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Digimod DigiMod 500 DigiMod 1000 DigiMod 1500 DigiMod 2000HV DigiMod 1000 NPS Service Manual ©2016 Powersoft powersoft_DigiMod500.1000.1500.2000HV.1000NPS_servman_en_v2.3 Keep this manual for future reference Intentionally left blank DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL Index: CAUTION 1. Testing Components Kit 4 2. Opening the Module’s Cover 5 3. Discharging the Module’s Capacitors Bank 6 4. Assembly Outline 6 5. Troubleshooting 7 Checking the Output Mosfets 7 Checking the R10 NTC 8 Checking the RV1 Varistor 8 Checking the F1 Fuse 8 Checking the Fan and Fan’s Driver 8 Main PCB Disassembly 9 DigiMod 500 | 1000 | 1500 | 2000HV 9 6. DigiMod 1000NPS 10 7. DC Voltage Testing 11 8. Output Current Offset Calibration Procedure 19 9. SilPad Replacement Procedure 20 10. FW Installation Procedure 21 11. Repair Kit List 22 12. Fake/Unauthorized Copies 23 RISK OF ELECTRICK SHOCK DO 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 DigiMod 500, 1000, 1500, 2000HV, 1000NPS Modules. 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. Tools: • • • • • • • • Phillips PH 0 screwdriver Phillips PH 1 screwdriver M3 hexagonal wrench M5 socket wrench Multimeter Soldering station Mains insulation transformer Function Generator INDEX Data are subject to change without notice. For the latest release please refer to the online version available on www.powersoft-audio.com. DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 1. Testing Components Kit: DigiMod Mains DC Cable PSU AUX Voltage Cable Lamp (min.40W/230V, best 60W/230V) for discharging the amplifier’s capacitors bank INDEX DigiMod AMP AUX Voltage Cable DigiMod Mains Cable 4 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 2. Opening the Module’s cover: Remove the Control Board by unscrewing the two steel spacers with a M5 socketed wrench and un-clipping the retainers highlighted in (Fig. 1) (Fig. 1) Locate and unscrew all 6 Phillips Head Screws holding the module’s cover, 3 per side. (Fig. 2,3) (Fig. 2) INDEX (Fig. 3) Carefully lift the cover, locate and unplug the fan’s power cable. (Fig. 4) (Fig. 4) 5 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 3. Discharging the Capacitor’s Bank: Connect one side of a 60W light bulb to the pins marked (+) and the other side to a ground point, repeat on the other side of the CN13 connector. (Fig. 5) ION ECT PS AM PS S ECT INDEX ION 4. Assembly Outline: Remove Jumper to Remove Jumper to insert external circuit enable DSP 6 Remove Jumper to enable DSP Remove Jumper to insert external circuit DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 5. Troubleshooting: Checking the Output Mosfets: Ω Ω DigiMod 500 | 1000 | 1500 | 2000HV Check for any short in the Output Mosfets by probing with a multimeter set to Ohm between the points highlighted in (Fig. 6). (Fig. 6) DigiMod 1000NPS Check for any short in the Output Mosfets by probing with a multimeter set to Ohm between the points highlighted in (Fig. 7). Ω Ω INDEX In case of any faults in the aforementioned components, please refer to the table below when ordering the Repair Kit. Model Kit Number Description DigiMod 500 KT000819.R KIT DM500 AMP 1CH DigiMod 1000 KT000821.R KIT DM1000 AMP 1CH DigiMod 1000NPS KT000822.R KIT DM1000NPS AMP 1CH DigiMod 1500 KT000824.R KIT DM1500 AMP 1CH DigiMod 2000 KT000827.R KIT DM2000 AMP 1CH (Fig. 7) 7 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL Checking the R10 NTC: With the Multimeter set to Ohm, check for continuity in the R10 NTC, by probing the points highlighted in (Fig. 8). Ω (Fig. 8) Checking the RV1 Varistor: Ω Flip the module upside down. With the Multimeter set to Ohm, check for continuity in the RV1 Varistor, by probing the points highlighted in (Fig. 9). (Fig. 9) INDEX Checking the F1 Fuse: With the Multimeter set to Ohm, check for continuity in the F1 Fuse, by probing the points highlighted in (Fig. 10). Ω In case of any faults in the aforementioned components, please refer to the table