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XM-7557
SERVICE MANUAL US Model
Ver 1.1 2004. 04 Canadian Model
AEP Model
UK Model
E Model
SPECIFICATIONS
STEREO POWER AMPLIFER
9-926-590-12 Sony Corporation
2004D02-1 e Vehicle Company
© 2004.04 Published by Sony Engineering Corporation
1
TABLE OF CONTENTS Notes on chip component replacement
· Never reuse a disconnected chip component.
1. SERVICE MODE ............................................................. 3 · Notice that the minus side of a tantalum capacitor may be
damaged by heat.
2. GENERAL .......................................................................... 4
3. DISASSEMBLY
3-1. Side Plate, Sub 1/Sub 2 and Filer Board ............................... 7
3-2. Amplifier/Power Board and LED Board .............................. 7
4. ELECTRICAL ADJUSTMENT .................................... 7
5. DIAGRAMS
5-1. Block Diagram Amplifier Section .................................. 8
5-2. Block Diagram Power Section ........................................ 9
5-3. Block Diagram Sub 1/Sub 2 Section ............................ 10
5-4. IC Block Diagrams ............................................................. 10
5-5. Printed Wiring Board Filter/Sub 1/Sub 2 Section .......... 11
5-6. Printed Wiring Board Amplifier Section ....................... 12
5-7. Schematic Diagram
Amplifier(1/3)/Filter/Sub 1/Sub 2 Section ..................... 13
5-8. Schematic Diagram/Printed Wiring Board
Amplifier (2/3)/LED/TR Section ................................... 14
5-9. Printed Wiring Board Power Section ............................. 15
5-10. Schematic Diagram
Power/Amplifier (3/3)/TR/LED Section ....................... 17
6. EXPLODED VIEWS
6-1. Plate and Cover Section ...................................................... 18
6-2. Board and Heat Sink ........................................................... 18
7. ELECTRICAL PARTS LIST ........................................ 19
2
SECTION 1
SERVICE NOTE
Clearing the Protector During Repairs
· OVER CURRENT : Detects overcurrent during output.
· OFF SET : Detects DC offset at the speaker terminal.
1. Clearing the OVER CURRENT protector
· When the position of the MODE switch (S801/power board)
is set to HI-CURRENT :
Cut the jumper wire JW230 of the amplifier board.
2. Clearing the OFF SET protector
· Cut the jumper wire JW307 of the amplifier board.
3. TEST TONE Function
1 Press the TEST TONE button (S710/SUB2 board) with the
power ON. The amplifier is normal if sound is produced from
the speaker.
2 If no sound
: Problem causer by incorrect connecttion of the power supply
system or sperker system.
: The signals input by the RCA cable before the amplifier system
are abnormal.
Adjustment Location
- SUB 2 BOARD - (Component side) - AMPLIFIER BOARD - (Component side)
S710
TEST
TONE
- POWER BOARD - (Component side)
JW307
JW230
S801
TP7 TP2
TP5 TP4 TP3
MODE
TP6 TP1
VR201 VR401 VR502
VR101 VR301 VR501
3
SECTION 2 This section is extracted from
GENERAL instruction manual.
4
5
6
SECTION 3 SECTION 4
DISASSEMBLY ELECTRICAL ADJUSTMENT
Note: Follow the disassembly procedure in the numerical order given.
IDLING CURRENT ADJUSTMENT
3-1. SIDE PLATE,SUB 1/SUB 2 AND FILTER BOARD 4 Bottom plate
· Perform adjustments in the HI-VOLTAGE mode.
1 Three screws
(BTP3x8) 1 Adjustment point
Semi-fixed resistors VR101, VR201, VR301, VR401, VR501,
2 Three screws
3 Two screws VR502 of amplifier board
(BTP3x8)
(BTP3x8)
2 Precautions on adjustments
!§ Filter board 1. Set the RCA input terminal to open.
2. Apply a voltage of 14.4V between the +12V terminal, REMOTE
! Screw (BTP3x8) terminal, and GND terminal.
5 Three screws 3. Rotate the above semi-fixed resistors completely in the counter-
!Ŗ Screw (BTP3x8)
(BTP3x8) clockwise direction while observing the component side.
@ŗ Sub 2 board
4. Check that the voltage at the adjustment point becomes 0 mV in
7 Side plate (L)
step 2.
5. Fine adjustments may be required according to the characteris-
@”Sub 1 board
tics of the MOS-FET used.
@§ Fan motor block · When adjusting the idling current
Rotating the semi-fixed resistor in the clockwise direction:
@¢ Screw (BTP3x8)
6 Screw (BTP3x8) Increases the idling current
Rotating the semi-fixed resistor in the counterclockwise direction:
@ TR board
Decreases the idling current
!¢ Auto fuse
0 Side plate (R) (F901 to F904) * Take note that rotating excessively in the clockwise direction
will increase the idling current suddenly.
