Orion 2500D Repair

Orion 2500D Class D 2500 watt Amplifier

This one came in from the Internet. Opened it up to find some smoked output FETs.

Click image to Enlarge the image

First off, this is a MONSTER amp. It will bang the living crap out of your subs.

Subwoofers fear this badge...

Heres the problem. Black soot on those output FETs

A closer look. Uh-oh.

An even closer look reveals it burned up some of those dinky little 1/8th watt gate drive and pulldown resistors as well. A real beeyoch to change those little resistors. Why couldn't Orion spend the extra $$ for 1/4 watt resistors? It's all about making money. They don't care. The 1/8th watt are fine till something goes wrong, which it isn't supposed to right? It's an Orion...

This is what the other side of the amp looks like... this is nice, clean, no soot. Everything appears okay here.

UH-OH again! As I get the board out of the heatsink, the FETs start falling off... Turns out there is no support in this area of the PCB and it really needed it, Orion ommitted it, and this is what happened. Vibration and flexing of the PCB in this area broke the legs off the FETs, causing the amp to go up in smoke. An expensive amp to repair too... It's a monster, and has a ton of parts crammed into it so it's very labor intesive to work on this amp, and to top that off, it's very sensitive. You have to match parts with same manufacturer parts, and any that work together in a group MUST have matching date codes. It doesn't work right if you don't do this. Replacing all those parts get's expensive.

The last 3 FETs that aren't smoked were not even bad, but the legs had broken off anyway, so they ALL had to be replaced.

A wider shot of this amp board. It's a huge amp, with lots of parts.

The last 11 FETs on this side of the amp had to be removed/replaced. Legs broken on all of them.

A shot of the top of the board after all of those resistors had been replaced. A tedious task, and messy too with all that soot you have to clean up.

The Driver Boards.... Pain in the **s to get loose from the main board. I had to remove the one in the front of this picture and replace 8 small transistors and 2 zener diodes on this board. They didn't look bad, but they were. No drive signal coming from this side of this board. Luckily the other board was OKAY.

One last look at the mainboard with the missing FETs.

WOW they magically appeared on the board now!! New FETs installed.

All tightened up and ready for testing!

DONE! Worked great! Took some time, and will be a $150 repair bill, but well worth it for this monster amp. And it aint too bad lookin either....

Glad this one is done, was a lot of work, but for a good cause, it's a badass amp!