below when ordering the Repair Kit. Model Kit Number Description DigiMod 500 KT000818.R KIT DM500 PSU DigiMod 1000 KT000820.R KIT DM1000 PSU DigiMod 1500 KT000823.R KIT DM1500 PSU DigiMod 2000 KT000827.R KIT DM2000 PSU (Fig. 10) Checking the Fan and Fan’s Driver (DigiMod1500, 2000HV only) During the module’s booting procedure, the fan spins at full speed for a brief period of time. A first indication of any fault in the fan or the fan’s driver is the absence of the aforementioned passage. In case of any fault, remove the fan from the casing and test it by supplying it with +24 Vdc. If the fan begins to spin, the fault is in the fan’s driver, by contrast, if the fan does not begin to spin, the fault coulbe be in both the fan and its driver. Please refer to the table below if there is a fault in the Fan or the Fan’s driver. Model Kit Number Description DigiMod 1500 KT000825.R KIT DM1500 FAN DigiMod 2000 KT000828.R KIT DM2000 FAN Take care in mounting the fan with the label facing downwards, and use the original screws, longer ones could damage the capacitor’s bank. 8 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 6. Main PCB Disassembly: DigiMod 500 | 1000 | 1500 | 2000HV Using a M5 Socketed Wrench, and a regular M5 Wrench, remove all 9 screws and nuts highlighted in the pictures below. Proceed by removing the retainer spring holding the Zobel resistor in place. The image below portrays all 8 screws needed to be removed in order to separate the PCB from its casing. INDEX It is now possible to carefully lift the main PCB out of its casing. 9 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL DigiMod 1000NPS Using a M5 Socketed Wrench, and a regular M5 Wrench, remove all 4 screws and nuts highlighted in the pictures below. Proceed by removing the retainer spring holding the Zobel resistor in place. INDEX The image below portrays all 7 screws needed to be removed in order to separate the PCB from its casing. It is now possible to carefully lift the main PCB out of its casing. 10 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 7. DC Voltage Testing: Connect a DC Power Supply to the CN4 connector by means of the PSU AUX VOLTAGE CABLE. (Fig. 11) Slowly increase the voltage to +18V, and verify the consumption, it should be as stated in the following table. 18Vdc Model Consumption DigiMod 500 20 mA ±10% DigiMod 1000 20 mA ±10% DigiMod 1500 20 mA ±10% DigiMod 2000HV 20 mA ±10% 20mA INDEX (Fig. 11) In case of any faults in the aforementioned components, please refer to the table below when ordering the Repair Kit. Model Kit Number Description DigiMod 500 KT000818.R KIT DM500 PSU DigiMod 1000 KT000820.R KIT DM1000 PSU DigiMod 1500 KT000823.R KIT DM1500 PSU DigiMod 2000 KT000827.R KIT DM2000 PSU 11 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL By means of the PSU AUX VOLTAGE CABLE, supply +18Vdc to the module through the CN4 connector. With an oscilloscope, check if the waveforms on the IGBTs pins are as portrayed in the picture below. INDEX 18Vdc 12 20mA DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL Connect a DC Power supply to the CN4 connector by means of the PSU AUX VOLTAGE CABLE, and supply +18 Vdc. By means of the DIGIMOD AMP AUX VOLTAGE CABLE, connect a second power supply and set the output voltage to ± 15Vdc, and check the absorption: it should be as portrayed in the table below. Model +15V Consumption -15V Consumption DigiMod 500 230 mA ± 10% 70 mA ± 10% DigiMod 1000 300 mA ± 10% 70 mA ± 10% DigiMod 1500 300 mA ± 10% 70 mA ± 10% DigiMod 2000HV 300 mA ± 10% 70 mA ± 10% +15Vdc -15Vdc 18Vdc 20mA INDEX In case of any faults in the aforementioned components, please refer to the table below when ordering the Repair Kit. Model Kit Number Description DigiMod 500 KT000819.R KIT DM500 AMP 1CH DigiMod 1000 KT000821.R KIT DM1000 AMP 1CH DigiMod 1000NPS KT000822.R KIT DM1000NPS AMP 1CH DigiMod 1500 KT000824.R KIT DM1500 AMP 1CH DigiMod 2000 KT000827.R KIT DM2000 AMP 1CH 13 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL