User's Manual - Crown Broadcast...RF Amplifier Package User's Manual ©2005 Crown Broadcast, a division of International Radio and Electronics, Inc. 25166 Leer Drive, Elkhart, Indiana,

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FM1000ARF Amplifier Package

User's Manual©2005 Crown Broadcast, a division of International Radio and Electronics, Inc.

25166 Leer Drive, Elkhart, Indiana, 46514-5425 U.S.A.(574) 262-8900

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ii

Revision ControlRevision Print Date

Initial Release (Rev. 0) 900413-1 November 1998

Revision 1 April 2002

Important Notices©2005, Crown Broadcast, a division of International Radio and Electronics, Inc.

All rights reserved. No part of this publication may be reproduced, transmitted,transcribed, stored in a retrieval system, or translated into any language in anyform by any means without the written permission of Crown International, Inc.

Printed in U.S.A.

Crown attempts to provide information that is accurate, complete, and useful.Should you find inadequacies in the text, please send your comments to thefollowing address:

International Radio and Electronics25166 Leer Drive, P.O. Box 2000

Elkhart, Indiana, 46515-2000 U.S.A.

dpettiforRevision 2

dpettiforMay 2005

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ContentsContentsContentsContentsContentsSection 1—Getting Acquainted1.1 Your Amplifier Package .......................................................................................1–21.2 Amplifier Package Specifications .........................................................................1–31.3 Safety Considerations ..........................................................................................1–41.3.1 Dangers ............................................................................................................1–41.3.2 Warnings ..........................................................................................................1–41.3.3 Cautions ...........................................................................................................1–4

Section 2—Installation2.1 Operating Environment .....................................................................................2–22.2 Tools Required ..................................................................................................2–22.3 Unpacking .........................................................................................................2–22.4 Preinstallation ...................................................................................................2–32.4.1 Power Amplifier Modules .............................................................................2–32.4.2 Hubble Twist Lock® Connector Wiring ........................................................2–42.5 Installation ........................................................................................................2–52.6 Remote I/O Connection .....................................................................................2–6

Section 3—Operation3.1 Initial Power-up Procedures..............................................................................3–23.2 Power Switches ................................................................................................3–43.2.1 AC Input Circuit Breaker ...............................................................................3–43.2.2 DC Power Switch ..........................................................................................3–53.2.3 Interlock Switch ............................................................................................3–53.3 Digital Multimeter .............................................................................................3–63.4 Fault Indicators .................................................................................................3–73.5 Fuse Indicators .................................................................................................3–8

Section 4—Principles of Operation4.1 PA1000 Power Amplifier ...................................................................................4–24.1.1 Power Modules ............................................................................................4–24.1.2 Power Combiner Board ................................................................................4–24.1.3 Backplane Assembly .....................................................................................4–34.1.3.1 Backplane DC Interconnect Board ........................................................4–34.1.3.2 Input Divider Board ...............................................................................4–34.1.3.3 Output Combiner Board ........................................................................4–34.1.4 Output Filter & Reflectometer .......................................................................4–34.1.5 Metering and Control Board .........................................................................4–44.1.6 DC Fuse and Power Distribution Board ........................................................4–44.1.7 Cooling Fans .................................................................................................4–4

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4.2 PS1000 Power Supply ...................................................................................... 4–44.2.1 AC Input Board ............................................................................................. 4–54.2.2 PFC (Power Factor Correcting) Switching Board .......................................... 4–54.2.3 DC Output Board .......................................................................................... 4–64.2.4 Cooling Fans ................................................................................................. 4–6

Section 5—Troubleshooting5.1 Troubleshooting Flow Chart Analysis ................................................................ 5–25.2 Digital Multimeter Parameters .......................................................................... 5–35.2.1 In Ref (Input Drive Reference) ...................................................................... 5–35.2.2 SWR (Standing Wave Ratio) ........................................................................ 5–35.2.3 ALC (Automatic Level Control) ..................................................................... 5–35.2.4 Power Out .................................................................................................... 5–35.2.5 PA Temp ....................................................................................................... 5–45.2.6 PA Voltage .................................................................................................... 5–45.2.7 Tot Current ................................................................................................... 5–45.2.8 PA1–8 ........................................................................................................... 5–45.3 Fault Indicators ................................................................................................. 5–55.3.1 Antenna ........................................................................................................ 5–55.3.2 RF Drive ........................................................................................................ 5–55.3.3 PA Temp ....................................................................................................... 5–55.3.3.1 Potential Causes for Non-functioning Cooling Fans .............................. 5–55.3.4 PA DC ........................................................................................................... 5–65.3.5 Multiple Indicators........................................................................................ 5–6

Section 6—Reference Drawings6.1 Views ................................................................................................................ 6–26.2 Diagrams and Schematics ................................................................................ 6–3

Section 7—Service and Support7.1 Service .............................................................................................................. 7–27.2 24–Hour Support .............................................................................................. 7–27.3 Spare Parts ....................................................................................................... 7–2

Glossary

Index

Getting Acquainted 1–1

IINFORMATION

Section 1—Getting Acquainted

This section provides a general description of the FM1000Apower amplifier system and introduces you to safety conventionsused within this document. Review this material before install-ing or operating the amplifier and power supply.

FM1000A User’s Manual

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1–2

1.1 Your Amplifier Package

The FM1000A is a highly efficient amplifier package designed to set a new standardin FM transmitter design offering modularity, ease of use, and long-term reliabil-ity. The FM1000A package includes a PA1000 amplifier, PS1000 power supply, andan FM1K accessory pack.

The PA1000 broadband amplifier requires no tuning and typically provides 80% RFefficiency across the band. The PS1000 power supply is power factor corrected and90% efficient. Modern MOSFET technology ensures high AC to RF efficiency(better than 70% overall) and long-term reliability. The unmatched efficiency ofthis power amplifier significantly improves your bottom line by providing cooleroperation and lower power costs.

These modular units are uniquely designed to be lightweight and compact forconvenient shipping, and require only seven RU spaces for installation. Installa-tion is made simple with just three interconnections between the amplifier andpower supply. In addition, built-in digital metering and status indicator capabili-ties enable intuitive operation to further augment the user-friendly design.

Economic long-term reliability is ensured through our carefully engineered solid-state design. The PA1000 features two field-replaceable 500–watt power modules.

This power amplifier delivers 500 to over 1000 watts of RF power output. Use yourexisting exciter or purchase the FM1000T which includes our award-winning FM30exciter for an unbeatable 1 kW transmitter package.

Illustration 1–1 FM1000A Amplifier Package

Fault

AntennaRF DrivePA TempPA DC

PA1PA2PA3PA4

PA5PA6PA7PA8

Power OutPA TempPA VoltageTot CurrentALC

SWRIn Ref

Metering

PA3 PA4 PA7 PA8

Fuses

®

Power

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O

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Getting Acquainted 1–3

1.2 Amplifier Package SpecificationsRF Power Output: 100 to 1100 watts continuous with remote

controlled power adjust

RF Drive Requirement: 30 watts for full output

RF Output Impedance: 50 ohms (unbalanced)

Maximum SWR: 1.7:1 (With power foldback at high SWR)

Frequency Range: 87–108 MHz

RF Harmonics/Spurious Products: Better than –80 dB

Asynchronous AM S/N Ratio: Better than –55 dB with 100% modulation at400 Hz, no de-emphasis, no FM modulation(typically > 60 dB)

Synchronous AM S/N Ratio: Better than –55 dB with 100% modulation at400 Hz, no de-emphasis, FMmodulation=75 kHz @400 Hz(typically > 60 dB)

Operating Environment:

Temperature Range: 0°–50°C at sea level

Humidity Range: 0–80% at 20°C (noncondensing)

AC Power: 240 Volts AC +10/-15%, 50–60 Hz

Power Consumption: Less than 1400 watts at 1000 watts RF outputtypical

Power Factor: .96 typical

Overall Efficiency: 70% typical

RF Output Connector: 7/8 in. EIA flange, 7–16 in DIN optional

Power Amplifier Chassis: 7 x 17.25 x 23 inches (17.78 x 43.82 x58.42 cm) exclusive of rack ears, but inclu-sive of connectors

Power Supply Chassis: 5.25 x 17.25 x 23 inches (13.34 x 43.82 x58.42 cm) exclusive of rack ears

Weight: PA1000—40 pounds (18.1 kg)RF PA Modules—8 pounds (3.6 kg) eachPS1000—43 pounds (19.5 kg)

Note: System performance is specified using Crown BroadcastModel FM30 Exciter where applicable.

