harman consumer group
SMPS
DPR
1005/2005
Theory of operation and
Service information
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
Email Techsupport@harman.com Web www.harmanservice.com
By Andy Andersen
Page 2
DPR 1005 / 2005 Block Diagram
Figure 1
A: Voltage Doubler and inrush
B: Over Voltage protect
C: Over Current protect
D: Over Current / Voltage protect
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
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Web www.harmanservice.com
E: Multi Voltage SMPS
F: Mosfet Bridge
Page 3
Operation summary
Applied AC line voltage for stand by.
AC line voltage from the relay board goes to connector CN101 and supplies the
voltage for transformer (T101). T101 supplies standby and run voltages +18VAB,
ST5V H8.4V (AC for display). These are the source voltages for the micro (IC62)
for stand by operation.
The applied AC flows through inrush resistors R105 and R104 then rectified by
BD101 to charge C106 and C107. BD101 with C106 and107 are configured as
voltage doublers for 120 operation. Jumper J102 is removed for 240 volt
operation. In either 120 or 240 volt operation 300 volts is developed for
secondary transformer T102.
Stand by to power on
When a High signal is received to connector P-S/W (from micro on main board)
Q201 turns on. Q201 controls optoisolator PC102. PC102 controls U101 at pin 3.
U101 is the driver IC for the SMPS that supplies run voltages +5VA, +5vd, +12V,12V, +18V, +24V, +44V for the main board.
Other activities at power on
When voltage is developed at D101 and C108 (off T102 of the SMPS) RL101
closes (Pins 3, 4 make contact) A short is produced across the in rush resistors
R105 and R104 (5W 15Ω) Current now flows through RL101 and not the inrush
resistors.
At the same time voltage is applied to relay SK41 (located on the Outlet Board
(rear relay board)). Its contacts are wired across the main power switch and is
used to prevent all the receivers current from flowing through the main power
switch (the switch is rated for 8amps, relay for 20 amps).
Power on
Once the secondary voltages are developed from T102 (smps), the micro sends
a signal to power on (4volt high) the high current SMPS used for the D2 audio
module (cn201 pin 11 P-CON, CN2 pin 1 PWR CNTR-2). IC U1 (PWM KA3525)
pin 10 goes low, and a PWM signal is developed to pins 11,14 (out A/B) to two
driver Transformers (T201, T202), then to a Mosfet Bridge to drive T103.
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
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Web www.harmanservice.com
Page 4
Details
When AC is applied to the SMPS,
R104 and R105 are used to protect
the inrush to capacitor C106 and
C107. After the voltages are
developed from the SMPS of T102,
Figure 2
For the 120 volt version to develop the 300
volts need to drive the two switch mode
power supplies a bridge diode assembly is
used for the full wave voltage doubler. For
the 230/240 volt SMPS a voltage doubler is
not necessary. To change from 120 to 240
volt operation, remove jumper J102 for the
SMPS part of the power supply. Please note
the standby transformer is specific for each
AC voltage.
Figure 3
Figure 4
DPR. For power down the D/C portion of the power switch sends a command to
the micro to sequence the power supply down, the last step is to release the
power relay.
Relay RL101 closes across the
inrush resistors.
The main power switch cannot
handle the current the DPR can
draw. A relay (SK41) was added to
shunt the power switch at turn on.
When the main switch is turned on
and after voltage is developed in
the stand by supply (from T101)
the relay will close. At this point the
main A/C portion of the power
switch assembly cannot turn off the
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
Email Techsupport@harman.com Web www.harmanservice.com
Page 5
Figure 5
A group of small transistors, the protection latch and the PWM IC with its related
components are located on a small upright daughterboard at the rear of the main
SMPS board. When servicing this board, be aware of differences from the
schematic and the actual PCB for CN1 (the schematic is correct but the PCB is
wrong).
U1, KA3525 is a common PWM IC. In servicing the PWM check for VCC pin 15,
and VC, VCC should be 15 volts. Power on SD pin 10 has to be low for the PWM
to work. If not low check the signal from the CPU (CN201 pin 11) for a high. If the
power on from the CPU is high check for a protect event trigger (could be a bad
Mosfet or an over voltage problem and protect has triggered and latched).
