S500

2-Way Passive Loudspeaker

SERVICE MANUAL

2000 MACKIE DESIGNS, INC.

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 SAFETY
Exposure to extremely high noise levels may cause permanent hearing loss. Individuals
vary considerably in susceptibility to noise-induced hearing loss, but nearly everyone will
lose some hearing if exposed to sufficiently intense noise for a period of time. The U.S.
Government’s Occupational Safety and Health Administration (OSHA) has specified the
permissible noise level exposures shown in this chart.
According to OSHA, any exposure in excess of these permissible limits could result in some
hearing loss. To ensure against potentially dangerous exposure to high sound-pressure
levels, it is recommended that all persons exposed to equipment capable of producing
these levels use hearing protectors while this unit is in operation. Ear plugs or protectors in
the ear canals or over the ears must be worn when operating this amplification system in
order to prevent a permanent hearing loss if exposure is in excess of the limits set forth
here.

Duration Per Day Sound Level dBA, Typical

In Hours Slow Response Example
8 90 Duo in small club
6 92
4 95 Subway Train
3 97
2 100 Very loud classical music
The S500 can 1.5 102
produce a 1 105 Patrice screaming about
maximum SPL deadlines
of 127 dB @ 1m 0.5 110
0.25 or less 115 Loudest parts at a rock concert

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 CONTENTS
Safety ................................................................................ 2
Introduction ..................................................................... 3
Overview .......................................................................... 4
Specifications ................................................................... 5
Parts ................................................................................... 6
Fold-out Sections
Wiring diagram and PCB ................................... Wiring-1

Introduction
SERVICE ON THIS EQUIPMENT IS TO BE PERFORMED BY
EXPERIENCED REPAIR TECHNICIANS ONLY

This manual contains basic service information. It is essential that you have a copy of the
user’s manual as this contains the complete operating instructions.

SERVICE TECHNICAL ASSISTANCE

Mackie Designs, Service Technical Assistance, is available 8AM - 5PM PST, Monday through
Friday for Authorized Mackie Service Centers, at 1-800-258-6883. Feel free to call with any
questions and speak with a carefully-calibrated technician. If one is not available, leave
a detailed message and a qualified Mackoid will return your call asap.

DISCLAIMER
The information contained in this manual is proprietary to Mackie Designs, Inc. The entire
manual is protected under copyright and may not be reproduced by any means without
express written permission from Mackie Designs, Inc.

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 Overview
The S500 is a high-efficiency, extreme-output, 2-way, wide-dispersion sound reinforcement
speaker system. The combination of precision-manufactured, high- efficiency acoustic
components and high-quality, low-impedance, phase-precise crossover technology
allows the S500 to operate continuously at peak output levels safely while providing high-
resolution audio.
The components inside the S500 incorporate several state-of-the-art advancements in
transducer technology. The compression driver is a new 1.75-inch titanium diaphragm
design featuring a 3-slot, low-distortion geometry phase plug. The S500 also features a
low-distortion, high-output horn design developed to provide the correct power
response and phase alignment characteristics at the crossover frequency. With the
resulting 75º x 65º dispersion pattern, the S500 provides very open, natural sound
reproduction at extreme output levels.
The S500 produces deep bass through a 15-inch high-efficiency RCF® precision woofer.
The magnetic structure designed for the woofer motor is responsible for the system’s
resulting high sensitivity of 100 dB (1 watt@1 meter). More importantly, the high-efficiency
motor provides an extraordinary amount of force that provides complete control of the
cone mass. This type of control allows the woofer to deliver extended bass response and
to reach the mid-frequency crossover point efficiently.
The S500 frequency response is linear between 65Hz and 18kHz. Protection for the high-
frequency driver is provided via an integrated MOSFET circuit that actively monitors and
controls the power delivered to the compression driver. There is also a circuit breaker
button on the rear control panel designed to protect the woofer from excessive power.
The breaker “sees” the amplifier signal being delivered to the woofer and opens when
the combination of amperage and voltage exceeds the maximum rated power levels.
The breaker switch can be reset by pressing the button.
The rear control panel features both a 1/4” speaker jack and a Neutrik Speakon™
connector, wired in parallel. The S500 cabinet is constructed using both multi-layered
plywood and pressure-injected structural resin. The top and bottom sections both have
handles for easy movement and relocation. There is an integrated pole-mount on the
bottom of the enclosure. In addition, there are two, three-part cast-aluminum handles
on each side of the enclosure as well as a full size, oval-punched, weather-resistant steel
grille.
The S500 has a 1/4” TS jack and a Neutrik Speakon™ connector, wired in parallel. Use
high-quality speaker cable as recommended by the amplifier manufacturer.
The 1/4” TS jack uses the following wiring standard:
Tip = Signal (+)
Sleeve = Ground (Shield)
The Speakon connector uses the following wiring standard:
Pin 1+ = Signal (+)
Pin 1– = Ground (–)

