JBL HTPS-400 User manual

JBL Incorporated
250 Crossways Park Dr.
Woodbury, New York 797
REV 1 10/2001
HTPS-400 THX®Subwoofer
SERVICE MANUAL

HTPS-400
CONTENTS
SPECIFICATIONS …….……………….…………….………………….3
DETAILED SPECIFICATIONS ……………………..…………………4
CONNECTIONS ………………………………………………..………6
OPERATION……………………………………..……..…..…….……..8
TROUBLESHOOTING…….…….………………….………………….9
AMPLIFIER BLOCK DIAGRAM…………..…………….……………10
PACKAGING …………………………….………………………….…11
EXPLODED VIEW ……………………………………….……………12
EXPLODED VIEW OF AMPLIFIER…………………….……………13
TEST SETUP and PROCEDURE……………….……..……………14
HTPS-400 ADJUST BIAS PROCEDURE…….…………..……………15
ELECTRICAL PARTS LIST (120v)……………….…….….…………16
INTEGRATED CIRCUIT DIAGRAMS ………………………………23
PRINTED CIRCUIT BOARD DIAGRAMS………………..…………24
SCHEMATICS……………….…..……….……………………………28

HTPS-400 SUBWOOFER
3
Specifications
Frequency Response: 28Hz - 200Hz
Input: THX®and normal line level
Output: Line level (loop through from input)
Sensitivity: 91dB
Maximum Amplifier Output: 1000 watts
Driver: 12" with aluminum cone and rubber
surround, video-shielded
Crossover Frequency: 50Hz - 150Hz (continuously
adjustable)
Dimensions (H x W x D): 14-5/8" x 14-5/8" x 14-5/8”
(371mm x 371mm x 371mm)
Weight: 62 lb (28kg)
THX is a registered trademark of Lucasfilm, Ltd.

HTPS-400 SUBWOOFER
4
Detailed Specifications

HTPS-400 SUBWOOFER
5
Detailed Specifications (Cont.)

HTPS-400 SUBWOOFER
6
Connections

HTPS-400 SUBWOOFER
7
Connections (Cont.)

HTPS-400 SUBWOOFER
8
Operation

HTPS-400 SUBWOOFER
9
Trou leshooting

Amplifier Block Diagram
HTPS-400 SUBWOOFER
0

HTPS-400 SUBWOOFER
Packaging

HTPS-400 SUBWOOFER
2
1
4
5
2
3
SCREW, (8)
#10-32X1"
61861
SCREW, (12)
#8X.75
PB,FPH
903601-012
00339
6
7
8
Exploded View
MECHANICAL PARTS LIST
1 AMPLIFIER (Not for Sale)
2 T-NUT (8) 61861
3 GRILLE CUP (4) 333249-001
4 12” WOOFER, 336063-001
SHIELDED, DCR=8.1 ohms ±10%
5 GRILLE ASSEMBLY, FRONT 336071-001
6 LOGO, GOLD, JBL 75060-01
7 WOOFER GASKET 335481-001
8 AMPLIFIER GASKET 336074-001

HTPS-400 SUBWOOFER
3
HTPS-400 Amplifier
6
4
5
4
3
2
7
1
9
00349
8
1 FEATURE BOARD
2 POTENTIOMETER, 50K DUAL, CROSSOVER RP0036
3 POTENTIOMETER, 10K SINGLE, GAIN RP0063
4 SWITCH, SPDT TOGGLE, EQ & PHASE SR0007
5 SWITCH, 3P TOGGLE, AUTO ON/OFF SR0013
6 DUAL RCA HORZ MT JACKS JC0106
7 POWER SUPPLY BOARD
8 LINEAR BOARD
9 EMI BOARD