FM1000A User’s Manual

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1–4

1.3 Safety Considerations

Crown Broadcast assumes the responsibility for providing you a safe product andsafety guidelines during its use. “Safety” means protection to all individuals whoinstall, operate, and service the transmitter as well as protection of the transmitteritself. To promote safety, we use standard hazard alert labeling on the product andin this manual. Follow the associated guidelines to avoid potential hazard.

1.3.1 DangersDANGER represents the most severe hazard alert. Extreme bodily harm or deathwill occur if DANGER guidelines are not followed.

1.3.2 WarningsWARNING represents hazards which could result in severe injury or death.

1.3.3 CautionsCAUTION indicates potential personal injury or equipment or property damage ifthe associated guidelines are not followed. Particular cautions in this text alsoindicate unauthorized radio-frequency operation.

Severe shock hazard!

Turn power off andwait approximately 1minute for capacitorsto discharge beforehandling them.

WARNINGType of Hazard

Pictorial Indicationof Hazard

Explanation ofHazard

Illustration 1–3 Sample Hazard Alert

2–1Installation

Section 2—Installation

This section provides important guidelines for installing yourpower amplifier and power supply. Review this information care-fully for proper installation.

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2–2 FM1000A User’s Manual

2.1 Operating EnvironmentYou can install the FM1000A amplifier system in a standard 19–inch componentrack or on a suitable surface such as a bench or desk. In any case, the area shouldbe as clean and well-ventillated as possible. The power supply must be installeddirectly above or below the power amplifier (for the included dressed cables toreach their respective connectors).

2.2 Tools RequiredTo install the power supply and power amplifier, you will need the following tools:

❑ Medium phillips screwdriver

❑ Medium flat-blade screwdriver

❑ Small flat-blade screwdriver

❑ 7/16–Inch wrench or nut driver

❑ ESD (Electrostatic Discharge) protection grounding strap and/or mat.

2.3 UnpackingBefore handling any exposed printed circuit boards, ground yourself with anantistatic strap and/or mat.

The power amplifier, power supply, and two power amplifier modules are packedand shipped in individual boxes because of their modular nature. (The FM1Kaccessory kit is packed inside one of the two power amplifier module boxes.) Foradded protection, both the PA1000 amplifier and PS1000 supply are packed in aninner box and then placed inside an outer box with styrofoam protective corners inboth boxes. You will need to unpack a total of four boxes (plus two inner boxes).

Note: Save the boxes and packaging material that the individualunits are packed in should you need to return them for factoryservice.

CAUTIONPossible equipment damage!Guard against electrostatic dischargethrough electronic components.

2–3Installation

2.4 Preinstallation2.4.1 Power Amplifier ModulesThe PA1000 incorporates four power amplifiers (two each in two modules). Due topossible damage during shipment, the power modules have been removed. Followthese steps to install the modules:

1. Remove the front panel of the PA1000 (four screws).

2. Taking ESD precautions (see page 2–2), unpack the power modules and placethem on your work area with the circuit sides up.

3. The warning labels on the front of the modules should all be positioned to thecenter of the chassis, also note the position of the connector on the modulesand in the chassis.

4. Insert the two power modules, using their slide rails, into the built in chan-nels of the right-side cavity as shown below. Note that the connectors andwarning labels are nearest the middle wall or partition of the PA1000.

Illustration 2–1 Power Amplifier Module

5. Be sure the modules are pushed in completely so that the connector makesproper contact.

6. Replace the front panel of the PA1000.

Illustration 2–2 Power Amplifier Module Placement

Middle Partition

Module A(amps 3 & 4)

Module B(amps 7 & 8)

Vacant Cavity

Connector

Slide Rail

Warning Label


WARNING

2.4.2 Hubble Twist Lock® Connector Wiring

Prepare the wiring for the Hubble Twist-Lock® connector in the following mannerbefore connecting to your AC power source:

1. Use round cord with a diameter of 0.385–0.780 inches (10–20 mm), Type SJ12/3 – 10/3; Type S 16/3 – 10/3.

2. Select conductor size from your National Electrical Code®.

3. Slide the cover onto the cord. Remove insulation from cable and conductorsas shown in Illustration 2–3. Do not tin conductors.

5. Tighten terminal screws to 18 pound•inches (2.1 N•m) of torque.

6. Tighten assembly screws to 10 pound•inches (1.1 N•m) of torque.

7. Tighten cord clamp screws to 10 pound•inches (1.1 N•m) of torque.

4. Loosen terminal screws. Insert conductors fully into proper terminals ac-cording to the table below. Take caution that there are no stray wire strands.

Illustration 2–3 Cover, Cable & Conductors

1 Inch(25 mm)

5/8 Inch(16 mm)

Possible Electric Shock Hazard!

Do not connect AC source until allother connections are made andinstallation is complete.

Terminal

Green Hex Head Screw Equipment grounding conductor(green or green/yellow)

Conductor

Brass Screw Hot circuit conductor, 240 VAC(NOT white, NOT green)

Brass/Black Screw Hot circuit conductor, 240 VAC(NOT white, NOT green)

2–5Installation

2.5 Installation1. Mount the units in an appropriate 19–inch wide cabinet. The power supply

must be installed directly below the power amplifier for the includedcables to reach their respective connectors (see illustration 2–4 below).

Note: The PS1000 weighs approximately 40 pounds (18.1 kg); thePA1000, approximately 43 pounds (19.5 kg). Use help to install.

2. Ensure that the PS1000 power switch is off, the circuit breakers of the 240VAC source on the back panel are off, and the AC connector is not plugged in.

3. Install the exciter source (such as a Crown Broadcast FM30) according to itsinstructions.

4. Connect the RF input cable from the exciter source to the N connector on theback of the PA1000.

5. Connect the RF output cable (from the antenna) to the 7/8 EIA or 7-16 DINconnector on the back of the PA1000.

6. Connect one end of the supplied control cable to the 9–pin D-sub connectoron the PA1000.

7. Connect the other end of the control cable to the 9–pin D-sub connector onthe PS1000.

Illustration 2–4 Rear Panel Connections240 VAC IN

RF Input

Remote I/O

Control

RF Monitor(Optional Connection)

RF Output

Circuit Breakers

+ DC Input

DC Input

+ DC Output

DC Output

PS1000

PA1000

Air Intakes/Filters

Ground Screws

FansPower

Control

Air Exhaust Vents

OFF OFF


2.6 Remote I/O Connection

LOCAL

MAXIMUM

+5V

LOCALPOWERADJUST

MINIMUM

REMOTE

TANSMITTERCONTROL

SW3RAISE

SW4LOWER

SW5

R62

Electro-ControlCircuit

REMOTERAISE POWER

Pin 4Remote I/O Conn.

REMOTELOWER POWER

Pin 15Remote I/O Conn.

Illustration 2–5 Local and Remote Functions

The Remote I/O Connector on the back of the PA1000 allows remote control andmonitoring of Certain transmitter functions. There are three basic control func-tions—AC on/off, RF power level adjustment, and RF down/off.

The AC power on/off remote control function, available at pin 7 of the Remote I/OConnector, turns DC power to the PA on when the pin is grounded.

