m-drive...lm7812. 5 m-drive service manual index 2. removing the module’s cover 3. main board...

M-Drive

Service Manual

Keep this manualfor future reference

©2016 Powersoftpowersoft_MDrive_servman_en_v0.6

Intentionally left blank

CAUTION

RISK OF ELECTRICK SHOCKDO NOT OPEN

WE RECOMMEND THAT ALL SERVICE OPERATIONS ARE CARRIED OUT BY A TECHNICIAN IN THE MANNER DESCRIBED IN THIS GUIDE.

IF NOT EXPLICITLY STATED OTHERWISE, DISCONNECT THE AMPLIFIER FROM THE MAINS BEFORE OPERATING THE AMPLIFIER.

WARNING! INTERNAL CAPACITORS BANK COULD BE CHARGED AND HARMFUL: TAKE CARE OF COMPLETELY DISCHARGE INTERNAL CAPACITORS BANK BEFORE HANDLING THE DEVICE

This technical document aims to be a support guide in repairing and low-voltage testing the M-Drive module.The troubleshooting approach will help you characterize the kind of fault you incur. A recovery method and the related assembly outline detail is thoroughly explained for the most common faults.The components to be replaced are clearly shown to help their identification. At the end of this guide you can find a detailed list with the description and the respective Powersoft internal reference code of the spare parts.Always use an anti-static wrist band while servicing the amplifier.This documentation contains proprietary information which is the sole property of Powersoft S.p.A.These documents are confidential and reserved and may not be disclosed, reproduced and shared with third persons or used without the express written permission from Powersoft S.p.A.Should the service centre agreement between the two companies be interrupted these documents must be returned to Powersoft S.p.A. Italy or proof of their destruction be provided.

M-Drive | SERVICE MANUAL

Data are subject to change without notice.For the latest release please refer to the online version available on www.powersoft-audio.com.

INDEX

Tools:

1. Testing Equipment 42. Removing the Module’s Cover 53. Main Board Layout 54. Discharging the Module’s Capacitors Bank 65. Troubleshooting 6

Checking the Output IGBTs 6Checking the Power Supply 8Checking the AUX Voltages 8Checking the PSU Mosfets 9

6. LED Charts 97. Switching the Module On in DC 108. Checking the Module in DC 10

Function Generator 10Setup 11Checking the AUX Tensions 12Checking the TEMPMON 1/2 Thermal Limits 12Checking the Rail’s Voltages in DC (No Load) 12Switching the Module ON in AC 13Checking the Rail’s Voltages in AC (With Load) 13Audio Tests 14DPC Board LED Status Charts 15

9. Main Board Disassembly: 1610. SilPad Replacement: 1611. Known Issues 17

Excessive Gain on the Output stage 1712. Firmware Update Procedure 1813. Initialization Procedure (restore to Factory Presets) 2014. Repair Kit List 21

Index:

• Phillips PH 0 screwdriver.• Phillips PH 1 screwdriver.• M5 socket wrench.• Small cutter• Tweezers

Required Instrumentation Q.ty Example/Comments

Dual stabilized power supply 30 Vdc 5 A 2 APLHA Electronica mod. AL852D or equivalent

Digital Oscilloscope 50 Mhz 1 TEKTRONIK TBS – 1052B-EDU or equivalent

Signal generator 1 Rigol DG1022, Feeltech FY3200S

Variac 1 Toroidal 3 KW (Mono phase)

Dummy load 1500 W 8 Ohm 1 TE CONNECTIVITY / CGS TE1500B10RJ Resistor

Soldering Station 1 WELLER PU81 + WSP80 or equivalent

SMD rework soldering station 1 GORDAK 952 or equivalent

Digital Multimeter 1 FLUKE 179 or equivalent

Pc with at least 1 eth board 1

Any evidence of tampering by unathorized personnel results in immediate termination of the warranty.

