smps - lcd-television-repair.com · u101 is the driver ic for the smps that supplies run voltages...
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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
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
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Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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.
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Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
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Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
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Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
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Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
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Harman Consumer Group 250 Crossways Park Dr. Woodbury, New York 11797 Email [email protected] Web www.harmanservice.com
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
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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
+
C535V47
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
T203IRON13Áè
+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
+
C21516V2200
C243105M
R2202K
BD201DF06
1 3
2 4
~ +
~ -
+39V
D212IN4007
Q2012N2222
C109630V472
+
C21310V1000
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
+C217
16V470
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