Crown CE-4000 Service Manual
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Crown CE-4000 Service Manual

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POWER AMPLIFIER

SERVICE MANUAL
CE Series
CE 4000
Some models may be exported under the name Amcron
®
© 2002 by Crown Audio, Inc., P.O. Box 1000, Elkhart, Indiana 46515-1000 U.S.A. Telephone:
574-294-8000. Trademark Notice: Amcron
®
and Crown
®
are registered trademarks of Crown
International. Other trademarks are the property of their respective owners.
130485-1
11/02
Rev. B

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Summary of Contents for Crown CE-4000

  • Page 1: Power Amplifier

    SERVICE MANUAL CE Series CE 4000 Some models may be exported under the name Amcron ® © 2002 by Crown Audio, Inc., P.O. Box 1000, Elkhart, Indiana 46515-1000 U.S.A. Telephone: 574-294-8000. Trademark Notice: Amcron ® and Crown ® are registered trademarks of Crown International.
  • Page 2 If you need special assistance beyond the scope of this manual, please contact the Crown Technical Support Group. Mail: P.O. Box 1000 Elkhart IN 46515-1000 Shipping: Crown Factory Service 1718 W. Mishawaka Road Elkhart IN 46517 Phone: (800) 342-6939 / (574) 294-8200 FAX: (574) 294-8301...

  • Page 3: Revision History

    Added missing parts list on Page 5-76. Updated area code and mailing address on Pages 1, 2 and 7. Updated sections 3.2.4, 4.3.3, 4.3.9, 4.4.5, 4.6.1, 4.6.8, 4.7.2, 4.7.3, Figure 4.16. Added notes to pages 5-39, 5-73, 5-97. ©2002 Crown Audio, Inc.
  • Page 4 130485-1 Rev. B CE 4000 Service Manual This page intentionally left blank ©2002 Crown Audio, Inc.

  • Page 5: Table Of Contents

    4.3.4 Input Module (SST) Removal............4-3 4.3.5 Output Panel Removal..............4-3 4.3.6 Back Panel Assembly Removal...........4-3 4.3.7 Line Filter PWA Removal ..............4-4 4.3.8 BFG PWA Removal...............4-4 4.3.9 Main PWA Removal ..............4-4 4.4 Troubleshooting ..................4-4 4.4.1 Troubleshooting Flyback Power Supply........4-4 ©2002 Crown Audio, Inc.
  • Page 6 5.3.5 CE4000 PS Output Heatsink Assembly........5-7 5.3.6 CE4000 Standard Input Assembly ..........5-8 5.3.7 CE4000 Standard Domestic Ouput Assembly ......5-9 5.3.8 CE4000 Power Switch Assembly ..........5-10 5.4 Circuit Board Parts................5-11 5.4.1 Circuit Board and Schematic Part Numbers ......5-11 6 Schematics..................6-1 ©2002 Crown Audio, Inc.

  • Page 7: Introduction

    1.2 The CE 4000 Amplifi er most Crown products carry a 3-Year Full Warranty (including round trip shipping within the United The Crown CE 4000 is a compact audio amplifi er States), all warranty service should be referred to designed for professional use, providing high-power the Crown Factory or Authorized Warranty Service amplification from 20 Hz–20 kHz with minimum...
  • Page 8 130485-1 Rev. B CE 4000 Service Manual Figure 1.1 CE 4000 Front and Rear Views Introduction 1-2 ©2002 Crown Audio, Inc.

  • Page 9: Specifi Cations

    * Per EN 55103-1: 1996 Annex B and Annex F. Highest reading from when distortion becomes audible in the amplifi er a sample of 10 random readings. output. ** Measured using binding-post output connectors. Specifi cations 2-1 ©2002 Crown Audio, Inc.
  • Page 10 Weight: The CE 4000 net weight is 33.3 pounds (15.1 Input Sensitivity: 0.775 volts or 1.4 volts for standard kg). Shipping weight is 39.3 pounds. 1-kHz power, or fi xed 26-dB gain. Figure 2.2 Output Pin Assignments Figure 2.1 Typical Frequency Response Specifi cations 2-2 ©2002 Crown Audio, Inc.

