
SEMICONDUCTOR PINOUTS..…..………………….….……………………….30
SCHEMATICS …………..……………………..…….…….….………..………….31
REVISIONS ……………..……………………..…….…….….………..………….39
Occasional refinements may be made to existing products without notice but will always meet or exceed original specifications
unless otherwise stated
Kappa 202a
KAPPA 202A SPECIFICATIONS
POWER
4 OHM 2 x 200 watts
2 OHM 2 x 300 watts
BRIDGE 4 OHM 600 watts
1 OHM STABLE PROTECTION
FREQUENCY RESPONSE 20-20KHz (+0 -3dB)
EQUALIZATION SEE CHART BELOW
FIXED AT 40Hz Q=1 +11dB
CROSSOVER
FLAT/LOW/HIGH PASS SWITCH 1
VAR. CONTROL 1
SLOPE 12
INPUT SENSITIVITY 250 mV ~ 9 V
FULL DIFFERENTIAL INPUT >100K IMP
POWER FUSE 40A X 2 (ATC)
THD + NOISE
4 ohm 0.05%
2 ohm 0.10%
bridge 4 ohm 0.10%
SIGNAL TO NOISE >95dB (A Weighted Referenced 1 Watt)
CHANNEL SEPARATION >50dB (100 TO 20KHz)
DAMPING FACTOR >203
TURN ON TIME 3 SEC
DC OFFSET <50 mv
OPERATING VOLTAGE 10 -16vdc
REMOTE ON CURRENT <2ma
QUIESCENT CURRENT <2.0 AMP
MAX CURRENT 80
PROTECTION auto reset
spkr short Yes
spkr to ground Yes
thermal Yes
over voltage 18vdc
under voltage 8vdc
DIMENSIONS 23 x 2 3 /16 x 8 1 /2 in. (W x H x L)
584.2 x 55.6 x 215.9 mm
All tests to be done from 20 to 20KHz at 14.4 VDC into 4 ohm loads, unless otherwise specified.
Infinity continually strives to update and improve existing products, as well as create new ones. The specifications and
construction details in this and related Infinity publications are therefore subject to change without notice.
2
Kappa 202a
FEATURES
The Kappa 202a is a 2-channel power amplifier that offers full-range stereo, bridged-mono or tri-
mode operation, and is rated at 200 watts (rms) per channel into a 4-ohm load. In a bridged-
mono configuration, it can deliver up to 600 watts (rms) for the same load. The 202a also
features:
·2-ohm operation, rated at 300 watts (rms) per channel
·A bridge/stereo switch for fast system setup
·A built-in 12 dB-per-octave electronic crossover, variable from 32 to 320 Hz
·Dynamic Bass Optimizer™ (DBO) 12 dB-per-octave subsonic filter with variable frequency
(20 to 80 Hz) and Q for enhancing low frequencies while conserving amplifier power
·Individually selectable high and low-pass filters (with through-pass) for amplifier and
auxiliary outputs
·Amplifier input sensitivity control to match a wide range of input signal levels from 250 mV to
9 V
·Separate power supplies for each channel
·Five protection levels guard against over-voltage, undervoltage, over-power, over-
temperature, and over-current situations
·2-color LED array indicates green when power is on and orange when protection is
activated
·Industrial-grade, gold-plated, “pre-wire and plug-in” connectors for an easy-to-install high-
quality interface
·Transparent control cover to deter tampering yet provide a clear view of installation settings
·Built-in automotive type fuses to protect the amplifier
·Unibloc™ chassis provides improved heat-sink capacity and exceptional RFI shielding
characteristics
3
Kappa 202a
APPLICATIONS
For your convenience, we’ve included several application
diagrams to help you plan your own system installation.
Figures 1 through 3 show how to configure the Kappa 202a
for stereo, bridged-mono, and tri-mode operation.
For system expansion ideas, see the next page.
NOTE: For simplicity, Figures 1 through 3 do not show power,
remote, and input connections.