The RF power level adjustment remote control function has an internal maximumlimit set on the Metering and Control Board. The Local Power Adjust (R62) setsthe maximum limit of RF power output. The limit is set by placing the Remote/Local switch (SW5) in the LOCAL position and adjusting the Local Power Adjust toyour desired maximum limit (see illustrations 2–5 and 2–6). However, for anyremote operation to work, the Remote/Local slide switch must be in the REMOTEposition. Then the on-board remote RAISE and LOWER push buttons and anyexternal remote switches attached to pins 4 and 15 of the I/O Connector can adjust

8. Using the supplied connector, tie together pins 6 and 7 of the Remote I/Oconnector. The amplifier will not operate without this connection or aremote switch on these pins. (See Section 2.6 for Remote I/O connection.)

9. If monitoring of the output signal is desired, connect the RF monitor cable tothe BNC connector on the PA1000.

10. Connect the DC input/output cables between the PA1000 and the PS1000 asillustrated (Illustration 2–4). The connector end with the ground lead con-nects to the PA1000. Be sure to attach the ground leads as indicated.

Note: The power lead shield is only grounded at the PA chassis.

11. Install the covers over the DC terminals of the PA1000 and the PS1000 usinghardware form the hardware kit (1/4–inch X 6–32 bolts with lock washers).

12. Connect to your AC power source by inserting the Hubble Twist-Lock connec-tor into the female Hubble connector on the PS1000 and turn to the rightuntil the connection locks.

2–7Installation

For remote I/O (Input/Output) connection, connect your remote I/O cable fromyour remote control location to the 25–pin (female) D-sub connector on the backpanel of the PA1000. The I/O Connector on the power amplifier is described in thefollowing diagram:

The Remote I/O Connector Pinout Table on the next page summarizes the RemoteI/O pin connections.

1

25

13

14

View from Rear of CabinetIllustration 2–7 Remote I/O connector (back panel view)

Illustration 2–6 On-board Remote Power & Related Controls

Local/RemoteSlide Switch

On-board RemotePower Adjust

Buttons

Local Power AdjustPot

Another remote control function, available at pin 5 of the Remote I/O Connector,turns RF down/off. Connecting this pin to ground through a resistor allows theRF power output level of the amplifier to be reduced below the internal limit set bythe Local Power Adjust pot or the remote Raise/Lower settings. However, somedrive power, less than one watt, may still be present at the antenna. Depending onthe resistor used, this pin can serve as a control for optional low power operation.

The remaining remote functions are for monitoring the variousparameters of the PA1000. They are either buffered metering outputs, directreading, or latched high/low indications. Further details of these functions aredescribed in the pin-out table on page 2–8.

Note: If Remote I/O controls are not used, tie pin 7 to pin 6 (GND.).

the level up to that limit and down to zero. When a specific output power level isset, the Metering and Control Board controls and maintains the setting to keep thepower constant. The location of the Local Power Adjust (R62), the on-board Raiseand Lower switches (SW3 & SW4), and the Local/Remote slide switch (SW5) areshown below.


Remote I/O Connector Pinout Table

Pin # Function

1 PA#8 Current Monitor (a buffered metering output with 1 V = 2 A)


3 Ground

4 Remote RAISE Power (a momentary switch, on this pin, when held low willraise the power level 10 watts every 0.5 seconds)

5 Remote RF Power Control (a resistor to ground on this pin reduces RFpower output level below internal limits. See Section 2.6, page 2–7)

6 Ground

7 Remote AC Power On (a latching switch, on this pin, when held low will turnthe AC power supply on)

8 Fault Summary (the voltage from this pin goes to +5 V if any fault occurs anddrops below 2V when the fault goes away)

9 Ground

10 ALC (the voltage from this pin is a direct reading of automatic level controlvoltage, not buffered)

11 PA Temperature (a buffered metering output with 1 V = 20° C)

12 SWR (a buffered metering output with a calculated reading of standing waveratio in VDC)

13 RF Output Power (a buffered metering output with a calculated reading ofoutput power of 1 V = 1000 W)

14 Input Power Reference (a buffered metering output with a DC voltagerepresenting input power)

15 Remote LOWER Power (a momentary switch, on this pin, when held low willlower the power level 10 watts every 0.5 seconds)



18 Ground



21 Ground



24 PA Total Current Monitor (a buffered metering output with 1 V = 20 A)

25 PA Volts (a buffered metering output with 1 V = 10 V)

Note: PA = Power Amplifier

3–1Operation

Section 3—Operation

This section provides general operating parameters of your poweramplifier system and a detailed description of the front paneldisplay.


These steps summarize the operating procedures you should use for the initialoperation of the power amplifier and power supply. More detailed informationfollows.

1. Ensure that the external remote control unit is properly connected (See thePin Out Description Table, Section 2.6, page 2–8 for proper pin configura-tion). If not using a remote control unit, pin 7 must be tied to ground pin 6.

2. Connect Antenna.

3. If using an external remote control, enable the power supply via the remoteI/O connector.

4. Turn on (flip up) the AC input circuit breaker located on the rear panel of thepower supply (do not turn on the front panel power switch yet).

3.1 Initial Power-up Procedures

5. Turn on the exciter (a Crown FM30 or equivalent) and adjust its RF poweroutput level until the In Reference (In Ref) voltage, as indicated on thePA1000 front panel Digital Multimeter, is between 0.4 and 0.8volts. This isnot a drive dependent amplifier; therefore drive must be at a constant levelregardless of main output power.

Note: The unit will not operate until the exciter is active.

Illustration 3–1 PS1000 Back Panel Functions

240 VAC IN

AC InputCircuit Breaker

Outputs toPA1000

Air Exhaust Vents

+ DC Output

DC Output

PS1000

FansPower

Control

OFF OFF

FanCircuit Breaker

3–3Operation

Illustration 3–3 PS1000 Front Panel Functions

8. Check the PA1000 parameters with the Digital Multimeter for a current (TotCurrent) of 20 to 30 amps and a voltage (PA Voltage) of 25 to 35 volts. Ifparameters are within range, increase the Local Power Adjust to the maxi-

6. Before power-up, place the Local/Remote switch (located on the Metering &Control board behind the front panel) in the Local position and adjust theoutput power limit to the mid-level position using the Local Power Adjust,also on the Metering & Control board (see Illustration 3–2 below). The unit isnormally shipped with this setting. See Section 2.6 for setting up remoteoperation and using the on-board remote buttons and other controls.

7. Turn on the main power switch located on the front panel of the powersupply. (The unit typically takes 30 seconds to power up.)

®

Power

I

O

Power Switch

Air Intakes/Filters

Illustration 3–2 Local Power Adjust and Other Controls

Local/RemoteSlide Switch

On-board RemotePower Adjust

Buttons

Local Power AdjustPot

mum level of desired operation.

Note: The Local Power Adjust pot is unconventional (CW lowers power).

9.Using an external remote control unit connected to the Remote I/O connector,adjust the PA1000 to the maximum power set by the Local Power Adjust.(This prevents adjusting to higher than permitted power levels.)


3.2.1 AC Input Circuit BreakerThe PS1000 supplies power to the PA1000 by converting single-phase 220/240 VACinto 50 VDC. The PS1000 is protected by a 20 A, double-pole circuit breakerlocated on the rear panel. This AC input circuit breaker must be in the “up”position (as shown below) for operation.

3.2 Power Switches

Illustration 3–4 AC Input Circuit Breaker

10. Verify that the following conditions are present as indicated by the PA1000’sDigital Multimeter:

a. In Ref—Should read between 0.4 and 0.8 volts (0.5 nominal, dependentupon power input level).

b. SWR—Should read 1.05 to 1.5.c. ALC—Should read between 4.00 and 6.00 volts for 1.1 kW output (less

for lower output or danger conditions, i.e. high SWR).d. Power Out—Should read 1.10 for 1.1 kW output.e. PA Temp—Should read 35 to 50°C with ambient temperature of 25°C.

