powersoft Powersoft K3, Powersoft K2 powersoft k2 k3 service info

powersoft_k2k3_service_man_v1.4.docx
© 2013 Powersoft

Version 1.4

July 2013

K2 – K3 Series

1. Opening the amplifier cover

3

2. Discharging the amp capacitors

3 – 4

3. Removing the power supply board

4 – 8

4. Removing the amplifier output board

9 –12

5. Removing the fan

12

6. Removing the display

13 –14

7. Instruments and tools for testing

14

8. Firmware update procedure

14 –15

9. Removing the control board (k-cntrl)

15

10. Error codes

15 –16

11. Mechanical parts

17 –18

12. K2-K3 spare parts list

19 –25

Index

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K2 – K3 Service Manual

Smaller screw, screwdriver Phillips PH 0

Bigger screws, screwdriver Phillips PH 1

Eight screws, screwdriver Phillips PH0

Rail LEDs should be off; if not, discharge capacitor banks

Position of connectors for discharging capacitors bank

Lamp (min.40W/230V, best 60W/230V): dummy load for discharging the

amplifier’s capacitors bank

1. OPENING THE AMPLIFIER COVER

Disconnect the amplifier from the mains. If the amplifier
has been connected to the mains in the last few minutes,
please proceed with attention as the internal capacitors
bank could be charged and harmful!
Remove the side support steel bars, unscrewing the four
bigger screws with a Phillips PH1 screwdriver. Then
remove the screw in the center using a smaller Phillips
PH 0.

Remove the amplifier cover unscrewing the eight screws
(four in the front, two in the centre and three in the
rear) using a screwdriver Phillips PH 0:

2. DISCHARGING THE AMP CAPACITORS

Before proceeding in operating inside the amplifier it is
necessary to check if the rails are completely discharged:
LEDs in picture below should be off, this should happen
about 15 minutes after the amplifier has been switched
off and disconnected from the mains.

If the LEDs are still on discharge the capacitors bank by
connecting a lamp of at least 40 W/230V

to the connectors seen in the two pictures below

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K2 – K3 Service Manual

Detail of connectors
Negative to this connector
Positive to this connector at first and then to this other one

Opened amp

Fastons between power supply board, output amplifier board and fan

Disconnected fastons between power supply board, output amplifier

board and fan power cables

Flat cable to be removed

Once the amplifier is open and its power supply fully
discharged, it is possible to start removing the single
boards.

3. REMOVING THE POWER SUPPLY BOARD

Disconnect the faston between the power supply board
and the output amplifier board :

power cables to be disconnected

Following this, unscrew the fans power cables close to
the previous faston.

Disconnect and remove the flat cable bridge between
the power supply board and output amplifier board:

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K2 – K3 Service Manual

Removed flat cable

Amplifier power switch cable to be removed

Detail of screws number 1-2

Detail of screws 3 and 4

Faston of the amplifier power switch cable removed

Disconnect the amplifier power switch cable removing
the faston behind it:

It is now possible to remove the power supply board by
unscrewing it from the amplifier chassis, removing with
a Phillips PH 1 screwdriver the 7 screws plus the brass
stand-off as illustrated below:

Overview of the 7 screws (1-7) and of the brass stand-off (8)

to unscrew for removing the power supply board

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K2 – K3 Service Manual

Detail of screw number 5

Detail of screw number 6

Detail of screw number 7

Detail of brass stand-off (screw number 8)

Heat sink screws to be removed

Once all the 8 screws have been removed, remove the
power supply board heat sink screws with an M3
hexagonal key:

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K2 – K3 Service Manual

Heat sink screws removed
Mains connector screws to be removed

Mains connector screws removed
Earth ground nut to be removed

Detached rear panel

Rear panel screws to be removed

Now remove the mains plug holder by pressing on its
sides; then remove the mains socket screws:

Proceed in unscrewing the nut that holds the earth
ground cable behind the mains connector:

Now remove the rear panel:

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K2 – K3 Service Manual

Fan screws to be removed
Fan power cable holders to be removed

Fan removed from the amplifier chassis
Power supply board removed from the amplifier chassis

Lift and pull the power supply board to remove it

from the amplifier chassis

The power supply board will not be freed until the fan is
not removed from the amplifier chassis. Remove the fan
power cable and the fan screws:

Now it is finally possible to remove the complete power
supply board from the amplifier chassis:

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K2 – K3 Service Manual

Mains connector screws to be removed

Removed mains connector screws

Rear panel screws to be removed

Detached rear panel
Flat cable to be removed

Flat cable removed
Unscrew this nut

4. REMOVING THE AMPLIFIER OUTPUT
BOARD

Before removing the amplifier output board, please
proceed in discharging the power supply capacitors as
explained in chapter 2.
Start from unscrewing the rear panel connectors
removing the mains connector screws and plug holder
as in the images below:

proceed in removing the all rear panel by unscrewing the
screws as marked in the images below

