Panasonic KX-TDA0103XJ User manual

1 SUBJECT 3
1.1. The Classification of Product 3
1.2. The Classification of Service Manual 3
2 ABOUT LEAD FREE SOLDER (PbF: Pb free) 4
2.1. SUGGESTED PbF SOLDER 4
3 FOR SERVICE TECHNICIANS 5
4 CAUTION 5
4.1. NOTE 5
4.2. SAFETY PRECAUTIONS 5
4.3. INSULATION RESISTANCE TEST 5
4.4. CAUTION 5
5 SPECIFICATIONS 6
5.1. GENERAL DESCRIPTION 6
5.2. SYSTEM CAPACITY 7
6 INSTALLATION 8
6.1. INSTALLING/REPLACING THE POWER SUPPLY UNIT
8
7 DISASSEMBLY INSTRUCTIONS 11
7.1. PSU-S (KX-TDA0108XJ/X) 11
© 2006 Panasonic Communications Co., Ltd. All
rights reserved. Unauthorized copying and
distribution is a violation of law.
KX-TDA0103XJ
KX-TDA0104XJ
KX-TDA0108XJ
KX-TDA0103X
KX-TDA0104X
KX-TDA0108X
(for Asia, Oceania, Middle Near East, Africa, Latin
America and Europe)
7.2. PSU-M (KX-TDA0104XJ/X) 12
7.3. PSU-L (KX-TDA0103XJ/X) 13
8 POWER SUPPLY UNIT CIRCUIT OPERATION 15
8.1. PSU-S (KX-TDA0108XJ/X) 16
8.2. PSU-M (KX-TDA0104XJ/X) 30
8.3. PSU-L (KX-TDA0103XJ/X) 45
9 TROUBLESHOOTING GUIDE 61
9.1. KX-TDA0108XJ/X POWER UNIT TROUBLESHOOTING
61
9.2. KX-TDA0104XJ/X POWER UNIT TROUBLESHOOTING
74
9.3. KX-TDA0103XJ/X POWER UNIT TROUBLESHOOTING
90
10 HOW TO REPLACE A FLAT PACKAGE IC 106
10.1. PREPARATION 106
10.2. PROCEDURE 106
10.3. REMOVING SOLDER FROM BETWEEN PINS 106
11 CABINET AND ELECTRICAL PARTS LOCATION 107
11.1. PSU-S (KX-TDA0108XJ/X) 107
11.2. PSU-M (KX-TDA0104XJ/X) 108
Power Supply Unit
Please file and use this supplement manual together with the service manual for Model No. KX-
TDA0103XJ/KX-TDA0104XJ/KX-TDA0108XJ/KX-TDA0103X/KX-TDA0104X/KX-TDA0108X Order No.
KMS0303680C8.
CONTENTS
Page Page
ORDER NO. KMS0612695SE

11.3. PSU-L (KX-TDA0103XJ/X) 109
11.4. SCREWS AND WASHER 110
11.5. EXTENSION CORD FOR SERVICING 111
12 ACCESSORIES AND PACKING MATERIALS 112
12.1. PSU-S (KX-TDA0108XJ/X) 112
12.2. PSU-M (KX-TDA0104XJ/X) 113
12.3. PSU-L (KX-TDA0103XJ/X) 114
13 REPLACEMENT PARTS LIST 115
13.1. KX-TDA0108XJ/X 115
13.2. KX-TDA0104XJ/X 120
13.3. KX-TDA0103XJ/X 125
13.4. FIXTURES AND TOOLS 131
14 FOR THE SCHEMATIC DIAGRAM 132
15 SCHEMATIC DIAGRAM / S-TYPE POWER SUPPLY UNIT (PSU-
S) / KX-TDA0108XJ/X 134
15.1. SUB BOARD 134
15.2. MAIN BOARD 136
15.3. WAVEFORM (PSU-S) / KX-TDA0108XJ/X 139
16 SCHEMATIC DIAGRAM / M-TYPE POWER SUPPLY UNIT
(PSU-M) / KX-TDA0104XJ/X 142
16.1. MAIN BOARD 142
16.2. SUB BOARD 3 144
16.3. SUB BOARD 2 146
16.4. SUB BOARD 1 148
16.5. WAVEFORM (PSU-M) / KX-TDA0104XJ/X 149
17 SCHEMATIC DIAGRAM / L-TYPE POWER SUPPLY UNIT (PSU-
L) / KX-TDA0103XJ/X 152
17.1. MAIN BOARD 152
17.2. SUB BOARD 4 154
17.3. SUB BOARD 3 155
17.4. SUB BOARD 2 156
17.5. SUB BOARD 1 157
17.6. WAVEFORM (PSU-L) / KX-TDA0103XJ/X 158
18 PRINTED CIRCUIT BOARD 160
18.1. S-TYPE POWER SUPPLY UNIT (PSU-S) / KX-
TDA0108XJ/X 160
18.2. M-TYPE POWER SUPPLY UNIT (PSU-M) / KX-
TDA0104XJ/X 163
18.3. L-TYPE POWER SUPPLY UNIT (PSU-L) / KX-
TDA0103XJ/X 170
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