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 Specifications
Transducer Specifications Physical Properties

Low-Frequency Transducer Height 32.1” (817mm)

Diameter 15” (381mm) Front Width 19.1” (484mm)
Voice Coil Diameter 2.5” (63.5mm) Rear Width 13.9” (352mm)
High-Frequency Driver and Horn Depth 18.1” (460mm)
Diaphragm Diameter 1.75” (44.5mm) Net Weight 75 lbs. (34kg)
Voice Coil Diameter 1.75” (44.5mm) Connector Type 1/4” TS jack and Neutrik
Diaphragm MaterialTitanium Speakon
Power Handling 30 watts rms Enclosure Geometry
(long term) Trapezoidal, 10º side angles, 18mm
Horn Type Constant multi-layered plywood, top and
Directivity bottom high pressure resin
Mouth Size 10.6” (270mm) W x injected “caps”
10.6” (270mm) H Handles One on top, one on bottom cap,
Throat Size 1.0” (25.4mm) two three-piece handles on each
side
System Specifications Color Black, PVC coated finish
Grille Custom perforated oval steel
Frequency Range (–10 dB) 50Hz-20kHz grille with anti-corrosive
Frequency Response (–3 dB) 75Hz-18kHz treatment
Horizontal Coverage (–6 dB) 75º averaged
1kHz-10kHz
Vertical Coverage (–6 dB) 65º averaged
1kHz-10kHz
Directivity Factor; DI (Q) 10.93 (12.38)
averaged
2kHz-10kHz
Sensitivity (1W@1m) 100 dB
Rated Maximum SPL@1m 124 dB long term
127 dB peak
Crossover Point 1300Hz
Nominal System Impedance 8 ohms
Power Handling 250 watts rms
long term
500 watts peak

Safety Features

High Frequency: Monitoring and limiting of

continuous input power via MOSFET-based
electronic circuit
Low Frequency: Monitoring of amplifier signal
delivered to woofer via current breaker
switch. Overpowering of the woofer opens
the circuit and requires resetting by
manually pressing the circuit breaker
button.

