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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


B: Over Voltage protect
C: Over Current protect
D: Over Current / Voltage protect

E: Multi Voltage SMPS


F: Mosfet Bridge

Harman Consumer Group


250 Crossways Park Dr.
Woodbury, New York 11797
Email Techsupport@harman.com
Web www.harmanservice.com

Page 2

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 15) 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
Email Techsupport@harman.com
Web www.harmanservice.com

Page 3

Details

Figure 2

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
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
main A/C portion of the power
Figure 4
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.
Harman Consumer Group
250 Crossways Park Dr.
Woodbury, New York 11797
Email Techsupport@harman.com
Web www.harmanservice.com

Page 4

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.

Harman Consumer Group


250 Crossways Park Dr.
Woodbury, New York 11797
Email Techsupport@harman.com
Web www.harmanservice.com

Page 5

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 6

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
Email Techsupport@harman.com
Web www.harmanservice.com

Page 7

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
i w 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 8

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
(1.6 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!
Figure 15
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.

Harman Consumer Group


250 Crossways Park Dr.
Woodbury, New York 11797
Email Techsupport@harman.com
Web www.harmanservice.com

Page 9

B
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

Harman Consumer Group


250 Crossways Park Dr.
Woodbury, New York 11797
Email Techsupport@harman.com
Web www.harmanservice.com

Page 10

T101
EI4115

6
7

1
2

RL101
ALE15B12

4
3

F101
250V T12A

LF101
10mH

CN101

LF102
10mH

C126
101 Y1

3
2
1

D101
UF4004

1
2

R105
5W15
R104
5W15

C127
152 Y1

C104
152 Y1

D102
1N4148

10

1
+

T102
EER3541

R123
1W1.5

C128
152 Y1

R102
1/2W1M

C101
275V474

C102
275V474X

R106
1W100K

C105
152 Y1

1
+

C109
630V472

R109
1W100K

C212
16V2200

D207
UF4004

11

R107
1W100K

C119
152 Y1

C107
200V1200

D204
31DF2

14

C120
102Y1

18

HS102

R202
1/4W 10

C114
224M

R114
1/4W22

16

Q203
A708

L101
L3550

KA1M088B-TV

Q103
IRFP350

U101
1M0880B

18

C116
224M

R118
1/4W22

R120
1/4W22

7
C117
224M

D218-221
1N4148

VR201
5K

R222
1K

15
11
14
13
6
5
7
R14
22

12

VCC

VREF

OUTA

+V

OUTB

-V

VC

COMP

RT

OSC

CT

SYNC

C11
104

R15
6.8KF

C229
10V470

SD

GND

CSS

R6
2.2K

C5
35V47

D2
1N4148

R11
4.7K

C6
223

R7
4.7K

Q2
2N2222

+
R12
62KF

C
50V4.7

C7
152J

R13
4.7KF

C13
104M

+
-

10

C8
35V47

R9
4.7KF

R10
22K

C4
104

C10
104

10

D224
1N4148

R225

R112
1/2W820K

+
C206
25V1000

L201
10uH

C220
16V2200

C232
104

C231
104

C204
10V1000

D213
1N4007

C221
10V470

C237
104

C238
104

R207
1/4W330

R208
1/4W4.7KF

H8.4V

GND

+44V

GND

P-S/W

ST5V

V.CK

+18VL

10

M.OCP

11

P-CON

On

2.6
2.6
.0
.0
.0
.0
5.7
4.4
.8
.0
.0

9.8
9.8
.0
42.5
.0
4.6
5.7
4.4
17.3
.0
4.

Pin 11 Red Wire

CN202
5267-10

L203
10uH

+18VA

+24V

GND

-12V

+12VA

GND

-5V

GND

+5VD

10

+5VA

+24V

GND

L204
10uH

R209
1/4W4.7KF

R204
1/2W 10K

CN204
5267-02
C209
35V470

C239
104

Q201
2N2222

R3
10KF

R224
1/4W4.7K

14

C246
104

C227
25V1000

+
-

22

CN1
5267-02

17

R214
1W22
D216
HER204
D217
HER204

1
2

L207
8uH

C243
105M

C222
50V2200

C223
50V2200

C224
50V2200

R215
10W1.5K

R216
10W2.2K

R217
10W2.2K

R218
10W2.2K

R219
10W2.2K

20

2
+

L206
100

D215
KCF25A20
11

R1
100KF

C241
1KV102

18

R122
5W470

R213
1W22

D214
KCF25A20

C118
2KV221

U208
KA7815

U2A
LM393A

C3
104

T103
EE5555A

C242
1KV102

L206-1
10

C225
25V1000

U207
KA7905
1

C226
10V470

C244
104

+39V

+39V

+39V

+39V

GND

GND

GND

GND

CN203
35313-08V

23

R4
4.7KF

C2
35V47

R2
9.1KF

C1
104

C245
104

C228
63V47

2.7KF
C254
1000PF

C203
10V2200

U201
TL431

R113
1/4W 47K

R5
2.2K

U2B
4
LM393A

Q1
2N2222

VR202
5K

C112
104

C121
250V 475K

D1
6.2V

DISC

+
C9
152J

16

4.7KF

C205
25V1000

C201
1KV102

OUT

R210
1/4W1K

- 4

R221
220

R18
1/4W100

R8

R201
1/4W 10

IN

H8.4V

R220
2K

2 +

R223
1/4W4.7

U1
KA3525

U202
S1117-50PI

Off

R211
1/4W4.7K

T202
EE1927
C247
104

R203
2W4.7K

PC102
ET1103

ZD104
1W15V

C110
104

Q101
C1008

T203
IRON13

Q105
IRFP350

R121
1/4W3.9K

C111
50V47

R111
1/4W47

C113
50V1

ZD103
1W15V

R17
10

C233
104

Q104
IRFP350

R119
1/4W3.9K

C213
10V1000

L202
10uH

C250
104

R110
1/4W100

D223
1N4148

Voltage

CN201
5267-11

C208
35V1000

PC101
ET1103

Q205
A708

C234
104

T201
EE1927

C249
105M

10

ZD102
1W15V

Q204
C1008

C215
16V2200

+
2

R116
1/4W22

R117
1/4W3.9K

R16
10

C235
104

C211
63V100

D201
31DQ06

12

D104
UF4004

ZD101
1W15V

C115
224M

Q102
IRFP350

R115
1/4W3.9K

C202
1KV102

ZD201
1/2W5V

C207
35V2200

D203
HER204

300 Volts DC

D222
IN4148

C217
+
16V470

C248
105M

C210
63V100

Q202
C1008

L205
10uH

D103
UF4007

C252
103

U204
KA7805

D202
31DQ06

O
G

10

C251
103

U205
KIA7812

C214
25V1000

R108
1W220K

GND

16

J102

C103
275V474

C106
200V1200

15

C125
101 Y1

C216
+
25V1000

M43160-0302

C219
25V220

R206
1/4W100K

D212
IN4007

U206
KA7912
1

D205
HER204

17

U203
KA7818
3

OUT

R205
1/4W1K

D206
HER204

C108
35V470

IN
G

C218
35V470

BD201
DF06

BD101
600V25A
-

BD202
DF06
1

C253
100PF
Title
Size
A2
Date:

Document Number

AUDIO POWER

Rev

KJP-7013/DPR1005 - US

Wednesday, August 11, 2004

Sheet

of

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