powersoft K2 Service Manual
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powersoft K2 Service Manual

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K2 K3
Top class amplification covering
any power needs in touring applications
Service Manual
©2019 Powersoft
Keep this manual
powersoft_K2K3_servman_en_v4.4
for future reference

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  • Page 1 K2 K3 Top class amplification covering any power needs in touring applications Service Manual ©2019 Powersoft Keep this manual powersoft_K2K3_servman_en_v4.4 for future reference...
  • Page 2 Intentionally left blank...
  • Page 3 8. Removing the display This technical document aims to be a support guide in repairing 9. Firmware update procedure and low-voltage testing the K2 and K3 power amplifiers. 10. Removing the control board (k-cntrl) The troubleshooting approach will help you characterize the kind Menu Diagrams of fault you incur.
  • Page 4 K2 K3 | SERVICE MANUAL 1. Service repairing kit: SERVICE CTRL BOARD firmware 2.0.5 SERVICE FRONT DISPLAY firmware 2.0.5 (testing purposes ONLY) (testing purposes ONLY) K LGT MAINS DC CABLE RAIL BUS VOLTAGE CABLE CB000582.R CB000587.R PSU AUX VOLTAGE CABLE ZOBEL RESISTOR CABLE CB000586.R...

  • Page 5: Opening The Amplifier Cover

    K2 K3 | SERVICE MANUAL 2. 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 lasrgest screws with a Phillips PH1 screwdriver.
  • Page 6 K2 K3 | SERVICE MANUAL If the LEDs are still on discharge the capacitors bank by connecting a 40 W/230V lamp to the connectors portrayed in (Fig. 4) Lamp (min.40W/230V, best 60W/230V) (Fig. 4) Once the amplifier is open and its power supply fully discharged, it is possible to start removing the single boards. (Fig. 5)
  • Page 7 K2 K3 | SERVICE MANUAL Power Supply Overview +Vdc MAINS DC/DC 90 V - 270 V CONVERTER Rectifier -Vdc When the amplifier is switched on, the following actions are performed: 1. The DC/DC converter starts, and the capacitors are charged 2.
  • Page 8 K2 K3 | SERVICE MANUAL Power Supply Stages Remove the card reader to access the components beneath. 6 Diodes - AUX Rectifier Colour Description Notes MAINS PARALLEL FUSES Grant Over-Current Protection 2 VARISTORS (385 Vac) Protect from Over-Voltage INPUT EMI FILTERS Filter electromagnetic interferences Act before P.F.C...
  • Page 9 K2 K3 | SERVICE MANUAL DC/DC Converter Colour Description Notes POWER IGBTs Used for the DC/DC Converter 3 DIODES Secondary Rectifier 2 PARALLEL TRANSFRMERS Manage current for the entire system and the AUX TRANSFORMER Senses the current in the DC/DC converter...
  • Page 10 K2 K3 | SERVICE MANUAL P.F.C. Booster The P.F.C. Booster boosts the P.F.C. Output to 410 VDC Colour Description COIL 3 MOSFETS DIODE CONTROL CIRCUIT...
  • Page 11 K2 K3 | SERVICE MANUAL Colour Description CONNECTION TO THE OUTPUT STAGE...
  • Page 12 K2 K3 | SERVICE MANUAL Output Stage Components + Vdc - Vdc Colour Description Notes CH 1 CH 2 FAST RECOVERY DIODES PARALLELED MOSFETS (2X) Remove the resistors before checking the Diode. 1 DIODE + 2 PARALLELED RESISTOR (2X) Diodes and MOSFETS are paralleled (Check both)
  • Page 13 K2 K3 | SERVICE MANUAL Driver Board Heatsink Removed - Driver Board still mounted KAESOP The Zobel Resistor Network is located underneath the Heatsink Control...

  • Page 14: Troubleshooting

    K2 K3 | SERVICE MANUAL 4. Troubleshooting: Power Supply Board With the multimeter set to Ohm, check for continuity in the fuses and the varistor highlighted in (Fig. 6) A blown fuse or varistor are indicors of a overvoltage induced fault, please proceed with the following tests and remove PSU board from the chassis.

  • Page 15: Amp Board

    K2 K3 | SERVICE MANUAL Amp Board Amp Board Overview With the multimeter set to Ohm, check for short circuit in the mosfets by probing between the highlighted end of the fuse holder and the top if the resistors as portrayed in the following pictures.