  • Page 11: Theory Of Operation

    The signal then is passed through a series of switch- event of over-current, the current limiter signal is able filters that allow the signal to be low pass shut off disabling the NAND gates. This results in no Theory of Operation 3-1 ©2002 Crown Audio, Inc.

  • Page 12: Triangle Generator

    The output of voltage, the “on” time of both switches will overlap, U119 and U123 are then sent to the output MOSFET even if one is on longer than the other. drivers. Theory of Operation 3-2 ©2002 Crown Audio, Inc.

  • Page 13: Output Filter

    2. Current feedback information for the modulators. change but the amplitude of the pulses stays at 2 * Vcc. Positive audio signals will cause the positive side of the output stage to be on more than 50% Theory of Operation 3-3 ©2002 Crown Audio, Inc.

  • Page 14: Current Limiter

    U117-C or U117-B will go low during power transformer to tell the amplifi er if action needs an IOC event. If this happens, U125-D goes high to be taken to reduce the temperature. RT1 and RT2 Theory of Operation 3-4 ©2002 Crown Audio, Inc.

  • Page 15: Power Supply Operation

    D45 if there is a fault detected by the parts on the primary side of the power distribution audio output stage or if the power supply detects an circuitry (including those on the EMI PWA) have all Theory of Operation 3-5 ©2002 Crown Audio, Inc.

  • Page 16: Pfc Boost Stage

    Over Current Detect Circuit and will latch both U2 and U4 off if currents above 50-55 Amps are detected in the bridge primary. The power to the amplifi er must be cycled to reset this latch. Theory of Operation 3-6 ©2002 Crown Audio, Inc.

  • Page 17: Maintenance

    ESD protection. Proper grounding straps supplies. See section 4.3.2 for instructions. Failure and test equipment are required. Failure to use to do so will result in circuit failure. proper protection will result in component failure. Maintenance 4-1 ©2002 Crown Audio, Inc.
  • Page 18 Output Panel Back Panel Power Supply Line Filter Assembly Assembly Assembly Discharge Figure 4.1 CE 4000 Top View A Line Filter Fan Wire BFG PWA Jack (J4) Figure 4.2 CE 4000 Top View B Maintenance 4-2 ©2002 Crown Audio, Inc.

  • Page 19: Flyback Supply Pwa Removal

    Figure 4.4 Flyback PWA and PFC Coils the chassis. Slide the back panel partially out and away from the amplifi er, then unplug the fan wires from the Main PWA at J4 (see Figure 4.3). Maintenance 4-3 ©2002 Crown Audio, Inc.

  • Page 20: Line Filter Pwa Removal

    11. Unplug the power switch wires at J26, J27, J28 and J29 on the Main PWA. 12. Remove the seven screws that secure the heatsink assembly and coil assembly to the chassis. Figure 4.7 Brown-Out Jumper Maintenance 4-4 ©2002 Crown Audio, Inc.

  • Page 21: Troubleshooting Trianglewave Generator And Bca Output Stage

    1. Using an oscilloscope check audio side triangle Figure 4.10 Gate Switching, View A waveforms at TP102 with respect to TP105 (see Figure 4.9). Figure 4.9 Output Signal of Triangle-Wave Generator Figure 4.11 Gate Switching, View B Maintenance 4-5 ©2002 Crown Audio, Inc.

  • Page 22: Troubleshooting Power Supply, Pfc Pwa And Full Bridge Dc To Dc Converter

    5. Using an external power supply apply 60VDC you can look for helpful information in Section 4.4.5 as to J23 and verify that the frequency changes, as to where the cause of the problem is located. shown in Figure 4.14. Maintenance 4-6 ©2002 Crown Audio, Inc.

  • Page 23: Identifying And Repairing The Cause

    TP50. If it is low, then troubleshoot the PFC boost fi lter. Readjust R178 and R278 for channel 1 and 2 stage. If 400 V is o.k., check the ±Vccs at L6 and L9. They should measure approximately 105 VDC to Maintenance 4-7 ©2002 Crown Audio, Inc.

  • Page 24: Required Test Equipment

    1. Possible problem on the Main PWA, and is likely successfully service the amplifi er. Recommended models are those used by Crown. Alternate oscilloscope choices: Tektronix TDS360 and HP HP54610B. The latter is a 500 MHz scope, which is needed to test newer BCA power supplies.