1 SUBJECT
The power supply unit is to be changed to RoHS-compliant.
Complete contents of the service manual will be revised in accordance with the change.
1.1. The Classification of Product
The product should be classified by the "Model No." displayed on the name plates of the power supply unit.
Model No. Model No. on Name plate
Before change After change
KX-TDA0103XJ
KX-TDA0103X PSLP1208 PSLP1432
KX-TDA0104XJ
KX-TDA0104X PSLP1207 PSLP1433
KX-TDA0108XJ
KX-TDA0108X PSLP1206 PSLP1453
1.2. The Classification of Service Manual
This supplement is issued for the original service manual of modified power supply unit.
Model No. Original Service Manual Order No.
Before change After change
KX-TDA0103XJ
KX-TDA0103X KMS0303680C8 KMS0612695SE
(Supplement-3)
KX-TDA0104XJ
KX-TDA0104X
KX-TDA0108XJ
KX-TDA0108X
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

2 ABOUT LEAD FREE SOLDER (PbF: Pb free)
Note:
In the information below, Pb, the symbol for lead in the periodic table of elements, will refer to standard solder or solder that
contains lead.
We will use PbF solder when discussing the lead free solder used in our manufacturing process which is made from Tin (Sn),
Silver (Ag), and Copper (Cu).
This model, and others like it, manufactured using lead free solder will have PbF stamped on the PCB. For service and repair
work we suggest using the same type of solder.
Caution
• • •
• PbF solder has a melting point that is 50 °F ~ 70 °F (30 °C ~ 40 °C) higher than Pb solder. Please use a soldering iron with
temperature control and adjust it to 700 °F ± 20 °F (370 °C ± 10 °C).
• • •
• Exercise care while using higher temperature soldering irons.:
Do not heat the PCB for too long time in order to prevent solder splash or damage to the PCB.
• • •
• PbF solder will tend to splash if it is heated much higher than its melting point, approximately 1100 °F (600 °C).
• • •
• When applying PbF solder to double layered boards, please check the component side for excess which may flow onto the
opposite side (See the figure below).
2.1. SUGGESTED PbF SOLDER
There are several types of PbF solder available commercially. While this product is manufactured using Tin, Silver, and Copper,
(Sn+Ag+Cu), you can also use Tin and Copper, (Sn+Cu), or Tin, Zinc, and Bismuth, (Sn+Zn+Bi). Please check the
manufacturer’s specific instructions for the melting points of their products and any precautions for using their product with other
materials.
The following lead free (PbF) solder wire sizes are recommended for service of this product: 0.3mm, 0.6mm and 1.0mm.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

3 FOR SERVICE TECHNICIANS
ICs and LSIs are vulnerable to static electricity.
When repairing, the following precautions will help prevent recurring malfunctions.
1.Cover the plastic parts boxes with aluminum foil.
2.Ground the soldering irons.
3.Use a conductive mat on the worktable.
4.Do not touch IC or LSI pins with bare fingers.
4 CAUTION
4.1. NOTE
When you note the serial number, write down all of the 11 digits.
The serial number may be found on the label affixed to the front of the unit.
4.2. SAFETY PRECAUTIONS
Refer to Service Manual for KX-TDA100, KX-TDA200 and KX-TDA600.
4.3. INSULATION RESISTANCE TEST
1.Unplug the power cord and short the two prongs of the plug with a jumper wire.
2.Turn on the power switch.
3.Measure the resistance value with ohmmeter between the jumpered AC plug and earth terminal.
4.If the measurement is outside the specified limits, there is a possibility of shock hazard. The equipment should be repaired and
rechecked before it is returned to the customer.
4.4. CAUTION
The power socket wall outlet should be located near this equipment and be easily accessible.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

