Composite

Video
or S-Video
Monitor
input
Audio Signal
Generator

Figure 2. 3•2•1 Console Test Setup Diagram

SPDIF converter
dB meter
Audio,
Optical converter SPDIF
Audio output
or Optical
input

23
IBM
compatible
+15V PC
Console DC power
test cable 3-2-1 Console
TAP cable
DC power
supply RF input
RF Signal
Generator
 Audio signal
generator

Bass
module Distortion
test cable meter

dB meter
Bass Module

AC mains cable

Figure 3. 3•2•1 Bass Module Test Setup Diagram

Driver 1 + terminal Driver 2 + terminal

Driver 1 - terminal Driver 2 - terminal

Figure 4. 3•2•1 and 3•2•1 GS Satellite Speaker Wiring Diagram

24
 TEST PROCEDURES
Console Procedures 2.2 Connect the output of the S/PDIF con-
verter to the VIDEO 1 coaxial digital input.
CAUTION: The DVD drive mechanism should
not be closed by pushing it shut with no power 2.3 Apply a 500 mV, 1 kHz signal to the
applied to the console. Doing so could damage analog input of the S/PDIF converter.
the drive. It must be closed with power applied
so that the locking mechanism inside the drive 2.4 On the console, select the VIDEO 1
will engage properly when the drawer is source.
closed.
2.5 Measure the output level at the line
Equipment required: outputs on the console rear panel. It should
be 300 mVrms + 10%.
Audio signal generator
Digital multimeter 2.6 Repeat steps 3.1 to 3.5 for the VIDEO 2
Analog to S/PDIF converter digital coaxial input.
S/PDIF to optical converter
AM/FM signal generator 2.7 Repeat steps 3.1 to 3.5 for the AUX
Video signal generator or DVD player digital coaxial input.
Abex test DVD (TDV-540A)
Video monitor 3. Optical Digital Audio Test
DC power supply or bass module w/cable
Composite Video cable 3.1 Connect the audio signal generator to
S-Video cable the input of the analog to S/PDIF converter.
Optical cable
3.2 Connect the output of the S/PDIF con-
Test Setup verter to the input of the S/PDIF to optical
converter.
Set up the unit under test as shown in
Figure 2 for the following tests. 3.3 Connect the output of the optical con-
verter to the VIDEO 1 optical input.
1. Analog Audio Test
3.4 Apply a 250 mV, 1 kHz signal to the
1.1 Apply a 1 Vrms, 1 kHz signal to the left analog input of the S/PDIF converter.
and right VIDEO 1 audio analog inputs.
3.5 On the console, select the VIDEO 1
1.2 On the console, select the VIDEO 1 source.
input.
3.6 Measure the output level at the line
1.3 Measure the output level at the audio outputs on the console rear panel. It should
outputs on the console rear panel. It should be 150 mVrms + 10%.
be 470 mVrms + 10%.
4. Video Tests
1.4 Repeat steps 1.1 to 1.3 for the VIDEO 2
and AUX audio analog inputs. 4.1 Connect the video generator or DVD
player to the COMPOSITE VIDEO INPUT
2. Coaxial Digital Audio Test only.

2.1 Connect the audio signal generator to 4.2 Connect the video monitor to the COM-
the input of the analog to S/PDIF converter. POSITE VIDEO OUTPUT.

25
 TEST PROCEDURES
4.3 Set the video generator to display a test 6.3 On the 3-2-1 system remote control,
pattern. If using a DVD player, load a DVD press the CD/DVD button to start playback
disc into the tray and start playback. of the DVD disc.

4.4 On the console, select the VIDEO 1 6.4 Verify that the audio plays.
source.
7. CD Playability Tests
4.5 Confirm that the test pattern or DVD
video appears on the video monitor and that Test discs required:
there are no obvious video problems. ABEX TCD-714R
ABEX TCD-721R
4.6 Connect the video generator or DVD ABEX TCD-725R
player to the S-VIDEO input only. ABEX TCD-732R
Philips TS4
4.7 Connect the video monitor to the
S-VIDEO output. 7.1 Insert the ABEX TCD-725R test disc
into the console CD/DVD tray.
4.8 Set the video generator to display a test • Play the defect tracking (interruption)
pattern. If using a DVD player, load a DVD track. Verify that the track plays properly.
disc into the tray and start playback. The nominal is a 1.0 mm defect, 0.8 mm
limit.
4.9 On the console, select the VIDEO 1 • Play the defect tracking (black dot) track.
source. Verify that the track plays properly. The
nominal is a 1.0 mm defect, 0.8 mm limit.
4.10 Confirm that the test pattern or DVD • Play the defect tracking (fingerprint)
video appears on the video monitor and that track. Verfiy that the track plays properly.
there are no obvious video problems. The nominal is a 75 um defect, 65 um
limit.
5. Internal DVD Video Test
7.2 Insert the ABEX TCD-721R test disc
5.1 Load the test DVD into the console. into the console CD/DVD tray. Play the
defect tracking (scratch) track. Verify that
5.2 Connect the video monitor to the the disc plays properly. The nominal is a
S-VIDEO output of the console. 1.6 mm defect, 1.0 mm limit.

