Harman Kardon DPR1005 & DPR2005 AV Receiver
Contents
1. 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 1103 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 PBDO4KAM20 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 Semiconductdamage on Processor PCB remove the connected w re first then load D2 AMP PCB PCB CON3 schematic PCB CONS bottom view Wire added LLL f P815 f uoO02Z2Fe zone a A A ae ei oa ie ooo P815 A y 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 parts2. Park Dr Woodbury New York 11797 Email Techsupport harman com Web www harmanservice com Page 10 T101 6 El4115 U203 KA7818 Da i C218 NS a 35V470 C251 C252 R205 103 103 1 4W1K R206 ZD201 1 4W100K 1 2W5V D212 RL101 IN4007 4 ALE15B12 3 EER3541 R105 t A 5W15 A C217 F101 LF101 LF102 D102 U205 6V470 250V T12A 10mH 10mH 1N4148 KIA7812 E C215 L_16v2200 CN201 5267 11 CN101 H8 4V D202 A MSS 1600302 R106 C106 C109 R109 31DQ06 0212 G C213 T C233 a 1W100K 200V1200 630V472 1W100K 10 L 16v2200 L205 L 1ovioo0 L 104 l D207 y 10uH 2 GND ia F4004 44V C102 R108 oon 4 2W1M 275V474X 1W220K gt P S W GND R107 C107 D103 SEN a 1W100K 200V1200 UF4007 152 Y1 A V CK L H V 18VL 0 M OCP P CON i 300 Volts DC 16V2200 10V470 CN202 Pin 11 Red Wire 5267 10 C114 R114 224 1 4W22 i 3 8 1 18VA AN a STL UF4004 R115 i i 2 24V 1 1 4W3 9K ZD101 C203 C204 mos 3 aad 1W15V g i _L_10v2200 _L_10v1000 L o R201 C201 veo i ik i 5 12VA D222 C115 R16 a IN4148 224 KA1MO88B TV R110 NY A ae 7 1 4W100 fd 1 6 i A E 7 5V 2 R117 PC101 R207 8 GN 1 4W3 9K ZD102 ET1103 1 4W330 D 1W15V U101 A nn aaa T201 KY R208 bs ESVA EE1927 NV 04 1 4W4 7KF 24V C116 R18 C111 C110 C112 i 224 1 4
3. volt operation In either 120 or 240 volt operation 300 volts is developed for secondary transformer 1102 otand 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 PC 102 PC 102 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 15Q 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 lts 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 1102 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 1201 1202 then to a Mosfet Bridge to drive 1103 Harman Consumer Group 250 Crossways Park Dr Woodbury New York 11797 Email Techsupport harman com Web w
4. C106 and C107 U101 1M0880B Figure 6 VV MK Harman Consumer Group 250 Crossways Park Dr Woodbury New York 11797 Email Techsupport harman com Web www harmanservice com Page 5 T103 EES555A 14 1N4148 24 Ci21 1K 220 250V 475K C118 1 R122 2 22K D2 Sa 1N4148 14148 TOKF 20 Rit U2A 4 7K LM393A TOOKF 22 R7 Q2 4 7K U2B le 4 N2222 LM39BA JJ ae c2 104 cNi R4 R2 Ci C245 C228 L _L_ 2N2222 R224 5267 02 4 7KF 35V47 9 1KF 104 104 63V47 1 4W4 7K 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 rae 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 shutdo
5. W22 Q104 R111 50V47 104 104 R209 peen 6 IMH IRFP350 1 4W47 U201 1 4W4 7KF R204 i TL431 L 1 2W 10K A V CN204 R119 5267 02 1 4W3 9K ZD103 i E Q101 A PC102 1W15V Y T203 C1008 ET1103 IRON13A8 NN i 1 R210 xXx 1 44W1K D223 R120 lA R112 xY 1N4148 1 4W22 Q105 1 2W820K R113 7 IM IRFP350 OOOO O D 1 4W 47K C117 ee E 1 8 2 224M R121 Fr L R211 1 4W3 9K ZD104 v v 1 4W4 7K 1W15V 8 B Y NY D218 221 4 A T202 1N4148 EE1927 NY T103 R213 C241 K 23 EE5555A d 1W22 1KV102 2 R223 VR201 R222 R221 C121 PL JT 1 dd 1 4W4 7 5K 1K a 220 250V 475K nea I 5 saar 10V470 KCF25A20 243 3 Era e a PI R18 gt gt gt 1 KA7815 1 4W100 O 4 t33V 3 1 l g C222 C223 C224 R215 R216 R217 R218 R219 EA GND 5 l 50V2200 50V2200 50V2200 10W1 5K 10W2 2K 10W2 2K 10W2 2K 10W2 2K A Gi R6 246 G D215 l ol 22K D2 D224 R3 104 C227 KCF25A20 i 7 D 1N4148 1N4148 10KF 25V1000 2 I i o l U2A l L206 1 U207 8 END D1 LM393A R1 R214 C242 l 10 l C225 KA7905 C226 C244 6 2V 100KF 1W22 1KV102 E 3 25V1000 10V470 104 CN203 3 22 1 Ea 3 35313 08V D216 HER204 3 17 SYNC 3 dal 3 D217 L DISC sD HER204 R14 23 oa css i ha CN1 C245 228 c9 2N2222 R224 5267 02 4 7KF 35V47 9 1KF 104 152J c 1 4W4 7K 50v4 7 L L C254 C253 104 6 8KF 35V47 152J 4 7KF 104M 10 7 4 6 i S Document Number a KJP 7013 DPR1005 US ea ednesda S Sheet 1 f
6. dbury 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 1102 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 de O EF aa 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
7. harman consumer group SMPS 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 Standby Supply FIL Line Filte V CK lg 18VA T20 Amp ST5V a Inrush Current Control 45VA 5VD 5 Regulated Single IC ee Multi Voltage 418V Switch Mode 444V Power Supply 120v Voltage Doubler or 240v Power on Filter command from CPU PWM IC Protect And JD Status to OCP OVP CPU TORORO 30 amp 50 volt 50V Supply for amp board 5 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 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 1101 1101 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
8. 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 60 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 I Caution must be used around the primary side of 1103 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 Harman Consumer Group 250 Crossways Park Dr Woodbury New York 11797 Email Techsupport harman com Web www harmanservice com Page 9 llaT 65 7kHz e Pins 16 18 on daughter board 1 ee oh Harman Consumer Group 250 Crossways
9. wn 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 IEA o ag Harman Consumer Group 250 Crossways Park Dr Woodbury New York 11797 Email Techsupport harman com Web www harmanservice com Page 6 TRONISIE Figure 9 D218 221 4 aa 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 C248 105M The output of the PWM IC U1 KA3525 pins11 14 drives two driver transformers 1201 1202 Using 1201 for the example trigger high 5 Volts through R16 turns on Q202 D222 1N4148 L and stores energy in T201 PEE d through C248 When the ma e Trigger goes low the energy Piguet 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
10. ww harmanservice com 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 Figure 2 Half Wave Voltage Doubler E For the 120 volt version to develop the 300 4 volts need to drive the two switch mode Full Wave power supplies a bridge diode assembly is Voltage Doubler 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 Full Wave Voltage Doubler using a Bridge Figure 3 5h LIVE a NEUTRA la ro power su so The main power switch cannot o gt 315 handle the current the DPR can Bil masas draw A relay SK41 was added to g gt shunt the power switch at turn on When the main switch is turned on and after voltage is developed in Je eal 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 4 Harman Consumer Group 250 Crossways Park Dr Woo
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