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DIYSG 1099 Crossover Issues and Troubleshooting Help

721 Views 4 Replies 3 Participants Last post by  mhutchins
8
In 2017 my dad bought a trio of 1099 for our theater upgrade from BIC Venturis and has sat in their boxes until last year, the summer before my senior year in high school where I started, and I finished one of the speakers. I completed the second speaker during the spring and started to work on the final speaker and I hope to finish this project before I start college.

The final 1099 board is where issues arise as the entire crossover board works perfectly fine for the tweeters and woofers. The mid drivers do not play any audio when paired together, but when one is connected the audio comes through at a very faint low volume in comparison to what the other two completed speakers put out when playing audio.

Front picture of the board:
3148463


Back picture of the wiring:
3148464

(The worst board that I made out of the three without considering the mid driver issue)

I am not sure if the issue is simply a bad wire connection between components or if it is something to do with a bad component that has been damaged or is faulty. I plan on replacing a few of the wires, checking the board with a multimeter, finally resoldering the entire board with potentially new electronics if needed.

Any other tips to troubleshooting crossovers would be greatly appreciated along with what your thoughts are on what the potential issue may be. I have also put in a few pictures below of progress and the entire theater.


3148465

(first board wiring test layout)

3148468

(first speaker testing)

3148469

(first one completed)

3148470

(only picture of the second and third board along with cnc cut parts for my robotics team)

3148472

(first and second speakers done being used as a pair)

3148474

(current state of the theater)

The final plan once this is completed is to build a wall or a curtain that surrounds the area, put the speakers behind a sound transparent screen and put sound proofing on the walls.
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If you have a multimeter check the resistance between the midrange outputs of the crossover without the mids connected it should be a little over 2 ohms. Also check resistance between the opposite end of the 27uF cap from the input and the positive midrange output wire, that should be a under 1 ohm.

Trying to trace the connections on the midrange circuit I didn't notice any mistakes on your board.
I would reflow the ground connection where the 4 wires come together. One of the wires didn't get any solder flow between the individual strands which suggests a cold solder joint.

I would also check the connections for most of the inductors. I noticed that the inductor wires have been cut short and most of the inductors show no signs of tinning on the component side of the board. The insulation on the inductor wires will not burn off from the heat from typical soldering irons and must be physically scraped off with a knife or sanded off before soldering. Therefor it's quite possible the inductor has a poor connection.

Lastly, I would reflow all of the solder joints for the mids circuit as a final step.

Mike
I would reflow the ground connection where the 4 wires come together. One of the wires didn't get any solder flow between the individual strands which suggests a cold solder joint.

I would also check the connections for most of the inductors. I noticed that the inductor wires have been cut short and most of the inductors show no signs of tinning on the component side of the board. The insulation on the inductor wires will not burn off from the heat from typical soldering irons and must be physically scraped off with a knife or sanded off before soldering. Therefor it's quite possible the inductor has a poor connection.

Lastly, I would reflow all of the solder joints for the mids circuit as a final step.

Mike
During this board, my iron started to lose it ability to properly let solder flow because the tip is not clean? I'm not to sure but my joints got worse as time went on and I did sand off the covering for all of the joints and looking at it now I found one joint where I forgot to do that, which is the cause of my problems, but I will be cleaning up this board and thank you for all the tips!
Keep a wet sponge handy while soldering and periodically wipe the hot tip of the iron on the wet sponge to remove the rosin crust that tends to build up on the tip. Then, immediately apply fresh solder to the tip to re-tin the iron and continue with your soldering. This should help with the heat transfer to reduce cold solder joints.

I'm glad you found the problem!

Mike
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