5.3 On the 3-2-1 system remote control, 7.3 Insert the ABEX TCD-714R test disc
press the CD/DVD button to start playback into the console CD/DVD tray. Play the
of the DVD disc. defect tracking (eccentric disc) track. Verify
that the disc plays properly. The nominal is a
5.4 Confirm that the test pattern or DVD 280 um defect, 210 um limit.
video appears on the video monitor and that
there are no obvious video problems. 7.4 Insert the ABEX TCD-732R test disc
into the console CD/DVD tray. Play the
6. DVD Audio Test defect tracking (warped disc) track. Verify
that the disc plays properly. The nominal is a
6.1 Load the test DVD into the console. 1.0 mm defect, 0.7 mm limit.

6.2 If necessary, connect the satellite arrays

to the 9-pin D-sub connector.

26
 TEST PROCEDURES
7.5 Insert the Philips TS4 test disc into the
console CD/DVD tray. Play tracks 1 through
15, verifying that each track cues up within
the test limits. Nominal is 2 seconds or less,
limit 3 seconds.

8. Laser Current Measurement Procedure

Note: The 3-2-1 system console CD/DVD

drive uses a separate laser for each medium.
You will need to perform these tests using a
CD disc to measure the CD laser current
and a DVD disc to measure the DVD laser
current.

8.1 Remove the console top cover and DVD

mechanism using Disassembly/Assembly
Figure 5. Laser Voltage Test Points
procedure 3.

8.2 Remove the bottom cover of the CD/

DVD mechanism to allow access to the
board.

8.3 Connect the DVD drive to the console

using the ATAPI and DVD power extender
cables.

8.4 Insert a CD disc into the mechanism tray.

Press the PLAY button on the console.

8.5 Measure and record the voltage at the

point 5V and L5V. Be sure to use the GND
pad near the 5V and L5V points.
See Figure 5.

8.6 Subtract L5V from 5V (5V-L5V) and

record the laser voltage (LmV). LmV/1 Ohm
Figure 6. Laser Current Rating Label
equals laser current (LC).

8.7 The measured laser current value should

be + 20% of the printed current rating on the
pickup head (PU). See Figure 6. If the value
is out of range, and the lens has been
cleaned, replace the DVD drive.

8.8 Repeat steps 8.4 to 8.7 for the DVD

laser assembly.

27
 TEST PROCEDURES
3-2-1 Console Tuner Adjustments/ 10.3 Tune the console to 1500 kHz or 1503
Measurements kHz (as appropriate) and adjust the red slug
(T2004) for maximum audio level at the left
The following tests can be performed without or right audio output. Verify that the level is
the use of an IBM compatible PC. greater than 40 mVrms.

AM Adjustments 10.4 Change the RF frequency to 600 kHz

(US, Dual) or 603 kHz (Euro, UK, AUS and
For all AM alignments and tests plug the AM Japan) and re-tune the console to 600 kHz
antenna, part number 199824-002, into the or 603 kHz (as appropriate).
console and position it 2 feet away from the
unit. Configure the AM antenna, a standard 10.5 Adjust the black slug (T2004) for maxi-
test loop and RF generator as shown below mum level. Verify that the level is greater
to create the specified field strength for each than 40 mVrms.
test. The equivalent field intensity in dBuV/m
is 20 dB less than the generator output level 10.6 Repeat steps 10.2 to 10.5 until maxi-
in dBuV EMF at the receiving antenna. mum audio output is obtained without the
The signal levels given do not include this need for further adjustment.
factor.
11. AM Sensitivity

11.1 Inject a 1080 kHz RF signal at a level

of 74 dBuV emf, 30% modulation, 400 Hz
modulation frequency.

11.2 Tune the console to 1080 kHz.

11.3 Connect a dB meter to the audio output

jacks and reference it (set to 0 dB) to the
current audio output.

11.4 Remove the AM modulation and mea-

sure the audio output jacks. The reading
should be less than -20 dB.

