SERVICE MANUAL

XTR-400

ACTIVE SPEAKER SYSTEM

SUBWOOFER / SATELLITES

CONTENTS:

Cautions, Connections, & Operations :.Page 2-4 Specifications:...Page 4 Parts Lists:...Page 5 PCBs:...Page 6-8 Schematics...Page 9 Gemini Sound Products Corp. 120 Clover Place P.O. Box 6928 Edison, NJ 08818-6928 732-738-9003 (Phone) 732-738-9006 (Fax)

INTRODUCTION:

Congratulations on your purchase of an XTR-400 speaker system engineered & manufactured by Gemini Sound Products. This state of the art speaker system is backed up by a three-year warranty. The XTR-400 offers ultimate fidelity, power handling, and an array of features that makes it a highly versatile, compact, self contained & powered speaker system.

OUTPUT SECTION:

Disconnect unit from the AC power source before making any connections. SPEAKER OUTPUTS (3): The speaker output connectors are Speakon connectors that will accept cables with Speakon connectors. (These cables must be purchased separately) The subwoofer is already connected internally, so you dont have to worry about connecting it to the amplifier.

FEATURES:

Active self-powered 400W rms tri-amp design. One 15-inch bandpass subwoofer. Features top-hat hardware for pole mounting of a satellite speaker and metal corner protectors. Two high quality satellite speakers featuring 10-inch woofers and dual piezo horns housed in trapezoidal cabinets. Satellite speakers are uniquely designed for placement on stands or for use as floor monitors, and protected by full front metal grill and metal corners. Built-in active optimized crossovers. Sensitivity/Volume controls. Satellites equipped with reliable Speakon connectors for exceptional sound. (cables must be purchased separately) Signal Ground Lift Switch for achieving the quietest possible hum-free operation. Airflow controlled by variable speed fan for maximum cooling and quietest possible operation. Mono or Stereo operation. AC line voltage selector switch allows reconfiguring amplifier for either 110-120V or 220240V AC lines. Compact design featuring large metal handles and casters for ease in transporting.

AC POWER SECTION:

POWER SWITCH (8): turns the unit on and off. POWER LED (9): the power LED lights when the power is on. FUSE (4): replace with proper type and rating. AC INLET (6) is used to attach the power cord to the unit. AC LINE VOLTAGE SELECTOR SWITCH (5) allows reconfiguring amplifier for either 110-120V or 220-240V AC lines.

OPERATION:

STEREO OPERATION:
The unit has two channels for stereo operation. Each channel provides a separate signal at the speaker outputs. The following instructions are for use with 8W speakers of matched power ratings. We suggest only using the speakers that come with the unit. 1. With the power OFF, connect your input cables from your music source (such as your mixer) to the Channel 1 and Channel 2 INPUTS using the XLR INPUT JACKS (1) or 1/4" PHONO INPUT JACKS (2). 2. Connect your speakers to the Channel 1 and Channel 2 SPEAKER OUTPUTS (3). 3. With the SENSITIVITY/VOLUME CONTROLS (10) of both channels set to zero (fully counter clockwise), turn the POWER SWITCH (8), ON. Okay, now try playing some music and/or talking into your microphone, and set the level of your input as high as you think youll need it. This way it will be as high above the amplifiers noise floor as possible so youll get the best possible sound with the least amount of noise. Now play some music and listen for audible distortion. If you do hear distortion decrease the output level using the SENSITIVITY/VOLUME CONTROLS (10).

CAUTIONS:

1. All operating instructions should be read before using this equipment. 2. To reduce the risk of electrical shock, do not open the unit. There are, NO USER REPLACEABLE PARTS INSIDE. Please refer servicing to a qualified Gemini Sound Products service technician.