  • Page 16: Removing The Power Supply Board

    K2 K3 | SERVICE MANUAL 5. Removing the power supply board: Unscrew the fan’s power cables and disconnect the faston between the power supply board and the output amplifier board. (Fig. 9) (Fig. 9) Disconnected fastons between power supply board, output amplifier...
  • Page 17 K2 K3 | SERVICE MANUAL Disconnect the amplifier power switch cable by removing the faston behind it as portrayed in (Fig. 11). (Fig. 11) 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.
  • Page 18 K2 K3 | SERVICE MANUAL Detail of screws number 1-2 Detail of screws 3 and 4 Detail of screw number 5 Detail of screw number 6 Detail of screw number 7 Detail of brass riser (screw number 8)
  • Page 19 K2 K3 | SERVICE MANUAL Once all 8 screws have been removed, remove the power supply board heat sink outer-most screws with an M3 hexagonal key as portrayed in (Fig. 13). (Fig. 13) Heat sink screws removed...
  • Page 20 K2 K3 | SERVICE MANUAL Now remove the mains plug holder by pressing on its sides; then remove the mains socket screws, as portayed in (Fig. 14). (Fig. 14) Mains connector screws removed Proceed in unscrewing the nut that holds the earth ground cable behind the mains power connector as portrayed in (Fig.
  • Page 21 K2 K3 | SERVICE MANUAL By unscrewing all 14 higlighted screws portrayed in (Fig. 16) it is possible to remove the rear panel. (Fig. 16) Removed rear panel Lastly, remove the Fan by unscrewing the two cable holders and the three screws higlighted in (Fig. 17, 18) (Fig.
  • Page 22 K2 K3 | SERVICE MANUAL Fan removed from the amplifier chassis Now it is finally possible to remove the power supply board from the chassis as portrayed in (Fig. 19). Gently lift and pull the board paying attention not to damage any of its components.

  • Page 23: Removing The Heatsink

    K2 K3 | SERVICE MANUAL Removing the Heatsink: Using a socketed screwdriver unscrew all 12 bolts highlighted in (Fig. 20). (Fig. 20) With a thin piece of strong plastic, pry all the components off the heatsink so that a little gap is formed between the two, as portrayed in (Fig.

  • Page 24: Cleaning The Heatsink

    K2 K3 | SERVICE MANUAL Cleaning the Heatsink: Peel off the SilPad from both sides of the heatsink Using a plastic scraper, remove the leftover glue Dampen a clean cloth with some isopropyl alcohol and wipe off the excess residues.

  • Page 25: Fault Finding

    K2 K3 | SERVICE MANUAL Fault Finding: Locate the F1, F2 fuses and the TP1, TP2 Test Points (Fig. 23) With the mutimiter set to Ohm, check for continuity on both F1, F2 fuses. (Fig. 24) Locate TP1 and TP2 on the KLASV11 board and check the resistance between these two Test Points.
  • Page 26 K2 K3 | SERVICE MANUAL Locate the Q3, Q4, Q5 Mosfets. (Fig. 26) Set the multimeter to Ohm and check the Mosfets as portrayed in (Fig. 27) (Fig. 26) If the resistance is = 0, ask for the KT000834.R K LGT PFC KIT (Fig.
  • Page 27 K2 K3 | SERVICE MANUAL Locate the CN5 Connector and insert the PSU VOLTAGE cable. (Fig. 28) Supply 18 Vdc by slowly incrementing the Voltage from 0 Vdc Check for proper absorption, it should be 45mA ± 10% (Fig. 29) If the absorption value doesn’t match the DC/DC...
  • Page 28 K2 K3 | SERVICE MANUAL By means of an oscilloscope, check the signal on the Q11, Q12 Gates. (Fig. 30) In case of absence of signal ask for either KT000833.R K LGT DC/DC CONV KIT KT000801.R K LGT DC/DC CONV KIT...
  • Page 29 K2 K3 | SERVICE MANUAL Final inspection (DC mains) By means of the PSU AUX VOLTAGE CABLE, and the LGT MAINS DC CABLE, connect the board to two DC power supply and slowly increment the voltages to the illustrated values in order to check the absorption. (Fig.
  • Page 30 K2 K3 | SERVICE MANUAL Locate the FA1, FA2, FA3 Faston connectors. (Fig. 32) (Fig. 32) With a multimeter, check the Rails’s voltages. (Fig. 38) FA1: + Rail: 10Vdc ~ 13Vdc FA2: Ground FA3: - Rail: -10Vdc ~ -13Vdc (Fig. 33)
  • Page 31 K2 K3 | SERVICE MANUAL Final inspection (AC mains) Plug a switch to the fastons highlighted in (Fig. 34), as portrayed in (Fig. 35). (Fig. 34) (Fig. 35)
  • Page 32 K2 K3 | SERVICE MANUAL By means of the K LGT MAINS DC CABLE, connect a variac to the main inlet as portrayed in (Fig. 36) (Fig. 36) Proceed by engaging the switch in (Fig. 35), and gradually increase the voltage on the variac to 80Vac.