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Lamp (min.40W/230V, best 60W/230V)NOT INCLUDED

IpalMod Pressure Sensor

CB000589.R DigiMod Mains DC Cable

CB000684.R DigiMod PFC2-PFC4 MDRIVE PSU AUX Voltage Cable

1. Testing Equipment

KT000291 Interface Board

KT000193 IpalMod Interface Board

CB000591.R PFC2-PFC4 PSU AUX Voltage Cable

+18Vdc

LM7812

5


INDEX

2. Removing the Module’s Cover

3. Main Board Layout:

By means of an M5 Socketed Screwdriver, remove the two metal spacers highlighted on (Fig. 1) and remove the DSP Board by unclipping it from the retaining brackets.

(Fig. 1)

(Fig. 2)

Using a PH1 Phillips Head Screwdriver, unscrew all 8 screws highlighted on (Fig. 2).Note that one of the screws could be hidden underneath the label.

Gently lift the cover from the DSP board side, disconnect the 2 fans power cables.It is now possible to safely remove the board.

CH1

CH2

PFC

EMI

FILTE

R

SECO

NDAR

Y BUL

KDS

P SL

OTS

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4. Discharging the Module’s Capacitors Bank:

5. Troubleshooting:Checking the Output IGBTs

(Fig. 3)

Highlighted on (Fig. 3) are pins 1/2 and 19/20.Connect one end of a 60w Light Bulb as indicated on (Fig. 3)

With a Multimeter set to Ohm, check for any short circuit in the Output IGBTs by probing the points highlighted on (Fig. 4)

Insert the DSP Board in the SO1000 socket.

Connect the Interface to the DSP Board.

Proceed by connecting the PFC2-PFC4 AMP AUX Voltage Cable to the PL2 connector on the module and replicate the connections on the portrayed External Power Supply.Slowly increase the output voltage on the power supply to +12Vdc and -12Vdc (Fig. 5).Check the absorption, fans and interface must be disconnected:Red +18Vdc: 40mABlack -18 Vdc: 40mAGreen +12Vdc: 470mA ± 15%Blue -12Vdc: 50mA ± 15%

The following page contains further testing procedures to be completed with the use of an oscilloscope.Zoom on the waveforms to check the shape of the resulting waves.

Out Of Range Values, Blown IGBTs are signs of malfunction in the AMP section, please order the KT000852.R KIT M-DRIVE AMP 1CH.

(Fig. 4)

Ω

Ω

(Fig. 5)

+18 V 40 mA

+12 V 470 mA

–18 V 40 mA

–12 V 55 mA

DSP Board interface connectors

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INDEX

5.00 V - 10us

5.00 V - 10us

5.00 V - 10us 5.00 V - 10us

Channel 1 Channel 2

5.00 V - 10us

5.00 V - 10us

40Vpp 48KHz

10Vpp 48KHz

1Vpp 48KHz

40Vpp 48KHz

10Vpp 48KHz

1Vpp 48KHz

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Checking the Power Supply

Checking the AUX Voltages 18 V 44mA

With a Multimeter set to Ohm, check the varistor by probing on the points highlighted on (Fig. 6)There should be no continuity between the two points.∞Ω

Ω

(Fig. 6)

Ω

(Fig. 7)

Unplug one end of both fuses and check for continuity on the points highlighted on (Fig. 7) by probing with a multimeter set to Ohm.There should be continuity between the two points.0Ω (Short)

Connect an external DC power supply to the PL1 connector by means of the PFC2 PFC4 AUX Voltage Cable, as portrayed on (Fig. 8).Slowly increase the output voltage and check the absorption:18Vdc : 44mA

(Fig. 8)

