powersoft IpalMod User manual

IpalMod
Service Manual
Keep this manual
for future reference
©2017 Powersoft
powersoft_IpalMod_servman_en_v3.1

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INDEX
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IPALMOD | SERVICE MANUAL
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 IpalMod amplier 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
identication. At the end of this guide you can nd 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 amplier.
Data are subject to change without notice.
For latest update please refer to the English online version available
on www.powersoft-audio.com.
Tools:
1. Testing Equipment 4
2. Discharging the Module’s Capacitors Bank 5
3. Removing the cover 6
4. Main Board Layout 6
5. Disassembling the main board 7
6. Troubleshooting 7
Checking the output mosfets 8
Checking the fuse and varistor 8
Checking the PSU Stage 9
Switching the module on in DC 10
Checking the Vrails voltage in DC 10
Checking the output stage 13
7. Testing the module in AC 13
Switching the Module on in AC 15
Checking the rails voltage in AC 16
Audio Tests 16
8. Offset calibration 17
9. LED charts 18
10. Known Issues 18
Excessive Gain on the Output Stage 18
11. Reassembling the module 18
12. Firmware Update Procedure 21
13. Initialization Procedure 23
14. Repair Kit List 24
Index:
• Phillips PH 0 screwdriver.
• Phillips PH 1 screwdriver.
• M5 socket wrench.
• Small cutter
• Tweezers
This documentation contains proprietary information which is the
sole property of Powersoft S.p.A.
These documents are condential 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.
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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IPALMOD | SERVICE MANUAL
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1. Testing Equipment:
CB000586.R PSU AUX VOLTAGE CABLE CB000589.R DIGIMOD DC MAINS CABLE
CB000691.R DIGIMOD AMP AUX VOLTAGE CABLE
KT000193 - IPALMOD INTERFACE BOARD
SM000530 - IpalMod Pressure sensor
Lamp (min.40W/230V, best 60W/230V) for discharging the
amplifier’s capacitors bank
NOT INCLUDED

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2. Discharging the Module’s Capacitors Bank:
Connect a 60W light bulb to the points indicated on (Fig. 1).
(Fig. 1)
3. Removing the cover:
In order to access internal components and circuitry
follow these instruction to remove the top cover.
Unplug the two CN09 and CN10 fan connectors
and remove the 2 pillars holding the Control boards
highlighted on (Fig. 2)
Unscrew the 6 lateral screws, 3 per side. (Fig . 3)
Gently lift the top cover. (Fig. 4)
(Fig. 2)
(Fig. 3)
(Fig. 4)

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4. Main Board Layout:
PFC
POWER SUPPLY
MAINS FILTER
AMP SECTION
CTRL BOARD
DSP BOARD
DC/DC
CONV
Please note that the output 5x20 fuses are not mounted by default.
Remove Jumper to
insert external circuit
Remove Jumper to
enable DSP
5. Disassembling the main board:
Unscrew all 9 screws and nuts holding the components
to the chassis sides and remove the 4 clips highlighted
in (Fig. 6).
Gently pry the heatsink-mounted components off from
the heatsink by means of a at head screwdriver. (Fig. 7)
(Fig. 6)
(Fig. 7)
CH1CH2

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IPALMOD | SERVICE MANUAL
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Unscrew all 13 M3 screws highlighted in (Fig. 8) from the
main board.
Gently lift the board from the chassis.
(Fig. 8)
6. Troubleshooting:
In case of any short circuit in the Mosfets ask for the
KT000842.R repair Kit.
Checking the output mosfets:
With a Multimeter, check for any short circuit in the Output
MOSFETS by probing the points highlighted on (Fig. 9)
In case of s.c., unsolder the jumper highlighted on (Fig.
10) and repeat the tests. This is done in order to identify
the faulty channel.
CH ∞ Mosfet OK
CH1 ø Mosfet KO
CH2 ø Mosfet KO
(Fig. 9)
Ω
Ω
(Fig. 10)
CH1
CH2

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Checking the fuse and varistor
Set the multimeter to Ohm
Check the continuity of the fuse F1
Check for short circuit of the varistor RV1
As portrayed in (Fig. 11)
Checking the PSU Stage
Plug the PSU AUX cable to the CN8 connector
Feed +18 VDC and check the current drawn by the module,
it should be 31 mA ±5%, as portrayed on (Fig. 12)
(Fig. 11)
18 Vdc 31 mA
(Fig. 12)
If the current draw exceed 35 mA, ask for the KT000840.R
repair Kit kit.
Ω Ω