In the USA: If you experience problems with this unit, please call 1 (732) 738-9003 for Gemini Customer Service. Do not attempt to return this equipment to your dealer.
3. Do not expose this unit to direct sunlight or to a heat source such as a radiator or stove. 4. This unit should be cleaned only with a damp cloth. Avoid solvents or other cleaning detergents. 5. When moving this equipment, it should be placed in its original carton and packaging. This will reduce the risk of damage during transit. 6. DO NOT EXPOSE THIS UNIT TO RAIN OR MOISTURE. 7. DO NOT USE ANY SPRAY CLEANER OR LUBRICANT ON ANY CONTROLS OR SWITCHES.

MONO OPERATION:

Connect your MONO signal to the Channel 1 input (1 or 2). Now create a link by connecting the remaining Channel 1 input to a Channel 2 input (1 or 2) using a standard balanced cable (may be purchased separately). You can adjust the level of each satellite speaker using its channels SENSITIVITY/VOLUME CONTROL (10).

CONNECTIONS:

INPUT SECTION:
There are two parallel input connectors (one female XLR and one 1/4 jack) per channel. Either can be used as an input or as a link to chain amplifiers. XLR INPUT JACKS: XLR INPUT JACKS (1) electronically balanced inputs accept a standard XLR male connector. Pin 1 = shield/ground, pin 2 = hot or positive (+) and pin 3 = cold or negative (-). 1/4" PHONO INPUT JACKS: 1/4" PHONO INPUT JACKS (2) accept a balanced as well as an unbalanced line. The unbalanced line uses a standard tip-sleeve connection. The tip is positive and the sleeve is negative/ground. The balanced line uses a tip-ring-sleeve connection. Tip = hot or positive (+), ring = cold or negative (-), and sleeve = shield/ground. SENSITIVITY/VOLUME CONTROLS: SENSITIVITY/VOLUME CONTROLS (10) control the input levels for each channel of the 2 satellite speakers. The volume level of the subwoofer is controlled automatically to match the volume levels of the satellite speakers. It will always maintain a perfect balance to give you incredible sound quality! SIGNAL GROUND LIFT SWITCH: SIGNAL GROUND LIFT SWITCH (7) is used to lift the balanced input connectors ground/shield from the amplifiers ground. When the signal ground lifted, the sound source disconnects from the amplifiers ground preventing ground loops which can generate hum and noise. See the Signal Ground Lift Switch Instructions for more detail.
USING THE SIGNAL GROUND LIFT SWITCH:
Depending on how your sound system is hooked up, sometimes applying the ground will create a quieter signal path. Sometimes lifting the ground can eliminate ground loops and that annoying hum to give you quieter and cleaner overall sound. 1. With the power amp ON, listen to the system in idle mode (no music or signal) with the ground ON. The SIGNAL GROUND LIFT SWITCH (7) will be in the left position. 2. Turn the power OFF before moving the SIGNAL GROUND LIFT SWITCH (7). Now lift the ground by moving the SIGNAL GROUND LIFT SWITCH (7) to the right. Turn the power back ON and listen to determine which position makes the overall sound quieter with the least amount of noise and hum.

CAUTION: DO NOT DISCONNECT THE AC GROUND ON THE POWER AMPLIFIER IN ANY WAY. THIS CAN BE VERY HAZARDOUS!!

SETUP:

There are various ways to set up this system:

SPECIFICATIONS:

Subwoofer XTR-400SUB: Amplifiers Output Power:..230 Wrms on subwoofer channel Frequency response:..32 Hz - 100 Hz Components:..15" woofer Features: Efficient band-pass cabinet design Large metal handles Metal protection corners Four 2" wheels Amplifier assembly on the back 35mm standmount cap on top Black carpet finish Rubber feet Dimensions:..WxDxH: 20"x31"x24.5" (508 x 788 x 622 mm) Weight:..96 lbs (44 kg) Satellites GT-1002s: Amplifiers Output Power:.2x85 Wrms on satellite channels Frequency response:..100 Hz 20 kHz Components:..10" woofer 6 dual piezo horn Features: Trapezoidal cabinet Full front protective metal grill Metal protection corners 35 mm standmount cup on the bottom Black carpet finish Rubber feet Neutrik Speakon connector Dimensions:..W x D x H 12.5" x 9" x 18" (318 x 229 x 458 mm) Weight:..18 lbs (8 kg) each Total System: Maximum SPL, continuous:..120 dB Sensitivity.. 1 Vrms Input Impedance..10 kOhm unbalanced/20 kOhm balanced Features: Balanced XLR and 1/4" Jack inputs Neutrik Speakons on Satellite Channels outputs Active electronic X-over (Fx=100 Hz) Variable speed fan Individual channel Sensitivity/Volume controls Signal Ground lift switch 110-120 VAC / 220-240 VAC switchable Total Weight:..132 lbs (60 kg) SPECIFICATIONS AND DESIGN ARE SUBJECT TO CHANGE WITHOUT NOTICE FOR PURPOSE OF IMPROVEMENT.