FM Adjustments

Figure 7. AM Loop Antenna Test Setup Note: Unless otherwise noted, set the RF
generator for 1 kHz, mono modulation, pilot
10. AM RF Tracking off and 75 kHz deviation. Power levels for
FM testing are given in dBf at the antenna
10.1 Connect an AC meter to the AUX OUT input to the unit.
jacks.
Typically a test setup will consist of an RF
10.2 Inject a 1500 kHz (US, Dual Voltage) or generator with a 50 Ohm output impedance
1503 kHz (Euro, UK, AUS and Japan) RF and a 50 Ohm to 75 Ohm impedance match-
signal at a level of 90 dBuV emf, 30% modu- ing element. The two most commonly used
lation, 1 kHz modulation frequency. impedance matching element are a resistive
network which has a 5.7 dB insertion loss or
a “lossless” transformer which has a
0.5 dB insertion loss.
28
 TEST PROCEDURES
To find the required setting in dBuV emf from 14. FM Stereo Separation
a given dBf value for an RF generator with a
50 Ohm output impedance use the conver- 14.1 Inject a 98.1 MHz (83.0 MHz Japan
sions in the following table. units) RF signal set to 1 kHz left only modu-
lation with 10% pilot modulation and 75 kHz
Using a Subtract 1.3 dB. eg: total deviation at a level 65 dBf into J2000.
“lossless” 65dBf => set generator
transformer to 66.8 dBuV emf 14.2 Reference a dB meter to the level at
Using a resistive Subtract 6.5 dB eg: the left audio output jack.
network 65dBf => set generator
(5.7dB loss) to 71.5 dBuV emf 14.3 Switch the RF signal modulation to
right only channel.
Note: For generators with RF level resolution
of only 1 dB round up. 14.4 Measure the level at the left audio
output jack. It should read -25 dB or less.
Note: For the following FM tests, you will
need an antenna adapter cable, part number Computer Assisted Tuner Test Procedures
261412, to go from an F connector to the
3.5mm connector used on the 3-2-1 console. Additional Equipment Required:

12. FM Distortion Measurement/Adjustment - IBM Compatible PC

- Model 3-2-1 TAP cable, p/n 266603
12.1 Inject a 98.1 MHz (83.0 MHz Japan - B+B Electronics RS-232 to TTL level
units), RF signal at a level of 65 dBf into shifter, model 232LPTTL
J2000.
Note: Refer to the computer set up instruc-
12.2 Tune the console to 98.1 MHz tions in the appendix for proper connection
(83.0 MHz Japan units). to an IBM compatible computer.

12.3 Measure the distortion plus noise Refer to Figure 4, AM antenna setup dia-
(THD+N) at the audio output jacks. If it is gram, to achieve the proper field strength
less than or equal to 0.50%, verify that the for the given RF generator setting.
audio level is greater than 190 mV. If these
are not the measurements you have, pro- Some of the commands will automatically
ceed to step 12.4. set the calibration, requiring only an external
RF signal at the input of the tuner. Other
12.4 If the THD+N is greater than 0.55%, or commands require the technician to make
the audio level is less than 190 mV, adjust measurements and adjustments.
T2001 for minimum distortion. Verify that the
level is greater than 190 mV and the distor- Before commencing with the tuner measure-
tion is less than 0.55%. ments/alignments enter the command LXOF
to disable communication between the
13. FM Sensitivity display microprocessor and the system
microprocessor. You should receive an ACK
13.1 Inject a 98.1 MHz (83 MHz for Japan (acknowledge) response on the computer’s
units) RF signal at a level of 19 dBf into screen. If not then re-try until successful. To
J2000. re-enable communication enter LXON.
Note: The console's display will not change
13.2 Measure the THD+N at the audio output to reflect the mode changes during tests.
jacks. It should be less than or equal to
3.0%.
29
 TEST PROCEDURES
AM Adjustments 15.8 Using a non-metallic tuning tool, adjust
the black slug of T2004 for maximum output
Enter the command TUAM to switch source at the audio output jacks. Verify that the level
to AM. is greater than 40 mVrms.

15. AM Alignment 15.9 Repeat steps 15.1 through 15.8 until

the audio level is at a maximum without
15.1 Inject an 1500 kHz (US, Dual Voltage) adjustment.
or 1503 kHz (Euro, UK, Aus and Japan) RF
signal at a level of 90 dBuV emf, 30% modu- 16. AM Stop Level
lation at 1 kHz.
16.1 Inject a 1080 kHz RF signal at a level
15.2 Enter the command TUSF15000 or of 78 dBuV emf, 30% modulation at 1 kHz.
TUSF15030 (as appropriate) into the com-
puter. This will tune the unit to 1500 kHz or 16.2 Enter the command TUSF10800 into
1503 kHz. the computer. This will tune the unit to
1080 kHz.
15.3 You should receive the response
“ACK>” (acknowledge) on the computer’s 16.3 You should receive an “ACK>”
screen. response on the computer screen.

Note: If you receive an error response on 16.4 Enter the command TUAR. The unit will
the computer screen, enter the TUAM com- then sample the AM S-meter level, and store
mand to ensure the correct mode is selected it in the EEPROM as the stop level and
and re-enter the command in 15.2. return an “ACK>” response.