From Standby to power on T102
develops the voltages for the
secondary regulators. T102 and
U101 are part of a single IC switch
mode power supply. The micro
sends an on command (pin6
CN201 P-S/W 5V) to optoisolator
PC102. PC102 keeps Q101 off so
a high can be developed on pin 3
of U101. The off state for U101 is
pin 3 low. Pin 4 of U101 is the
regulation control for the SMPS.
Figure 6
Regulation is controlled by
reference IC U201 (adjustable
precision shunt regulators) controlling optical coupler PC101.Caution must be
observed when working on this circuit. This is hot to the AC line voltage and is
supplied by 300 volts from the main filter caps C106 and C107.
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
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Page 6
Figure 7
Protection for the D2 audio module is accomplished by monitoring over voltage
and over current of the supply voltages developed by T103. If a fault event is
detected the output of U2 will be latched high to keep pin 10 of the PWM IC U1
high (power off).
Over voltage is detected
by IC U2A. A reference
voltage is set for pin 2
(about 4.8 volts) and if
that reference is
exceeded at pin 3, pin 1
will go high. When the
rise of pin 1 exceeds 6.2
volts (Zener D1 prevents
false trigger), a high will
Figure 8
be sent to pin 5 of U2B.
The output pin 7 will now
send a high to shut the D2 audio module supply off. The high from pin 7 is also
sent through diode D2 to latch pin 7 high. The output of the op amp can not go
low until power is removed from the op amp. The protection state is monitored by
the CPU (CN201 pin10 M.OCP), and if a fault is detected a command is sent to
put the DPR in standby. There is no other indication of a protect shutdown for the
power supply, but there are protect modes for the D2 module (as mentioned in
the D2 audio info in the service manual) that would be displayed.
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
Email Techsupport@harman.com Web www.harmanservice.com
Page 7
Figure 9
Figure 10
Current sense transformer T203 detects the AC current flow for the high current
needed for the D2 module. The AC from T203 goes to a diode bridge, rectified
and the dc is sent to the protection IC U2. When the voltage exceeds 5 volt
reference, the protect will trigger and latch. Do not adjust the over current pot
VR201. This is set at the factory for a protect trigger of 31.2 amps at the 50 volt
output (1.6 load).
The output of the PWM IC (U1
KA3525 pins11, 14) drives two
driver transformers (T201,
T202). Using T201 for the
example, trigger high (5 Volts
through R16) turns on Q202
and stores energy in T201
through C248. When the
Trigger goes low the energy
Figure 11
stored in T201 is replaced
through D222 and Q203. The
result of using this dual transistor setup is almost perfect square wave at the
output of T201. The result is no ringing or over shoot at the pulse transformer
dual outputs.
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
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Page 8
300 volts DC supplies the
mosfets Q102-Q104. The
high current supply for the
D2 module comes from
T103. T103 is driven by 4
mosfets in a bridge mode to
produce 600 volt PP for
T103. Extreme caution is
needed when working
around the mosfets.
Figure 12
How to test and run the DPR with the D2 amp board removed from the
receiver.
After removing PCB (T/F code : PBD04KAM20) loaded with D2Audio,
and connecting wire as pictured, then you will be able to check the operation of
processor PCB and the SMPS. You can also check the signal 2ch-out and 8chpreout
(Remark): After checking, because of possible Semiconductor damage on
Processor PCB, remove the connected wi re first then load D2 AMP PCB.
[PCB CON3: schematic] [PCB CON3: bottom view]
Wire added
P814
P815
Figure 13 Figure 14
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
Email Techsupport@harman.com Web www.harmanservice.com
Page 9
DPR1005/2005: Tech notes in no order
Protection check connector CN1 is hooked up in the print correctly but on the
daughter board is hooked up to pin 5 of IC U2.
The pin outs for CN201 have a different description on the main board and the
pin numbers are reversed.
The output mosfets on the DPR1005 are not IRFP3050 but SKH30N40.
The service manual shows only the 120 version. You must refer to the parts list
for the correct value of the AC input components.
