ION Karaoke Star User manual

Confidential ION Audio Service Manual
ION Audio
Karaoke Star
[iPK2]
Service Manual
v1.0
2018-01-30
The information in this document contains privileged and confidential information. It is
intended only for the use of those authorized by ION Audio. If you are not the authorized,
intended recipient, you are hereby notified that any review, dissemination, distribution or
duplication of this document is strictly prohibited. If you are not authorized, please
contact ION Audio and destroy all copies of this document. You may contact ION Audio
at [e-mail].
© Copyright ION Audio
ATTENTION!
This document contains sensitive proprietary information.
All recipients must have a current non-disclosure agreement
on file with ION Audio.
Do not make illegal copies of this document.

Confidential ION Audio Service Manual
Preface
This document is intended to assist the service technician in the operation, maintenance and
repair of the ION Audio device. Together with the User Reference Manual, this document provides
a complete description of the functionality and serviceability of the Device. Any comments or
suggestions you may have pertaining to the document are welcome and encouraged.
Read This!
In addition to any purchase price that ION Audio may charge as consideration for ION Audio
selling or otherwise transferring this service manual (“Manual”) to you, if you are not a service and
repair facility (“Service Center”) authorized by ION Audio in writing to be an authorized Service
Center, ION Audio sells or transfers the Manual to you on the following terms and conditions:
Only Service Centers authorized by ION Audio in writing are authorized to perform service and
repairs covered by an ION Audio warranty (if any), and transfer of the Manual to you does not
authorize you to be an authorized Service Center. Therefore, if you perform, or if the Manual is used
to perform, any service or repairs on any ION Audio product or part thereof, any and all warranties
of ION Audio as to that product and any service contract with ION Audio for that product shall be
voided and shall no longer apply for such product, even if your services or repairs were done in
accordance with the Manual.
All service or repairs done by you or with reference to the Manual shall be solely your responsibility,
and ION Audio shall have no liability for any such repairs or service work. All such service or repairs
are performed at the sole risk of the person performing the service or repairs. You agree that all
such work will be performed in a competent, professional and safe manner at all times and to
indemnify and fully hold ION Audio and its successors and assigns harmless in the event of any
failure to so perform.
Your purchase of the Manual shall be for your own ultimate use and shall not be for purposes of
resale or other transfer.
As the owner of the copyright to the Manual, ION Audio does not give you the right to copy the
Manual, and you agree not to copy the Manual without the written authorization of ION Audio.
ION Audio has no obligation to provide to you any correction of, or supplement to, the Manual, or
any new or superseding version thereof.
ION Audio shall have the right to refuse to sell or otherwise transfer repair parts or materials to you in
its sole discretion. You shall not use, sell or otherwise transfer spare or replacement parts supplied by
ION Audio to you (i) to repair or be used in products manufactured for or by third parties or (ii) to
any third parties for any purpose.
You shall not make any warranties or guarantees with respect to the products of ION Audio or the
use thereof on behalf of ION Audio or in your own name.
The foregoing describes the entire understanding related to sale or transfer of the Manual to you,
and no other terms shall apply unless in a writing signed by an authorized representative of ION
Audio.
All Trademarks are property of their respective companies.

Confidential ION Audio Service Manual
Warnings
TO REDUCE THE RISK OF ELECTRIC SHOCK OR FIRE, DO NOT EXPOSE THIS PRODUCT TO
WATER OR MOISTURE.
The arrowhead symbol on a lightning flash inside a triangle is intended to
alert the user to the presence of uninsulated “dangerous voltage” within the
enclosed product which may be of sufficient magnitude to constitute a risk
of electric shock to persons.
The exclamation point inside a triangle is intended to alert the user to the
presence of important operating, maintenance and servicing instructions in
the literature which accompanies the product.
REPAIR BY ANY PERSON OR ENTITY OTHER THAN AN AUTHORIZED ION AUDIO SERVICE
CENTER WILL VOID THE ION AUDIO WARRANTY.
PROVISION OF THIS MANUAL DOES NOT AUTHORIZE THE RECIPIENT TO COMPETE WITH ANY
ION AUDIO DISTRIBUTOR OR AUTHORIZED REPAIR SERVICE CENTER IN THE PROVISION OF
REPAIR SERVICES OR TO BE OR MAKE REPAIRS AS AN AUTHORIZED SERVICE CENTER.
ALL REPAIRS DONE BY ANY ENTITY OTHER THAN AN AUTHORIZED ION AUDIO SERVICE
CENTER SHALL BE SOLELY THE RESPONSIBILITY OF THAT ENTITY, AND ION AUDIO SHALL HAVE
NO LIABILITY TO THAT ENTITY OR TO ANY OTHER PARTY FOR ANY REPAIRS BY THAT ENTITY.
Regarding the Power Supply Fuse
Caution: The product under service may employ the use of a
replaceable fuse. Danger of fire or electrocution if fuse is
incorrectly replaced. Replace with only the same type or
equivalent type recommended by the equipment manufacturer.
Regarding the Internal Battery
Caution: The product under service may employ the use of a
internal battery. Danger of explosion if battery is incorrectly
replaced. Replace only with the same or equivalent type
recommended by the manufacturer. Dispose of used batteries
according to the manufacturer’s instruction.