HTPS-400 SUBWOOFER
4
Test Set Up and Procedure
General Function (UUT = Unit Under Test)
1. Connect a single (RCA) cable from the signal generator to the "line in" jack on the UUT.
GAIN control should be full counterclockwise.
Off/Auto/On switch should be OFF.
EQ switch should be on Normal.
Turn Crossover knob to full CW (150)
Position of phase switch is irrelevant.
2. Turn on generator, adjust to 200mV, 30 Hz.
3. Plug in UUT; red LED should be ON. Turn GAIN control full clockwise.
4. Bass response should be substantial, and woofer at near maximum excursion.
5. Turn off generator, turn VOLUME control fully counterclockwise, disconnect RCA cable.
Sweep Function
1. Follow steps 1-4 above, using a sweep generator as a signal source.
2. Sweep generator from 20Hz to 300Hz. Listen to the cabinet and drivers for any rattles, clicks,
buzzes or any other noises. If any unusual noises are heard, remove driver and test.
Driver Function
1. Remove driver from cabinet; detach + and - wire clips.
2. Check DC resistance of driver; it should be 8.1 ohms ±10%.
3. Connect a pair of speaker cables to driver terminals. Cables should be connected to an integrat-
ed amplifier fed by a signal generator and adjust so that speaker level output is 5.0V.
4. Sweep generator from 20Hz to 1kHz. Listen to driver for any rubbing, buzzing, or other unusual
noises.
SIGNAL
GENERATOR
AC VOLT
METER (6V)
HTPS-400
UNDER TEST
00367
00368

HTPS-400 ADJUST BIAS PROCEDURE
(Mandatory when any output MOSFET transistors Q305,310,320,321,306,307,311,312 are replaced)
1. Amplifier should be unplugged and OFF.
2. Remove Amp assembly from cabinet.
3. Identify the Linear board assembly (PCB with the output transistors)
4. Adjust RP301 and RP302 fully Counter Clockwise. See diagram below.
5. Apply 120 VAC power to unit.
6. Verify LED is ON.
7. Connect voltmeter set to DC millivolt range to twin pins on terminal J303, on Linear board.
8. Verify initial voltage is less then 0.1 mV.
9. Adjust RP301 Clockwise until voltmeter reads 0.3 mV + the initial current from step #8.
10. Adjust RP302 Clockwise until voltmeter now reads 0.6 mV + the initial current from step #8.
11. Turn amplifier OFF. Disconnect AC power to unit.
12. Remove voltmeter from terminal J303.
13. Replace amp assembly back into cabinet.

HTPS-400 SUBWOOFER
16
Electrical Parts List
Part Reference Quantity Description
No. Designator
PCB, INPUT FEATURE
Semiconductors
UA0003 U2,U3,U4 3 OPAMP, QUAD 14PIN DIL LM324N
UA0009 U1 1 OPAMP, QUAD 14P DIL TL074/084
DS0001 D1,D2,D3,D4,D5,D6,D7,D9, 16 RECT, 100mA 75V SIGNAL 1N4148T
D10,D11,D12, D13,D14,D15,
D16,D17
QB0017 Q2 1 TRANS, NPN 150V 0.6A 2N5551TR
QM0035-S Q1 1 JFET, J111 SELECTED TR ONLY
Capacitors
CC0025 C12 1 CAP, CA 1000PF 100V 10%
CC0059 C11,C18 2 CAP, CA .1UF 100V 20%
CC0072 C21,C22 2 CAP, CA 100PF 100V 10%
CC0098 C17 1 CAP, CA .047U 50V 20%
CC0003 C3 1 CAP, C 100PF 100V 5%
CE0098 C19 1 CAP, E 22UF 50V 20% 5X11 5MMLS
CE0103 C13 1 CAP, E 100UF 35V 85DEG 5MMLS
CE0116 C20 1 CAP, E 2.2UF 50V BP 6X11 5MMLS
CF0104 C2,C10 2 CAP, F 1UF 63V 5% 5MMLS
CF0118 C9 1 CAP, F .33UF 63V 10% 5MMLS
CF0119 C4 1 CAP, F .047UF 100V 5% 5MMLS
CF0125 C8 1 CAP, F .068UF 100V 5% 5MMLS
CF0128 C7 1 CAP, F .033UF 100V 5% 5MMLS
CF0144 C5 1 CAP, F .082UF 63DC 5% 5MMLS
Resistors
RP0036 RP2 1 POT, B50K DUAL 10%
RP0063 RP1 1 POT, A10K SINGLE/BRACKET
RC0136 R31 1 RES, CF 160K 1/4W 5%
RC0273 R7,R14,R22,R25,R40,R42 6 RES, ZERO OHM 1/4W
RC0285 R34 1 RES, CF 2M7 1/4W 5%
RM0001 R33 1 RES, MF 1K00 1/4W 1%
RM0002 R32, R44, R45, R47, R48, R49, 11 RES, MF 10K0 1/4W 1%
R50, R52, R55, R56, R60
RM0011 R30,R37,R38,R39,R53 5 RES, MF 100K 1/4W 1%
RM0012 R5 1 RES, MF 100R 1/4W 1%
RM0024 R58 1 RES, MF 2K21 1/4W 1%
RM0031 R28 1 RES, MF 3K32 1/4W 1%
RM0035 R10,R11,R12 3 RES, MF 4K75 1/4W 1%
RM0038 R27 1 RES, MF 56K2 1/4W 1%
RM0039 R2 1 RES, MF 5K11 1/4W 1%
RM0058 R35 1 RES, MF 110R 1/4W 1%
RM0075 R6 1 RES, MF 475R 1/4W 1%
RM0082 R23 1 RES, MF 1K21 1/4W 1%
RM0083 R59 1 RES, MF 1K50 1/4W 1%
RM0085 R26 1 RES, MF 2K00 1/4W 1%
RM0089 R54 1 RES, MF 2K43 1/4W 1%
RM0111 R3 1 RES, MF 17K8 1/4W 1%
RM0113 R8 1 RES, MF 20K0 1/4W 1%
RM0114 R19,R20,R36 3 RES, MF 22K1 1/4W 1%
RM0120 R51 1 RES, MF 30K1 1/4W 1%
RM0147 R17,R18 2 RES, MF 16K2 1/4W 1%
RM0256 R4 1 RES, MF 13K3 1/4W 1%
RM0260 R29,R57 2 RES, MF 1M0 1/4W 1%
RM0304 R9 1 RES, MF 7K87 1/4W 1%