!TM Screw (M4)
!£ Cover 3 Approximate adjustment values
Adjust as follows so that the following voltages become
!¶ CNP710 (10P) 1.2 to 0.3 mV around 0.7 mV .
8 Three screws
(BTP3x8) !· Screw (BTP3x12) FL channel :
9 Screw (BTP3x8) Voltage between TP7 and TP6: Use VR101 of the amplifier board
@£ CNP708 (2P)
@TM CNP803 (3P) FR channel :
!” Screw (M4) Voltage between TP7 and TP5: Use VR201 of the amplifier board
3-2. AMPLIFIER/POWER BOARD AND LED BOARD RL channel :
3 Six screws Voltage between TP7 and TP4: Use VR301 of the amplifier board
!” Six screws (BVTP3x14) RR channel :
(P3x10) Voltage between TP7 and TP3: Use VR401 of the amplifier board
2 Four screws
(P4x40)
SUBWOOFER Channels :
!£ Sub heat sink First, adjust so that the voltage between TP1 and TP2 becomes
(Amplifier) 4 Two Retainers 1.2 to 0.3 mV around 0.7 mV using VR501 of the amplifier
5 Two screws (BVTP3x10)
board.
0 Screw (BTP3x8) Next, adjust so that the voltage between TP1 and TP2 becomes
2.4 to 0.6 mV around 1.4 mV using VR502 of the amplifier Adjustment Location
board."
9 Four screws AMPLIFIER BOARD (Component side)
(P3x10) Connection :
8 Two screws 6 Power board
(P3x14)
!TM Three screws Digital voltmeter
(P3x6) 7 Amplifier board
!¢ Two insulating sheets
(AMP)
! Two screws
(P2x10)
TP7 JW307
!§ LED board TP1 JW230
!¶ LED holder (SUB WOOFER) TP6 (FL-CH)
TP5 (FR-CH)
TP4 (RL-CH) TP7 TP2
TP3 (RR-CH) TP5 TP4 TP3
TP2 (SUB WOOFER)
TP1 (SUB WOOFER) TP6 TP1
VR201 VR401 VR502
VR101 VR301 VR501
1 Five screws
(BTP3x12)
7 7
XM-7557
SECTION 5
DIAGRAMS
5-1. BLOCK DIAGRAM AMPLIFIER SECTION
LINE SWITCH DIRECT
Q102 SW703
ON OFF SPEAKER OUT
DIFFERENTIAL POWER AMP
LOWBOOST AMP (VOLTAGE STAGE) CN704
PRE AMP H.P.F H.P.F L.P.F L.P.F HPF CNJ702 LINE SWITCH Q104-105 Q108
IC701 Q103
CNJ701 IC703 LEVEL IC702 IC709 FILTER IC708 FILTER IC707 3 3 POWER AMP
FLAT
VR701 VR702 VR702 5 (FINAL STAGE)
2 2 7 BIAS
FL 5 7 6 7 5 7 6 7 6 7 6 Q111-112
LPF CNP702 VR101,Q110 L
MONO-L CNP702 CNJ702 FILTER B+
S702 DIFFERENTIAL POWER AMP
FR AMP MONO-L
(VOLTAGE STAGE) NFB ON OVERLOAD
LEVEL SHIFT Q106-107 Q109 Q113-114 R-CH
L-CH X10,X1 Q101
NFB OFF R
S701
FILTER B- LINE SWITCH
LOWBOOST RY701
Q302
VR703 DIRECT
INPUT
FILTER BOARD SW706
ON OFF DIFFERENTIAL POWER AMP
AMP (VOLTAGE STAGE) CN705
Q304-305 Q308
POWER AMP
LOWBOOST LINE SWITCH (FINAL STAGE)
PRE AMP H.P.F H.P.F L.P.F L.P.F HPF CNJ703 IC706 BIAS
Q303 Q311-312
IC704 LEVEL IC702 CNP703 IC710 FILTER IC711 FILTER IC712 3 3 VR301,Q310 L
FLAT
VR704 2 2 VR705 VR705 5
RL 7
5 7 6 7 5 7 6 7 6 7 6 DIFFERENTIAL POWER AMP
MONO-R LPF CNP703 MONO-R
AMP (VOLTAGE STAGE) NFB ON
CNJ703 FILTER Q306-307 Q309 OVERLOAD R-CH
RR B+
S705 Q313-314
NFB OFF R
LEVEL SHIFT
R-CH X10,X1 Q301 RY702
CNJ710 S704 FILTER
9
TO
SUB 1 7 LOWBOOST B- DIFFERENTIAL POWER AMP
BOARD AMP (VOLTAGE STAGE) CN707