KAPPA 202a
(rear panel)
REM –R+–
+L
+
-
+
-
R Speaker L Speaker
Set Mode Switch
To STEREO
(on top panel)
Set Filter Switches
To FLAT
(on top panel)
KAPPA 202a
(rear panel)
REM –R+–
+L
+
-
+
-
-
+
R Speaker
Subwoofer
L Speaker
Set Mode Switch
To STEREO
(on top panel)
Set Filter Switches
To FLAT
(on top panel)
CapacitorCapacitor
Inductor
Figure 1. This wiring diagram
shows a Kappa 202a amplifier
set to stereo to drive a pair of
full-range speakers.
Figure 2. This wiring
diagram shows a Kappa
202a amplifier set to
bridge (mono) to drive a
single subwoofer.
Figure 3. This wiring diagram
shows a Kappa 202a amplifier
set for tri-mode operation. For
a desired crossover frequency,
use the chart to select a low-
pass inductor for the sub-
woofer, and corresponding
high-pass capacitors for left
and right speakers.
KAPPA 202a
(rear panel)
REM –R+–
+L
-
+
Subwoofer
Set Mode Switch To
BRIDGE (on top panel)
Set Filter Switches
(on top panel)
FREQUENCY INDUCTOR CAPACITOR
Crossover 6 dB/oct. LP 6 dB/oct. HP
(4 ohm) (4 ohm)
75Hz 8.0 mH 530 µF
100 Hz 6.4 mH 400 µF
125 Hz 5.0 mH 318 µF
150 Hz 4.2 mH 265 µF
175 Hz 3.6 mH 227 µF
200 Hz 3.2 mH 198 µF
4
Kappa 202a
SYSTEM EXPANSION
+
-
+
-
-
+
5 1⁄4" Speakers
12" Subwoofer
+
-
+
-
1" Tweeter
4" Midrange
System
+
-
+
-
6" Mid/Bass Speakers
-
+
12" Subwoofer
+
-
1" Tweeter
4" Midrange
System
L/R Inputs
L/R Outputs
(Low-Pass)
L/R Inputs
L/R Inputs
L/R Outputs
(Low-Pass)
L/R Outputs
(Low-Pass)
L/R Inputs
L/R Inputs
KAPPA
5
2
a
KAPPA 52a
KAPPA 102a
KAPPA 102a
KAPPA 202a
Figure 4. In this example
system, a Kappa 52a drives
a pair of 51⁄4" speakers.
The 102a’s stereo low-pass
outputs feed a bridged-
mono Kappa 102a to drive
a single 12" subwoofer.
Figure 5. In this expanded
system, a Kappa 52a drives
a pair of component
systems. The 52a’s low-
pass outputs feed a Kappa
102a to drive a stereo pair
of 6" mid/bass speakers.
The 102a’s low-pass
outputs feed a bridged-
mono Kappa 202a to drive
a single 12" subwoofer.
NOTE: Many different
systems are possible using
the crossover settings on
Kappa amplifiers,
including ones with 24 dB
per octave slopes achieved
through cascaded
configurations. For more
information, consult your
Infinity Car Audio dealer.
5
Kappa 202a
PRECAUTIONS AND NOTES
•The Kappa 202a has five levels of circuit protection
that monitor the amplifier and will shut it down if the
electrical system voltage drops below 10 Vdc or
exceeds 15.5 Vdc, temperatures are above 194°F (90°
C), short circuits occur, or current draw exceeds
product specifications. For best performance, check
the intended mounting site to make sure the
operating environment does not create conditions that
will trigger circuit protection.
•Prior to installation, turn off all audio systems and
other electrical devices. Also disconnect the (–)
negative lead from the vehicle’s battery.
•At the installation site, locate and make a note of all
fuel lines, hydraulic brake lines, and electrical wiring.
Use extreme caution when cutting or drilling in and
around these areas.
•Use the amplifier as a mounting template to mark
locations for the mounting holes.
•Check clearances on both sides of a planned mounting
surface before drilling any holes or installing any
screws. Remember that mounting screws can extend
up to an inch behind the surface.
•Always wear protective eyewear when using tools.