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 Parts List
13112050 LOUDSPEAKER S 500
PART# DESCRIPTION QTY COMMENTS
21110330 WOOFER L15-S500 1
23030400 CROSSOVER ASSEMBLY 1 SEE NEXT PAGE
23103720 CABLE ASSEMBLY 1
23103910 HANDLE ASSEMBLY 2
23103930 CASE ASSEMBLY 1
25110570 TWEETER N 450-S 500 1
33050380 TERMINAL BOARD 35567 1
33090460 HANDLE CASE 34278 2
33140390 HORN 35416 1
33160360 GASKET FOR HANDLE 36052 2
33161130 GASKET FOR TERMINAL BOARD 30347 1
33221420 PROTECTION GRILLE 34324 1
33221460 INNER PROTECTION PACKAGING 35560 2
33890190 FEET FOR CABINET 34344 4
33900360 BLACK COVER FOR STAND HOLE 34360 1
33920650 HANDLE 34335 2
33920900 BRASS RING 35647 1
33951980 ROUND BLUE RUN-MAN LABEL 34844 1
33951990 BOTTOM BLACK MACKIE LABEL 34891 1
33953030 BLUE S500 LABEL 35462 1
33953050 LABEL WITH SERIAL# AND DATE 35565 1
33953060 IMPEDANCE LABEL 35567 1
33960580 WARRANTY MOD.1712 1
33963280 OWNER’S MANUAL MOD.1803 1
33991010 INNER PACKAGING 34367 4
33994330 INNER PACKAGING 35421 1
33995400 INNER PACKAGING CORNER 33326 0.5
33995460 PACKAGING (BOX) 35562 1
33995630 COVER FOR PACKAGING 35822 0.1
43040030 GLASS WOOL INSULATION SP.30 40
43900580 GASKET “U” SHAPED ESPACE200S 0.1
43900820 GASKET 32181 0
51150353 SCREW V.TC+M4X30 INOX ZNN U7687 8
51150446 SCREW V.TC+M5 X30ZNN U7687 4
51170415 SCREW V.TSC+M5 X10ZNN U7689 8
51190246 SCREW V.TCEI M5 X35 ZNN U5931 6595 8
51190315 SCREW V.TCEI M6 X18 ZNN U5931 4
51240217 SCREW V.TC+AB 2,9X13 ZNN U6954 2
51310415 SCREW V.TC+SL 3,5X18 ZNN 50067 1/2”4
51310426 SCREW V.TC+SL 3,5X25 ZNN 50221 8
51310535 SCREW V.TC+SL 4X30 ZNN 4
51310545 SCREW V.TC+SL 4X40 ZNN 8
51992015 SCREW V.T1/2T+SL 4,5X20 ZNN 35725 18
52100211 WASHER 4,3X12ZNN 13087 1/2” 4
52100216 WASHER 5,3X10ZNN U6592 50239 1/2” 8
52201004 WASHER 5 DIN6798 0239 4
54302001 HEXAGONAL NUT 35059 2
59025285 BAG 800+300+300X1600 35171 1
83121010 C3P21-010*302-THERMAL SWITCH 1
83412015 C3C12-014F003-STEREO JACK 1 1/4” JACK
83415001 C3C15-001F004-FEMALE CONNECTOR 1 SPEAKON® INPUT CONNECTOR

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 23030400 CROSSOVER ASSEMBLY
PART# DESCRIPTION QTY COMMENTS
33030770 BOARD C.S.MR 35572 1
51150230 SCREW V.TC+M3 X14ZNC U7687 50175 1
52100103 WASHER 3.2X 6ZNC U6592 12272 2
52301010 WASHER A 3.2 U1751 50234 1/2 1
53101005 NUT M3 U5588-A-6S 11625 1
59999992 CABLE TIE T & B M 24 3
59999995 CABLE TIE T & B M 25 2
81121029 C1R21-251J221-RES.STR. 1/4W5% 220 1 Resistor
81121034 C1R21-251J561-RES.STR. 1/4W5% 560 1
81121041 C1R21-251J222-RES.STR. 1/4W5% 2.2K 1
81121110 C1R21-501J102-RES.STR. 1/2W5% 1K 1
81244022 C1F44-153J5R6-RES.FILO 15W5% 5.6 1 Resistor, wire-wound
81244023 C1F44-153J6R8-RES.FILO 15W5% 6.8 1
81244025 C1F44-153J100-RES.FILO 15W5% 10 4
81244170 C1F44-203J220-RES.FILO 20W5% 22 1
81412001 C1C12-101K156-CAP.FILM 100V10% 15U 1 Capacitor, Film
81412020 C1C12-101K155-CAP.FILM 100V10%1.5U 1
81412021 C1C12-101K225-CAP.FILM 100V10%2.2U 2
81412023 C1C12-101K475-CAP.FILM 100V10% 4.7U 1
81521053 C1E21-250*102-CAP.ELYTIC. 25V 1000U 1 Capacitor, Electrolytic
81612029 C1L12-202H182-INDUCTOR 1 Inductor
81612048 C1L12-102A651-INDUCTOR 1
81612049 C1L12-401G701-INDUCTOR 1
81632017 C1L32-321A231-INDUCTOR 1
82112001 C2D12-750*151-DIODE 1N4148 1
82122015 C2D22-101*402-DIODE MUR410 4
82131050 C2D31-501J120-ZENER 0.5W 12V 1
82262014 C2T62-313A101-MOSFET IRFP140 1
83444020 C3C44-020M001-FASTON 6
83816006 C3A16-006 -HEATSINK 1

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 Woofer

Capacitors Semiconductors

Tweeter
ZENER

FET

Resistors

Inductor specifications

S500 Service Manual ©2000 Mackie Designs Inc. All rights reserved Crossover and protection circuit WIRING-1

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 S500 Service Manual ©2000 Mackie Designs Inc. All rights reserved Crossover and protection circuit WIRING-2

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