The remainder of this section describes the functions of the front and rear panelindicators and switches of the PA1000 and PS1000.

240 VAC IN

FansPower

Control

AC InputCircuit Breaker

ONON

3–5Operation

3.2.2 DC Power SwitchThe main on/off power switch located on the front panel of the power supplycontrols high voltage output. (The control circuit activates this voltage.)

Illustration 3–5 DC Power Switch

Illustration 3–6 Interlock Switch

Interlock Switch

®

Power

I

O

Power Switch

WWARNINGARNING Lethal voltages are still present on the AC Input Board !So, handle with care.

3.2.3 Interlock SwitchThis switch is located on the fan mounting bracket in the power supply. When thetop cover of the power supply is removed, the Interlock Switch interrupts thepower supply control circuit disabling the high and low voltage supplies.


3.3 Digital Multimeter

Illustration 3–7 Digital Multimeter

The 3–digit numeric display in the upper left corner of the front panel providesinformation on the amplifier’s operation. Use the “up” and “down” push-buttons toselect one of the following parameters as indicated by a green LED.

In Ref—Input reference is a relative voltage level used to determine input RFpower level. This varies between frequency of operation and input power level.

SWR—Direct reading of the antenna Standing-Wave Ratio (the ratio of the actualload impedance to the desired 50 ohm load impedance).

ALC—Automatic level control is DC gain control bias used to regulate PA supplyvoltage. With the PA power supply at full output voltage, ALC will read about 6.0volts. When the RF output is being regulated by the RF power control circuit, thisvoltage will be reduced, typically reading 5.0 to 6.0 volts. The ALC voltage will bereduced during PA DC overcurrent, SWR, or overtemperature conditions.

Power Out—Actually reads RF voltage squared, so the accuracy can be affected bySWR. Tolerance of ± 10% is normal. For exact set-up on site, an external powermeter is recommended.

PA Temp—Highest temperature of all individual RF power amplifier heatsinks indegrees C.

PA Voltage—Supply voltage of the RF power amplifier.

Tot Current—Sum total current of all individual RF power amplifiers in amperes.

PA1–8—Individual RF amplifier current reading in amperes.

Fault


PA1PA2PA3PA4

PA5PA6PA7PA8


SWRIn Ref

Metering

PA3

®

Multimeter Metering Selection Buttons Metering Indicators

3–7Operation

3.4 Fault Indicators

Illustration 3–8 Fault Indicators

CAUTIONPossible equipment damage!

Do not exceed 40 watts of input drive.Damage to the PA1000 will result ifthis level is exceeded.

Faults are indicated by illuminated red LED’s when the following occurs:

Antenna—Load SWR exceeds 1.5:1. ALC voltage is reduced to limit the reflectedRF power.

RF Drive—Lack of or insufficient RF drive. If the RF drive fault LED is lit, inputdrive must be increased. To achieve full output power, 30 watts of input drive isrequired.

PA Temp—PA heatsink temperature is greater than 75°C (power foldback willbegin at this point).

PA DC—Power supply current for the PA (power amplifier) is at the preset limit, orthere is a difference of more than 2.5 amps in current between the individual PAs.When this indicator is on ALC, the voltage is reduced automatically which holdsthe supply current to the preset limit.

Fault


PA1PA2PA3PA4

PA5PA6PA7PA8


SWRIn Ref

Metering

PA3 PA4 PA7 PA8

Fuses

®

Fault Indicators


3.5 Fuse Indicators

Illustration 3–9 Fuse Indicators

The PA1000 consists of two field-replacable power modules with two amplifiers ineach module. Each of the paralleled amplifiers is protected by a 10 amperefast-acting fuse. When a fuse opens, the indicator light next to it illuminates.Fuses 3 and 4 represent amplifiers 1 and 2 on the top right module. Fuses 7 and 8represent amplifiers 3 and 4 on the lower right power module.

Fault


PA1PA2PA3PA4

PA5PA6PA7PA8

Power OutPA TempPA VoltageTot Current

PA3 PA4 PA7 PA8

Fuses

®

Fuses and Indicators

4–1Principles of Operation

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Section 4—Principles of Operation

This section discusses the circuit principles upon which thepower amplifier and power supply function. This information isnot needed for day-to-day operation, but may be useful for ad-vanced users and service personnel.

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IntroductionThe FM1000A is a solid state RF amplifier package designed to deliver 500 to 1000watts. The package consists of two separate, compact units—a power supply(PS1000) and a power amplifier (PA1000). In turn, these units consist of modularcomponents which provide for efficient operation as well as ease-of-service.

4.1 PA1000 Power AmplifierThe PA1000 power amplifier features adjustable output to deliver 500–1000 watts ofRF output power for broadcast transmission. The amplifier is broadband; no tuningis required. The design, however, ensures efficient operation. Typical RF efficiencyis 75% to 85% across the FM band.

4.1.1 Power ModulesThe primary components of the PA1000 are two, 500–watt power modules. Thesepower modules are mounted by stacking two in the right cavity of the chassis. Thetwo slots on the left side are unpopulated.

The chassis of the power modules acts as a heat sink for the MOSFET amplifiers.There are two power amplifiers mounted to spacer plates on each of the heat sinks,for a total of four power amplifiers in all. (The power amplifiers are the same asthose utilized in the Crown Broadcast 100, 250, and 500–watt transmitters.)

Power from the amplifiers is combined through a micro-strip combiner to convertfrom 50 Ω output impedance for each amplifier to an intermediate impedance andthen return to the 50 Ω output at the Low Pass Filter. This technology eliminatestuning and adjustments throughout the 88–108 FM band and enables each amplifierto equally share the power load. The power combiner is also designed to allow amodule to be disconnected from the combiner and removed without adverselyaffecting the impedance balance of the unit. With one module removed the imped-ance change allows the remaining module to continue operation at approximatelyone-third of the full output power.

4.1.2 Power Combiner BoardThere are two Power Combiner Boards; one attached to each of the two heatsinksoverlapping the amplifiers. Each board takes the power from two amplifiers andcombines it through a parallel quarter-wave transmission line transformer network.The power is then summed in a common point junction on the Output CombinerBoard.


4.1.3 Backplane AssemblyThe backplane assembly is located in the vertical center of the PA1000 behind thepower modules. The Backplane Assembly is the common connection point for themajor sections of the transmitter. This assembly consists of the Input DividerBoard, Output Combiner Board, and Backplane Interconnect Board.

4.1.3.1 Backplane DC Interconnect Board

This board is located nearest the metal inner brace of the chassis. It distributes DCpower to each of the four MOSFET amplifiers, provides the interconnections forcontrol of the power supply, and enables connection to the remote control inter-face. The Backplane/DC Interconnect Board contains interconnections from theControl and Metering Board to the DC Fuse and Power Distribution Board, as wellas power connections to the power amplifier modules.

4.1.3.2 Input Divider Board

The Input Divider Board is the middle board sandwiched between the Backplane DCInterconnect Board and the Output Combiner Board. It provides the power divisionand impedance transformation needed to supply proper drive to each of the fouramplifiers (two modules).

4.1.3.3 Output Combiner Board

The Output Combiner Board is located nearest the Output Filter It consists of amicro-strip transmission line that combines the output power from the four ampli-fiers (two modules) so that ultimately, all the power comes together at one commonpoint junction. Here the currents and voltages of all four power amplifiers are inphase and producing equal RF output power. From this common point junction,the Output Combiner Board uses a second quarter-wave transformer to convert theoutput power to the 50–ohm impedance needed at the output of the unit.

4.1.4 Output Filter & ReflectometerThe Output Filter/Reflectometer is located behind the Backplane Assembly in thecenter of the PA1000. See the accompanying schematic in Section 6 for moreinformation.