BASIC SETUP:

Okay, this is your basic setup, perfect for small parties and venues. The ideal location for your subwoofer is close to a wall or in a corner. This will give you the fullest bass response. Your 2 satellite speakers can be placed up on stands on each side (stands must be purchased separately).

TWO-SYSTEM SETUP:

This setup is perfect for larger venues. This setup requires 2 XTR-400 systems. This will give you a total of 800 watts rms! Place a subwoofer on each side to the left and right. Using the high-hat hardware and connecting pole (which can be purchased separately), place the pole in the high-hat socket on the subwoofer, and a satellite speaker on top of the pole. The 2 remaining satellite speakers may be used as either floor monitors, or placed on stands elsewhere in the room giving you a louder and fuller sound. Each speaker system in this setup must be used in MONO mode (see Mono section). Connect the system that is on the left side of the audience to the LEFT channel of your mixer, and the system that is on the right side of the audience to the RIGHT channel of your mixer.
ACTIVE SPEAKER SYSTEM SUBWOOFER/SATELLITES
The XTR-400 features a unique design for ease in transporting. The 2 satellite speakers conveniently fit into a special recessed section of the subwoofer and are securely fastened using a strap that attaches to the handles (included).

SHOULD YOU EXPERIENCE ANY DIFFICULTIES OR PROBLEMS, PLEASE CALL: 1 (732) 738-9003 FOR GEMINI CUSTOMER SERVICE.

PARTS LIST:

Item # Designators Description MAIN PCB: ZENER DIODE 1/2W 12V (RD12EB2) SILICON DIODE 1N4148 ZENER DIODE 1/2W 24V (RD24EB2) SILICON TRANSISTORS 2SC1815 SILICON TRANSISTOR 2SC4793 ELECTROLYTIC CAPACITORS 6800/50V BRIDGE RECTIFIER KBPC804W INTEGRATED CIRCUIT TDA7294V CROSSOVER PCB: ROTARY VR 10KA L:15MM LED (GREEN) 5
INTEGRATED CIRCUIT NJM4558DD (BA15218,M5218AP)

Part Number

ZD3, ZD2 D3, D1, D2 ZD1 Q1 Q2 C18, C13 REC1 U3, U2, U4, U1
079-012 079-003 079-020 076-003 076-100 050-198 086-019 074-189
VR1, VR2 LD1 IC1, IC3, IC2

071-228 080-086 074-163

SW1 IC1 X3, X2 XLR2, XLR1
INPUT PCB: SLIDE SWITCH SV70050
PHONE JACK 6.3TRS 1/4" BAL XLR XLF-3PH OUTPUT PCB: SPEAKON CONNECTORS NL4MP OTHER: AC CORD AC INLET DC FAN 24V TRANSFORMER SLIDE SWITCH POWER SWITCH FUSE VBS UTE 3.15A 250V FUSE VBS UTE 6.3A 250V
081-030 074-163 092-078 092-069

X1, X2

092-149
093-369 092-105 001-613 059-247 081-023 083-121 100-068 100-071
In the USA: If you should experience problems with this unit, please call 1 (732) 738-9003 for Gemini Customer Service. Do not attempt to return this equipment to your dealer.