Now remove the two flat cables between the power
supply board and the amplifier output board:

Remove the nuts that hold the amplifier output board
heat sink:

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K2 – K3 Service Manual

1

Nuts unscrewed and removed

Screws 1, 2 and 3 to be removed

Amplifier output board overview

Screw 4 to be removed
Screw 5 and 6 to be removed

Screw 7 to be removed

Now remove the amplifier output board by unscrewing
the 7 screws marked in the overview image below and
in the following images:

Once all the 7 screws have been removed, unplug the
two flat cables that connect the optional KAESOP board
(if installed) to the front panel RJ45 plugs:

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K2 – K3 Service Manual

Lift and pull out the amplifier output board from the amplifier
chassis

KAESOP flat cable to unplug

KAESOP flat cables unplugged
Control board flat cables to unplug

Control board flat cables unplugged

Pull back the amplifier output board to be able to unplug
the two flat cables of the control board on the other
hand masked by the chassis:

Now it is finally possible to remove the amplifier output
board from the amplifier chassis:

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K2 – K3 Service Manual

Amplifier output board out of the amplifier chassis
Fan power cables to be disconnected

Disconnected fan power cables
Fan removed from the amplifier chassis

Removed fan power cable
Fan power cable holders to be removed

5. REMOVING THE FAN

Before starting to remove the fan please proceed in
discharging the power supply as explained in chapter 2.
Begin the fan disassembly by unscrewing the fans power
cables.

Remove the fan power cable holders:

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K2 – K3 Service Manual

Amplifier power switch cable to be disconnected

Disconnected faston of the amplifier power switch cable

Screw for removing left ear
Screws for removing the protection plates

Front panel removed from the amplifier chassis
Unplug these two flat cables from the display
These four screws needs to be removed to free the display

Screw for removing right ear

6. REMOVING THE DISPLAY (K-FRONT)

Before removing the display, discharge the power supply
capacitors as explained in chapter 2.
Remove the faston that connects the amplifier power
switch:

Now remove the front panel left and right ears:

Remove the left and right protection plates:

The front panel is now free from the amplifier chassis.

Remove the display from the front panel by unscrewing the
four screws seen below:

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K2 – K3 Service Manual

Plugs 4mm

2

AMP CPC Mains

Display removed from front panel

Molex 3 pin female 2,54

Plugs 4mm

7. INSTRUMENTS AND TOOLS FOR TESTING

 DC POWER SUPPLY 0-50 Vcc f.s. 5 A.
 DC POWER SUPPLY +/- 30Vcc 0-3 A.
 FUNCTION GENERATOR OR CD

PLAYER.

 OSCILLOSCOPE DOUBLE TRACE. (IT

MUST BE DISCONNECTED FROM THE
GROUND)

 DIGITAL MULTIMETER.
 BOOST VOLTAGE CABLE (CB000081)

 VOLTAGE AUXILIARY CABLE

(CB000077)

8. FIRMWARE UPDATE PROCEDURE

There is no need to update the amp’s firmware when
replacing power supply boards.
The following will illustrate actions to be undertaken in
case of amplifier or K front boards replacement (see K
front de-mounting procedure at the end of this chapter
if needed).
Due to the fact that the amplifier model type is stored
in the k front board and that this instructs the amplifier
control board, both boards must run the same firmware
version.
Should the system detect a different firmware version in
the 2 boards at power on, the LCD display will show the
message error “NO LINK”.
To avoid this, we suggest updating to the latest release
all K amps DSP you receive for service. To help solve
this “NO LINK” error easily, we can also ship a
FIRMWARE UPDATE CARD (Powersoft code
PC000112).
K amps without DSP DO NOT NEED TO BE
UPGRADED.

FIRMWARE UPDATE procedure for K Series

Main functional parts of K Series amplifiers:

1. KFRONT = microcontroller that handles the front

panel interface (4 pushbuttons + display)

2. KCNTRL = microcontroller that supervises the

amplifier and power supply if DSP is installed

3. KDSP = microcontroller that handles the DSP

parameters

4. SHARC = signal processor

5. The FW update procedure updates the KFRONT,

then the KDSP, then the KCNTRL, and finally the
SHARC.

UPDATING AMPLIFIER (MAIN)

1. Turn the amplifier off

2. Insert the firmware smartcard. The upper code is the

FW revision number (e.g. 3.8.6-161). The bottom
code is the KDSP and SHARC revision number (e.g.

3.8.6-1406). Contacts on bottom.

3. Press the first and second push-buttons on the left

hand side of the front panel. Keep them pressed
(with one hand)

4. With the other hand, turn the amplifier on and wait

3-6 seconds.