Confidential ION Audio Service Manual
Safety Instructions
Carefully read the applicable items of the operating instructions and these safety suggestions
before using this product. Use extra care to follow the warnings written on the product itself and in
the operating instructions. Keep the operating instructions and safety suggestions for reference in
the future.
1. Power Source. The product should only be connected to a power supply which is described
either in the operating instructions or in markings on the product.
2. Power Cord Protection. AC power supply cords should be placed such that no one is likely to
step on the cords and such that nothing will be placed on or against them.
3. Periods of Non-use. If the product is not used for any significant period of time, the product’s
AC power supply cord should be unplugged from the AC outlet.
4. Foreign Objects and Liquids. Take care not to allow liquids to spill or objects to fall into any
openings of the product.
5. Water or Moisture. The product should not be used near any water or in moisture.
6. Heat. Do not place the product near heat sources such as stoves, heat registers, radiators or
other heat producing equipment.
7. Ventilation. When installing the product, make sure that the product has adequate ventilation.
Improperly ventilating the product may cause overheating, which may damage the product.
8. Mounting. The product should only be used with a rack which the manufacturer recommends.
The combination of the product and rack should be moved carefully. Quick movements,
excessive force or uneven surfaces may overturn the combination which may damage the
product and rack combination.
9. Cleaning. The product should only be cleaned as the manufacturer recommends.
10. Service. The user should only attempt the limited service or upkeep specifically described in
the operating instructions for the user. For any other service required, the product should be
taken to an authorized service center as described in the operating instructions.
11. Damage to the Product. Qualified service personnel should service the unit in certain situations
including without limitation when:
a. Liquid has spilled or objects have fallen into the product,
b. The product is exposed to water or excessive moisture,
c. The AC power supply plug or cord is damaged,
d. The product shows an inappropriate change in performance or does not operate
normally, or
e. The enclosure of the product has been damaged.

Bill of Materials (BOM)
Part No. Part Name Spec Qty
10530036 Iron prop DN-MB6036 4
12030030 Rocker switch AN-S330,PS8A-2B1B2-1H-01,250VAC/10A 125VAC 1
16040046 cable AN-W446,1P,16#,UL1015,60mm 1
16040842 cable AN-W4402,2P,18#,UL1617 1
16041065 cable AN-W4626,2P,18#,UL1007,150mm 1
19020111 glass tube fuse 218,1A/250V,Φ5*20mm 1
20110149 lens DN-PL1117 1
20320036 handle DN-PE2035,ABS,80%,UL94V-0, MT11020,ROHS,V1.0 2
20360105 塑胶片 DN-PE6055, ABS,80%,UL94V-0, ROHS,V1.0 2
20410129 buttons DN-PEB084,ABS,80%, Pantone Cool Gray 6C,ROHS,V1.0 1
20460013 fixed button KY-CLT-2 1
30060494 foam EVA1030,bk,10*5*2mm, V1.0 8
30110004 gasket ring IPA76C, T=1mm,Φ3.5*Φ12mm,ROHS.V1.0 8
30150163 grill cloth 329*304*0.3mm,V1.0 1
40010038 power socket AN-J0138,DB-14-F,3P 1
60100020 wireless 2.4G,2DBi, bk, ROHS,L=30MM 1
70010046 whole teeth screw M3*6mm 4
70010048 whole teeth screw AN-C10048,M3*6mm 4
70010088 whole teeth screw Φ3*8mm 4
70010111 whole teeth screw Φ3*10mm 10
70010331 whole teeth screw Φ2.6*6mm 16
70010337 whole teeth screw Φ2.6*8mm 8
70010556 whole teeth screw Φ2.6*6mm 8
70010605 whole teeth screw Φ2.6*7mm 2
CR011091 IPA82 LED01 IPA82 LED01 ASSY 1
CR011093 IPA82 LED02 IPA82 LED02 ASSY 1
CR011101 NPK2 LED03 NPK2 LED03 ASSY 1
CR011119 NPK2 POWER&AMP NPK2 POWER&AMP ASSY 1
CR011161 NPK2 DSP MODULE NPK2 DSP MODULE ASSY 1
CR011176 IPK2 MAIN IPK2 MAIN ASSY 1
CR011177 IPK2 LCD IPK2 LCD ASSY 1
DR001881 IPK2 top housing
silkscreen ASSY
DN-PC2118,ABS,UL94V-0, cool grey 8C,V1.0 1
DR002328 IPK3 button
silkscreen ASSY
DN-PEB084,(1),ABS,80%, White C,V1.0 1
DR002329 IPK3 button
silkscreen ASSY
DN-PEB083,ABS,80%, White C,V1.0 1
DR002334 IPK3 button
silkscreen ASSY
DN-PEB084,(2),ABS,80%, White C,V1.0 1
DR002335 IPK3 button
silkscreen ASSY
DN-PEB084,(3),ABS,80%, White C,V1.0 1
DR002339 IPK3 button
silkscreen ASSY
DN-PEB084,(4),ABS,80%, White,V1.0 1
10410198 grill DN-ME5153,SPCC,T=1mm, Pantone 877C,V1.0 1
16040929 cable AN-W4489,2P,18#,UL1015,L=450mm 1
16141108 cable 1P,22#,UL1007,L=150mm, bk 1
16141109 cable 1P,22#,UL1007,L=150mm 1
16150041 3.5 cable AN-W1540,UL2547,26#,610mm 1