To verify the AM tuning frequency enter the 16.5 Enter the command TURA to see the
TUGF command to get the presently tuned stored level; the response on the computer
frequency. The response on the computer should be as follows: XX (where XX is the
screen should be "1500" or “1503“ followed stored level in hexadecimal form). Enter the
by an “ACK>” EECS command to write the new level
setting to the EEPROM before removing
15.4 Using a non-metallic tuning tool, adjust power.
the red slug of T2004 for maximum output at
the audio output jacks. Verify that the level is The current AM S-meter voltage level =
greater than 40 mVrms. 5 x (stored level in decimal) / 256. Refer to
the hex to decimal to voltage tables in the
15.5 Inject a 600 kHz (US, Dual Voltage) or appendix.
603 kHz (Euro, UK, Aus and Japan) RF
signal at a level of 90 dBuV emf. FM Tuner Tests

15.6 Enter the command TUSF06000 or For all FM measurements and adjustments,
TUSF06030 (as appropriate) into the com- the RF signal is to be connected from the
puter. This will tune the unit to 600 kHz or signal generator to J2000 via a 50 to 75
603 kHz. Ohm impedance matching network.
The input levels are to be as read at the
15.7 You should receive an ACK response input of J2000.
on the computer screen.

30
 TEST PROCEDURES
FM Adjustments 18. FM Distortion Measurement/
Adjustment
Enter the command TUFM to switch source
to FM. 18.1 Inject a 98.1 MHz (83.0 MHz Japan
units), 1 kHz mono modulation, pilot OFF,
17. FM IF Centering Adjustment 75 kHz deviation RF signal at a level of
65 dBf into J2000.
17.1 Inject a 98.1 MHz (83.0 MHz Japan
units), 1 kHz mono modulation, pilot OFF, 75 18.2 Enter the command TUSF09810
kHz deviation RF signal at a level of 50 dBf (TUSF08300 Japan units) into the computer.
into J2000. This will tune the unit to the appropriate
frequency.
17.2 Enter the command TUSF09810
(TUSF08300 Japan units) into the computer. 18.3 Measure the distortion plus noise
This will tune the unit to the appropriate (THD+N) at the audio output jacks. If it is
frequency. less than or equal to 0.50%, verify that the
audio level is greater than 190 mV. If these
17.3 You should receive an ACK response are not the measurements you have, pro-
on the computer screen. ceed to step 18.4.
Note: If you receive an error response on
the computer screen, enter the TUFM com- 18.4 If the THD+N is greater than 0.55%, or
mand to ensure the correct mode is selected the audio level is less than 190 mV, adjust
and re-enter the command in 17.2. T2001 for minimum distortion. Verify that the
level is greater than 190 mV and the distor-
To verify the FM tuning frequency enter the tion is less than 0.55%.
TUGF command to get the presently tuned
frequency. The response on the computer 19. FM Sensitivity
screen should be “98.1” ("83.0" Japan units).
19.1 Inject a 98.1 MHz (83.0 MHz Japan
17.4 Enter the command TUIF into the units), 1 kHz mono modulation, pilot OFF,
computer. The unit will then go through an 75 kHz deviation RF signal at a level of
algorithm that determines the optimum offset 19 dBf into J2000.
for the local oscillator (L.O.) setting to ac-
count for filter variances in the IF strip. This 19.2 Measure the THD+N at the audio
offset is then stored in the EEPROM. output jacks. It should be less than or equal
to 3.0%.
17.5 Enter the command TUGI to see the
stored offset; the response on the computer 20. FM Stereo Separation
should be as follows: “TUGI X >” followed
by an “ACK>” (where X is the stored offset). 20.1 Inject a 98.1 MHz (US, Dual, Euro, UK
The actual frequency offset of the L.O. is and Aus) or 83.0 MHz (Japan) RF signal set
this offset multiplied by 25 kHz. Valid offsets to 1 kHz left only modulation with 10% pilot
are –1, 0 or 1. Enter the EECS command to modulation and 75 kHz total deviation at a
write the new level setting to the EEPROM level 65 dBf into J2000.
before removing power.
20.2 Enter the command TUSF09810
(TUSF08300 Japan units) into the computer.
This will tune the unit to the appropriate
frequency.

31
 TEST PROCEDURES
20.3 Reference a dB meter to the left audio Note: You can enter the command TURF to
output jack. see the stored level; the response on the
computer should be as follows: XX (where
20.4 Switch the RF signal modulation to right XX is the stored level in hexadecimal form).
only channel. Enter the EECS command to write the new
level setting to the EEPROM before remov-
20.5 Measure the left audio output jack. ing power.
It should read -25 dB or less.
The current FM S-meter voltage level =
21. FM Stop Level 5 x (stored level in decimal) / 256. Refer to
the hex to decimal to voltage tables in the
21.1 Inject a 98.1 MHz (83.0 MHz Japan appendix.
units), 1 kHz mono modulation, pilot OFF,
75 kHz deviation RF signal at a level of 22. FM Stereo & Force Mono Threshold
30 dBf into J2000.
22.1 Inject a 98.1MHz (83.0 MHz Japan
21.2 Enter the command TUSF09810 units) RF signal set to 1kHz stereo L=-R
(TUSF08300 Japan units) into the computer. modulation with 10% pilot modulation and
This will tune the unit to the appropriate 75 kHz total deviation at a level of 42 dBf
frequency. into J2000.