5. Right after the fan test (full throttle blow), when the

yellow LEDs on the panel begin blinking, you can
release the buttons. The KFRONT panel monitors
the update process.

6. After about 4 minutes, a message box (if you are

upgrading from a 2.0.x firmware release) appears,
telling you that the current settings are lost, and that
you should verify the settings after the update.

Please check your amplifier settings after the
update. Updating from a 2.94.x or 3.x.x should

however maintain your settings.

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K2 – K3 Service Manual

Error code

Error descr.

1

192KHz clock not present

2

Positive 15V aux

4

Negative 15V aux

8

Positive 5V analog

100

Negative power bus Ch1

200

Negative power bus Ch2

2000

Positive power bus Ch1

4000

Positive power bus Ch2

8000

External auxiliary voltage

Check rail fuses

Check rail fuses Ch1 and Ch2

Offset output current regulations

7. If a KDSP (i.e., an optional DSP board) is present, the

KDSP update begins, its progress indicated by a
progress bar. After about 4 minutes the update is
complete. If a KDSP is NOT present, a START
ERROR message is displayed, requiring a BACK
push-button confirmation.

8. The KCNTRL update begins, its progress mapped by

a progress bar. After about 2 minutes the update is
complete.

9. Finally, a message asking you if you want to update

the SHARC DSP is displayed. By pressing OK the
SHARC DSP is updated. The update lasts as long as
15 minutes and works only if the amplifier is powered
from the mains (NOT from a PowerHub!);
therefore, take care in assuring that the mains supply
is not disconnected during the above process.

10. Verify the update: go to Setup->Hardware Info,

press more, the following should appear:
KFRONT: X.Y.Z – B KCNTRL: X.Y.Z – B KDSP:
X.Y.Z – S
WHERE: X.Y.Z is firmware version, B is the build
number (meaningless) and S is the SHARC firmware
version.

CAUTION:
If the update process terminates before
completion, you must repeat the process starting
from point 1), because you could have 2 different
FW versions on your boards. This could cause the
amplifier to malfunction.
Always check that the update was successfully
completed as explained on point 10.

9. REMOVING THE CONTROL BOARD (K­CNTRL)

To remove the amp control board please proceed in
discharging the power supply as explained in chapter 2.
Remove the 3 screws over the board as in the picture
below:

Menu → setting → amplifier setting → Max output
voltage → setting the value with the two ± button.

After replacement of the K-CNRTL and/or the KFRNT
boards, recalibrate the offset output current by
following this procedure:

1. Output current offset: Insert a 1 KHz sine wave

signal at the input without any output load. Set the
zero current offset value following the menu display
indication:
Menu → Display → Output meters → set the Arms
value to 0, turning the multiturns pot as in the picture
below:

10. ERROR CODES

Extract care the amp board with care.
Once the control board is replaced, firmware reinstall
illustrated in chapter 8 is mandatory. Once the firmware
is reinstalled, set the desired max output voltage by
following the on display indications:

The error code value displayed in the main screen is the
sum of the single error code value.

Example: 4301=4000+200+100+1 means

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K2 – K3 Service Manual

Positive power bus Ch2 +
Negative power bus Ch2 +
Negative power bus Ch1 +
192 KHz clock not present

16

K2 – K3 Service Manual

11. MECHANICAL PARTS

17

K2 – K3 Service Manual

ME000214

BLACK PLATE

ME000284

ALUMINIUM HANDLE

ME000220

LEFT BLUE FRONT GRID

ME000219

RIGHT BLUE FRONT GRID

IN000010

SWITCH MAINS

ME000215

ALUMINIUM FRONT

TA000005

LEXAN K-FRONT

ME000359

COVER

ME000370

REAR PANEL SILSKREENED

ME000360

LATERAL INOX PLATE

ME000358

HALF REAR PANEL

ME000357

CHASSIS

ME000210

LEFT BLACK PLATE

ME000213

RIGHT BLACK PLATE

ME000218

FRONT BLUE PANEL

FI000018

AIR FILTER

ME000334

FRONT LEXAN

ME000258

LEXAN PROTECTION

VN000025

COOLER FAN

ME000263

LEXAN PROTECTION K ALIN

ME000391

LEXAN FAN AIR CONDUCT K/LGT

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K2 – K3 Service Manual

KALIN

Part Number

Description

PCB position

SMD00611

K/LGT/ALIN/12+TEST+HSINK

RES00120 R52, R53

CA000200

ELET.1000UF 200V 25X35 SNAP IN 85° P10

C50 C51 C52 C53 C54 C55 C56 C57 C58
C59 C60 C61 C62 C63 C64 C65 C66 C67

C68 C69 C71 C72

DI000070

IRC 30EPH06

D9

DI000083

GSIB1580 PONTE A DIODI

D1 D2

DIS00007

5.1 VZ MMSZ5231B SOD123

D14

DIS00033

US1J DO214AC

D11,D13

DIS00030

13 VZ SML4743 DO214AC

D12

DIS00021

SS14 -E3/61T Schottky_Barrier_Rectifier

D44

DIS00026

BAS28 High_Speed_Double_Diode

D19

DIS00009

15 VZ MMSZ5245B SOD123

D71 D72

DIS00039

15 VZ 1W SML4744 DO214AC

D10 D18 D60

DS000009

HTSK-AL-OSA56-145 OXN HORZ. FINS REV.02 Taric.