•The Kappa 202a uses gold-plated, industrial-grade
Weco®plug-in connectors for power and speaker
wiring. Because of precision tolerances, do not insert
the connectors into the amplifier without pre-wiring
them first. Once the wires are fastened in each shell,
they provide additional gripping area for easy
connector removal.
•When routing cables, keep input signal cables away
from power cables and output speaker wires, as
shown in Figure 6 (below).
•When making connections, make sure that each
connection is clean and properly secured. Observe the
polarity markings on the rear panel. Refer to the
application drawings (Figures 1 through 3 on page 3)
to set up the amplifier for operation in stereo, bridged-
mono, bi-amp, or tri-mode configurations.
•If the amplifier’s fuse needs replacement, use only
the same rating and type as a replacement. Do not
substitute another kind.
+–
Battery Fuses LF
RF
Kappa 202a
Amplifier
POWER and
REMOTE Cables
Chassis
Ground
Chassis
Ground
Chassis
Ground
Source
Unit
Ignition
SPEAKER Cables
AUDIO Cables
Figure 6. To minimize possible noise pickup, use this suggested
cable routing scheme to plan your amplifier installation.
6
Kappa 202a
INSTALLATION
The Kappa 202a is easy to install. For optimum
performance, we recommend using high-quality, twisted-
pair shielded RCA audio cables and 14-gauge or larger
speaker wire. Also, you’ll need a minimum of 12-gauge
stranded copper wire (e.g., red and black jackets) for the
power connections. Use 18-gauge (e.g., blue jacket) wire
for remote turn-on.
Depending on your total system plan, allow for adequate
time and the possibility of overnight storage of your
vehicle, since it may take more than one day to complete
the installation.
PARTS LIST...
Examine and verify that the package includes the
following items:
•(1) Kappa 202a Power Amplifier
•(2) Spare ATC fast-blow fuses (40 A)
•(1) Control cover with (2) machine screws
•(1) Weco 5-pin audio connector
•(1) Weco 2-pin power connector
•(4) #8 mounting screws
MOUNTING THE AMPLIFIER...
The Kappa 202a can be mounted in virtually any location
inside the vehicle. However, make sure to keep the
amplifier away from heater vents or ducts.
1. At the chosen site, use the amplifier as a mounting
template and mark locations of the four mounting holes.
2. Drill a small pilot hole at each marked location.
3. Mount the amplifier and securely tighten the
mounting screws.
WIRING THE AMPLIFIER...
Refer to Figure 7 (below) for details of the Kappa 202a’s
front and rear panel connections.
1. For power, remote, and speaker wires, strip 1⁄4" off
one end of each jacket to reveal bare wire for insertion
into the Weco connectors.
2. Using the Weco 2-pin power connectors, connect
individual black wires from the nearest bare-metal
chassis component to each (–) terminal. Then, connect
individual red wires from the vehicle’s +12-volt
battery terminal to each (+) terminal.
KAPPA 202a WIRING CONNECTIONS
(front panel)
KAPPA 202a WIRING CONNECTIONS
(rear panel)
Figure 7. Wiring connections for the Kappa 202a amplifier.
7
Kappa 202a
INSTALLATION (continued)
3. Make sure the wires are firmly seated in each Weco
2-pin connector and that each screw is completely
tightened. Insert the wired connectors into the POWER
sockets on the amplifier. Press each one in until it stops.
4. Using the Weco 5-pin connector, connect a blue wire
from the source unit’s remote connection to the REM
terminal. Depending on polarity requirements (e.g.,
bridged-mono or tri-mode configurations –see Figures
1 through 3 on page 3), connect speaker wires from
the speakers to the L and R (+ and –) terminals, as
required by your system plan.
5. Make sure the wires are firmly seated in the Weco 5-pin
connector and that each screw is completely tightened.
Insert the wired Weco 5-pin connector into the 5-pin
socket on the amplifier. Press it in until it stops.
6. Connect RCA cables from a source unit to the L and R
INPUT jacks.
SETTING THE CROSSOVER...
IMPORTANT: If you plan to use the Kappa 202a to drive
full-range speakers, set both AMP and AUX filters to
FLAT (refer to Figure 1 on page 3 and Figure 8 below)
and skip to the next section, “Setting Input Sensitivity”.