21.3 You should receive an ACK response 22.2 Enter the command TUSF09810
on the computer screen. (TUSF08300 Japan units) into the computer.
This will tune the unit to the appropriate
21.4 Enter the command TUFR. The unit will frequency.
then sample the FM S-meter level, and store
it in the EEPROM as the stop level. 22.3 Enter the command TUSR. The unit will
then sample the FM S-meter level, and store
21.5 Set the RF generator for 98.9 MHz (US, it in the EEPROM as the stereo level.
Dual Voltage), 98.3 MHz (Euro, UK, Aus) or
83.0 MHz (Japan), 1 kHz mono modulation, 22.4 Enter the command TURS to see the
pilot OFF, 75 kHz deviation RF signal at a stored level; the response on the computer
level of 35 dBf into J2000. should be as follows: XX (where XX is the
stored level in hexadecimal form).
21.6 On the console, press the SEEK UP
button. Verify that the unit stops at 98.9 MHz, 22.5 Reduce the RF signal level by 2dB.
98.3 MHz or 83.0 MHz as appropriate.
22.6 Enter the command TUSM. The unit will
21.7 Set the console for 98.1 MHz (US, then sample the FM S-meter level, and store
Dual), 98.3 MHz (Euro, UK, Aus) or 83.0 it in the EEPROM as the force-mono level.
MHz (Japan).
Enter the command TUMS to see the stored
21.8 Set the RF generator for 98.9 MHz level; the response on the computer should
(US, Dual, Euro, UK and Aus) or 83.3 MHz be as follows: XX (where XX is the stored
(Japan), 1 kHz mono modulation, pilot OFF, level in hexadecimal form).
75 kHz deviation RF signal at a level of 25
dBf into J2000. FM S-meter voltage levels for each of these
settings can be calculated as per the stops
21.9 On the console, press the SEEK UP level.
button. Verify that the unit does not stop.

32
 TEST PROCEDURES
22.7 Inject a 98.1MHz (US, Dual, Euro, UK Bass Module Procedures
and Aus) or 83.0 MHz (Japan) RF signal set
to 1kHz stereo L=-R modulation with 10% Equipment required:
pilot modulation and 75 kHz total deviation at
a level of 45 dBf into J2000. • Audio signal generator
• dB Meter
22.8 Enter the command TUSF09810 • Distortion meter
(TUSF08300 Japan units) into the computer. • Digital multimeter
This will tune the unit to the appropriate • 2 Ohm, 50 Watt load resistor
frequency. • Bass module test cable (see instructions
in the appendix)
22.9 Verify that the audio output level is
> 400 mVrms. On the console display, verify Test Setup
that the STEREO LED is lit. Refer to Figure 11 for the following tests.

22.10 Decrease the RF generator level to a 1. Unpowered Transformer Impedance Test

level of 35 dBf into J2000.
1.1 On the bass module, set the AC mains
22.11 Enter the command TUSF09810 switch to the ON position (if applicable). For
(TUSF08300 Japan units) into the computer. the International variation, set the voltage
This will tune the unit to the appropriate select switch to 115V.
frequency.
1.2 Using a DMM, measure the DC resis-
22.12 Verify that the audio output level is tance of the transformer at the locations
< 10 mVrms. On the console display, verify shown in the table below.
that the STEREO LED is not lit.
Trans- Measurement Reading in
former location Ohms
Enter the EECS command to write the new
US/Canada J3 pins 1 to 2 3.14 – 4.25
level setting to the EEPROM before remov-
Euro, UK, J4 pins 1 to 2 8.3 – 11.3
ing power.
Aus
J5 pins 1 to 2 .121 – .164
23. FM Signal to Noise Ratio
J5 pins 4 to 5 446 – 493k
23.1 Set the RF signal generator to 98.1 Japan J4 pins 1 to 2 2.9 – 4.0
MHz (83.0 MHz Japan units), 1 kHz modula- J5 pins 1 to 2 .121 – .164
tion, pilot off, 75 kHz deviation and at the J5 pins 4 to 5 446 – 493k
level that corresponds to 65 dBf into J2000. Dual Voltage J2 pins 1 to 2 8.3 – 11.3
(S2 to 230V)
23.2 Measure the output level at the left or J5 pins 1 to 2 .113 – .139
right audio output jack. Reference a dB J5 pins 4 to 5 446 – 493k
meter to this level.

23.3 Turn off the RF modulation and verify

that the level drops by > 70 dB.