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INDEX

Checking the PSU Mosfets

13Vpp 44KHz

Color Label Description Led Status

D39 Channel Mute Default OFF

D37 Temperature Protection Default OFF

D6 +VCC Default ON

D8 -VCC Default ON

Color Label Description Led Status

D2 +5Vdc SOLID ON

D8 Signal Clip ON

D4 Protection Active ON

D5 Ready SOLID ON

6. LED Charts:

D39

D37

D6

D8

D2

D8

D5

D4

Interface BoardColor Label Signal Status

RED PROTECT

Signal protection active SOLID ON

No pressure sensorconnected BLINKING

RED LIMIT Limiter active SOLID ON

GREEN SIGNAL Input signal present SOLID ON

GREEN E.SAVE - SOLID OFF

YELLOW TEMP Thermal protection active SOLID ON

GREEN READY No faults, system fully operating SOLID ON

GREEN ON System on SOLID ON

Keep the board alive by supplying 18Vdc through the PL1 connector by means of the PSU AUX Voltage Cable.Using an oscilloscope, check the waveform’s shapes by probing the points indicated .As portrayed on (Fig. 9).

(Fig. 9)

Out Of Range Values, Blown Fuses/Varistor are sign of malfunction in the PS Section, please order the KT000851.R KIT M-DRIVE PSU Repair Kit.

18 V 44mA

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7. Switching the Module On in DC:

8. Checking the Module in DC:

Function Generator

Connect the Interface Board and the Pressure Sensor, disconnect the Fans.

Portrayed on (Fig. 10) is the connection’s diagram between two DC Power Supplies and the PL15 Connector by means of the DigiMod Mains DC Cable.

Slowly increase the voltages on both power supplies to spec, whilst on stationary regimen the current absorption should fall to 200 mA.

If the Fans are inserted the absorption should fall to 217 mA.

CAUTION: the inrush current may rise up to 3.15 Apeak!

A Function generator is needed in order to test the module’s Output Stage, since the module is DC powered and operates without a Heatsink, it is very important to test it with an adequate input signal.

The function generator must be capable of generating a signal composed by 80 ms of a 50 Hz sine-wave burst every 560 ms of silence (50 Hz 4/32 sine-wave), as portrayed on (Fig. 11).

For testing purposes, the amplitude is set to 1 VRMS

30 V 200mA

30 V 200mA 30 V 200mA

30 V 200mA

(Fig. 10)

time (ms)0 100 200 300 400 500 600

0,7

-0,7

-1,4

1,4

64080

voltage (V)

time (ms)0

0,7

-0,7

-1,4

1,4

voltage (V)

3010 20

(Fig. 11)

DISCONNECT ALL PREVIOUSLY MADE CONNECTIONS

NO LOADS CONNECTED

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INDEX

Connect the IpalMod Pressure Sensor to the CN109 connector on the module’s DSP Board.

Complete the rest of the connection between the DPC Board and the module’s DSP Board.

Connect the module to the KT000291 Interface.

Setup

PAY EXTRA ATTENTION WHEN USING THE KT000291 SERVICE BOARD, ANY IMPROPER AC-CIDENTAL CONNECTION MAY CAUSE DAMAGES

TO THE AMPLIFIER.

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Checking the AUX Tensions

Checking the TEMPMON 1/2 Thermal Limits

Checking the Rail’s Voltages in DC (No Load)

V

V

(Fig. 12)

V

(Fig. 13)

V

(Fig. 14)

With a multimeter set to V, check the tensions on the KT000291 Interface board by probing on the points highlighted on (Fig. 12)

+12Vdc: +12Vdc ±10%-12Vdc: -12Vdc ±10%+5Vdc: +5Vdc ±5%

With a multimeter set to V, check the tensions on the KT000291 Interface board by probing on the points highlighted on (Fig. 13)

TEMPMON 1/2: 1.75Vdc ±15%

Switch on the module in DC and wait 30 seconds in order to trigger the Stand-By modeWith a multimeter set to V, check the tensions on the KT000291 interface board by probing on the points highlighted on (Fig. 14)

+VCCMON 1/2: +30 Vdc ±5% (+VRail: +60 Vdc)-VCCMON 1/2: -30 Vdc ±5% (-VRail: -60 Vdc)

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INDEX

Switching the Module ON in AC

(Fig. 12)

Remove al previously made connections.