HTPS-400 SUBWOOFER
17
Miscellaneous
JC0106 J1 1 CNCTR, DUAL RCA HORZ MT BLK/GD
JH0008 J3 1 CNCTR, HEADER 5PIN .100CTR
JH0074 J4 1 CNCTR, HEADER 8PIN LOCKING .1C
MM0025 WB1 1 MISC, PC MT SCREW TERM 6-32
SR0007 SW1,SW2 2 SWITCH, SPDT TOGGLE C/W CAP PC
SR0013 SW3 1 SWITCH, 3P TOGGLE C/W CAP
PCB, LINEAR/BUCK
Semiconductors
DS0001 D301, D302, D303, D304, D305, 24 RECT, 100mA 75V SIGNAL 1N4148T
D306, D307, D308, D309, D310,
D311, D312, D313, D314, D315,
D316, D317, D318, D319, D320,
D321, D323, D325, D330
DR0085 D324 1 RECT, 8A 400V TO220AC MUR860
QB0002 Q314,Q315,Q317 3 TRANS, NPN 40V .6A TO92 2N4401
QB0017 Q303,Q308,Q322,Q323 4 TRANS, NPN 150V 0.6A 2N5551TR
QB0018 Q302,Q304,Q309,Q313, 6 TRANS, PNP 150V 0.6A 2N5401TR
Q316,Q324
QB0033 Q319 1 TRANS, NPN 250V 1A TO220 TIP47
QM0015 Q305,Q310,Q320,Q321 4 MOSFET, IRF640 TO220AB
QM0032 Q306,Q307,Q311,Q312 4 MOSFET, IRF9640 T0220AB
QM0035-S Q301 1 JFET, J111 SELECTED TR ONLY
UV0007 U303 1 VREG, LINEAR TO220 LM7905CT
UV0013 U302 1 VREG, +5V 100MA TO220 LM7805CT
UA0003 U306 1 OPAMP, QUAD 14PIN DIL LM324N
UA0009 U301 1 OPAMP, QUAD 14P DIL TL074/084
UF0013 U304 1 FOTO, 6PIN MOC3012
UP0004 U307 1 PWM, 8PIN DIL UC3842N
DZ0002 Z303 1 ZENER, 500mW 12V 5% 1N5242B
DZ0021 Z301,Z302 2 ZENER, 500MW 15V 5% 1N5245B
DZ0034 Z304 1 ZENER, 500MW 10V 5% 1N5240B
DZ0018 U305 1 ZENER, 2.5-37V SHUNT TL431CLP
Capacitors
CC0020 C335,C366 2 CAP, CA 470PF 100V 5%
CC0040 C313,C324,C331 3 CAP, CA 4700PF 100V 10%
CC0059 C311,C312,C322,C323, 6 CAP, CA .1UF 100V 20%
C372,C373
CC0065 C337,C367 2 CAP, CA 2200P 100V 10%
CC0072 C341 1 CAP, CA 100PF 100V 10%
CC0082 C350,C351,C370,C371 4 CAP, CA .1UF 50V 20%
CC0087 C332,C338 2 CAP, CA .01UF 100V 20%
CC0108 C307,C317 2 CAP, CA 22PF 50V 10
CC0032 C358 1 CAP, C 2200PF 500V 10% .2LS TR
CC0095 C345,C347 2 CAP, C 470P 100V 5
CE0018 C329,C330 2 CAP, E 100UF 25V 20% 5MMLS
CE0098 C301,C309,C310,C319,C320 5 CAP, E 22UF 50V 20% 5X11 5MMLS
CE0103 C348 1 CAP, E 100UF 35V 85DEG 5MMLS
CE0106 C315 1 CAP, E 22UF 35V BP 8X11 5MMLS
CE0141 C326 1 CAP, E 47UF 35V BP 8X11 5MMLS
CF0008 C342 1 CAP, F 2200PF 100V 5% 5MMLS
Electrical Parts List
Part Reference Quantity Description
No. Designator