  • Page 33: Removing The Amplifier Output Board

    K2 K3 | SERVICE MANUAL 6. Removing the amplifier output board: Before removing the amplifier output board, please discharge the power supply capacitors as illustrated in chapter Start from unscrewing the rear panel connectors removing the mains connector screws and plug holder.
  • Page 34 K2 K3 | SERVICE MANUAL Remove the two flat cables between the power supply board and the amplifier output board. (Fig. 40) (Fig. 40) Flat cable removed Remove the nuts holding the amplifier output board heat sink as portrayed in (Fig. 41) (Fig.
  • Page 35 K2 K3 | SERVICE MANUAL Now remove the amplifier output board by unscrewing all 7 screws marked in the following pictures. Amplifier output board overview Screw 1 Screws 2, 3, and 4 Screw 5 and 6 Screw 7...
  • Page 36 K2 K3 | SERVICE MANUAL Once all 7 screws have been removed, unplug the two flat cables connecting the optional KAESOP board (if installed) to the front panel RJ45 plugs as portrayed in (Fig. 42) (Fig. 42) Unplugged KAESOP flat cable Pull back the amplifier output board in order to unplug the two control board’s flat cables (Fig.
  • Page 37 K2 K3 | SERVICE MANUAL Now it is finally possible to remove the amplifier output board from the amplifier chassis as portrayed in (Fig. 44). Gently lift and pull the board paying attention not to damage any of its components.
  • Page 38 K2 K3 | SERVICE MANUAL Removing the Heatsink: In order to access the mosfets remove the heatsink by first unplugging the 4 fastons highlighted in (Fig.45). Using a socketed screwdriver unscrew all 10 bolts highlighted in (Fig. 45). (Fig. 45)
  • Page 39 K2 K3 | SERVICE MANUAL Cleaning the Heatsink: Peel off the SilPad from both sides of the heatsink Using a plastic scraper, remove the leftover glue Spray some WD40 (or equivalent) on a clean cloth and wipe off the excess residues.
  • Page 40 K2 K3 | SERVICE MANUAL Fault finding Verify the two CH1 F1001 and F1002 fuses and the two CH2 F2001 and F2002 fuses by means of a digital multimeter set to Ohm. In case of fault in one of the fuses we recommend to check the condition of the Mosfets of every channel.

  • Page 41: Final Inspection

    K2 K3 | SERVICE MANUAL Final Inspection: Remove the existing CTRL BOARD from the output stage board Insert the SERVICE CTRL BOARD (Fig. 49) (Fig. 49) Install the three heat sink on the each voltage regulator as showed in U1, U2 and U3 (Fig. 50) (Fig.
  • Page 42 K2 K3 | SERVICE MANUAL On the dual voltage power supply set the output voltage at ±18 V Connect the K AMP VOLTAGE AUX CABLE ribbon cable (20 pins) between CN14 of output stage board and the power supply as portrayed in (Fig. 53, 54) (Fig.
  • Page 43 K2 K3 | SERVICE MANUAL Consumption of the output stage board Verify the consumption of the auxiliary voltage of the output stage board (Fig. 56): +18 V approx. 0,90 A (with rail bus voltage at 0 V -18 V approx. 0,25 A (with rail bus voltage at 0 V...