The ninth-order, elliptic, low-pass filter attenuates harmonics generated in thepower amplifier. The capacitors for the filter are circuit board pads. The reflecto-meter uses printed circuit board traces for micro-strip transmission lines. Trans-mission line segments (with an impedance of about 100 ohms) on either side of a50–ohm conductor provide sample voltages representative of the square root offorward and reverse power. DC voltages, representative of forward and reflectedpower, go through a bulkhead Filter Board to the Backplane/DC InterconnectBoard, then to the Metering Board where they are processed for power control andmetering and for SWR metering and protection.

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4.1.5 Metering and Control BoardThe Metering and Control Board is located above the upper left cavity. This boardsupplies readings of voltages and currents, and provides information on the opera-tion of the amplifier.

The Local Power Adjust pot sets the upper limit (maximum) of RF power output.The on-board RAISE and LOWER push buttons and any external remote control ofthe power level is activated within that limit by placing the Local/Remote slideswitch on the board into the Remote position. When a specific output power is set,the Metering and Control Board controls and maintains the setting keeping powerconstant. A long-life battery supplies power to retain the power setting after theamplifier is turned off.

This board also takes samples from the RF amplifier boards and PS1000 powersupply and processes all the data. It provides SWR readings from the Output Filterand folds back the amplifier power if the SWR exceeds safe operating limits. Protec-tion circuitry for overcurrent and overtemperature conditions is designed into thisboard as well, providing additional precaution against overheating. This board isfail-safe, like all the other circuit board components in the FM1000A and can beremoved for repair/replacement if necessary.

4.1.6 DC Fuse and Power Distribution BoardThis board is located above the right cavity over Power Modules A and B. The DCFuse and Power Distribution Board takes power direct from the power supplythrough one 80–amp power line, divides it into four separate DC power lines, anddistributes it to the four power amplifiers. Metering resistors in each of the fourpower lines monitor the current drawn by each of the four amplifiers to ensureproper function for monitor and control of the unit.

4.1.7 Cooling FansThere is a cooling fan located in the back of the PA1000 powered by the PS1000.The fan operates at 24 volts and is rated at 235 cubic feet per minute. Cool air isdrawn through the heatsinks where a flushing moves the air over the DC Distribu-tion Fuse board, the Control and Metering Board, the Output Filter circuits, andthen out through the air vents on the side panel. If a fan fails, the amplifier willfold back power to prevent overheating.

4.2 PS1000 Power SupplyThe PS1000 supplies power to the PA1000 by converting single-phase 240VAC into 50 VDC. The PS1000 is protected by a 20 A double-pole circuit breaker.This highly efficient power supply utilizes switching technology and is power factorcorrected. The PS1000 consists of three printed circuit boards described below.


4.2.1 AC Input BoardThe AC Input Board is located on the left side of the PS1000. AC power from thecircuit breaker connects to the AC Input Board where it connects to a ±12 volt DCpower supply and three relays. The ±12 volts is used to close the three relays whenthe DC Power Switch on the front panel is switched on. In addition, the ±12 voltsare supplied to the PA1000 for use in the Control and Metering Board. The 240-volt AC input to the power supply is connected through a Hubble Twist Lockconnector on the back panel to a 20–amp circuit breaker mounted inside the backpanel.

When the power supply is turned on and enabled, the AC power comes throughtorroidal inductors which prevent harmonics and spurious products from feedingback into the AC power lines. The current flows from the inductors to a bridgerectifier that converts the current to DC Power, and from there to the PFC Switch-ing Board where the rectified DC is filtered. The filtered DC power is then fed fromthe PFC Switching Board through an 80–turn boost inductor and back to the PFCSwitching Board.

4.2.2 PFC (Power Factor Correcting) Switching BoardThe PFC Switching Board is located directly behind the cooling fans (front panel) inthe PS1000. This board takes the voltage from the Torroidal Boost Inductor andsends it to the Boost Switching Transistor. The switching transistor chops the DCinput power at a 25 kHz rate. The chopped voltage is then rectified, filtered, andsent as DC voltage to a set of four transistors which form a second switching stage.The second switching stage chops the DC voltage at a 22.5 kHz rate. This choppedDC power is fed through a blocking capacitor to a transformer on the DC OutputBoard. The second switching stage controls the amount of power sent to the DCOutput Board. This ensures that the transformer output voltage and current arecorrect for providing the selected RF output power to the amplifier.

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4.2.3 DC Output BoardThe DC Output Board is located in the back of the unit directly behind the PFCSwitching Board. This board rectifies and filters the transformer output voltageonce again to produce the clean DC power required for the power modules. The DCOutput Board also provides the 24–volts that operate the cooling fans in both thePS1000 and the PA1000. There are two parallel paths from the DC Output Board,with half the power going through each set of output cables. These cables cometogether at the terminal in back of the unit providing the maximum output powerof 50 volts at 60 amperes.

4.2.4 Cooling FansThere are two cooling fans located in the front section of the PS1000. Their pri-mary function is to cool the semiconductors used in the switching and rectifyingprocess which are subject to high currents. The fans blow cool air through theheatsinks and out through the vents on the back and side panels of the PS1000.The fans have a dedicated circuit breaker located on the back panel of the powersupply.

5–1Troubleshooting

TROUBLETROUBLETROUBLE

Section 5—TroubleshootingThis section describes procedures for service personnel to diag-nose and troubleshoot potential fault conditions in the poweramplifier and power supply.



5.1 Troubleshooting Flow Chart Analysis

Does your amplifier have output power?

Yes NoIs power

output at the proper level?

Yes No

See Section 3.1 Initial Power-up

procedures.

Do you have power now?

Yes No Is your exciter turned on?

Secure all connections to the

PS2000.

Ensure AC input circuit breaker is

flipped up

Ensure main power switch is

turned on.

Is exciter delivering sufficient RF drive?

(Check In Ref meter reading.)

Are there any fault

indicators?Yes No

Yes No

Antenna: See Section 5.3.1

RF Drive: See Section 5.3.2

PA Temp: See Section 5.3.3

PA DC: See Section 5.3.4

Yes No

See Section 3.1 Initial Power-up

procedures.

Call Support— See Section 8

Turn the exciter on.


WWARNINGARNING

5.2 Digital Multimeter ParametersThe following procedures are general in nature; for in-depth service, and repair seethe Service & Support section of this manual.

Lethal voltages present!

Only technically qualifiedindividuals shoud attempttroubleshooting or serviceprocedures .

If any abnormal readings are displayed for any of the following parameters on theDigital Multimeter, try troubleshooting in the following manner:

5.2.1 In Ref (Input Drive Reference)If this indication of drive level is not between 0.4 and 0.8 volts, then:

q Check the exciter to ensure proper power input level of 25–30 watts.

q Check RF input cable for secure connection.

5.2.2 SWR (Standing Wave Ratio)If the SWR is over 1.5:1, then look for:

q effects of inclement weather such as icing on the antenna and feed line.

q for moisture in the feedline.

q insecure antenna connections.

5.2.3 ALC (Automatic Level Control)If this indication is not between 4.00 and 6.00 volts for 1.1 kW output, then:

q Check for overheating (see PA Temp fault LED).

q Check for overcurrent (see PA DC fault LED).

q Check for high SWR (see Antenna fault LED).

5.2.4 Power OutThis reading is user adjustable, but for full output should read 1.10 for 1.1 kW.

q If lower than desired, check for proper input drive, and/or proper adjustmentof the Local Power Control (see section 3.1 #6).



5.2.5 PA TempThe meter should read between 35–50°C with an ambient temperature of 25°C. Iftemperature is 75°C or above, then check and do the following:

❑ Ambient temperature higher than 50°C; reduce temperature.

❑ Restricted air flow; remove any obstructions, clean dirty air filters by usingmild detergent and warm water.

❑ Possible antenna mismatch; check for icing, moisture in the feedline, andsecure antenna connections.

❑ Overcurrent: If PA DC fault indicator is flashing, monitor the current for aproper level—the total current and the current of individual Power Amps.