HTPS-400 SUBWOOFER
18
CF0035 C306,C316 2 CAP, F .022UF 100V 5% 5MMLS
CF0105 C302,C303 2 CAP, F .15UF 63V 5% 5MMLS
CC0017 C340 1 CAP, C 330PF 100V 10% 5MMLS BU
CC0021 C360,C362,C363 3 CAP, C 470PF 1KV 10% BULK
CC0078 C344 1 CAP, C .22UF 50V 10% .2LS BULK
CC0079 C343 1 CAP, C .1UF 50V 20% .2LS
CE0121 C355,C356 2 CAP, E 470UF 200V 20% 30X25
CF0146 C361 1 CAP, F 6.8UF 250V 10% 27MMLS
CC0059 C304 1 CAP, CA .1UF 100V 20%
CE0106 C305 1 CAP, E 22UF 35V BP 8X11 5MMLS
Resistors
RC0004 R399 1 RES, CF 1M0 1/4W 5%
RC0006 R349 1 RES, CF 10K 1/4W 5%
RC0061 R350 1 RES, CF 4K7 1/4W 5%
RC0083 R303 1 RES, CF 100K 1/4W 5%
RC0087 R323,R326,R327,R339, 6 RES, CF 330R 1/4W 5%
R340,R341
RC0116 R3107 1 RES, CF 330K 1/4W 5%
RC0127 R3106 1 RES, CF 30K 1/4W 5%
RC0128 R376 1 RES, CF 33K 1/4W 5%
RC0273 R313,R395,R3114 3 RES, ZERO OHM 1/4W
RM0001 R344,R370,R371,R372,R3101 5 RES, MF 1K00 1/4W 1%
RM0002 R377,R380 2 RES, MF 10K0 1/4W 1%
RM0003 R312,R329 2 RES, MF 15K0 1/4W 1%
RM0011 R352,R353,R354,R364, 6 RES, MF 100K 1/4W 1%
R3104,R3105
RM0024 R315,R317,R331,R333 4 RES, MF 2K21 1/4W 1%
RM0031 R320,R321,R336,R337,R369 5 RES, MF 3K32 1/4W 1%
RM0035 R3108 1 RES, MF 4K75 1/4W 1%
RM0037 R367 1 RES, MF 51K1 1/4W 1%
RM0039 R304 1 RES, MF 5K11 1/4W 1%
RM0043 R319,R322,R335,R338,R384 5 RES, MF 6K81 1/4W 1%
RM0065 R373 1 RES, MF 200R 1/4W 1%
RM0069 R390,R391 2 RES, MF 274R 1/4W 1%
RM0071 R389,R392 2 RES, MF 332R 1/4W 1%
RM0073 R324,R342 2 RES, MF 392R 1/4W 1%
RM0079 R3112,R3113 2 RES, MF 750R 1/4W 1%
RM0082 R368 1 RES, MF 1K21 1/4W 1%
RM0083 R345 1 RES, MF 1K50 1/4W 1%
RM0089 R382 1 RES, MF 2K43 1/4W 1%
RM0093 R306,R316,R318,R332,R334 5 RES, MF 4K53 1/4W 1%
RM0113 R308,R309,R375,R381 4 RES, MF 20K0 1/4W 1%
RM0114 R357,R361 2 RES, MF 22K1 1/4W 1%
RM0118 R351 1 RES, MF 210R 1/4W 1%
RM0120 R358,R362 2 RES, MF 30K1 1/4W 1%
RM0139 R314,R330 2 RES, MF 267K 1/4W 1%
RM0144 R363 1 RES, MF 47K5 1/4W 1%
RM0148 R302,R307 2 RES, MF 6K34 1/4W 1%
RM0180 R311,R328,R355,R356,R359,R379 6 RES, MF 4K99 1/4W 1%
RM0247 R360 1 RES, MF 38K3 1/4W 1%
RM0276 R365 1 RES, MF 294K 1/4W 1
RM0304 R305 1 RES, MF 7K87 1/4W 1%
RM0336 R385 1 RES, MF 47R 0.6W 1% FLAME ROOF
RM0339 R396,R397 2 RES, MF 10R 0.6W 1% FLAMEPROOF
RM0352 R3100 1 RES, MF 2K05 1/4W 1%
Electrical Parts List
Part Reference Quantity Description
No. Designator