  • Page 44: Removing The Fan

    K2 K3 | SERVICE MANUAL 7. Removing the fan: Prior to removing the fan please proceed in discharging the power supply’s capacitors bank as explained in chapter Begin the fan disassembly by unscrewing the fans power cables (Fig. 59). (Fig. 59)
  • Page 45 K2 K3 | SERVICE MANUAL 8. Removing the display (K-FRONT): Before removing the display, discharge the power supply capacitors bank as explained in chapter Remove the Faston connectors connecting the amplifier power switch as portrayed in (Fig. 62) (Fig. 62)
  • Page 46 Remove the display from the front panel by unscrewing the four screws highlighted in (Fig. 67) (Fig. 67) When replacing the K-FRONT, please provide Powersoft the Model and Serial Number of the amplifier, since the K-FRONT will be customized for that specific amp.

  • Page 47: Firmware Update Procedure

    K2 K3 | SERVICE MANUAL 9. Firmware update procedure: There is no need to update the amp’s firmware when replacing the power supply board. The following will illustrate actions to be undertaken in case of amplifier board or K front board replacement (see K front de-mounting procedure at the end of this chapter if needed).
  • Page 48 K2 K3 | SERVICE MANUAL Updating the Smart Card: By means of the PFF file and the Powersoft Firmware Updater Software it is possible to update the firmware stored into the Powersoft Firmware Update Smart Card. The PFF file is a package of firmwares for KFRONT, KCNTRL and KDSP boards of K Series or Duecanali amplifier.
  • Page 49 (Fig. 72) If you forget to press the first right-hand MENU button on your amplifier BEFORE inserting the smart card, the Powersoft Firmware Updater Software displays the warning message portrayed on (Fig. 73) (Fig. 73) Remember to mark the smart card according to the firmware version.

  • Page 50: Removing The Control Board (K-Cntrl)

    K2 K3 | SERVICE MANUAL 10. Removing the control board (K-CNTRL): To remove the amp control board please proceed in discharging the power supply’s capacitors bank as explained in chapter Remove the 3 screws higlighted in (Fig. 74) (Fig. 74) Extract the amp board with care.

  • Page 51: Further Settings

    K2 K3 | SERVICE MANUAL Offset output current reset procedure Output attenuation shall be set at 0 dB: go to Menu → setting → amplifier setting → Output attenuation Gain shall be set to 32 dB and V shal be set according to the amplifier model: go to Menu →...

  • Page 52: Menu Diagrams

    K2 K3 | SERVICE MANUAL Menu Diagrams Main Menu Diagram DSP Settings...
  • Page 53 K2 K3 | SERVICE MANUAL 11. Copying the PAM files from a Virtual Machine to a Real Machine Import a Virtual AMP from the Model List. Open Discovery Remote Entities. Drag&Drop the real amp onto the virtual one. An arrow should appear when hovering the real AMP over the virtual one.

  • Page 54: Error Codes

    K2 K3 | SERVICE MANUAL 12. Error codes: Expired FW 5.3.8 displayed: contact service centre. Error Code Error Description Board 192KHz clock not present CNTRL Positive 15V aux Negative 15V aux Positive 5V analog Negative power rail Ch1 Negative power rail Ch2...
  • Page 55 K2 K3 | SERVICE MANUAL 14. Repair KIT list: KIT NUMBER DESCRIPTION KT000801.R K LGT PSU DC/DC CONVERTER KT000803.R K LGT PSU OVRVTG KT000804.R K LGT FAN KT000805.R K LGT AMP 1CH KT000833.R K LGT PSU DC/DC CONVERTER KT000834.R K LGT PSU PFC KT000888.R...

