K2 – K3 Series

K2 – K3 Series
K2 – K3 Series
Version 1.4
July 2013
powersoft_k2k3_service_man_v1.4.docx
© 2013 Powersoft
Index
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
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K2 – K3 Service Manual
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.
Smaller screw, screwdriver Phillips PH 0
Rail LEDs should be off; if not, discharge capacitor banks
Bigger screws, screwdriver Phillips PH 1
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:
If the LEDs are still on discharge the capacitors bank by
connecting a lamp of at least 40 W/230V
Lamp (min.40W/230V, best 60W/230V): dummy load for discharging the
amplifier’s capacitors bank
to the connectors seen in the two pictures below
Eight screws, screwdriver Phillips PH0
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.
Position of connectors for discharging capacitors bank
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K2 – K3 Service Manual
Fastons between power supply board, output amplifier board and fan
power cables to be disconnected
Following this, unscrew the fans power cables close to
the previous faston.
Negative to this connector
Positive to this connector at first and then to this other one
Detail of connectors
Once the amplifier is open and its power supply fully
discharged, it is possible to start removing the single
boards.
Disconnected fastons between power supply board, output amplifier
board and fan power cables
Disconnect and remove the flat cable bridge between
the power supply board and output amplifier board:
Opened amp
3. REMOVING THE POWER SUPPLY BOARD
Disconnect the faston between the power supply board
and the output amplifier board :
Flat cable to be removed
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K2 – K3 Service Manual
Removed flat cable
Disconnect the amplifier power switch cable removing
the faston behind it:
Overview of the 7 screws (1-7) and of the brass stand-off (8)
to unscrew for removing the power supply board
Amplifier power switch cable to be removed
Detail of screws number 1-2
Faston of the amplifier power switch cable removed
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:
Detail of screws 3 and 4
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K2 – K3 Service Manual
Detail of brass stand-off (screw number 8)
Detail of screw number 5
Once all the 8 screws have been removed, remove the
power supply board heat sink screws with an M3
hexagonal key:
Detail of screw number 6
Detail of screw number 7
Heat sink screws to be removed
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K2 – K3 Service Manual
Mains connector screws removed
Proceed in unscrewing the nut that holds the earth
ground cable behind the mains connector:
Heat sink screws removed
Now remove the mains plug holder by pressing on its
sides; then remove the mains socket screws:
Earth ground nut to be removed
Now remove the rear panel:
Rear panel screws to be removed
Mains connector screws to be removed
Detached rear panel
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K2 – K3 Service Manual
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:
Fan power cable holders to be removed
Lift and pull the power supply board to remove it
from the amplifier chassis
Fan screws to be removed
Power supply board removed from the amplifier chassis
Fan removed from the amplifier chassis
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K2 – K3 Service Manual
4. REMOVING THE AMPLIFIER OUTPUT
BOARD
Now remove the two flat cables between the power
supply board and 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:
Flat cable to be removed
Mains connector screws to be removed
Flat cable removed
Remove the nuts that hold the amplifier output board
heat sink:
Removed mains connector screws
proceed in removing the all rear panel by unscrewing the
screws as marked in the images below
Rear panel screws to be removed
Detached rear panel
Unscrew this nut
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K2 – K3 Service Manual
Screw 4 to be removed
Screw 5 and 6 to be removed
Nuts unscrewed and removed
Now remove the amplifier output board by unscrewing
the 7 screws marked in the overview image below and
in the following images:
3
4
5
2
1
7
6
Amplifier output board overview
Screw 7 to be removed
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:
Screws 1, 2 and 3 to be removed
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K2 – K3 Service Manual
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:
Control board flat cables to unplug
KAESOP flat cable to unplug
Control board flat cables unplugged
Now it is finally possible to remove the amplifier output
board from the amplifier chassis:
KAESOP flat cables unplugged
Lift and pull out the amplifier output board from the amplifier
chassis
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K2 – K3 Service Manual
Remove the fan power cable holders:
Amplifier output board out of the amplifier chassis
5. REMOVING THE FAN
Fan power cable holders to be removed
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.
Fan power cables to be disconnected
Removed fan power cable
Fan removed from the amplifier chassis
Disconnected fan power cables
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K2 – K3 Service Manual
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:
Screw for removing right ear
Remove the left and right protection plates:
Screws for removing the protection plates
The front panel is now free from the amplifier chassis.
Amplifier power switch cable to be disconnected
Front panel removed from the amplifier chassis
Disconnected faston of the amplifier power switch cable
Unplug these two flat cables from the display
Now remove the front panel left and right ears:
Remove the display from the front panel by unscrewing the
four screws seen below:
These four screws needs to be removed to free the display
Screw for removing left ear
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K2 – K3 Service Manual
8. FIRMWARE UPDATE PROCEDURE
Display removed from front panel
7. INSTRUMENTS AND TOOLS FOR TESTING
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