The grounds are common on the SMPS but note that current and digital will take
a different path out of the connectors. If a complaint of noise is noted check the
solder on the connectors.
The DPR series is not lead-free or ROSH compliant.
The standby transformer T101 will run warm. This is normal.
The Over Current pot can not be adjusted by the service centers. In the case of
the DPR2005 the 50 volt output load current would have to be set at 31.2 amps
(1.6Ω Load)
There are replacement components available except for the transformers.
The heat sink of U101 can be used has the hot ground
(ground for IC 101 and the power mosfets). Do not hookup
without adding a screw, the coating on the heat sink is an
insulator.
!! Caution !! must be used around the primary side of T103.
There is a 600 volt PP AC signal around the components!
Power on Timing:
The regulator SMPS (using IC U101) will turn on about one second before the D2
supply voltage raises. CN201 pin 6 (P-S/W) will turn on before pin11 (P-CON).
The voltage out of CN203 (50 volts for the DPR2005, 39 volts for the DPR1005)
turns on with a slow rise of 20v / Second.
Figure 15
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
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Web www.harmanservice.com
p
Page 10
A
B
Pins 16, 18 on daughter board
C
Pin 1 of T202 off D223
5 volts
er division
E
300 volts PP
One half BTL output. 50 volts per division
D
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
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16
A
18
B
CN101
3
2
1
M43160-0302
GND
R16
10
R15
C11
6.8KF
104
T101
EI4115
5
3
1
RL101
4
F101
250V T12A
C126
101 Y1
C125
101 Y1
R102
1/2W1M
C101
275V474
C119
152 Y1
LF101
10mH
ALE15B12
3
R106
1W100K
R107
1W100K
1
2
+
D102
1N4148
+
C106
200V1200C128
R108
1W220K
+
C107
200V1200
R105
5W15
HS102
C104
152 Y1
C105
152 Y1
R104
5W15
- +
J102
BD101
600V25A
LF102
10mH
C127
152 Y1
152 Y1
C102
275V474X
0
C103
275V474
C120
102Y1
C108
35V470
C109
630V472
D103
UF4007
D101
UF4004
R123
1W1.5
R109
1W100K
8
6
5
4
300 Volts DC
Q202
C1008
C248
105M
D222
IN4148
Q203
A708
Q204
C1008
C249
105M
D223
1N4148
Q205
A708
R17
10
C247
104
R18
1/4W100
R14
22
152J
U1
KA3525
15
VREF
VCC
11
14
13
6
7
12
C9
OUTA
OUTB
VC
RT
DISC
GND
50V4.7
+V
-V
COMP
OSC
SYNCCT
SD
CSS
+
C
C8
35V47
1
2
T201
EE1927
1
C
2
T202
EE1927
R223
1/4W4.7
16
2
1
9
4
35
10
8
R8 4.7KF
C6
R10
223
22K
+
C13
R13
C7
152J
4.7KF
104M
C114
224M
6
5
7
8
6
5
7
8
R12
62KF
10
R9
4.7KF
C10
104
C115
224M
C116
224M
C117
224M
R114
1/4W22
R11
4.7K
Q2
2N2222
VR202
5K
R115
1/4W3.9K
R116
1/4W22
R117
1/4W3.9K
R118
1/4W22
R119
1/4W3.9K
R120
1/4W22
R121
1/4W3.9K
C110