HTPS-400 SUBWOOFER
19
RM0365 R386 1 RES, MF 100R 0.6W 1% FLAMEPROOF
RX0072 R3102 1 RES, MO 100R 1W 5%
RX0074 R325,R343 2 RES, MO 4K7 1W 5%
RX0097 R348 1 RES, MO 3K9 2W 5% PR01 SERIES
RC0005 R388 1 RES, CF 10K 1/2W 5%
RC0229 R3103 1 RES, CF 200K 1/2W 5% 1/4W BODY
RP0056 RP301,RP302 2 POT, 5K 8MM HOR TOP ADJ/COVER
RW0022 R346,R347,R393,R394 4 RES, WW 0R1 2W 5%
RC0006 R310 1 RES, CF 10K 1/4W 5%
Miscellaneous
480015 FO308/FO310 1 SUB, #18B 5 1/4 STRIP BOTH
480020 FO309/FO311 1 SUB, #18R 5 1/4 STRIP BOTH
480084 1 SUB, #18G 4 187X032/#6 RING J308
(CONNECTS TO HEARSINK VIA ONE
OF THE FOUR PCB SUPPORTS)
480090 FO301 1 SUB, #18R 9 187X032/1/4STRP
480097 FO302 1 SUB, #18B 9 187X032/1/4STRP
540130 L302 1 IND, CM CHOKE 150UH ELYTONE
BF0007 L301 1 BEAD, FERRITE
JH0008 J302 1 CNCTR, HEADER 5PIN .100CTR
JH0016 J303 1 CNCTR, HEADER 2PIN .100CTR
JH0074 J301 1 CNCTR, HEADER 8PIN LOCKING.1C
KS0017 TH302,TH303 2 THERMISTOR, 100K @ 25C NTC BUL
KS0019 TH301 1 THERMISTOR, PTH9L04BD22TS2F510
MT0003 FO303 1 TERM, FASTON MALE PCMT 250X032
MT0005 2 TERM, KWIKDISC .187 X.032 FEMA
USED ON 480097 AND 480090
MT0031 FO304 1 TERM, FASTON MALE PCMT 205X020
TS0019 12 TUBING, #5 CLEAR CUT TO 0.250 FOR
USE ON FET
PCB, PWR SUPPLY ISO 1000W
Semiconductors
DR0086 D403,D404,D406 3 RECT, 1A 600V ULTRAFAST MUR160
DS0002 D409,D410 2 RECT, 100MA 200V SIGNAL 1N3070
DR0084 D407,D408 2 RECT, 8A 600V ULTRAF MUR1660CT
QB0014 Q401 1 TRANS, PNP TO92 MPSA92TR
DD0003 Q402 1 RECT, 1A2 60V DIAC
QM0055 Q403,Q404,Q406,Q407 4 MOSFET, IRF740 TO220AB IR ONLY
DZ0021 Z401,Z402,Z403,Z404, 8 ZENER, 500MW 15V 5% 1N5245B
Z405,Z406,Z407, Z408
Capacitors
CC0040 C409 1 CAP, CA 4700PF 100V 10%
CC0087 C421 1 CAP, CA .01UF 100V 20%
CE0013 C415,C416,C418 3 CAP, E 47UF 50V 20% 5MMLS
CF0093 C406,C408,C412,C414 4 CAP, F 4700PF 100V 5% 5MMLS
CE0040 C401,C402,C403,C422,C423,C424 6 CAP, E 680UF 200V 25X35 85DEG
CF0020 C432 1 CAP, FY2 4700PF 250V 20%
CF0050 C426,C427,C430,C431 4 CAP, F .1UF 250V 10% 10MMLS
Electrical Parts List
Part Reference Quantity Description
No. Designator