  • Page 25: Electrical Checkout Procedures

    1 kHz reference voltage ±0.25 using an A-weighted fi lter. dB. Switch the frequency to 20 kHz and verify that the input voltage is still 0.1 Vrms. Measure the Maintenance 4-9 ©2002 Crown Audio, Inc.

  • Page 26: Crosstalk At 20 Khz

    Figure 4.18 Correct Overlap Adjustment 4.7.2 Overlap Correction and Adjustment (Less than 10V) Conditions: • Amplifi er output assembly MUST be room tem- perature (72 degrees F/21 degrees C) • No input signal • No load Maintenance 4-10 ©2002 Crown Audio, Inc.

  • Page 27: Current Sensing Calibration

    If you suspect the slugs ( L101, L102 for Channel 1 while L201 and L201 for Channel 2) have been moved, the amplifi er should be sent to CROWN Factory Service for proper adjustment. Transition Figure 4.20 Excessive Overlap (No Smooth Transition) 4.7.3 Current Sensing Calibration...
  • Page 28 130485-1 Rev. B CE 4000 Service Manual This Page Intentionally Left Blank Maintenance 4-12 ©2002 Crown Audio, Inc.

  • Page 29: Parts

    All serviceable parts and assemblies Normal terms are prepaid. Net-30 Days applies to will have a Crown Part Number (CPN) listed in this only those having pre-established accounts with chapter. The parts listed are current as of the date Crown.

  • Page 30: Ce4000 Amplifi Er Assembly

    3) SLIDE CABLE TIES (ITEM 25) THRU LANCES A11056-1 10-12 IN LBS. IN CHASSIS, PLACE RIBBON CABLE (PART OF 128345-1 16-18 IN LBS ITEM 5) AGAINST CHASSIS SIDE PANEL BETWEEN LANCES, THEN SECURE CABLE TIES AROUND A11056-2 10-12 INLBS RIBBON CABLE. Parts 5-2 ©2002 Crown Audio, Inc.
  • Page 31 CE 4000 Service Manual 130485-1 Rev. B Figure 5.1 Amplifi er Assembly (Exploded View) Parts 5-3 ©2002 Crown Audio, Inc.

  • Page 32: Back Panel Assembly

    1) CONNECT ITEM 8 TO “J9” & ITEM 9 TO “J10” ITEM NO. C.P.N. TORQUE SETTINGS ON ITEM 6 PWA PRIOR TO ASSEMBLING ITEM 103436-70604 13-15 IN LBS. A11056-2 10-12 IN LBS. Figure 5.2 CE4000 Back Panel Assembly (Exploded View) Parts 5-4 ©2002 Crown Audio, Inc.

  • Page 33: Ce4000 Ps Primary Heatsink Assembly

    WAFER, 3.000 X .90X.04 CERAMIC 127204-1 EXTRU, CE4000L-FR HS MACHINED 127976-3 ASM. NUMBER: 128009-1 RECOMMENDED ASSEMBLY TORQUES ITEM NO. C.P.N. TORQUE SETTINGS 103415-10805 22-24 IN LBS. Figure 5.3 CE4000 PS Primary Heatsink Assembly (Exploded View) Parts 5-5 ©2002 Crown Audio, Inc.

  • Page 34: Ce4000 Ps Diode Heatsink Assembly

    WAFER, 3.00 X.90 X .04 CERAMIC 127204-1 EXTRU,CE4000 L-RR HS MACHINED 127977-3 ASM. NUMBER: 128010-1 RECOMMENDED ASSEMBLY TORQUES ITEM NO. C.P.N. TORQUE SETTINGS 103415-10805 22-24 IN LBS. Figure 5.4 CE4000 PS Diode Heatsink Assembly (Exploded View) Parts 5-6 ©2002 Crown Audio, Inc.

  • Page 35: Ce4000 Ps Output Heatsink Assembly

    WAFER, 2.7000 X .90 X .04 CERAMIC 127564-1 EXTRU, CE4000 R-HALF HS MACHINED 127978-3 ASM. NUMBER: 128011-3 RECOMMENDED ASSEMBLY TORQUES ITEM NO. C.P.N. TORQUE SETTINGS 103415-10805 22-24 IN LBS. Figure 5.5 CE4000 PS Output Heatsink Assembly (Exploded View) Parts 5-7 ©2002 Crown Audio, Inc.