33
 TEST PROCEDURES
2. Woofer DC Resistance Test 4.4 Reference a dB meter to the input level.

2.1 Remove the bass module rear enclosure 4.5 Measure the output gain level at J7.
using bass module disassembly/assembly It should be +26.0 dB + 2.0 dB.
procedure 1.
4.6 Measure the distortion level at J7.
2.2 Remove the woofer harness from J7 on It should be < 0.1%.
the bass module PCB. Measure the DC
resistance of the woofer voice coil by mea- 4.7 Apply a 0 Vdc level to MUTE at J6 pin
suring across the two pins of the woofer 13 (open the SPST mute/un-mute switch on
harness. It should be 1.55 Ohms + 15%. the bass module test cable). This DC level
will mute the bass module amplifier.
3. Power Up Test
4.8 Measure the mute attenuation level at
3.1 Apply a short across BASS-EQ (J6 pin J7 relative to the input level. It should be
6) and AGND (J6 pin 5). Apply 0 V (open the > 40 dB.
SPST mute/un-mute switch on the bass
module test cable) to MUTE (J6 pin 13). 5. Air Leak Test

3.2 Apply AC mains voltage to the bass 5.1 Apply a 200 mVrms, 45 Hz signal
module. between BASS-EQ (J6 pin 6) and AGND
(J6 pin 5).
3.3 Measure the transformer quiescent
primary current. It should be < 250 mArms. 5.2 Listen for air leaks around all cabinet
seams, joints and wire harness thru-holes.
3.4 Measure the V supply voltage at J6 pins Air leaks will be heard as a hissing or sput-
7, 8, 14 and 15. It should be +16.5 + 1.0 tering noise. Repair any air leaks. All repairs
VDC. Remove the short applied in step 3.1. must be hidden.

3.5 Measure the J7 speaker output DC 6. Frequency Sweep Test

potential on each pin of the connector rela-
tive to PGND at J6 pin 2 or 3. It should be 6.1 Apply a 350 mVrms, 10 Hz signal be-
+ 8.2 + 1.0 Vdc. tween BASS-EQ (J6 pin 6) and AGND
(J6 pin 5).
4. Gain, Distortion and Mute Tests
6.2 Sweep the input frequency from 10 Hz
4.1 Unplug the woofer harness connector at to 500 Hz. Listen for any extraneous noises
J7 on the bass module PCB. Connect a such as buzzes, rattles, ticks, port noise or
2 Ohm, 50 Watt load resistor to the bass distortion.
channel output to J7 on the bass module
PCB.

4.2 Apply a +5 Vdc level to MUTE at J6 pin

13 (close the SPST mute/un-mute switch on
the bass module test cable). This DC level
will unmute the bass module amplifier.

4.3 Apply a 100 mV, 100 Hz signal between

BASS-EQ (J6 pin 6) and AGND (J6 pin 5).

34
 TEST PROCEDURES
Satellite Array Procedures 3.3 Listen for any rubbing or ticking noise
from the Twiddler. Replace any driver that is
Notes: defective.
• Refer to Figure 12 for the following
procedures. Note: There is a normal suspension noise.
• The satellite arrays are non-repairable. To distinguish between a rub or tick and
The grilles can be replaced using the suspension noise, displace the cone slightly
disassembly/assembly procedures. with your finger. If the rubbing can be made
• Each satellite array contains two identical to go away or get worse, then it is a rub or
drivers that are wired independently. tick. If the noise stays the same, it is
You must test each of them separately suspension noise.
unless otherwise specified.
3.4 Repeat steps 3.1 to 3.3 for the other
1. DC Resistance Test driver in the array.

1.1 Using a DMM, measure the DC resis- 4. Frequency Sweep Test

tance of each of the array drivers. Each
should measure 3.2 Ohms + 10%. 4.1 Jumper both of the drivers in a single
array together. Both center pins of the array
2. Phase Test connector are negative (-). The two outer
pins are the positive (+) pins.
2.1 Remove the array grille using array
disassembly procedure 1. 4.2 Apply a 100 Hz, 3.0 Vrms signal to both
of the array drivers.
2.2 Observing polarity, apply a +6 Vdc level
to one driver on the array input connector. 4.3 Slowly sweep the signal generator from
100 Hz to 2.0 kHz. Listen for any extraneous
2.3 Observe the TwiddlerTM under test. When noises such as buzzes, rattles, ticks, port
the DC level is applied, the driver should noise or distortion. Replace any array with
move outward. If it does, the Twiddler is wired an extraneous noise that can be heard at a
correctly. If not, it is wired incorrectly. Repeat distance greater than 1 foot (0.3m).
steps 2.2 and 2.3 for the other driver in the
array.

3. Air Leak Test

3.1 Apply a 180 Hz, 3 Vrms signal to one

of the Twiddler drivers in the satellite array
for 5 seconds minimum.

3.2 Listen for air leaks around all enclosure

seams, joints and the input connector. Air
leaks will be heard as a hissing or sputtering
noise. Repair any air leaks. All repairs must
be hidden.