INPUT PCB

SW1 C1 R5

R1 R2 X2

R6 C3 C2 C5 R8 IC1 R7 R4 R9 C4

OUTPUT PCB

R3 X3 XLR2

XTR400-4 XTR400-3

Page 6

MAIN PCB

TOP LAYER

X-OVER

L4 LD1 R7 R13 ZD2 R25 J6 C2 IC1 R5 R6 C12 R19 R20 X3 C3 C4 R8 R9 R2 R3 R4 R12 VR1 VR2 J1 C1 R10 R11 C7 C8 C6 C9 C5 R1 R15 R16

XTR400-2

XTR400-1

R13 R14 R19 C19

RED/BLK
R37 X10 C29 C27 C17 R11 J1 R15

R26 R30 R21

C16 C22 X12 L3 C21 J10
U1 C5 L1 X1 R1 R2 DRED C2 L2 J2

J5 C15 J8 R21 R16 C20

R31 R32

C9 R4 R9 R12 C10

R36 X11 BLK X2 R18

R22 R17 R23 R18 R24

R7 Q1 R5 ZD1 C3

R10 C11 C12

C14 X13 BLK

C31 R28 R22 X1

RED X7

C18 C26 ZD3 R29

R33 R34

X5 BLK

X6 BLK

C32 C30

RED X8

R14 J3 C13

X2 RED

BOTTOM LAYER

L4 LD1 R7 R13 ZD2 R25 J6 C2 IC1 R5 R6 C12 R19 R20 X3 C3 C4 R8 R9 R2 R3 R4 R12 VR1 VR2 J1 C1 R10 R11 C7 C8 C6 C9 C5 R1 R15 R16 C14 R19 C19 R37

15 RED/BLK XTR400-2

R13 R14

X10 C29 C27

C17 R11 C1
R15 U1 C5 C15 C9 R4 R9 R12 C10

J5 J8 R21 R16 C20

L1 X1 R1

X5 BLK 1

X2 RED RED

SCHEMATIC

X+ 12V X-OVER PCB 1 R11 22.1K 1% R9 13K 1% + 12V 8 SUB OUTPUT (+) 1 IC1A NJM4558DD 4 - 12V R10 39.2K 1% R12 60.4K 1% R18 10K 1% R14 10K 1% R15 13K 1% + 12V 1 IC2A NJM4558DD 4 R3 39.2K 1% R4 39.2K 1% 5 IC2B NJM4558DD R21 13K 1% R17 13K 1% R4 1K 1% 6 R22 13K 1% R2 13K 1% CH.2 (R) OUTPUT + 12V 8 C8.1uF 5% C5.1uF 5% 5 IC3B NJM4558DD SUB OUTPUT (-) R9 X3 X2 CH.2 (R) INPUT SUB INPUT (-) R17 5.1K R18 5.1K 5.1K C10 2200pF R12 13K 1% C9 22uF25V 1 IN IN + IN+MUTE MUTE STBY STBY-GND U2 TDA7294V +PWVs +Vs OUT BOOTSTRAP -Vs -PWVs C11 22uF50V R10 8R2 1W L2 1.0uH C14 0.1 SUBWOOFER OUTPUT (+) X1 RED C2 0.1uF100V +E R14 1K 1% 2 R8 5.1K C4 390pF R13 13K 1% C8 10uF25V 1 R15 5.1K R16 5.1K IN IN + IN+MUTE MUTE STBY STBY-GND +E U1 TDA7294V +PWVs +Vs OUT BOOTSTRAP -Vs -PWVs C15 0.1 C5 10uF50V R3 8R2 1W L1 1.0uH CH.1 (L) OUTPUT X2 RED C1 0.1uF100V 18AWG RED CH.1 (L) OUTPUT 4 X4 XCH.1 (L) INPUT 4 SUB INPUT (+) C6 10pF C7 10pF MAIN PCB C7 10uF25V NP 5 CH.1 (L) INPUT 4 C6 10uF25V NP VR2 10KA CH.1 (L) VOLUME CONTROL C4.047uF5% C3.047uF5% 2 3