DC POWER SUPPLY 0-50 Vcc f.s. 5 A.

DC POWER SUPPLY +/- 30Vcc 0-3 A.

FUNCTION
PLAYER.

OSCILLOSCOPE DOUBLE TRACE. (IT
MUST BE DISCONNECTED FROM THE
GROUND)

DIGITAL MULTIMETER.

BOOST VOLTAGE CABLE (CB000081)
GENERATOR
OR
CD
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)
AMP CPC Mains
3 way
1
2
Plugs 4mm

VOLTAGE
(CB000077)
Molex 3 pin female 2,54
AUXILIARY
CABLE
Plugs 4mm
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
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.
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:
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.
Offset output current regulations
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:
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:
10. ERROR CODES
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
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
12. K2-K3 SPARE PARTS LIST
KALIN
Part Number
Description
SMD00611
K/LGT/ALIN/12+TEST+HSINK
PCB position
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
IN000010
IRG4PC50UDPbF N-Channel Gate Bipolar Trans IGBT 600V 50A
TO-247AC
Switch Rocker Single Pole SP-ON 6A 250Vac 13-Round Body
(Ø=20.2)mm Color
Q11 Q12
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
RE000335
TO000099.2
TR000003
TRS00009
TRS00010
VN000025
VR000007
FCH47N60F_F133 NChannel_SuperFET Vds=600V
ID@25°C=47A Pd=417W TO-247 PTH
NTC 2 Ohm 12A 20% P5.1W (21x7x28)mm Pitch 7.5mm S364
Series CONF(100)
"K-LGT" RES.CONV.TRASF.135015 E42/21/15 3C92 CSA from
20/09 Furukawa
BDW93CFP NPN_Darlington_Power_Transistor Vceo=100V
Pd=33W 100<hFE@10A(Ic)3V(Vce)<20000 TO220FP PTH
PBSS5320T PNP_Transistor Vceo=-20V Ic=-2A Pd=300mW(su
footprint standard) hfe=220_max SOT23 SMD
PBSS4320T NPN_Transistor Vceo=20V Ic=2A Pd=300mW(su
footprint standard) hfe=220_max SOT23 SMD
ADDA AB1212XB-Y01 12V 1.4A Ieff=1.12A v=3100rpm
Airflow_Max=36.323CFM N=57dB/A W120.5D120.5H32mm
VARISTOR S20K385 EPCOS CONF(200)
Q3 Q4 Q5
R54
T5 T6 (ORA SONO CSA)
Q13 Q14
Q2 Q8 Q10
Q1 Q7 Q9
SM000645
RV1
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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
F1001A F1002A F2001A F2002A
IN000012
Fuse 10A 250VDc (5x20mm) Time Delay
Dip-Switch 10Position BCD 0.4VAC, DC20Vmax Series Body
(10x10)mm CRD
IS000041
HI-FLOW300 145x32 AMPL.KALIN.LGT $1,25
1 pc. X channel
ML000001
MOLLE Q&D INOX
4 pc. X channel
ML000007
MO000039
MOLLE K&Q&D INOX SP. 1.2
N-Channel SuperFET Vds 600V Id 141A 417W TO-247
FDH45N50F-133
12 pc. X channel
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
SO000004
K/LGT/CONTROL/16
P6KE18CA Bidirectional Vbr=18V Ipp=24A Pd=5W Ppp=600W
DO15 PTH
SM000635B
K/STD/FRONT/15 senza SM000326
SW3 SW4
rev.02 del 27/06/2008
RV1001 RV1002 RV2001 RV2002
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K2 – K3 Service Manual
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