Connect a variac to the PL15 Connector, and slowly increase the voltage to 120 VAC.

Checking the Rail’s Voltages in AC (With Load)Connect the Function Generator to the module’s DPC Board. (Fig. 15)

Turn the potentiometer completely clockwise.

Feed the module with a 50Hz 8/32 Burst Sine Wave @ 1 Vrms (0 dBV, 2.21 dBu) amplitude.

(Fig. 15)

With a multimeter set to V, check the tensions on the KT000291 interface board by probing on the points highlighted on (Fig. 117)

+VCCMON 1/2: +75 Vdc ±5% (+150Vcc)-VCCMON 1/2: -75 Vdc ±5% (-150Vcc)

V

(Fig. 17)

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(Fig. 15)

Connect a FUnction Generator to input (CN11)

By means of the DigiMod Mains DC Cable, connect a Variac to the CN4 Connector and slowly increase the voltage to 120 VAC.

Genate a signal @ 0.1 Vrms - 100 Hz

Connect an oscilloscope to the CH1 output and confront the resulting wave. Repeat the operation with the remaining Channel.

Once this tests are carried out succesfully, connect a 1000W 8Ω Load to the Output and leave the unit one for at least 10 minutes (PER CHANNEL)

5.00 V - 10us 5.00 V - 10us

14.5Vpp 100Hz 14.5Vpp 100Hz

100 Hz Sine

Audio Tests

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INDEX

DPC Board LED Status Charts

Color Label LED Status

Green PRESET OFF

Green ON SOLID ON

Green READY SOLID ON

Yellow TEMP OFF

Green ESAVE OFF

Green SIGNAL SOLID ON

Red LIMIT SOLID ON

Red PROTECT OFF

LED Configuration at Startup


Green PRESET OFF

Green ON SOLID ON


Yellow TEMP OFF

Green ESAVE OFF

Green SIGNAL OFF

Red LIMIT OFF

Red PROTECT OFF

LED Configuration after 3 seconds


Green PRESET OFF

Green ON SOLID ON


Yellow TEMP OFF

Green ESAVE OFF

Green SIGNAL OFF

Red LIMIT OFF

Red PROTECT OFF

LED Configuration after 30 seconds

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9. Main Board Disassembly:

By means of a PH1 Phillips Head screwdriver, screw all 19 screws highlighted in purple.Remove the nut marked orange with a M5 socketed hex screwdriver.Gently lift the board.

10. SilPad Replacement:

IS000036 38x23mmIS000060 52x30mm

IS00

0060

IS00

0060

IS00

0060

IS00

0060

IS00

0036

IS00

0036

IS00

0036

IS00

0036

IS00

0040

IS00

0040

Always replace all silpads once the service procedure has been ultimated.Cut the IS000040 SilPad with a pair of sharp scissors.

IS000040 18x30mm

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INDEX

11. Known IssuesExcessive Gain on the Output stageSymptom: low input signals yelding to +6dB gain on the output stage.

Check R1011, R2011 (marked blue in the picture below), with a multimeter, the resistance should be 100 Ω

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X

12. Firmware Update ProcedureIn order to update the Firmware, download the latest version of the Firmware Updater on the Powersoft Website. (RESTRICTED AREA > SERVICE CENTRE AMP MODULES > MDRIVE TOOLS)Contact the Powersoft Service in order to obtain the latest firmware version.

Install the RS485 driver.

Connect the DPC Interface to the module.

Connect the module to the PC by means of the PC000096 adapter and the CB000214 cable.

Set the ID to 9.9.

Run the Firmware Updater (v1.1.40 onward).

Select “Update MDrive Firmware”. (Fig. 38)

WARNING: DO NOT DISCONNECT THE MODULE WHILST TESTING!!!