  • Page 56: Mechanical Parts

    K2 K3 | SERVICE MANUAL 15. Mechanical parts: Part Number Description VI000009 Top Side Cover Screw (short) VI000024 Heatsink Screw ME000235 Heatsink Brass Spacer VI000034 Rear Connector Screw VI000057 Internal Board Screw VI000110 Internal Board Pillar VI000112 Rear Bracket Screw...
  • Page 57 K2 K3 | SERVICE MANUAL Powersoft K LGT ME000214 ME000220 ME000215 ME000219 ME000284 TA000005.00 ME000214 ME000284 ME000359 ME000360 ME000370.2 (RS485) ME000371.2 (ETH) ME000391 ME000358 ME000363 ME000213 ME000357 ME000334 ME000218 ME000210...
  • Page 58 ME000363 Chassis lexan protection ME000218 K Series Powersoft blue front plate ME000389 PSU coil lexan protection ME000219 K Series Powersoft RX blue front side ME000391 Fan lexan air conduct ME000220 K Series Powersoft LX blue front side ML000016 EMI Spring...
  • Page 59 K2 K3 | SERVICE MANUAL Martin Audio 5.2 K ME000324 ME000330 ME000328 ME000329 TA000005.00 ME000324 ME000359 ME000376 ME000368 (RS485) ME000391 ME000358 ME000363 ME000327 ME000357 ME000334 ME000487 ME000326...
  • Page 60 K2 K3 | SERVICE MANUAL K - Series Mechanical parts “Martin Audio vers.” K - LGT No ETH version Part Number Description SM00F819.3 MA_Front_side SM00P819.3 MA_5.2_Front_Rear_side Rs 485 Vers. SM00F819.3 MA_Front_side SM00P819.3 MA_5.2_Front_Rear_side Rs 485 Vers. Part Number Description Part Number...
  • Page 61 K2 K3 | SERVICE MANUAL OUTLINE T5 ME000327 ME000320 ME000215 ME000319 ME000284 TA000005 ME000321 ME000284 ME000359 ME000375 ME000366.2 (RS485) ME000391 ME000358 ME000363 ME000213 ME000357 ME000334 ME000487 ME000210...
  • Page 62 K2 K3 | SERVICE MANUAL K - Series Mechanical parts “Outline vers.” K_LGT_No_ETH version Part Number Description SM00F910.3 Outline_Front_side SM00P910.3 Outline_T5_Front_Rear_side Rs 485 Vers. SM00L645.3 K_LGT_Platform Rs 485 Vers. SM00F910.3 Outline_Front_side SM00P910.3 Outline_T5_Front_Rear_side Rs 485 Vers. Part Number Qty Description...
  • Page 63 OP000003 CV000068 - K-LGT China *When Ordering, inform the Powersoft Customer Care about Product Serial Number and Amp Model for customization. **If the unit displays the “Check Rail Fuses” message after the FW Upgrade, please contact the Powersoft Customer Care.
  • Page 64 Powersoft, please contact Powersoft for further informations. Powersoft KDSP upgrade kit Powersoft DSP upgrade Kit comes as a DSP board protected in an electrostatic shielding envelope, two brass spacers and a kit of labels.
  • Page 65 Open the front panel left grid removing the screw as in (Fig. 83). It is possible to retrofit the optional KAESOP board on every K Series amplifier with serial number greater than 19062, older serial numbers need to be sent to Powersoft, please contact Powersoft for further informations.  ...
  • Page 66   K2 K3 | SERVICE MANUAL Screw the brass spacers provided with the KAESOP kit. (Fig. 92) Once the flat cables are inserted, position the new RJ45 board using the same black screw and brass spacer support standoff that were  ...
  • Page 67 Install procedure is showed in the following pictures.     The Powersoft Firmware Updater utility can be used to update the KAESOP board firmware with an easy guided procedure. The software can update an unlimited number of amplifiers in a parallel manner, taking just a couple of minutes for completing the  ...
  • Page 68 K2 K3 | SERVICE MANUAL         Lastly, perform a Firmware update as described in the previous section.
  • Page 69 JP 2000 SA20 2 MA 5.2 K T FIVE JP 3000 BIAS V3 SA30 2 OEM STEP UP PROCEDURE WARNING In order to perform the step-up procedure for OEM amplifiers, please contact Powersoft to receive a customized step up card.

  • Page 70: Safety Precautions

    K2 K3 | SERVICE MANUAL IMPORTANT SAFETY ADDENDUM The aim of this addendum is to describe the safety precautions to be undertaken when servicing any Powersoft amplifier/module. WE RECOMMEND THAT ALL SERVICE OPERATIONS ARE CARRIED OUT BY A TRAINED TECHNICIAN IF NOT EXPLICITLY STATED OTHERWISE, DISCONNECT THE AMPLIFIER FROM THE MAINS.
  • Page 71 Intentionally left blank...
  • Page 72 Fax: +39 055 735 6235 General inquiries: info@powersoft.it Sales: sales@powersoft.it Application & technical support: support@powersoft.it Service & maintenance: service@powersoft.it powersoft-audio.com powersoft_k2k3_service_man_v2.1 Data are subject to change without notice. For latest update please refer to the online version available on www.powersoft-audio.com.

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