5.2.6 PA VoltageSupply voltage to the RF power amplifiers should be 50 V. If it is not check:

❑ drive level to ensure proper power level input of 30 watts

❑ for high SWR

❑ for overcurrent; check PA DC fault indicator and if flashing, check current forproper levels (total and individual Power Amps)

❑ for overtemperature; ambient temperature higher than 50°C; reduce tempera-ture. Check air flow; remove any obstructions and clean dirty air filters.

5.2.7 Tot CurrentIf total current reading is over 35 amperes, then check or do the following:

❑ Reduce power output; check all fault indicators and troubleshoot accordingly.

❑ If one or more of the 250–watt power modules has failed; replace.

❑ High SWR; check for icing, moisture in the feedline, and secure antennaconnections.

5.2.8 PA1–8If there is 2.5 amps or more difference between the individual PA current readings(7 to 9 amps typical), then check the following:

❑ Failed/faulty power module (reading directly correlates to failed power mod-ule); replace.

❑ Blown individual power amplifier fuses 1–8; replace as indicated by red LED.

❑ Reduced power output; check all fault indicators and troubleshoot accordingly.


If one of the LED fault indicators is illuminated red, troubleshoot using the follow-ing suggestions:

5.3 Fault Indicators

5.3.1 AntennaAntenna mismatch.

❑ Effects from inclement weather conditions such as icing.

❑ Check for moisture in the feedline.

❑ Secure antenna connections.

5.3.2 RF DriveDenotes lack of or insufficient drive level.

❑ Ensure proper drive level of 25–30 watts input power.

❑ Check RF input cable for secure connection.

5.3.3 PA TempTemperature has reached the internal preset limit for safe operation (75°C).

❑ Ambient temperature higher than 50°C; reduce temperature.

❑ Restricted air flow; remove any obstructions, clean dirty air filters by usingmild detergent and warm water.

❑ Antenna mismatch; check for icing, moisture on the feedline, and secureantenna connections.

❑ Overcurrent; check PA DC fault indicator, if flashing monitor current forproper levels (total and individual Power Amps).

❑ Faulty DC Output Board; replace (see Section 7, Service & Support).

❑ Faulty or non-functioning cooling fan; determine the cause for malfunctionin the following section.

5.3.3.1 Potential Causes for Non-functioning Cooling Fans

The PA1000 has one and the PS1000 has two cooling fans each. All three fans arepowered by the same circuit of the PS1000. There are two potential causes for anon-functioning fan or fans:

1. If a single fan does not operate, the fan is faulty and must be replaced. (SeeSection 7, Service & Support.)

2. If none of the fans operate, a blown circuit breaker, a short circuit in thePS1000, or a damaged winding on the main transformer of the DC OutputBoard (in the PS1000) is the cause. In this case, do one of the following:



5.3.5 Multiple IndicatorsCall your Crown Broadcast service representative. See Section 7, Service andSupport, for contact information.

a. The circuit breaker is located on the rear panel of the power supply. If thebreaker has popped out, reset it by pushing it in. If the breaker continuesto trip, check for a short circuit.

b. Check each fan with a volt-ohm meter by disconnecting and testing it for ashort circuit. Replace the fan/fans as needed (see Section 7).

c. If none of the fans have short circuits, there is damage on thewinding of the transformer. It will have to be replaced (see Section 7).

5.3.4 PA DCDiscrepancy in current between the individual amplifiers, or in total current.

❑ There is a difference of current greater than 2.5 amps between any one of the4 individual amplifiers. This could occur as a result of a blown or faulty powermodule, or a blown fuse; replace as appropriate (see Section 7, Service &Support).

❑ There is too much total current—power foldback will occur above maximumtotal amperage of 35 amps due to antenna mismatch. Examine the antennafor arcing and moisture. Also, check output power for proper current; the RFdetection circuit could malfunction causing an overcurrent situation.

Fault


PA1PA2PA3PA4

PA5PA6PA7PA8


SWRIn Ref

Metering

PA1 PA2 PA3 PA4 PA5 PA6 PA7 PA8

Fuses

®

®

Power

I

O

®

6–1Reference Drawings

Section 6—Reference Drawings

The illustrations in this section may be useful for makingadjustments, taking measurements, troubleshooting, orunderstanding the circuitry of your RF power amplifier andpower supply.


Illustration 6–1 Front View

240 VAC IN

RF Input

Remote I/O

Control

RF Monitor(Optional Connection)

RF Output

Circuit Breakers

+ DC Input

DC Input

+ DC Output

DC Output

PS1000

PA1000

Air Intakes/Filters

Ground Screws

FansPower

Control

Air Exhaust Vents

OFF OFF

Illustration 6–2 Back View

6.1 Views

Fault


PA1PA2PA3PA4

PA5PA6PA7PA8


SWRIn Ref

Metering

PA3 PA4 PA7 PA8

Fuses

®

®

Power

I

O


Illustration 6–3 FM1000A Block Diagram

30 W Exciter(Crown FM30)

PA1000Power Amplifier

1 kW RFPower Output

Remote I/OConnector

Power SupplyControl

0–50 VDCPA Supply

PS1000Power Supply

RF InputExcitation

240 VAC50/60 Hz Input Power

Single Phase

6.2 Diagrams and Schematics

6–4FM

1000A User’s Manual

Illustration 6–4 PS1000 Block Diagram

240 VACAC

CIRCUITBREAKER

AC INPUT

NEUTRAL

GROUND

ACINPUTCCA

POWERSWITCH

RECTIFIERPFC &

CONTROLCCA

DCOUTPUT

CCA

+ 0 to 50 VDC

RETURN

PS CONTROL9-PINDSUB

220 VDC

+/ 12 VDC

VOLTAGEBOOST

INDUCTOR

360 VDC

360 VDC

CONTROL

GND EARTH

GND CHASSIS

GND SIGNAL

GND FIELD SIGNAL

L1

T1

1

2 4

5

650-ohmREAR PANEL

From PFC Switcher Board

To DC OUTPUT BOARD

L100(FRONT PANEL)

NOTES :______________

1. ALL RESISTORS ARE IN OHMS,1/4W, 5% UNLESS OTHERWISESPECIFIED.

2. ALL CAPACITORS ARE INMICROFARADS UNLESSOTHERWISE SPECIFIED.

220-240VAC IN

REV

Q43521-6DWG. NO.

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THESE DRAWINGS AND SPECIFICATIONS ARE THEPROPERTY OF INTERNATIONAL RADIO ANDELECTRONICS CORP., AND SHALL NOT BEREPRODUCED, COPIED, OR USED AS THE BASISFOR THE MANUFACTURE OR SALE OF APPARATUSOR DEVICES WITHOUT PERMISSION.

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R58 for AC current foldback.

Install R58.

*

*

*

NOTES :______________



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dpettifor

dpettifor

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THESE DRAWINGS AND SPECIFICATIONS ARE THE PROPERTY OFINTERNATIONAL RADIO AND ELECTRONICS CORP.AND ARE NOT TO BE REPRODUCED, COPIED OR USED AS THE BASISFOR THE MANUFACTURE OR SALE OF APPARATUS ORDEVICES WITHOUT PERMISSION. 1 1SHEET OFSCALE : NONE PROJ NO.FILENAME:

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IREC

DZ116V

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+ C21220/35V

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D2

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D4

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D15

1N4004

1 23 45 67 89 10

HD1

HEADER 5X2

+C8.47/160V

R51K5W

R615K1/2W

C90.1

+12V

R1010K

R9

51K1%

1 2 3

HD3HEADER 3

R13100K

R7234K

C11220pF

1%

L2

89 uH

L4

89 uH

+C13300

+C43300

+C23300

+C53300

C31

C61

1234

J3

4 HEADER

1234

J4

4 HEADER

123456

HD2

HEADER 6

R25.11K1% R3

1M1%

R4

510K

C10

.1

R18

5.11K1%

C12.01 R8

10K1%

ALC

FAN +24VDC

FAN +24VDCFAN GND

R12

3.01K

R112.0K

1%

1%

CONTROL0-6VDC IN

(5V FOR 50V OUT)ALC

INT/EXT

LOCALCONTROL

R1410

3W

R1510

3W

C15.0047

C16.0047

R1610

3W

R1710

3W

C17.0047

C18.0047

TO RF PA'S50V 24A

TO RF PA'S50V 24A

1

J5

1

J6

1

J1

1

J2

TOFAN FUSE

NOTES:UNLESS OTHERWISE SPECIFIED:1. ALL RESISTORS ARE IN OHMS, 1/4W, 5% TOL.