5 SPECIFICATIONS
5.1. GENERAL DESCRIPTION
KX-TDA0108XJ/X (PSLP1453)
Input voltage AC100-130V/AC200-240V
current 1.4A/0.8A
frequency 50/60Hz
Output ch. +15V +15VPT +30V +41V
voltage 15V 15V 30V 41V
current (rated) 1.86A 1.92A 0.37A 1.13A
total output power 74 W
KX-TDA0104XJ/X (PSLP1433)
Input voltage AC100-130V/AC200-240V
current 2.5A/1.4A
frequency 50/60Hz
Output ch. +15V +15VPT +30V +40V
voltage 15V 15V 30V 41V
current (rated) 3.20A 3.84A 0.73A 2.4A
total output power 140.4 W
KX-TDA0103XJ/X (PSLP1432)
Input voltage AC100-130V/AC200-240V
current 5.1A/2.55A
frequency 50/60Hz
Output ch. +15V +15VPT +30V +41V
voltage 15V 15V 30V 41V
current (rated) 3.20A 15.4A 0.73A 4.50A
total output power 279 W
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

5.2. SYSTEM CAPACITY
5.2.1. Power Supply Unit Selection
Hybrid IP-PBX needs an optional power supply unit (PSU) suitable for its configuration. Calculate the amount of "load figures"
from the type and number of equipment to be connected, and determine the type of PSU that will be required.
Load Figure Calculation
Equipment Type Load Figure
PT DPT (T76xx series and T7560, T7565) 1
Other DPT/APT/DSS Console 4
Extension Card *1 DHLC8 8
SLC8 8
SLC16 16
MSLC16 16
CS 4
ISDN Extension 2
Voice Mail 1
*1 Only the extension cards that can support SLTs count for the load figures.
PSU Capability
Each PSU supports a different amount of load figures.
PSU Type Maximum Load Figures Available
PSU-S (KX-TDA0108XJ/X) 64 Available for the KX-TDA100
PSU-M (KX-TDA0104XJ/X) 128 Available for the KX-TDA100, KX-TDA200 and KX-TDA600
PSU-L (KX-TDA0103XJ/X) 512 Available for the KX-TDA200 and KX-TDA600
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

6 INSTALLATION
6.1. INSTALLING/REPLACING THE POWER SUPPLY UNIT
6.1.1. Function
PSU Type Lower/Upper Input Voltage Range Current Input Frequency
PSU-S
(for KX-TDA100) Lower: 100 V AC to 130 V AC 1.4 A 50 Hz or 60 Hz
Upper: 200 V AC to 240 V AC 0.8 A
PSU-M
(for KX-TDA100/200/600) Lower: 100 V AC to 130 V AC 2.5 A
Upper: 200 V AC to 240 V AC 1.4 A
PSU-L
(for KX-TDA200/600) Lower: 100 V AC to 130 V AC 5.1 A
Upper: 200 V AC to 240 V AC 2.55 A
Accessory and User-supplied Items
Accessory (included): screws x 4
User-supplied (not included): earthing wire, Back-up Battery Cable (KX-A228 for PSU-S and PSU-M, or KX-A229 for PSU-L)
Note:
• • •
• For details about frame earth connection, refer to "Installation Manual".
• • •
• For details about backup batteries connection, refer to "Installation Manual".
Safety Instructions
Each PSU complies with Safety Class 1 of IEC60950, EN60950, UL60950, CAN/CSA-C22.2 No.60950, and AS/NZS60950;
therefore a protective earth connection exists between the mains outlet ground and the PSU case. To ensure the PBX chassis
is safely grounded, it is essential that the PSU case be securely fastened to the PBX chassis with the 4 screws provided with
each PSU.
When installing or replacing PSU, basic safety precautions should always be followed to reduce the risk of fire, electric shock
and injury to persons, including the following:
1.Never install or replace PSU during a lightning storm.
2.Never install or replace PSU in wet locations.
3.Never install or replace PSU unless the AC supply and backup battery supply are disconnected.
4.To protect the back board from static electricity, do not touch parts on the back board in the main unit and PSU. To
discharge static, touch ground or wear an earthing strap.
Do not replace or remove the PSU for any other purpose.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