17050104 Non-polar electrolytic
capacitance
4.7UF/100V,±20%,-40/+85℃,Φ10*17 1
20300115 rubber feet TPU,80%, bk, hardness 70°, MT-11010, ROHS,V1.0 4
20310046 corner caps DN-PE1030,TPU,90%, Pantone Cool Gray 3C, hardness
90A,ROHS,V1.0 8
20660045 mound layer DN-PC6040,(1),ABS,80%, white, MT11020, V1.0 1
20660046 mound layer DN-PC6041,(2),ABS,80%, white, MT11020, V1.0 1
20660047 mound layer DN-PC6042,(3),ABS,80% , white, MT11020, V1.0 1
21010520 wooden case DN-X10218,MDF,T=9mm, CARB,V1.0 1
22011120 manual ION, safety manual, 7-51-1340-B 1
22011185 manual IPK2, english manual,V1.4 1
22050006 drying agent 50g,DMT,SGS 1
23010533 packing bag （290+390）*750*0.1mm 1
23010562 packing bag PE,120*280*0.06mm 1
23010563 packing bag PE,160*260*0.025mm 1
23020262 polystyrene foam IPA76C,EPS, 510*340*100mm,V1.0 2
23031465 carton IPK2,A=A,T=6mm,502*365*556mm 1
23070029 pearl sheet LGA8,500*350*2mm,V1.0 2
23100092 inner box 250g+CE,270*65*60mm.V1.0 2
30060079 foam 50*150*5mm 4
30060095 foam 10*1000*1mm,EVA1030 3
30060116 foam 4.5*2360*4.2mm,EVAE1030 1
30060423 foam EVA1030, bk, 288.5*6*1mm,T=1mm,V1.0 1
30060424 foam EVA1030, bk, (2),315*6*1mm, V1.0 2
30060489 foam EVA1030, bk, 5*300*2mm,V1.0 3
30090009 beam line 2.5*120mm, bk 6
30150164 double faced
adhesive tape
NPK2, (3M9495), V1.0 1
60190185 microphone AN-M19077,GD-201 1
70010151 whole teeth screw Φ3*15mm 4
70010236 whole teeth screw Φ4*16mm 4
70010678 whole teeth screw Φ3*13mm 4
70010855 whole teeth screw Φ4*25mm 4
70010925 whole teeth screw Φ3.5*15mm 29
80130047 8" woofer AN-LD41,4ohm,25W 1
80320005 3" tweeter AN-LX05,4ohm,10W 1
90021680 serial label IPK2, V1.3 5
90041718 barcode lable IPK2, V1.2 2
90060198 compliance label IPK2, V1.1 1
90080001 destinaltion lable GA0/GA1/GA2 3
90220078 special lable ALESIS,30*30mm, PANTONE 361C, V1.0 1
90220431 special label 40.5*6.5mm, V1.0 1
90250035 CARB label pantone802C,25.4*25.4mm, V1.7 1
90250046 CARB label ION, 78*23mm, V1.1 1
90270014 date label ION, 13*6mm, V1.2 1
DR001885 IPK2 lens silkscreen
ASSY
DN-PL1123, PC, cool grey 8C/White C,V1.0 1
DR001886 IPK2 Knob silkscreen
ASSY
DN-PN2132,ABS,80%, white, cool grey 6C,V1.0 2
16070013 power line AN-W915,3C,18#,SVT,1830mm,BK. UL 1
16070047 power line AN-W950,3C,0.75mm2,H05VV-F,1830mm, bk, UK 1
16070050 power line AN-W953,3G,0.75mm2,H05VV-F,1830mm, bk, EU 1
16070073 power line AN-W976,3C,0.75mm2,VCTF,1830mm, bk, Jap 1