M-D

RIVE

PC

DPC

INT

RS48

5

KT000193 Interface

M-DRIVE

Pressure Sensor

SET 9.9

RS485

PCPC000096

CB000214

1

19


INDEX

Once the update has been completed, disconnect the module from the mains power supply and wait a few minutes in order to discharge the internal capacitors bank.

Cycle the module (power it on, wait for the completion of the startup procedure and switch it off)

The Firmware Update Procedure is completed.

Select the .bin file (available on the restricted area)

Select the module to be updated.Click on the right arrow.

Wait for the Red Text to disappear (approx 3 minutes) Once the Update is complete, the program will prompt a confir-mation box, click OK. The Update is now complete.

Click on “YES” to confirm the FW Update Procedure.

Tick the “Use RS485” Box, and select the assigned COM PortClick on the right arrow, the LED on the RS485 should be blinking

red.

2

4

6

3

5

7

m_drive

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Launching the PowerControl Manager

Click on the module

Select the “default preset 1.5.7.bin” File (or any of its latest releases avail-able on the restriced area)

The procedure will be over once the “loading preset” pop up disappears.

Click on the EQ Window

Click on “Load”

Click on “Find Amplifiers”Verify that the RED LED on the RS485 is blinking

Set up the working area in the same manner described in the FirmWare Update Procedure.The factory preset is available in: restricted area - service amp modules - MDrive toolsSwitch the MDrive On.

Launch the PowerControl Manager (v 2.3.15 onward)

1

3

5

2

4

6

13. Initialization Procedure (restore to Factory Presets)

21


INDEX

14. Repair Kit List:

Kit Number Description

KT000851.R KIT M-DRIVE PSU __FOR REPAIR

KT000852.R KIT M-DRIVE AMP 1CH __FOR REPAIR

KT000851.RKIT M-DRIVE PSU __FOR REPAIR

KT000852.RKIT M-DRIVE AMP 1CH __FOR REPAIR

Part Number Description Quantity

IS000036 GAP PAD 3000S30 38x23mm 4

IS000040 GAP PAD Ultra Soft 18x30mm 1

IS000060 GAP PAD 3000S30 52x30mm 4

Part Number Description

SM010001.R DSP-CTRL BOARD

VN000033 FAN

FU000026 MAINS FUSE 10A 250 Vdc (5x20 mm)

Verify that the EQ is set to Flat.

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22


IMPORTANT SAFETY ADDENDUMThe 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.

Common signs description:The following is a description of all the warning signs that are commonly implemented throughout our range of products, and those that are mandatory in every service station or workplace.

Label Meaning

General Danger

Danger: High Voltage

Danger: Hot Surface

Danger: Electrostatic Discharge (ESD)

Electrical Grounding Point

Protective Footwear Must be Worn

Observe precaution for handling Electrostatic Discharge sensitive devices

Safety precautions:We recommend to follow all precautions stated by the law while handling sensitive electrical components.

All of the servicing work must be carried in a EPA ESD compliant environment, with the exception of the mere handling of the mechanical parts.

An ESD protected workstation consists in:• Static-Dissipative working surface connected to the EBP (Farnell 1503198)• Wrist-chord and wrist band connected to the EBP (Farnell 1546970)

The technician must wear:• Protective Footwear• ESD EPA clothing (Farnell 1735510)• Static dissipative gloves (Farnell 1503210)

ALWAYS DISCHARGE THE INTERNAL CAPACITORS BANK PRIOR TO SERVICING THE AMPLIFIER

The following pictures portray the minimum ESD-Protected setup, including static dissipative working surface and wristband connected to an Earth Bonding Point connected to the ground.

Intentionally left blank

Data are subject to change without notice. For latest update please refer to the online version available on www.powersoft-audio.com

Powersoft S.p.A.Via Enrico Conti, 5

50018 Scandicci (FI) Italy

Tel: +39 055 735 0230Fax: +39 055 735 6235

General inquiries: [email protected]: [email protected]

Application & technical support: [email protected] & maintenance: [email protected]

powersoft-audio.com
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