35
Console Main PCB troubleshooting module also requires a test cable for test
and troubleshooting. This is a simple cable
Disassembly that can be made up using the part list and
instructions on the following pages.
Remove the top cover of the console using This cable allows you to un-mute the bass
Console Disassembly procedure 1. Use the module, apply an audio input signal, and
other disassembly/assembly procedures to check the output of the power supply cir-
remove the CD/DVD mechanism. Once that cuitry in the bass module. The bass module
is out of the way, remove the casting over supplies the console with its DC voltages.
the main PCB. You will need to remove the
clip on the amplifier IC and to pry the ampli- Cable Extenders
fier IC slightly away from the heatsink before
you can remove the casting. Make sure that The 3•2•1 system console uses a DVD
the LCD display board is still connected for mechanism that is the same style as those
troubleshooting. You will be able to power up used in computers. You cannot operate the
and troubleshoot the board while it is still in console without the DVD drive connected.
the console base with the casting and You will need to extend the 40 pin ATAPI
heatsink removed. Do not connect the 9 pin cable and the power cable so that you can
speaker array cable to J150. Make sure the reach the console main PCB for trouble-
console volume level is all the way down so shooting. These parts are readily available
that the amplifier IC U150 does not overheat in any electronics or computer parts store.
when operated with no heatsink on it.
Extending these cables will allow you to
Test Cables troubleshoot the main PCB with the casting
removed. Observing polarity, plug one end
You will need several test cables in order to of the longer ATAPI cable into the main PCB.
be able to troubleshoot the 3•2•1 console Plug the other end of the ATAPI cable into
and bass module. This is for several rea- the back of the CD/DVD mechanism. Refer
sons. The tuner adjustments for the console to Figure 8. Plug one end of the extender
require the use of a TAP (test access port) power supply cable into the console power
cable and an IBM compatible PC. The Bose® supply cable. Plug the other end of the
part number for the TAP cable is 266603, and power supply cable into the power connector
it may be ordered through Bose Product and on the back of the CD/DVD mechanism.
Technical Support at 800-233-4408.

You will also need an ATAPI extender cable

and an extender power cable for the DVD
mechanism. These are used to allow the
DVD drive to be connected to the console
main PCB, yet still allow access to the PCB
for troubleshooting. The console will not
power up without the DVD drive connected
to the main PCB.

Another test cable that is useful for trouble-

shooting the console is a simple DC power
cable. This cable and a DC power supply will
allow you to power up and troubleshoot the
console without the bass module attached.
The part list and instructions for making this
cable are in the following pages. The bass Figure 8. DVD Mechanism Rear Panel
36
Console Power cable Bass
Module Test Cable

You can power up the 3•2•1 system console PGND

1
2
BLACK
GND
without the need for a bass module by PGND 3 BASS AUDIO INPUT
CABLE SHIELD
4
making up a simple cable and using a DC AGND 5
GREEN
BASS AUDIO INPUT GND
YELLOW
power supply. The supply must be capable BASS EQ 6
RED
BASS AUDIO INPUT
V+ 7 V+ OUTPUT
of putting out +15Vdc at approximately 3A. 8
9
10
Parts needed: PGND 11

• 15 pin female subminiature D connector 12

/MUTE 13
WHITE SPST MUTE/
UNMUTE SWITCH
• DC power supply 14

• 4 ft of red AWG 18 wire

V+ 15

15 pin D-Sub 10k 5k

• 4 ft of black AWG 18 wire connector

8 7 6 5 4 3 2 1
1. Twist the black and red wires together to
make a twisted pair. This is to help prevent
coupling noise into the console. Strip about 15 14 13 12 11 10 9

1/4" of insulation from one end of each of the END VIEW (FRONT)
This is the part that plugs into the 3-2-1 console

wires. 1 2 3 4 5 6 7 8

2. On the rear of the 15 pin D-sub connector, 9 10 11 12 13 14 15

solder the red wire to pin 7 and the black REAR VIEW (BACK)
This is the part that the wires are soldered to
wire to pin 2. Refer to the figure below.
Figure 9. Bass Module Test Cable Wiring
8 7 6 5 4 3 2 1

Bass Module Test cable

15 14 13 12 11 10 9

END VIEW (FRONT)

You will need to be able to check the output
This is the part that plugs into the 3-2-1 console
of the bass module's power supply circuitry,
1 2 3 4 5 6 7 8 as well as to input an analog audio signal to
check the bass module operation. You can
11 12 13 14
do this by making a simple test cable.
9 10 15

REAR VIEW (BACK)

Note: The bass module will not un-mute
This is the part that the wires are soldered to
without +5 Vdc on the /MUTE line at pin 13.
3. Strip about 1/2" of insulation from the other
Parts needed:
end both wires. Connect the red wire to the
positive terminal and the black wire to the • 1 male 15 pin subminiature D connector
ground terminal of the DC power supply. with solder terminals
• 1 10k Ohm, 1/4 Watt resistor
4. Plug the 15 pin D-sub connector into the • 1 5k Ohm, 1/4 Watt resistor
rear panel of the 3-2-1 system console. • 1 ft of red AWG 18 wire
• 6 inches of black AWG 18 wire
5. Turn on the DC power supply, and set the • 4 ft of shielded twisted-pair AWG 18 wire
output voltage for +15Vdc. • 6 inches of white AWG 18 wire

You can now power up the 3•2•1 system

console without the need for a bass module.