1. Set the CROSSOVER control to the frequency
recommended by speaker manufacturer (refer to Figure
8). If the value is unknown, set the control midway.
Figure 8. Kappa 202a controls for crossover, input, output, and
DBO (Dynamic Bass Optimizer).
2. Depending on your system plan, set the AMP and
AUX switches to LP (low-pass), HP (high-pass), or
FLAT (refer to Figure 8).
SETTING INPUT SENSITIVITY...
Initially, turn the input sensitivity GAIN control to its
minimum (counter-clockwise) position (refer to Figure 8).
1. Reconnect the (–) negative lead to your vehicle’s
battery. Apply power to the audio system and play a
favorite music track from CD or tape.
NOTE: After the source unit is on, green LEDs (on the top
pane)l will illuminate, indicating the amplifier is on. If not,
check the wiring, especially the remote connection from the
source unit. Also refer to “Troubleshooting”on the next page.
2. On the source unit, increase the volume control to
maximum position. Slowly increase the GAIN control
(clockwise) towards three o’clock and, at the same
time, listen to the quality of the reproduced sound. At
some point, you’ll hear distortion on the music peaks.
Stop the adjustment and turn it back slightly.
SETTING DBO...
Dynamic Bass Optimizer (DBO) is a new approach to
enhancing low-frequency reproduction in a vehicle.
Conventional bass boost controls add bass at a fixed
frequency and cause the amplifier to consume
considerable power. DBO conserves valuable power at
the lowest frequencies and allows you to adjust the level
and “character”of the bass sound, instead of just the
amount of boom.
Since a subwoofer in a tuned box is given to overexcursion
below the tuned frequency, set the FREQ control below
the box’s resonant (tuned) frequency (see Figure 9 on the
next page). Power typically wasted in this region will now
be conserved and instead be available for frequencies the
enclosure will reproduce. Use the Q control to boost the
bass at the set frequency by as much as 12 dB (at MAX
position –see Figure 9 on the next page).
For sealed enclosures, use DBO to enhance the output so
it sounds more like a tuned box. This is a result of 12 dB
of rolloff being added to the enclosure’s rolloff and a
flattening of frequency response (at the curve’s knee)
when Q is boosted.
For infinite baffles, set the FREQ control to the speaker’s
Fsvalue (to keep the subwoofer from trying to create bass
below the resonant frequency) and adjust the Q control
according to personal taste.
INSTALLING THE CONTROL COVER...
After wiring and testing the Kappa 202a amplifier, install
the control cover using the enclosed machine screws to
deter tampering and help seal out dust.
NOTE: Do not over-tighten the machine screws. Doing so may
crack the cover.
8
Kappa 202a
TROUBLESHOOTING
Use the following guide to identify symptoms and solve
problems. Make sure the vehicle’s electrical system is
working properly and power is reaching the Kappa 202a
(i.e., green LEDs on the top panel are on).
SYMPTOM LIKELY CAUSE SOLUTION
No audio Low/No Remote Check connections;
Turn-On Voltage test turn-on voltage
Speakers are not Check wiring; use
connected or are VOM/DVM to
blown measure speaker
coil impedance
Distorted audio Input sensitivity See Setting Input
and/or bass control Sensitivity and
is not set properly Setting DBO
on previous page
Audio lacks Speakers are wired Check polarity of
“punch”with wrong polarity connections; refer to
Applications (page 3 )
SYMPTOM LIKELY CAUSE SOLUTION
Audio cycles A protection circuit Verify the following–
off and on; is turning the electrical system is
Amber protec- amplifier off and on between
10 ~ 15.5
Vdc;
tion LEDs (on temperature is not
top panel) are on over 194°F (90°C);
no short circuits;
speaker loads are not
less than 1 ohm
(2 ohms in mono)
Audio cycles GAIN is set too high Set Input Sensitivity
off and on; correctly (see previous
Amber protection page)
LEDs (on top
panel) are on
Fuse blows Incorrect wiring or Check connections;
short circuit refer to Applications
(see page 3)
9
Kappa 202a