harman consumer group

SMPS

DPR
1005/2005

Theory of operation and

Service information
By Andy Andersen
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797
Email Techsupport@harman.com Web www.harmanservice.com
 DPR 1005 / 2005 Block Diagram

Figure 1

A: Voltage Doubler and inrush E: Multi Voltage SMPS

B: Over Voltage protect F: Mosfet Bridge
C: Over Current protect
D: Over Current / Voltage protect

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 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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 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,
Relay RL101 closes across the
Figure 2
inrush resistors.

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

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
Figure 4 main A/C portion of the power
switch assembly cannot turn off the
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.

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 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.
Regulation is controlled by
Figure 6
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.

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 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.
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 Figure 10
Figure 9

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.

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 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 8ch-
preout
(Remark): After checking, because of possible Semiconductor damage on
Processor PCB, remove the connected i w re first then load D2 AMP PCB.
[PCB CON3: schematic] [PCB CON3: bottom view]

Wire added

P814

P815

Figure 13 Figure 14

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 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: Figure 15

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.

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 A

Pins 16, 18 on daughter board

Pin 1 of T202 off D223

5 volts per division

300 volts PP

One half BTL output. 50 volts per division

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 T101 6
EI4115

U203
5 KA7818
8 1 3 1 3
~ + IN OUT
+ +
2 4 G
C218 C219
~ -
35V470 25V220
3 9 BD202 2 C251 C252
DF06 R205 103 103
1/4W1K
1 3
~ +

1 10 2 4 R206 ZD201
~ -
1/4W100K 1/2W5V
BD201 D212
RL101 DF06 U206 IN4007
4 ALE15B12 D101 T102 KA7912
3 UF4004 EER3541
R105 1 7 17 1 3
2 I O
5W15
D206
+ HER204 C216 G C217 C235
F101 LF101 LF102 R104 D102 C108 +
25V1000 U205 +
16V470 104
250V T12A 10mH 10mH 5W15 1N4148 35V470 R123 2 KIA7812
1W1.5
8 16 1 3
I O
+ +
BD101 D205
600V25A HER204 C214 G C215 C234
CN101
C126 C127 C104 25V1000 U204 16V2200 104 Voltage
101 Y1 152 Y1 152 Y1 - + 6 2 KA7805 CN201
3
2 15 1 3
5267-11 Off On
1 I O

M43160-0302
+ D202
+ + 1 H8.4V 2.6 9.8
R106 C106 C109 R109 31DQ06 C212 G C213 C233
C125 C128 C105 1W100K 200V1200 630V472 1W100K 10 16V2200 L205 10V1000 104
2 H8.4V 2.6 9.8
101 Y1 152 Y1 152 Y1 D207 10uH 2
UF4004
3 GND .0 .0
11
5
+ +
4 +44V .0 42.5
R102 C101 C102 C103 J102 R108
5 GND .0 .0
1/2W1M 275V474 275V474X 275V474 1W220K C210 C211 R203 U202
63V100 63V100 2W4.7K S1117-50PI
+ D204
6 P-S/W .0 4.6
GND R107 C107 D103 31DF2
C119 1W100K 200V1200 UF4007 14
3
IN OUT
2
7 ST5V 5.7 5.7
152 Y1 +
1
8 V.CK 4.4 4.4
C207 +
4 35V2200 L202
+ 9 +18VL .8 17.3
C120 R202 C202 10uH
0
102Y1 1/4W 10 1KV102
10 M.OCP .0 .0
18
HS102
11 P-CON .0 4.
D203 + + + C220 D213 C221 C237
300 Volts DC HER204 C205 C206 C232 16V2200 1N4007 10V470 104 CN202 Pin 11 Red Wire
25V1000 25V1000 104 5267-10
C114 R114 L201
Q202 224M 1/4W22 Q102 3 D201 10uH
C1008 6 IRFP350 31DQ06
12 1 +18VA
D104
C248 UF4004
+ + 2 +24V
105M R115 C231
1 +
1/4W3.9K ZD101 C203 C204 104 L203
3 GND
1W15V 10V2200 10V1000 10uH
5 2 10 R201 C201
4 -12V
1/4W 10 1KV102
5 +12VA
D222 C115 R116 L101 C208 C238
IN4148 224M 1/4W22 Q103 KA1M088B-TV L3550 R110 35V1000 104
6 GND
7 IRFP350 1/4W100