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IPALMOD | SERVICE MANUAL
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(Fig. 13)
Switching the module on in DC
Plug the DigiMod AMP AUX cable to the CN8 connector
and feed +18 VDC.
Plug a second DC power supply to the mains connectors
FA01 and FA02.
Feed +30VDC.
The current drawn by the module should not exceed:
3 mA ± 5% FA01/FA02.
31 mA ± 5% from CN8.
Check the diode’s bridge by repeating the test
inverting the polarities on the +30Vdc feed.
As portrayed in (Fig. 13)
30 Vdc 3 mA 18 Vdc 31 mA
(Fig. 14)
Checking the Vrails voltage in DC
Power the module on in DC
Leave the module on for at least 2 minutes.
Check the positive rail bus from CH2:
+20 VDC ± 5% FA8 to F3
Check the negative rail bus from CH1:
–20 VDC ± 5% FA6 to F2
As portrayed on (Fig. 14)
Positive Rail Bus
+20V
Negative Rail Bus
-20V
In case this values are out of range, proceed by opening
the module as portrayed on Pages 5,6,7, and proceed
the test as portrayed on (Fig. 15)

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Checking the output stage
Remove any DC power supply that may be connected
on the primary side.
Plug the DIGIMOD AMP VOLTAGE AUX at cable to the CN13
connector.
Connect the Pressure Sensor to the DSP Board.
Connect the DPC Interface Board to the DSP Board
Supply auxiliary voltages ±18 VDC and rail voltages ±12 VDC
and monitor the current drawn by the module:
Positive +18 VDC @ 670 mA ±10%
Negative –18 VDC @ 66 mA ±10%
Positive/Negative rail ±15 VDC @ 20mA ±10%
Check the auxiliary voltage at the CN14 connector:
–12 VDC ± 5% pin4 @ CN14 to FA8
+12 VDC ± 5% pin3 @ CN14 to FA6
Check the voltage by probing between the MUTE pin 2
and a ground connector (pin 1, 2):
3.5 VDC ±10%
As portrayed on (Fig. 16) (Fig. 16)
+18 V 670 mA
+12 V 20 mA
–18 V 66 mA
–12 V 20 mA
Pressure Sensor
V
Switch the module on in DC (18Vdc)
With an oscilloscope, check the gates of the mosfets Q8
and Q9, as portrayed in (Fig. 15)
Q9
(Fig. 15)
Q8
+ -

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IPALMOD | SERVICE MANUAL
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With the oscilloscope measure the signal at
Q3 gate to GND
Q4 gate to GND
As indicated on (Fig. 17)
In case of exceeding values, replace with the
KT000842.R repair Kit and repeat the measurement.
With the oscilloscope measure the signal at
Q5 gate to GND
Q6 gate to GND
As indicated on (Fig. 18)
In case of exceeding values, replace with the
KT000842.R repair Kit and repeat the measurement.
(Fig. 17)
(Fig. 18)
DSP CONTROL BOARD
DSP CONTROL BOARD

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IPALMOD | SERVICE MANUAL
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(Fig. 19)
Check the output signal (200mVpeak @ 96 kHz) by probing with an oscilloscope on the indicated points (Fig. 19)
DSP CONTROL BOARD

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Audio input
Input attenuator
Micro Match
12 pin
RS-485
interface
CN1 CN102
CN102
CN101
CN106
Pressure
sensor
Control
board
Amp
module
DPC
interface
board
CN101CN109
CN103
Audio link
(pass through)
7. Testing the module in AC
Remove all connections that may be present from previous testing.
Plug the pressure sensor to the CN109 connector on the control
board (Fig. 20)
(Fig. 20)
(Fig. 21)
Plug the DPC interface board to the CN101 and CN102 connectors
on the control board (Fig. 21)
Connect a Variac to the CN8 Connector, and slowly increase the
voltage to 100 VAC. (Fig. 22)
Remove all connections to the DC Power Supplies.
Switching the Module on in AC
(Fig. 22)

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IPALMOD | SERVICE MANUAL
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DPC interface board’s LED after 3 seconds
Color Label Condition
RED PROTECT OFF
RED LIMIT OFF
GREEN SIGNAL OFF
GREEN E.SAVE OFF
YELLOW TEMP OFF
GREEN READY SOLID ON
GREEN ON SOLID ON
GREEN PRESET OFF
DPC interface board’s LED after 30 seconds
Color Label Condition
RED PROTECT OFF
RED LIMIT OFF
GREEN SIGNAL OFF
GREEN E.SAVE SOLID ON
YELLOW TEMP OFF
GREEN READY SOLID ON
GREEN ON SOLID ON
GREEN PRESET OFF
DPC interface board’s LED at start-up
Color Label Condition
RED PROTECT OFF
RED LIMIT SOLID ON
GREEN SIGNAL SOLID ON
GREEN E.SAVE OFF
YELLOW TEMP OFF
GREEN READY SOLID ON
GREEN ON SOLID ON
GREEN PRESET OFF