6.1.2. Installing the Power Supply Unit
1. Insert the PSU along the guide rails.
Caution:
For safety reasons, do not touch parts in the PSU.
2. Push the release lever in the direction of the arrow, so that the PSU is made to engage with the connector on the back board
securely.
3. Turn the 4 screws clockwise, in the order indicated by the numbers 1 to 4, to fix the PSU.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

6.1.3. Replacing the Power Supply Unit
1. Unplug the AC power cord and Back-up Battery Cable.
2. Turn the 4 screws anticlockwise to loosen them.
3. Pull the release lever in the direction of the arrow to disconnect the PSU from the back board.
4. Replace the PSU.
5. Follow the steps in "Installing the Power Supply Unit".
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

7 DISASSEMBLY INSTRUCTIONS
7.1. PSU-S (KX-TDA0108XJ/X)
1. Remove the eight screws (A).
2. Remove the screw (B).
3. Remove the chassis cover.
1. Remove the eight screws (F).
2. Remove the two screws (B).
3. Remove the angle.
4. Remove the screw (E).
5. Remove the main board.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

7.2. PSU-M (KX-TDA0104XJ/X)
1. Remove the seven screws (A) ( 3 × 6 mm).
2. Remove the screw (G) ( 3 × 4 mm).
Caution:
When putting the screw again, use the screw (G).
3. Remove the three screws (B).
4. Pull out the three connectors.
5. Remove the angle.
6. Separate the chassis body and chassis cover.
1. Remove the seven screws (F).
2. Remove the screw (E).
3. Remove the sub board 3.
1. Remove the eight screws (F).
2. Remove the main board.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

7.3. PSU-L (KX-TDA0103XJ/X)
1. Remove the two screws (A).
2. Remove the cover.
3. Pull out the connector.
1. Remove the eight screws (A).
2. Remove the three screws (B).
3. Pull out the four connectors.
4. Remove the angle.
5. Separate the chassis body and chassis cover.
(Sub Board 4)
1. Remove the sub board 4.
(Sub Board 3)
1. Remove the seven screws (F).
2. Remove the screw (E).
3. Remove the sub board 3.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

1. Remove the eight screws (F).
2. Remove the main board.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

8 POWER SUPPLY UNIT CIRCUIT OPERATION
The power unit supplies power to the various cards of the KX-TDA100, KX-TDA200 and KX-TDA600.
The functions of the power unit are listed below.
Function Description
DC voltage generation function This function generates four DC voltages (+40V, +30V, +15VPT, and +15V) from the AC power supply and
supplies them to the system.
AC cutoff detection function This function detects any cutoff of AC power supply and outputs an AC alarm signal to the MPR card.
DC abnormality detection function This function detects any abnormality in the DC voltage and outputs a DC alarm signal to the MPR card.
Overheating detection function This function detects any overheating of the power unit and shuts down the power supply in order to
preserve the safety of the system.
Two kinds of power supply unit are provided as an option depending on the card structure and the terminal structure for KX-
TDA100, KX-TDA200 and KX-TDA600.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

8.1. PSU-S (KX-TDA0108XJ/X)
This power supply unit consists of two boards.
8.1.1. Block Diagram and Circuit Description of PSU-S
[Block Diagram of PSU-S]
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