16 Q203
A708
2 R117
5
PC101 R207
7

8
-5V

GND
1/4W3.9K ZD102 ET1103 1/4W330

A R16
10

T201
8
1W15V U101
1M0880B
4

3
C250 R208
9

10
+5VD

+5VA
EE1927 104 1/4W4.7KF L204
2
10uH
+
1 +
1 +24V
C116 R118 C111 C110 C112
224M 1/4W22 Q104 R111 50V47 104 104 R209 GND
6 + 2
Q204 IRFP350 1/4W47 U201 1/4W4.7KF R204
C1008 C113 TL431 1/2W 10K
C249 50V1 CN204

E
105M R119 5267-02
1 1/4W3.9K ZD103 Q101 PC102
1W15V T203 C1008 ET1103 C209 C239
5 IRON13Áè 35V470 104

D223
C R120 R112
R210
1/4W1K

D
1N4148 1/4W22 Q105 1/2W820K R113 Q201
Q205 7 IRFP350 1/4W 47K 2N2222
A708
C117
18 2 224M R121
1/4W3.9K ZD104
R211
1/4W4.7K
1W15V

B R17 8 R220
10 D218-221 1 2K
T202 1N4148
EE1927 T103 R213 C241
2 + - 4 EE5555A 1W22 1KV102
5 14
1 +39V
C247 R223 VR201 R222 R221 C121
104 1/4W4.7 5K 1K + 220 250V 475K L206 L207
D214 + 2 +39V
C229 100 + + 8uH
KCF25A20
10V470 C118 C243
3 3 +39V

1
U208 2KV221 105M
R18 KA7815
9 18 4 +39V
1/4W100
3 1
O I 5 GND
U1 R122 C222 C223 C224 R215 R216 R217 R218 R219

15
KA3525

16
R8 4.7KF +
C5
R6
2.2K D2
5 D224 R3
C246
104 C227
G
5W470
D215
KCF25A20
50V2200 50V2200 50V2200 10W1.5K 10W2.2K 10W2.2K 10W2.2K 10W2.2K
6 GND

VCC VREF 2 7 GND

35V47 1N4148 1N4148 R5 10KF 25V1000
11 2 2.2K 11 20
OUTA +V 8 GND
R11 U2A L206-1 U207
14 1 4.7K D1 LM393A R1 R214 C242 10 C225 KA7905 C226 C244
OUTB -V
6.2V 8 100KF 1W22 1KV102 25V1000 10V470 104 CN203
13 9 3 22 1 3 35313-08V
VC COMP 8 + I O
R9 5 1
+
6 4 C6 R10 4.7KF 7 2 D216
RT OSC -
223 22K 6 HER204 G
-
5 3 + + 17 + +
CT SYNC 2
R7 C3
7 10 4 D217
Q2 4.7K U2B 104
DISC SD 1 HER204
2N2222 4
LM393A
12 8 2 23
R14
GND CSS
22

C4
+ + C10 104 Q1 CN1 R4 C2 R2 C1 C245 C228
C9 R12 104 2N2222 R224 5267-02 4.7KF 35V47 9.1KF 104 104 63V47
152J C 62KF 1/4W4.7K
50V4.7 VR202
5K R225 2.7KF

C254 C253
C11 R15 C8 C7 R13 C13 1000PF 100PF
104 6.8KF 35V47 152J 4.7KF 104M
10 7 4 6 Title
AUDIO POWER
Size Document Number Rev
A2 KJP-7013/DPR1005 - US 1
Date: Wednesday, August 11, 2004 Sheet 1 of 1