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IPALMOD | SERVICE MANUAL
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Checking the rails voltage in AC
Switch the module on in AC. (100Vac)
Wait 30 seconds without input signal.
Check the positive rail bus from CH2:
+133 VDC FA8 to F3
Check the negative rail bus from CH1:
–133 VDC FA6 to F2
As portrayed on (Fig. 23)
Positive Rail Bus Negative Rail Bus
+133V-133V
(Fig. 23)
The Signal LED starts blinking and the ESAVE LED turns
off (Fig. 25)
Check the positive rail bus from CH2
-185 VDC FA8 to F3
Check the negative rail bus from CH1
+185 VDC FA6 to F2
As portrayed on (Fig. 26)
(Fig. 25)
(Fig. 26)
Switch the module on in AC.
Plug a Signal Generator to the input connector of the
DPC interface board
Turn the potentiometer on the DPC interface board
completely clockwise.
As portrayed on (Fig. 24)
Program the Signal Generator so that it outputs a 100Hz
stationary waveform, and calibrate the output level in
order to have 1 Vrms (0 dBV, 2.21 dBu).
(Fig. 24)
+185V-185V

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Connect a function generator to the inputs (CN11.
By means of the DigiMod Mains DC Cable, connect a
Variac to the CN4 Connector, and slowly increase the
voltage to 100 VAC.
Generate a 8/32 Burst Signal @ 0.5 Vrms - 100Hz
Connect an oscilloscope to output 1 and confront the
resulting wave, repeat the operation with the remaining
channel.
In both cases the reading from the oscilloscope should
show an 8/32 Burst signal. (Fig. 27)
Once all these tests are carried out successfully, connect
a 1000W 8Ohm Load to the outputs and leave the unit on
for at least 10 minutes (per channel).
Audio Tests
CN11
8/32 Burst
If the module passes all the tests, solder in place the
JP6 jumper highlighted on (Fig. 28)
(Fig. 28)
(Fig. 27)
8. Offset calibration
Switch the module on in AC.
Turn the potentiometer on the DPC interface board
completely clockwise.
Plug a Function Generator into the input connector of
the DPC interface board. (Fig. 29)
Feed a stationary 100 Hz Sine Wave and calibrate the
output level in order to have 1 Vrms (0 dBV, 2.21 dBu).
NO LOAD MUST BE CONNECTED DURING THE
CALIBRATION PROCEDURE!
Turn the indicated trimmer on the DSP board until the
highlighted D8 red LED turns off. (Fig. 30)
(Fig. 29)
(Fig. 30)
100 Hz Sine

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9. LED charts:
Main PCB LED chart
Left-hand LEDs:
Color Code Signal Status
GREEN D26 –18VDC SOLID ON
GREEN D1025 +7VDC SOLID ON
GREEN D1022 –VCC (RAIL) SOLID OFF
Right-hand LEDs:
Color Code Signal Status
GREEN D1021 +VCC (RAIL) SOLID OFF
—— D303 NC —
GREEN D1024 +18VDC SOLID ON
CTRL/DSP board LED chart Interface board LED chart
D2 D8 D5
D4
Color Code Signal Status
GREEN D2 +5VDC SOLID ON
RED D5
signal clip OFF
No pressure sensor
connected BLINKING
GREEN D4 ready SOLID ON
RED D8 protection active OFF
Color Label Signal Lighting
RED PROTECT
Signal protection
active SOLID ON
No pressure sensor
connected BLINKING
RED LIMIT Limiter active SOLID ON
GREEN SIGNAL Input signal present SOLID ON
GREEN E.SAVE Energy save mode
active SOLID ON
YELLOW TEMP Thermal protection
active SOLID ON
GREEN READY No faults, system
fully operating SOLID ON
GREEN ON System on SOLID ON

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11. Reassembling the module
Carefully clean the components on the PCB: remove any residue of glue, dirt and dust. (Fig. 32)
(Fig. 32)
10. Known Issues
Excessive Gain on the Output Stage
Symptom: low input signals yelding to +6dB gain on the
output stage.
Check R49, R50, highlighted on (Fig. 31), with a
multimeter set to OHM.
(Fig. 31)

INDEX
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IPALMOD | SERVICE MANUAL
GAP_PAD 3000S30 GAP_PAD VO Ultra soft GAP_PAD HI-FLOW 300P 40x53 GAP_PAD HI-FLOW 300P 37x33
Stick the GAP_PAD VO Ultra soft on top of each thermal regulator (Fig. 33)
(Fig. 33)
Peel the gap pads 3000S30 and properly apply them as shown in (Fig 34)
(Fig. 34)
Carefully clean the chassis: remove any residue of glue, dirt and dust. (Fig. 35)
(Fig. 35)

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Carefully insert the PCB into the chassis. (Fig. 36)
Screw the board in place by tightening all 13 Phillips Head Screws highlighted on (Fig. 37)
Peel the gap pad HI-FLOW 300P and properly apply them as indicated in the following pictures.
(Fig. 36)
(Fig. 37)