8.1.1.1. AC Input ~ PFC Output
This section explains about the operations of AC filter circuit, Rectifier circuit and PFC circuit.
1) Filter Circuit, Rectifier Circuit 1
The filter part eliminates the noise from power supply unit not to leak it out, and also the circuit prevents an incoming noise.
Varistor Z2 deals with the excessive surge voltage from thunder, etc.
Rectifier circuit 1 rectifies input AC voltage at D1, which is input to PFC circuit. Varistors Z3 and Z4 deal with the excessive
surge voltage from thunder, etc.
Refer to Fig.1 (A), (B), (C)
2) PFC Switching Circuit
Rectified input voltage at D1 is boosted by the switching operation of transformer L4, FET Q2, diode D10, and smoothed by
electrolytic capacitor C30.
The voltage between both terminals of C30 becomes PFC output voltage (DC390V TYP.).
Refer to Fig.1 (D)
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

3) PFC Controller Circuit
When the voltage is added to the Vcc terminal (Pin 8 of IC1) of PFC controller circuit, oscillation signal output (Pin 7 of IC1) is
led to the PFC switching circuit, and switches the rectified DC voltage.
As for supplying the voltage to Vcc terminal (Pin8 of IC1), it is fed from PFC start-up circuit on start-up and from Vcc voltage
feeding circuit at normal times. The supply voltage to Vcc voltage feeding circuit is fed from T1 (Sub winding).
(*1) Although it is fed from sub winding of T1 at normal times, mainly fed from Vcc voltage feeding circuit of PFC circuit.
PC1 (on Sub board) detects the operating state of PFC circuit operation and transmits the result to DC alarm detection circuit
(Refer to Alarm Signal Sending Circuit (P.28)).
Refer to Fig.1 (E), (H), (I)
IC1 (on Main board)
Pin1 FB: Voltage error amp -input
Pin2 COMP: Voltage error amp output
Pin3 MUL: Multiplexer input
Pin4 IS: Current sense
Pin5 ZCD: Zero cross current detector input
Pin6 GND: GND
Pin7 OUT: Gate pulse output
Pin8 VCC: Input voltage
4) AC Detection Circuit
Provided the input AC voltage rectified by D16 and D17 at Rectifier Circuit 2 is 80Vrms or above, transistors Q7, Q8 and Q9
(on Sub board) turn ON. The current flows through a diode of PC2 (on Sub board) and reaches the AC alarm detection circuit
(Refer to Alarm Signal Sending Circuit (P.28)).
To put it simply PC2 detects the operating state of the AC detection circuit operation and transmits the result to the AC alarm
detection circuit (Refer to Alarm Signal Sending Circuit (P.28)).
Refer to Fig.1 (F), (G)
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

8.1.1.2. Main Converter
This section mainly explains about the operation of main converter circuit which converts PFC output voltage to 41V (TYP.)
output.
1) Switching Circuit
This circuit uses Self-excited Pseudo Resonance Type Converter. This system supplies DC voltage through the following
process: The DC voltage provided from the Rectifier and Smoothing Circuit is converted into RF pulse by switching ON/OFF
MOS FET Q11 repeatedly. While Q11 is switched ON, the energy is charged in the primary of T1, and it will be discharged to
the secondary of T1 while Q11 is OFF.
Constant voltage is controlled by giving feedback to the control circuit from the output through PC601.
The main switch Q11 is controlled by IC2.
Refer to Fig.2 (A), (B).
2) Main Converter Output Circuit
T1 output voltage is rectified by D101, and smoothed by capacitors C104 and C105 (41V TYP.).
Refer to Fig. 2 (C)
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X

IC2 (on Sub board)
Pin1 Corrector
Pin2 Vout
Pin3 Emitter
Pin4 VF
Pin7 ON/OFF
Pin8 OVP
Pin9 DET
Pin10 F/B
Pin11 T-ON
Pin12 CF
Pin13 T-OFF
Pin14 CT
Pin17 GND
Pin18 CLM-
Pin19 CLM+
Pin20 Vcc
Pin5, 615, 16 Heat Sink Pin
3) Latch Circuit
When secondary side protection circuit (Refer to Protection Circuit (P.29)) worked in abnormal state, the signal is sent to OVP
terminal (Pin8 of IC2) of primary side through PC4. Therefore, switching operation of Q11 is stopped and the main converter
operation is stopped.
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KX-TDA0103XJ / KX-TDA0104XJ / KX-TDA0108XJ / KX-TDA0103X / KX-TDA0104X / KX-TDA0108X