HTPS-400 SUBWOOFER
20
Resistors
RC0082 R403 1 RES, CF 100K 1/2W 5%
RC0138 R422 1 RES, CF 200K 1/4W 5%
RM0001 R401 1 RES, MF 1K00 1/4W 1%
RM0012 R405 1 RES, MF 100R 1/4W 1%
RM0075 R406,R408,R409,R411,R413, 8 RES, MF 475R 1/4W 1%
R415,R416, R418
RM0198 R402 1 RES, MF 205K 1/4W 1%
RM0340 R407,R410,R414,R417,R419, 8 RES, MF 22R 0.6W 1% FLAMEPROOF
R420,R425,R426
RX0046 R421 1 RES, MO 47K 1W 5%
Miscellaneous
500113 T403,T404 2 XFMR, POWER 500W ETD44 CLASS F
JH0008 J401 1 CNCTR, HEADER 5PIN .100CTR
KS0021 TH401 1 SURGISTOR, 4R 8A 70J SL154R008
MT0023 FO401,FO402,FO403,FO404 4 TERM, FASTON MALE PCMT 187X032
TS0016 6 TUBING, #5 BLACK CUT TO .3 USED
ON D407,D408,Q403,Q404,Q406,Q407
PCB, AC FILTER w AUTO-OFF
Semiconductors
DR0038 D502,D503,D504,D505 4 RECT, 1A 400V GENERAL 1N4002
DS0001 D512 1 RECT, 100mA 75V SIGNAL 1N4148T
DB0006 D501 1 RECT, 8A 400V BRIDGE
QB0002 Q501 1 TRANS, NPN 40V .6A TO92 2N4401
UV0007 U502 1 VREG, LINEAR TO220 LM7905CT
UV0013 U501 1 VREG, +5V 100MA TO220 LM7805CT
DZ0029 Z502,Z503 2 ZENER, 500MW 5V1 5% 1N5231B
Resistors
RC0004 R501 1 RES, CF 1M0 1/4W 5%
RX0051 R502 1 RES, MO 680R 1W6 5%
RX0083 R503 1 RES, MO 150R 3W 5%
Capacitors
CE0003 C505,C506 2 CAP, E 2.2UF 50V 20% 105C
CE0103 C503,C504 2 CAP, E 100UF 35V 85DEG 5MMLS
CF0057 C501,C502 2 CAP, FX .22UF 250V 10%
Miscellaneous
480110 2 SUB, #16B 8 187X020/1/4 STRP 1 USED
FOR FO502 TO POWER BD PRI DC IN-;
1 USED BETWEEN FO503 AND FUSE
HOLDER
480111 1 SUB, #16R 8 187X032/1/4 STRP FO501
TO POWER BD PRI DC IN+;
500103 T501 1 XFMR, POWER 60HZ 24V FT3245
540124 L501 1 IND, CM CHOKE YT7271
JH0008 J502 1 CNCTR, HEADER 5PIN .100CTR
JH0016 D507 1 CNCTR, HEADER 2PIN .100CTR
KV0001 Z501 1 VARISTOR, 275V 100J .6W
MT0005 1 TERM, KWIKDISC .187 X.032 FEMA ON
ONE OF THE END OF 480111;
Electrical Parts List
Part Reference Quantity Description
No. Designator