By means of the DIGIMOD AMP AUX VOLTAGE CABLE, connect a DC power supply and set the output voltage to ± 15Vdc. Check the shape of the waveforms by first probing on the 2, 4 pins of the U15 IC, then check the shape of the waveforms by probing on pins 6, 8. The waveforms should be shaped as portrayed in the figure below. INDEX +15Vdc 14 -15Vdc DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL By means of the DIGIMOD AMP AUX VOLTAGE CABLE, connect a DC power supply and set the output voltage to ± 15Vdc. Check the shape of the waveforms by probing the highlighted pins on the Q3, Q4, Q5, Q6 Mosfets. The waveforms should be shaped as portrayed in the figure below. +15Vdc -15Vdc INDEX 15 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL By means of the DIGIMOD PSU VOLTAGE CABLE, connect a DC power supply to the CN4 connector and set the output voltage to 18Vdc. By means of the DIGIMOD MAIN DC CABLE, connect a second DC power supply and slowly supply +30Vdc to the module. Verify the Rail Bus Voltage by probing on the highlighted points in the CN13 connector, it should be as portrayed in the following table. Model Rail Bus Voltage DigiMod 500 +/- 6.5 Vdc ±10% DigiMod 1000 +/- 6.5 Vdc ±10% DigiMod 1500 +/- 8.5 Vdc ±10% DigiMod 2000HV +/- 14.5 Vdc ±10% +30Vdc INDEX 18Vdc Ω V 16 Ω V DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL By means of the DIGIMOD AMP AUX VOLTAGE CABLE, connect a DC power supply and set the output voltage to ± 15Vdc. Check the AUX voltages by probing on the highlighted points in the CN14 connector. Alternatively it is possible to check the Aux Voltages while the board is removed from its chassis by checking the voltage regulators on the back side of the board, as indicated on (Fig. 12) +15Vdc -15Vdc INDEX -12Vdc +12Vdc +5Vdc Ground V Ground +5Vdc +12Vdc -12Vdc (Fig. 12) 17 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL By means of the DIGIMOD AMP AUX VOLTAGE CABLE, connect a DC power supply and set the output voltage to ± 15Vdc. (Fig. 13) +15Vdc -15Vdc INDEX (Fig. 13) Check the Control board by measuring its oscillator’s clock signal, it should be 12MHz. (Fig. 14) (Fig. 14) In this configuration, all 3 green LEDs should be on, whilst both yellow ones should be OFF. (Fig. 15) Any other LED configuration is a sign oaf a CNTRL Board fault, in this case replace the CNTRL Board. (Fig. 15) 18 Signal CH2 Protect -12Vdc Signal Indicated on (Fig. 16) are the Control Board LEDs and their functions. CH1 Protect +5Vdc +12Vdc DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL (Fig. 16) Connect the power cable to the CN1 connector located on the opposite side of the control board. Check if all 3 green LEDs are on. CH1 OUT - CH1 OUT + Signal Ground 1 Signal Ground 1 CH1 OUT + Balanced Input +1 Balanced Input +1 CH1 OUT - Balanced Input -1 Balanced Input -1 Signal Ground 2 Balanced Input +2 Balanced Input -2 Indicated on (Fig. 17) is the pin out of the CN7, CN12, CN11, CN3 connectors. (Fig. 17) 8. Output Current Offset Calibration Procedure: Connect a Signal Generator/Cd Player to the module via the CN12, CN11 Connectors. Supply a 1Vrms 1 KHz Sine Wave or play the first track of the Powersoft Test CD, in which case check with a multimeter if the output signal of the cd player is 1Vrms. Signal Ground 2 Balanced Input +2 Balanced Input -2 CH2 OUT + Portrayed on (Fig. 18) are the CH1, CH2 inputs, the Output Current Offset Trimmers and the Yellow LEDs. CH2 OUT - Located on both top corners of the Control Board are the Output Current Offset Trimmers, adjust them by turning the flat head screw until the yellow LEDs below turns off. (Fig. 18) 19 INDEX CH2 OUT + Verify the presence of audio signal by probing on the CN7, CN3 connectors with an oscilloscope. CH2 OUT - Connect a function generator or a cd player to the module through the CN12, CN11 connectors. Select an audio track from the Powersoft Test CD, or a Sine wave test tone. DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 9. SIlpad Replacement Procedure Once the repair procedure has been ultimated, replace all silpads. Remove any residue of dirt, glue or dust that might have been trapped in the module. The following images portray where to place the IS000040 Silpad. IS000031 HI-FLOW 40x55 mm INDEX IS000040 ULTRASOFT 18x30 mm DigiMod 1000NPS When replacing the IS000031 SilPad, clean all the components and the heatsink prior to tightening te retainer springs in place. 