2. ALL CAPACITORS ARE IN MICROFARADS.

5

67 U1B

LM358SCH, POWER SUPPLY DC OUTPUT

533

DW 01/17/05

200983-SCH

DW 01/17/05

C REDRAWN ON IREC FORMAT, AND ADDED U2,D16,L5,C20-21,R20-21 01/17/05 DW DW

12

11

13,14

15,16,17,18

19,20

9,10

5,6,7,8

3,4

2

1

FAN +24VDC

dpettifor

dpettifor

dpettiforReference Drawings

dpettifor6-7

6–8FM

1000A User’s Manual

Illustration 6–5 PA1000 Block Diagram

dpettifor

dpettifor

dpettifor

dpettifor

dpettifor

dpettifor

dpettifor

dpettifor

dpettifor

dpettifor

dpettifor


PA1000 RF Input

RFOUTPUT

C247PF NP0 R4

10

FWD

REFL

C147PF NP0

C3.001

C6.01

C5.01

D11N6263

R720K

R520K

C4.001

D21N5263

R620K

R182

R820K

1 2 3 4 5

HD1

R282

R310

BNC 1

3. C1201-1209A,1217 are circuit board pads.

NOTES :______________



RF InputReflectometer & Splitter

J0744-3m

RF INPUT(Back Panel)

Coa

xual

Cab

le C

onne

ctio

n

Coa

xual

Cab

le C

onne

ctio

n

RF IN


RFI

NR

FOU

T

VPW

R

RFI

NR

FOU

T

VPW

R

DZ11

101N

4735

6.2V

R111

920

0 3W

R112

02.7

K

C112

10.0

1DI

SC

R111

25.6 2W

R111

35.6 2W

R110

115

K

R111

010

K

R111

724 3W

C113

80.0

68

C111

20.0

1C1

113

0.01

C111

40.0

1C1

115

0.01

R111

610

C111

627

PF

C111

0

0.01

C111

10.0

1

C112

20.0

1DI

SC

L112

250

NH

L112

150

NH

C112

560

PF

C112

30.0

1C1

124

0.01

PA O

UTPU

T BD

T112

1

T11S

R111

45.6 2

W

R111

55.6 2

W

PA IN

PUT

BD

Q110

1BL

F278

T111

1P

R111

110

KPO

T V

DZ11

101N

4735

6.2V

R111

920

0 3W

R112

02.7

K

C112

10.0

1DI

SC

R111

25.6 2

W

R111

35.6 2W

R110

115

K

R111

010

K

R111

724 3W

C113

80.0

68

C111

20.0

1C1

113

0.01

C111

40.0

1C1

115

0.01

R111

610

C111

627

PF

C111

0

0.01

C111

10.0

1

C112

20.0

1DI

SC

L112

250

NH

L112

150

NH

C112

560

PF

C112

30.0

1C1

124

0.01

PA O

UTPU

T BD

T112

1

T11S

R111

45.6 2

W

R111

55.6 2

W

PA IN

PUT

BD

Q110

1BL

F278

T111

1P

R111

110

KPO

T V

L24

PA O

UT

PA O

UT

PA O

UT

L14

PA IN

PA IN

PA IN

C1 1.0

C2 1.0

L18

GN

D

GN

D

GN

D

PA IN

GN

D

AMPB

DC

PW

R

AMPB

DC

PW

R

AMPB

DC

PW

R

AMPA

DC

PW

R

AMPA

DC

PW

R

L28

GN

D

GN

D

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D

PA O

UT

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D

C5 1.0

C6

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LM35

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TEM

PER

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SE

C3

1.0

C4 1.0

GN

D

GN

D

AMPA

DC

PW

R

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D

GN

D

TEM

P V+

TEM

P AM

P A&

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NO

TES

:__

____

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____

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TER

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dpettiforCROWN INTERNATIONAL, INC.1718 WEST MISHAWAKA ROADELKHART, IN. 46517

dpettiforPHONE (219) 294-8000

dpettiforJ0746-8

dpettiforREVb

dpettiforTHESE DRAWINGS AND SPECIFICATIONS ARE THESHALL NOT BE REPRODUCED, COPIED, OR USEDAS THE BASIS FOR THE MANUFACTURE OR SALEOF APPARATUS OR DEVICES WITHOUT PERMISSION.PROPERTY OF CROWN INTERNATIONAL, INC. AND

dpettiforSHALL NOT BE REPRODUCED, COPIED, OR USEDAS THE BASIS FOR THE MANUFACTURE OR SALE

dpettiforOF APPARATUS OR DEVICES WITHOUT PERMISSION.


RF Output Combiner


RF OUTPUT FILTER & REFLECTOMETER

PA R

FO

UT

PU

T

C12

1147

PF

NP

0R

1212

10 0.50

W

C12

067.

1PF

C12

079.

3PF

C12

085.

13P

F

L120

394

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HL1

204

87.5

NH

(195

MH

z)(1

76M

Hz)

(252

MH

z)

C12

09A

1PF

L120

577

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H

RF

IN

C12

001.

35P

F

L120

290

.5N

H

(455

MH

z)

C12

0115

.4P

FC

1202

40.9

PF

L120

125

0NH

C12

01A

10P

F

C12

0338

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FC

1204

37.7

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C12

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1210

82P

F S

M

F W D

R E F L

C12

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PF

NP

0

C12

13.0

01

C12

15.0

1C

1214

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D12

011N

6263

R12

1610

0K

R12

151K

C12

16.0

01

D12

111N

5263

R12

181K

R12

1420

00.

5 W

R12

1710

0K

12

34

5

HD

1202

HE

AD

ER

5

R12

1610

0

14

3 3 3 3

LEN

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0.7"

0.6"

GU

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#17

#12

#12

#12

#12

0.6"

0.5"

0.7"

L120

1

L120

2

L120

3

L120

4

L120

5

I.D.

TU

RN

S

0.25

"

0.5"

0.5"

0.5"

0.43

75"

IND

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____

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OH

MS

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NLE

SS

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put

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R12

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1-10

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dpettiforJ0750-0


Backplane Distribution

Note: All bypass capacitors are 0.01 mf

6–14 FM1000A User's Manual

Ribbon Cables and Connectors

Ribbon Cables and Connectors

J2-12

10mv per degree C.

(0.2VDC at 2000W)

SWR CAL

DENOM

NUMER

POWER CAL

SWR clamp @


Notes:

7–1Service and Support

Section 7—Service and SupportWe understand that you may need various levels of support orthat the product could require servicing at some point in time.This section provides information for both of these scenarios.

7.1 Service The product warranty (see opposite page) outlines our responsibility for defective products. Before returning a product for repair or replacement (our choice), call our Customer Service department using the following telephone number:

(866) 262-8917 Our Customer Service Representative will give you further instructions regarding the return of your product. Use the original shipping carton or a new one obtained from Crown. Place shipping spacers between the slide-out power amplifier assembly and the back panel. Please fill out the Factory Service Instructions sheet (page 7–5) and include it with your re-turned product. 7.2 24–Hour Support In most instances, what you need to know about your product can be found in this manual. There are times when you may need more in-depth information or even emergency-type information. We provide 24–hour technical assistance on your product via a toll telephone call. For emergency help or detailed technical assistance, call

(866) 262-8917

You may be required to leave a message at this number but your call will be returned promptly from our on-call technician.