104Q104
C118
2KV221
R122
5W470
C228
63V47
3
2
5
9
11
+
Q102
IRFP350
ZD101
1W15V
+
C2
35V47
+
C227
25V1000
3
U208
KA7815
R2
9.1KF
L101
L3550
R111
1/4W47
Q101
C1008
G
2
C1
104
IO
R1
100KF
Q103
IRFP350
ZD102
1W15V
IRFP350
ZD103
1W15V
ZD104
1W15V
R222
VR201
1K
5K
+
C4
104
C5
35V47
R7
4.7K
R225 2.7KF
Q1
2N2222
7
R6
2.2K
U2B
LM393A
7
4
+
D2
1N4148
8
+
-
4
C229
10V470
5
5
6
R224
1/4W4.7K
E
Q105
IRFP350
D218-221
1N4148
R221
220
D224
1N4148
D1
6.2V
C3
104
2
1
R5
2.2K
1
3
8
4
T203
IRON13Áè
U2A
LM393A
+
-
1M0880B
R220
2K
3
2
KA1M088B-TV
5
U101
4
3
2
1
D
-+
4
1
R3
10KF
1
2
CN1
5267-02
C246
104
R4
4.7KF
C113
50V1
C121
250V 475K
1/2W820K
1
R112
R110
1/4W100
+
C111
50V47
6
C245
104
D104
UF4004
T102
EER3541
C112
104
R113
1/4W 47K
T103
EE5555A
6
7
U203
KA7818
IN OUT
G
2
R206
1/4W100K
+
C219
25V220
ZD201
1/2W5V
2
+
C237
C221
104
10V470
+
C238
C208
104
35V1000
+
C209
C239
35V470
104
C243
105M
R218
R217
10W2.2K
C244
104
R219
10W2.2K
10W2.2K
Title
Size Document Number Rev
A2
Date: Sheet of
AUDIO POWER
KJP-7013/DPR1005 - US 1
C251
103
1 1Wednesday, August 11, 2004
CN201
5267-11
1
2
3
4
5
6
7
8
9
10
11
CN202
5267-10
1
2
3
4
5
6
7
8
9
10
1
2
CN204
5267-02
1
2
3
4
5
6
7
8
CN203
35313-08V
C252
103
H8.4V
H8.4V
GND
+44V
GND
P-S/W
ST5V
V.CK
+18VL
M.OCP
P-CON
+18VA
+24V
GND
-12V
+12VA
GND
-5V
GND
+5VD
+5VA
+24V
GND
+39V
+39V
+39V
+39V
GND
GND
GND
GND
Voltage
Off On
2.6 9.8
2.6 9.8
.0 .0
.0 42.5
.0 .0
.0 4.6
5.7 5.7
4.4 4.4
.8 17.3
.0 .0
4.
.0
Pin 11 Red Wire
C218
35V470
D212
IN4007
3
R204
1/2W 10K
C253
100PF
R205
1/4W1K
U202
S1117-50PI
IN OUT
1
D213
1N4007
L204
10uH
R216
10W2.2K
C226
10V470
+
1 3
1/4W 10
1/4W 10
U201
TL431
Q201
2N2222
1 3
2 4
BD202
DF06
1 3
2 4
BD201
DF06
D206
HER204
D205
HER204
D202
31DQ06
D207
UF4004
D204
31DF2
R202
D203
HER204
D201
31DQ06
R201
R207
1/4W330
C250
104
D216
HER204
D217
HER204
~ +
~ -
~ +
~ -
R213
1W22
R214
1W22
C202
1KV102
C201
1KV102
D214
KCF25A20
D215
KCF25A20
C216
+
25V1000
+
C214
25V1000
+
C212
16V2200
+
C210
63V100
+
C207
35V2200
+ +
C205
25V1000
+
C203
10V2200
R208
1/4W4.7KF
R209
1/4W4.7KF
R210
1/4W1K
R211
1/4W4.7K
C241
1KV102
L206
100
L206-1
C242
1KV102
10
L205
10uH
L202
10uH
L201
10uH
U206
KA7912
1 3
I O
G
U205
2
KIA7812
1 3
I O
G
U204
2
KA7805
1 3
I O
G
2
+
C211
63V100
C206
25V1000
+
C204
10V1000
+
C222
50V2200
+
C223
50V2200
C225
25V1000
+
+
16V470
+
16V2200
+
10V1000
R203
2W4.7K
+
C232
104
C231
104
L207
8uH
C217
C215
C213
C235
104
C234
104
C233
104
+
C224
50V2200
U207
KA7905
1 3
I O
G
2
C254
1000PF
C220
16V2200
R215
10W1.5K
L203
10uH
+
+
8
9
10
177
16
15
10
11
14
18
12
10
PC101
ET1103
PC102
ET1103
14
18
20
22
17
23
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