20 DigiMod 500, 1000, 1500, 2000HV DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 10. DSP FW installation procedure: Once the repairing procedure is over, reset the DSP board by upgrading the FW. DigiMod comes with two types of DSP boards: DSP-C (Black PCB, 4 Micro Match) DSP-D (Blue PCB, 3 Micro Match) Preset DSP Version Firmware Version Tens Units DSP-C 1.2.0 1 0 DSP-D 1.0.0 1 0 After having identified the board, connect the ribbon cable between the respective matching Programming Board and the Module’s DSP board (Or the interface board if present). (Fig. 19) (Fig. 19) Select the appropriate preset from the Preset Bank Selection control dials, by confronting the aforementioned table. Verify the position of jumper 4 should be “OPEN” (Fig. 20) Turn on the module and wait 10 sec. INDEX (Fig. 20) Verify if the green power led “PWR” and “D16” are on (Fig. 21) (Fig. 21) Press switch “S7” on the programming board Verify if the orange led “DATA” is blinking (Fig. 22) Wait for the 3 beeps signaling the end of the FW upgrade procedure. Turn off the module and remove the ribbon cable (Fig. 22) 21 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 11. Repair Kit List: Model 500 1000 1000NPS 1500 Description Part Number Description KT000818.R KIT DM500 PSU IS000031 HI-FLOW 40x55 mm KT000819.R KIT DM500 AMP 1CH IS000040 ULTRASOFT 18x30 mm KT000820.R KIT DM1000 PSU ML000009 WIRE SPRING 1.2mm cod. 28950 KT000821.R KIT DM1000 AMP 1CH SM000699.R Control Board KT000822.R KIT DM1000NPS AMP 1CH SM000700.R Control Board (DigiMod 2000HV) KT000823.R KIT DM1500 PSU VN000027 Fan 24V 0.1A (DigiMod 1500, 2000HV) KT000824.R KIT DM1500 AMP 1CH KT000825.R KIT DM1500 FAN KT000826.R KIT DM2000 PSU KT000827.R KIT DM2000 AMP 1CH KT000828.R KIT DM2000 FAN KT000818.R KIT DM500 PSU KT000819.R KIT DM500 AMP 1CH KT000820.R KIT DM1000 PSU KT000821.R KIT DM1000 AMP 1CH KT000822.R KIT DM1000NPS AMP 1CH KT000824.R KIT DM1500 AMP 1CH KT000823.R KIT DM1500 PSU KT000825.R KIT DM1500 FAN KT000826.R KIT DM2000 PSU KT000827.R KIT DM2000 AMP 1CH KT000828.R KIT DM2000 FAN INDEX 2000HV Kit Number 22 DigiMod 500 1000 1500 2000HV 1000NPS | SERVICE MANUAL 12. FAKE/UNAUTHORIZED COPIES: Please take note that the modules portrayed in the following pictures ARE FAKE UNAUTHORIZED COPIES AND ARE NOT POWERSOFT PRODUCTS. These modules are very similar to our DigiMod 500–2000HV Series and you can recognize them from the PCB layout, Control board and labels. Those fake modules’s chassis is Golden/Yellow instead of being either Black, Light Blue or Gray. Powersoft Authorized Service Centres are NOT authorized to repair these modules. Never use our kits or components in order to repair those unauthorized copies. Document any kind of encounter with fake modules and don’t hesitate to inform us. Thank you for your cooperation. INDEX 23 DigiMod 500 1000 1500 2000HV 1000NPS | 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. ALWAYS DISCHARGE THE INTERNAL CAPACITORS BANK PRIOR TO SERVICING THE AMPLIFIER 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 INDEX 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) 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. 24 Intentionally left blank Powersoft S.p.A. Via Enrico Conti, 5 50018 Scandicci (FI) Italy Tel: +39 055 735 0230 Fax: +39 055 735 6235 General inquiries: [email protected] Sales: [email protected] Application & technical support: [email protected] Service & maintenance: [email protected] powersoft-audio.com Data are subject to change without notice. For latest update please refer to the online version available on www.powersoft-audio.com