76169990 90

SM000645

FU000032

Fuse 15A 250VDc (6x32mm) Fast UL Serie 3AB Fast Series

F1 F2

ICS00019

IR2156S SOIC14 BALLAST_CONTROL_IC SMD

U2

ICS00120

IRC IR1150ISTRPbF PFC One Cycle Control PFC IC

U1

IG000003

IRG4PC50UDPbF N-Channel Gate Bipolar Trans IGBT 600V 50A

TO-247AC

Q11 Q12

IN000010

Switch Rocker Single Pole SP-ON 6A 250Vac 13-Round Body

(Ø=20.2)mm Color

ME364

IS000041

HI-FLOW300 145x32 AMPL.KALIN.LGT $1,25

1 pc. X channel

ML000001

MOLLE Q&D INOX

2 pc. X channel

ML000007

MOLLE K&Q&D INOX SP. 1.2

13 pc. X channel

MO000038

FCH47N60F_F133 NChannel_SuperFET Vds=600V

ID@25°C=47A Pd=417W TO-247 PTH

Q3 Q4 Q5

RE000335

NTC 2 Ohm 12A 20% P5.1W (21x7x28)mm Pitch 7.5mm S364

Series CONF(100)

R54

TO000099.2

"K-LGT" RES.CONV.TRASF.135015 E42/21/15 3C92 CSA from

20/09 Furukawa

T5 T6 (ORA SONO CSA)

TR000003

BDW93CFP NPN_Darlington_Power_Transistor Vceo=100V

Pd=33W 100<hFE@10A(Ic)3V(Vce)<20000 TO220FP PTH

Q13 Q14

TRS00009

PBSS5320T PNP_Transistor Vceo=-20V Ic=-2A Pd=300mW(su

footprint standard) hfe=220_max SOT23 SMD

Q2 Q8 Q10

TRS00010

PBSS4320T NPN_Transistor Vceo=20V Ic=2A Pd=300mW(su

footprint standard) hfe=220_max SOT23 SMD

Q1 Q7 Q9

VN000025

ADDA AB1212XB-Y01 12V 1.4A Ieff=1.12A v=3100rpm

Airflow_Max=36.323CFM N=57dB/A W120.5D120.5H32mm

SM000645

VR000007

VARISTOR S20K385 EPCOS CONF(200)

RV1

12. K2-K3 SPARE PARTS LIST

19

K2 – K3 Service Manual

KAMIN

SMD00565

K/LGT/AMIN/12+DRIVER+CNTRL+COLL+HSINK

CA000257

EL.330UF200V 18X35.5 105GR LESR 7,5mm Lead spacing

3,32A Ripple 10.000hrs

C1001 C1002 C1003 C1004 C1005
C1006 C2001 C2002 C2003 C2004

C2005 C2006

DI000073

IXS DSEC29-06AC

D1005 D1006 D2005 D2006

DIS00037

FFB20UP20S 20A 200V D2 PACK

D1003 D1004 D2003 D2004

FU000026

Fuse 10A 250VDc (5x20mm) Time Delay

F1001A F1002A F2001A F2002A

IN000012

Dip-Switch 10Position BCD 0.4VAC, DC20Vmax Series Body

(10x10)mm CRD

SW3 SW4

IS000041

HI-FLOW300 145x32 AMPL.KALIN.LGT $1,25

1 pc. X channel

ML000001

MOLLE Q&D INOX

4 pc. X channel

ML000007

MOLLE K&Q&D INOX SP. 1.2

12 pc. X channel

MO000039

N-Channel SuperFET Vds 600V Id 141A 417W TO-247

FDH45N50F-133

Q1001 Q1002 Q1003 Q1004 Q2001

Q2002 Q2003 Q2004

SM000291

K/STD/DRIVER/12

rev.01 del 03/11/2004

SM000526

K/LGT/RES/10

SM000741

K/LGT/CONTROL/16

rev.02 del 27/06/2008

SO000004

P6KE18CA Bidirectional Vbr=18V Ipp=24A Pd=5W Ppp=600W

DO15 PTH

RV1001 RV1002 RV2001 RV2002

SM000635B

K/STD/FRONT/15 senza SM000326

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K2 – K3 Service Manual