VR708
CNB710 8 Q504-505 Q507
POWER AMP
6 (FINAL STAGE)
BIAS Q510-511
2 VR501,Q509 SUB WOOFER
3
5 B+ DIFFERENTIAL POWER AMP
B- AMP (VOLTAGE STAGE) NFB ON
4
Q505-506 Q508
CNP805 NFB OFF
CNP708 CNJ708 SPEAKER OUT
TO 8 B+ RY703(1/2)
POWER 2 FN801
BOARD M DC FAN MOTOR
CNB805 4 FAN CTL FAN DRIVER DIFFERENTIAL POWER AMP
Q702 Q701 AMP (VOLTAGE STAGE)
Q512-513 Q516
CNP803 CNB803 POWER AMP
(FINAL STAGE)
POWER D708 BIAS Q519-512
CONTROL T701 +42V VR502,Q518
POWER
DRIVE Q703 INVERTER +14V
Q704 Q705 D709 DIFFERENTIAL POWER AMP
AMP NFB ON
9 TR BOARD -14V
Q514-515
(VOLTAGE STAGE)
Q517 OVERLOAD
Q521-Q524
THERMAL D710 NFB OFF
3 DET INVERTER
1 TH701 Q706 -42V
RY703(2/2)
D711
10
6
OFFSET
7 SET
Q707-713
5
AMPLIFIER BOARD
09
· Signal path
: Audio
8 8
XM-7557
5-2. BLOCK DIAGRAM POWER SECTION
POWER BOARD MODE HI-C HI-V LED BOARD D803
OVER CURRENT
D804
OFFSET
D805
THERMAL
S801
CNB805 CNP804
OFFSET LED 4
7 OFFSET CONTROL SET
TO Q809-810 5 D801 D802
Q804 D806
AMPLIFIER
BOAD 6 HI-VOLTAGE HI-CURRENT
CNP805 8 OR
MUTE CONTROL MUTE SWITCH MUTE ENABLER 7
9 D808,Q811 Q812 IC813 3
4 1 1
3 2 D911
G G R G R G R G
MODE
2 S801 THERMAL SWITCH
HI-C HI-V TH905,Q919
OVER CURRENT
5 CONTROL
Q807-808
IC903
MODE DC DET 12 REF-REG
S801 OVER CURRENT D910 T902 D912 B+
2 DRIVER Q801 Q802 Q803
HI-V LED SWITCH 3 14 11 INVERTER CNB804 SWITCH SWITCH SWITCH
Q921 +28V B+
Q805 1 4 Q924,926,928
1 TO
6 NFB 10 SWITCHING
HI-C 2 AMPLIFIER
ON S802 OFF CONTROL
BOARD
Q922-923
10 INVERTER
15 DRIVER -28V
8 Q925,927,929
4 16 Q920 B-
THERMAL DETECTOR D913
D907 9
(For H,S) D908
TH903
THERMAL THERMAL THERMAL 3
OR CONTROL SWITCH LED SWITCH
THERMAL DETECTOR Q918 Q917 Q806
(For TRANS) DC-DC
TH904 CONVERTER
D909
IC904
3 OR
THERMAL SWITCH
TH902,Q906
THERMAL
DET
TH901
CN802 F903 (25A)
+12V D904 12 REF-REG
SWITCH T901 D905 B+
SUB-WOOFER 14 11 DRIVER
BATTERY Q901-902 Q908 INVERTER +28V
F904 (25A) Q911,913,915
D903 2 3 1 TO
GND F901 (25A) 10 SWITCHING
1 4 2 CONTROL AMPLIFIER
SWITCH CTL Q909-910 BOARD
4-CHANNEL Q903
BATTERY IC901
F902 (25A) 15
INVERTER -28V
+12V DC DET DRIVER Q912,914,916
8 B-
CNJ801 D901 16 Q907
SWITCH D906
REMOTE 9
Q904
3
SWITCH
Q905 DC-DC
CONVERTER
IC902
09
9 9
XM-7557
5-3. BLOCK DIAGRAM SUB 1/SUB 2 SECTION
THIS NOTE IS COMMON FOR PRINTED WIRING
BOARDS AND SCHEMATIC DIAGRAMS.
(In addition to this, the necessary note is printed
in each block.)
TO
CNJ711 CNJ709 CNP709 SUB 1 BOARD
1 1 1
SUB 1 For schematic diagrams.
BOARD 2 4 4 BOOST
S708 LOW CUT
Note:
(US/CND) 8 8 FREQ · All capacitors are in µF unless otherwise noted. pF: µµF
BOOST
IC714(2/2) BOOST LEVEL 50 WV or less are not indicated except for electrolytics
VR709 IC714(1/2)
9 9 5
(US/CND) and tantalums.
6
7 3
1 · All resistors are in and 1/4 W or less unless otherwise
2
FILTER BOOST LEVEL specified.
VR707 MODE · C : panel designation.