Harman-Kardon-AV-SMPS.pdf

Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com

harman consumer group

SMPS

DPR 1005/2005

Theory of operation and Service information

By Andy Andersen


DPR 1005 / 2005 Block Diagram

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

Figure 1

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.

Page 3


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 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.

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

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.

Figure 2

Figure 3

Figure 4

Page 4


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 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.

Figure 5

Figure 6

Page 5


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 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.

Figure 7

Figure 8

Page 6


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 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.

Figure 9 Figure 10

Figure 11

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.

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

Figure 12

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

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! 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

Page 9


A

B

C

D

E

300 volts PP

Pin 1 of T202 off D223 5 volts per division

Pins 16, 18 on daughter board

One half BTL output. 50 volts per division

Page 10

C250104

+

C22250V2200

Q105IRFP350

Q101C1008

C2541000PF

R1121/2W820K

Q102IRFP350

C103275V474

R156.8KF

ZD2011/2W5V

C115224M

R1055W15

L20110uH

D203HER204

U203KA7818

1 3

2

IN OUT

G

C238104

T102EER3541

6

8

3

4

10

177

2

5

18

11

12

14

15

16

10

C231104

R1071W100K

R21810W2.2K

+C108

35V470

R2081/4W4.7KF

C232104

R1045W15

Q103IRFP350

+39V

L20310uH

BD202DF06

1 3

2 4

~ +

~ -

R1101/4W100

C11104

Q202C1008

LF10210mH

GND

R2041/2W 10K

R2011/4W 10

ST5V

R44.7KF

+C5

35V47

C9152J

C125101 Y1

R8 4.7KF

R2091/4W4.7KF

R1225W470

C21835V470

+18VA

CN2025267-10

1

2

3

4

5

6

7

8

9

10

ZD1021W15V

L206100

- +

BD101600V25A

RL101ALE15B124

312

C126101 Y1

U1KA3525

2

1

35

6

7

8

9

10

16

4

11

14

13

15

12

+V

-V

SYNCCT

RT

DISC

CSS

COMP

SD

VREF

OSC

OUTA

OUTB

VC

VCC

GND

D207UF4004

R181/4W100

GND

L20410uH

D2241N4148

R1231W1.5

R2241/4W4.7K

GND

LF10110mH

C247104

R310KF

C101275V474

R1091W100K

R2101/4W1K

C20525V1000

D217HER204

R1422

R1211/4W3.9K

C13104M

R2061/4W100K

0

C127152 Y1

-+

D218-2211N4148

1

2

3

4

KJP-7013/DPR1005 - US 1

AUDIO POWERA2

1 1Wednesday, August 11, 2004

Title

Size Document Number Rev

Date: Sheet of

U206KA7912

1 3

2

I O

G

C105152 Y1

+18VL

C121250V 475K

R52.2K

C20625V1000

+C22910V470

C21063V100

VR2025K

C251103

C120102Y1

R1191/4W3.9K

R2231/4W4.7

CN20335313-08V

1

2

3

4

5

6

7

8

C11150V47

+39V

+44V

L2078uH

R114.7K

R1161/4W22

C102275V474X

Q205A708

ZD1011W15V

C50V4.7

C119152 Y1

C249105M

R1131/4W 47K

U207KA7905

1 3

2

I O

G

T201EE1927

1

6

2

5

7

8

R134.7KF

C246104

Q12N2222

R2021/4W 10

H8.4V

D103UF4007

C116224M

Q22N2222

C2411KV102

C234104

C3104

R94.7KF

R225 2.7KF

C6223

Q204C1008

R1171/4W3.9K

R1100KF

GND

C1104

R21610W2.2K

D104UF4004

U204KA7805

1 3

2

I O

G

R1021/2W1M

-12V

C11350V1

C244104

R221220

R2032W4.7K

U201TL431

R2141W22

C22725V1000

C114224M

C20410V1000

C7152J

C235104

R2071/4W330

P-CON

PC101ET1103

D101UF4004

T203IRON13

+C107

200V1200

M.OCP

V.CK

Q203A708

R1081W220K

PC102ET1103

C20310V2200

D16.2V

+C216

25V1000

L101L3550

U202S1117-50PI

1

3IN OUT

D21N4148

H8.4V

C110104Q104

IRFP350

ZD1031W15V

D222IN4148

R2111/4W4.7K

P-S/W

R21910W2.2K

F101250V T12A

D2231N4148

+

C22450V2200

GND

D215KCF25A20

C20835V1000

C112104

R29.1KF

GND

C21425V1000

C10104

ZD1041W15V

R1061W100K

T103EE5555A

5

9

11

17

18

14

23

20

22

R21510W1.5K

D206HER204

+5VA

D20231DQ06

C20935V470

C22016V2200

L20210uH

C117224M

C21163V100

R62.2K

R1181/4W22

GND

T101EI4115

3

1

5

6

7

9

10

8

GND

C1182KV221

CN2015267-11

1

2

3

4

5

6

7

8

9

10

11

T202EE1927

1

6

2

5

7

8

R1141/4W22

+

C22863V47

R74.7K

D214KCF25A20

HS102

C21925V220

CN15267-02

12

C245104

+

-

U2BLM393A

5

67

8

4

+

C22350V2200

R21710W2.2K

+C106

200V1200C128152 Y1

U208KA7815

13

2

IO

G

C248105M

R2131W22

D1021N4148

C104152 Y1

C253100PF

CN2045267-02

1

2

L206-110

+C215

16V2200

C243105M

R2202K

BD201DF06

1 3

2 4

~ +

~ -

+39V

D212IN4007

Q2012N2222

C109630V472

+C213

10V1000

GND

+

C235V47

R2221K +39V

+

-

U2ALM393A

3

21

8

4

C239104

R1111/4W47

D216HER204

R1201/4W22

CN101

M43160-0302

123

C237104

D20131DQ06

R1710

-5V

D205HER204

U205KIA7812

1 3

2

I O

G

R1610

R1262KF

C835V47

GND

C4104

C233104

R1022K

C21216V2200

C2021KV102

+

C22610V470

C252103

+12VA

+5VD

D20431DF2

R1151/4W3.9K

C22110V470

+24V

GND

+ C21716V470

D2131N4007

C20735V2200

L20510uH

C2011KV102

U1011M0880B

1

2

3

4

5

+

C22525V1000

VR2015K

C2421KV102

R2051/4W1K

+24V

+

+

+

+

+ + +

+ +

+

++

+

+

+ +

++

+ +

2

16

18

10 7 4

5

1

6

2.6 9.82.6 9.8.0 .0.0 42.5.0 .0.0 4.65.7 5.74.4 4.4.8 17.3.0 .0

Off On

Voltage

J102

300 Volts DC

KA1M088B-TV

A

B

CD

E

.0 4.

Pin 11 Red Wire

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Harman-Kardon-AV-SMPS.pdf

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