37
Bass Module Test cable (continued) When the switch is open, you will be apply-
ing 0 Vdc to pin 13 to mute the bass module.
1. Strip and tin about 1/2" of the twisted pair
wires at one end of the twisted pair cable. 3•2•1 System Date of Manufacture
Cut the shield back about 2" at this end. At Information
the other end of the twisted pair cable, strip
and tin about 1/4" of the twisted pair wires. Console - The product label for the console
Twist and tin about 1" of the shield. Solder the is located on the bottom of the unit. The date
shield to pin 3 (PGND) of the 15 pin D-Sub of manufacture for the console is embedded
connector. The shield should be grounded at in the serial number on the label. The follow-
the 15 pin D-Sub connector end only. This is ing is an example:
to help prevent coupling noise into the
console. Solder the positive (+) lead of the Ser. No. 027748C12675109AZ
twisted pair wires to pin 6 of the 15 pin D-
Sub connector. Solder the negative (-) of the You will notice that there are four numbers
twisted pair wires to pin 5 of the D-Sub underlined. This is the date of manufacture.
connector.
The way it is read is that the first digit under-
2. Strip and tin about 1/4" of insulation from lined represents the year of manufacture.
one end of each of the red and black wires The 1 indicates 2001.
and about 1/2" from the other ends. On the
rear of the 15 pin D-sub connector, solder The next three digits are the Julian date for
the red wire to pin 7 and the black wire to pin the day of the year. In this example that
2. The red wire at pin 7 is the +15V coming would be the 267th day of the year.
out of the bass module power supply. This
voltage is also present on this connector at Bass Module - The date of manufacture
pins 8, 14 and 15. Be careful to not short the information is embedded into the product
+15V to anything when testing. The black serial number in the same format as is used
wire at pin 2 is connected to PGND. Pins 4, for the console.
9, 10 and 11 are also tied to PGND.
The product label for the bass module is
3. Twist one end of the leads of the 10k and located on the rear of the cabinet. The follow-
5k resistors together to put them in series. ing is an example:
Strip and tin about 1/4" from both ends of the
white wire. Solder one end of the white wire Ser. No. 027724912420677AS
to the the point between the two resistors.
Solder the other end of the white wire to pin You will notice that there are four numbers
13 on the 15 pin D-Sub connector. This pin is underlined. This is the date of manufacture.
where the +5 Vdc /MUTE input signal that
normally comes from the 3-2-1 console to The way it is read is that the first digit under-
un-mute the bass module audio amplifier IC lined represents the year of manufacture.
U1 is brought in. The bass module will not The 1 indicates 2001.
un-mute without this DC voltage level. Solder
the other end of the 10k resistor to pin 15 of The next three digits are the Julian date for
the D-Sub connector. Solder the other end of the day of the year. In this example that
the 5k resistor to pin 11 of the 15 pin D-Sub would be the 242nd day of the year.
connector. Solder a SPST switch in series
with the white wire. This is your bass module
mute/un-mute switch. When the switch is
closed, you will be applying +5 Vdc to pin 13
to un-mute the bass module.
38
Checking Console Firmware Revisions Display PCB Firmware Procedure

The 3•2•1 console uses two separate To check the display PCB firmware from the
microprocessors, one located on the main front panel, perform the following steps:
PCB and another located on the display
PCB. 1. Remove power from the console for at
least five seconds.
These two versions of firmware must both
be updated when an update is performed. 2. Re-apply power, and within five seconds,
press the EJECT, SKIP UP and SOURCE
The revisions of firmware for each PCB DOWN buttons all at once for at least seven
must be compatible with each other. A listing seconds. You may see the display flashing
of compatible revisions of each firmware will during this time.
be maintained on the Bose® Service Opera-
tions web page at 3. After seven seconds, release all of the
http://serviceops.bose.com. buttons at once. You should see a display
like "03.52:7321" on the console. This ex-
If one microprocessor's firmware updated ample shows that version 3.52 of the display
properly and the other one's didn't, then the PCB firmware is installed on this particular
console may fail to operate properly. console.

Note: Once you have successfully checked

the firmware revision for either display PCB
or the main PCB, you can check the other
one immediately. It is not necessary to cycle
the power again between tests.

Main PCB Firmware Procedure

To check the main PCB firmware from the

front panel, perform the following steps:

1. Remove power from the console for at

least five seconds.

2. Re-apply power, and within five seconds,

press the EJECT, SKIP UP and VOLUME
UP buttons all at once for at least seven
seconds. You may see the display flashing
during this time.

3. After seven seconds, release all of the

buttons at once. You should see a display
like "321 247" on the console. This example
shows that version 2.47 of the main PCB
firmware is installed on this particular con-
sole.

39