R6 26.7K 1%

R11 26.7K 1%

3 CH.2 (R) INPUT 2 1

R8 39.2K 1%
OUTPUT PCB P1 RED X1 NL4MP 1+ 1OUTPUT 2+ 2CH.1 (L)

2 R13 60.4K 1% 3 4

1 IC3A NJM4558DD - 12V

R34 5.1K R23 5.1K

R1 39.2K 1%

C11 0.033uF5%

- 12V R7 39.2K 1%
C1 0.033uF5% R33 5.1K X1 + 12V C13 100uF16V - 12V C10 0.R16 2.4K LD1 GRN X+12V -12V R25 1K 1% D3 1N4148 R24 8.2K

C32 22uF25V

R22 5.1K

R20 5.1K

P3 RED/BLACK STRIP
X2 NL4MP 1+ 1OUTPUT CH.2 (R)

R20 22.1K 1%

R6 13K 1%

C30 10uF25V

R21 5.1K

C28 10pF

18AWG RED 45sm Twisted pair to Subwoofer terminal Ends striped 15mm

R19 5.1K

C27 10pF
2+ 218AWG RED/BLACK STRIP
R38 26.7K 1%K +E UR35 5.1K C24 2200pF R27 13K 1% C25 22uF25V 1 IN IN + IN+MUTE MUTE STBY STBY-GND TDA7294V +PWVs +Vs OUT BOOTSTRAP -Vs -PWVs C21 22uF50V R36 8R2 1W L3 1.0uH C16 0.1 SUBWOOFER OUTPUT (-) X11 BLACK C23 0.1uF100V

18AWG BLACK 45sm

R26 26.7K 1% +E UIN IN + IN+MUTE MUTE STBY STBY-GND TDA7294V +PWVs +Vs OUT BOOTSTRAP -Vs -PWVs C17 0.1 C19 10uF50V R37 8R2 1W L4 1.0uH C29 0.1uF100V CH.2 (R) OUTPUT X10 RED/BLACK STRIP

P2 BLACK

C2.047uF 5% VR1 10KA CH.2 (R) VOLUME CONTROL

C12.047uF 5%

IC1B NJM4558DD

C14 100uF16V

C9 0.1

R32 1K 1%

R19 39.2K 1% R5 39.2K 1%

R30 5.1K C22 390pF

R31 13K 1%

C20 10uF25V

POWER PCB CH.1 (L) INPUT INPUT PCB CCXLR2 XLF-3PH 2 R3 10K 1% T R S X3 TRS 1/4" BAL R4 10K 1% CIC1B NJM4558DD + 12V - 12V 1 R9 10K 1% 7 XX13 BLACK To CHASSIS X5 BLACK To SPEAKER OUTPUTS -E CH.2 (R) OUTPUT CH.1 (L) OUTPUT AC INLET BLK WHT X7 RED To POWER TRANSFORMER 1 N L E SW4 VOLTAGE SELECTOR 115v 230v FUSE 6.3A / 110-120V 3.15A / 220-240V F D1 1N4148 P3 X6 BLU BLACK To CENTER TAP POWER TRANSFORMER +E R29 1.2K 3W +12V P1 SW3 SW-POWER P2 BRN T1

2.4K R5 2.4K Q2 2SC4793

8.2K RQ1 2SC1815 X4 T D2 1N4148 ZD1 24V 0.5W C12 4.7uF50V C3 220uF25V FAN 24 Vdc FAN1 24Vdc/0.19A

R7 10K 1%

RED To POWER TRANSFORMER 2

RC1 0.047uF

REC1 KBPS10-02 4
C13 6800uF50V C18 6800uF50V

ZD3 12V 0.5W

C26 100uF16V
SW1 "Signal ground lift"

ZD2 12V 0.5W

C31 100uF16V
CR8 10K 1% 1 + 12V XLR1 XLF-3PH R6 10K 1% 8

R28 1.2K 3W -12V

3 T R S X2 TRS 1/4" BAL CH.2 (R) INPUT R1 10K 1% C2

1 IC1A NJM4558DD 4

18AWG BLACK

- 12V R2 10K 1%

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