16070080 power line AN-W982,3C,0.75mm2,H05VV-F,1830mm, bk, Austrial 1
22150003 service card ION, V1.2 1
23090679 giftbox 300+C3+C3,T=6mm,487*352*533mm, V1.0 1
23090749 giftbox 300+C3+C3,T=6mm,487*352*533mm, CA,V1.0 1
90041719 bar code label IPK2,6*50mm, UL, V1.1 1
90041738 bar code label IPK2, 76*50mm,CA,V1.0 1
90200056 mark label BLACK&361C Φ30mm, V1.0 1
90200071 mark label green circle label 1

FX MIC
Frequence sense(OSC1) AMP B PEAK Red
MIC FX & DSP POWER
1.0
DRAWN:
SCALE: SIZE: A3
TITLE:
DATED:APPROVED:CHECKED: DATED:DATED:
Jason Li
DWG NO: REV: SHEET: 1 OF 2
245
6
D
C
B
AA
B
C
D
+
FB
FB
FB
FB
FB

DSP & SDRAM I/O
1.0
DRAWN:
SCALE: SIZE: A3
TITLE:
DATED:APPROVED:CHECKED: DATED:DATED:
Jason Li
DWG NO: REV: SHEET: 2 OF 2
2345
6
D
C
B
A
A
B
C
D
+
+
FB
FB
FB
FB
FB
FB
FB
FB
FB
+
FB

NPK2 INPUT
1.1 SHEET: 1 OF 6
REV:DWG NO:
DRAWN: DATED: DATED:CHECKED: APPROVED: DATED:
TITLE:
SIZE: A3
SCALE:
Jason Li
AUX/CD/MP3
MIC 1
D
C
B
A
A
B
C
D
2345
6
MIC 2
MIC 6.35 INPUT PCB

NPK2 PRE
SHEET: 2 OF 6
REV:DWG NO:
DRAWN: DATED: DATED:CHECKED: APPROVED: DATED:
TITLE:
SCALE:
A
B
C
D
C
B
A
2345
6
D
1.0
SIZE: A3
Jason Li
+

NPK2 BT MODULE
1.0
DRAWN:
SCALE: SIZE: A3
TITLE:
DATED:APPROVED:
CHECKED: DATED:
DATED:
Jason Li
A
B
C
D
2345
6D
C
B
A
DWG NO: REV: SHEET: 3 OF 6
+
FB

TPA3112D AMP PCB
NPK2 AMP
1.1
DRAWN:
SCALE: SIZE: A3
TITLE:
DATED:APPROVED:CHECKED: DATED:DATED:
Jason Li
DWG NO: REV: SHEET: 4 OF 6
2345
6
D
C
B
AA
B
C
D
4 OHM
SD
SPEAKER OUT
FAULT
GND
GND
GAIN0
GAIN1
AVCC
AGND
GVDD
PLIMIT
INN
INP
NC
AVCC
PVCC
PVCC
PVCC
PVCC
BSN
OUTN
PGND
OUTN
BSN
BSP
OUTP
OUTP
PGND
BSP
+
+
+

NPK2 LCD & KEYPAD
1.0
DRAWN:
SCALE: SIZE: A3
TITLE:
DATED:APPROVED:CHECKED: DATED:DATED:
Jason Li
DWG NO: REV: SHEET: 5 OF 6
2345
6
D
C
B
A
A
B
C
D

NPK2 POWER
1.0
1
DRAWN:
SCALE: SIZE: A3
TITLE:
DATED:APPROVED:CHECKED: DATED:DATED:
Jason Li
A
DWG NO: REV: SHEET: 6 OF 6
2345
6
A
B
C
D
D
C
B
A
POWER INPUT
+16V
+
+
+
++
+
+
+
+
+
+
+
+
+
+
FB
FB
FB