7.3 Spare Parts To obtain spare parts, call Crown Broadcast Service at the following number.

(866) 262-8917

You may also write to the following address:

International Radio & Electronics Corporation 25166 Leer Drive

Elkhart, Indiana, U.S.A. 46514-5425

FM600 User’s Manual 7-2

Service and support 7 – 3

Crown Broadcast Three Year Limited Product Warranty

SUMMARY OF WARRANTY Crown Broadcast, IREC warrants its broadcast products to the ORIGINAL PURCHASER of a NEW Crown Broadcast product, for a period of three (3) years after shipment from Crown Broadcast. All products are warranted to be free of defects in materials and workmanship and meet or exeed all specifications published by Crown Broadcast. Product nameplate with serial number must be intact and not altered in any way. This warranty is non - transferable. This warranty in its entirety is the only warranty offered by Crown Broadcast. No other warranties, expressed or implied, will be enforceable.

EXCLUSIONS Crown Broadcast will not warranty the product due to misuse, accident, neglect and improper installation or operation. Proper installation included A/C line surge supression, lightning protection and proper grounding of the entire transmitter, and any other recommendations designated in the Instruction manual. This warranty does not extend to any other products other than those designed and manufactured by Crown Broadcast. This warranty does not cover any damage to any accessory such as loads, transmission line or antennas resulting from the use or failure of a Crown Broadcast transmitter. Warranty does not cover any loss of revenue resulting from any failure of a Crown Broadcast product, act of God, or natural disaster.

Procedure for Obtaining Warranty Service Crown Broadcast will repair or service, at our discretion, any product failure as a result of normal intended use. Warranty repair can only be performed at our plant facility in Elkhart, Indiana USA or at a factory authorized service depot. Expenses in remedying the defect will be borne by Crown Broadcast, including two-way ground transportation cost within the continental United States. Prior to returning any product or component to Crown Broadcast for warranty work or repair, a Return Authorization (RA) number must be obtained from the Crown Broadcast Customer Service Department. Product must be returned in the original factory pack or equivalent. Original factory pack materials may be obtained at a nominal charge by contacting Crown Broadcast Customer Service. Resolution of the defective product will be made within a reasonable time from the date of receipt of the defective product.

Warranty Alterations No person has the authority to enlarge, amend, or modify this warranty, in whole or in part. This warranty is not extended by the length of time for which the owner was deprived the use of the product. Repairs and replacement parts that are provided under the terms of this warranty shall carry only the unexpired portion of the warranty.

Product Design Changes Crown Broadcast reserves the right to change the design and manufacture of any product at any time without notice and without obligation to make corresponding changes in products previously manufactured.

Legal Remedies of Purchaser

This written warranty is given in lieu of any oral or implied warranties not covered herein. Crown Croadcast disclaims all implied warranties including any warranties of merchantability or fitness for a particular purpose.

Crown Broadcast 25166 Leer Drive

Elkhart, Indiana 46514-5425 Phone 574-262-8900 Fax 574-262-5399 www.crownbroadcast.com

dpettifor

dpettifor


Notes:

Factory Service Instructions

To obtain factory service, complete the bottom half of this page, include it with the unit, and ship to:

International Radio & Electronics Corporation 25166 Leer Drive

Elkhart, Indiana, U.S.A. 46514-5425

For units in warranty (within 5 years of purchase from any authorized Crown Dealer): We pay for ground UPS shipments from anywhere in the continental U.S. and Federal Express Second Day service from Hawaii and Alaska to the factory and back to you. Expedited service/shipment is available for an additional charge. You may forward your receipt for shipping charges which we will reimburse. We do not cover any charges for shipping outside the U.S. or any of the expenses involved in clearing customs. If you have any questions about your Crown Broadcast product, please contact Crown Broadcast Customer Service at:

Telephone: (866) 262-8917 or (866) 262-8972 Fax: (866) 262-8909

Name: Company: Shipping Address: Phone Number: Fax: Model: Serial Number: Purchase Date:

Nature of the Problem (Describe the conditions that existed when the problem occurred and what attempts were made to correct it.) Other equipment in your system: If warranty has expired, payment will be: Cash/Check VISA Mastercard

Please Quote before servicing

Card Number: Exp. Date: Signature: Return Shipment Preference if other than UPS Ground: Expedite Shipment Other

ENCLOSE WITH UNIT—DO NOT MAIL SEPARATELY

Service and Support 7-5

G–1Glossary

GlossaryThe following pages define terms and abbreviations usedthroughout this and other Crown Broadcast manuals.

A B C

G–2 FM1000A User's Manual

A B CAF Audio Frequency; the frequencies between 20 Hz

and 20 kHz in the electromagnetic spectrum.

ALC Automatic Level Control

AM Amplitude Modulation; the process of impressinginformation on a radio-frequency signal by varyingits amplitude.

bandwidth The range of frequencies available for signalling.

BCD Binary-Coded Decimal; a digital system that usesbinary codes to represent decimal digits.

BFO Beat Frequency Oscillator

BNC A bayonet locking connector for miniature coax;said to be short for Bayonet-Neill-Concelman.

broadband As used in the FM transmitter, refers to the entireaudio spectrum as opposed to the spectrum influ-enced by the pre-emphasis; also called "Wideband."

carrier A continuous signal which is modulated with asecond, information-carrying signal.

crosstalk In FM broadcasting, this term generally refers tothe interaction between the main (L+R) and thesubcarrier (L–R) signals as opposed to "separation"which generally refers to leakage between left (L)and right (R) channels.

density (program) A high average of modulation over time.

deviation The amount by which the carrier frequencychanges either side of the center frequency.

DIP Dual In-line Package; term used to describe an ICor socket that has two parallel rows of pins.

distortion The unwanted changes in signal wave shape thatoccur during transmission between two points.

DPM Digital Panel Meter

EPROM Erasable Programmable Read Only Memory

ESD Electrostatic Discharge; a discharge that is poten-tially distructive to sensitive electronic compo-nents.

G–3Glossary

exciter (1) A circuit that supplies the initial oscillator usedin the driver stage. (2) A transmitter configurationwhich excludes stereo generation and audioprocessing.

FET Field-Effect Transistor

frequency synthesizer A circuit that generates precise frequency signalsby means of a single crystal oscillator in conjunc-tion with frequency dividers and multipliers.

FM Frequency Modulation; the process of impressinginformation on a radio signal by varying its fre-quency.

FSK Frequency Shift Keying; an FM technique forshifting the frequency of the main carrier at aMorse code rate. Used in the on-air identificationof frequencies.

gain reduction The process of reducing the gain of a given ampli-fier.

harmonics Undesirable energy at integral multiples of adesired, fundamental frequency.

HF High Frequency; Frequencies in the 3.0 to 30.0MHz range.

Highband Frequencies affected by the pre-emphasis.

IC Integrated Circuit

I/O Input/Output

LED Light-Emitting Diode

modulation The process by which a carrier is varied to repre-sent an information-carrying signal.

MOSFET Metal Oxide Semiconductor Field Effect Transistor;a voltage-controlled device with high input imped-ance due to its electrically isolated gate.

nearcast A transmission within a localized geographic area(ranging from a single room to a several kilome-ters).

PA Power Amplifier

G–4 FM1000A User's Manual

A B CPAI Power Amplifier Current

PAV Power Amplifier Voltage

pilot A 19–kHz signal used for stereo transmissions.

pre-emphasis The deliberate accentuation of the higher audiofrequencies; made possible by a high-pass filter.

Documents

User's Manual - Crown Broadcast...RF Amplifier Package User's Manual ©2005 Crown Broadcast, a division of International Radio and Electronics, Inc. 25166 Leer Drive, Elkhart, Indiana,