  • Page 36: Ce4000 Standard Input Assembly

    PANEL, CE INPUT CHARCOAL 126787-5 ASM. NUMBER: 127049-1 RECOMMENDED ASSEMBLY TORQUES ITEM NO. C.P.N. TORQUE SETTINGS A10111-70408 4-5 IN LBS. 2 (REF) 103435-70608 13-15 IN LBS. Figure 5.6 CE4000 Standard Input Assembly (Exploded View) Parts 5-8 ©2002 Crown Audio, Inc.

  • Page 37: Ce4000 Standard Domestic Ouput Assembly

    BAR, CE4000 OUTPUT BUSS AP 127672-2 PWA, CE4000 SPEAKON/BDG POST OTPT See section 5.4 ASM. NUMBER: 127831-1 RECOMMENDED ASSEMBLY TORQUES ITEM NO. C.P.N. TORQUE SETTINGS 103436-70604 13-15 IN LBS Figure 5.7 CE4000 Standard Domestic Output Assembly (Exploded View) Parts 5-9 ©2002 Crown Audio, Inc.

  • Page 38: Ce4000 Power Switch Assembly

    ASM. NUMBER: 128425-1 NOTES: 1) MARKINGS 1, ID, 2, 2D ARE IDENTIFIED ON SWITCH HOUSING. 2) J26, J27, J28, J29 ARE CORRESPONDING LOCA- TIONS ON PWA. Figure 5.8 CE4000 Power Switch Assembly (Exploded View) Parts 5-10 ©2002 Crown Audio, Inc.

  • Page 39: Circuit Board Parts

    This section includes electrical parts lists for this PWA NUMBER: 127563-3 product. All serviceable parts and assemblies will have a Crown Part Number (CPN) listed in this CE 4K SPEAKON/BDG POST OTPT section. The parts listed are current as of the date printed.
  • Page 40 130485-1 Rev. B CE 4000 Service Manual Parts 5-12 ©2002 Crown Audio, Inc.
  • Page 41 CE 4000 Service Manual 130485-1 Rev. B Parts 5-13 ©2002 Crown Audio, Inc.
  • Page 42 130485-1 Rev. B CE 4000 Service Manual Parts 5-14 ©2002 Crown Audio, Inc.
  • Page 43 CE 4000 Service Manual 130485-1 Rev. B Parts 5-15 ©2002 Crown Audio, Inc.
  • Page 44 130485-1 Rev. B CE 4000 Service Manual Parts 5-16 ©2002 Crown Audio, Inc.
  • Page 45 CE 4000 Service Manual 130485-1 Rev. B Parts 5-17 ©2002 Crown Audio, Inc.
  • Page 46 130485-1 Rev. B CE 4000 Service Manual Parts 5-18 ©2002 Crown Audio, Inc.
  • Page 47 CE 4000 Service Manual 130485-1 Rev. B Parts 5-19 ©2002 Crown Audio, Inc.
  • Page 48 130485-1 Rev. B CE 4000 Service Manual Parts 5-20 ©2002 Crown Audio, Inc.
  • Page 49 CE 4000 Service Manual 130485-1 Rev. B Parts 5-21 ©2002 Crown Audio, Inc.
  • Page 50 130485-1 Rev. B CE 4000 Service Manual Parts 5-22 ©2002 Crown Audio, Inc.
  • Page 51 CE 4000 Service Manual 130485-1 Rev. B Parts 5-23 ©2002 Crown Audio, Inc.
  • Page 52 130485-1 Rev. B CE 4000 Service Manual Parts 5-24 ©2002 Crown Audio, Inc.
  • Page 53 CE 4000 Service Manual 130485-1 Rev. B Parts 5-25 ©2002 Crown Audio, Inc.
  • Page 54 130485-1 Rev. B CE 4000 Service Manual Parts 5-26 ©2002 Crown Audio, Inc.
  • Page 55 CE 4000 Service Manual 130485-1 Rev. B Parts 5-27 ©2002 Crown Audio, Inc.
  • Page 56 130485-1 Rev. B CE 4000 Service Manual Parts 5-28 ©2002 Crown Audio, Inc.
  • Page 57 CE 4000 Service Manual 130485-1 Rev. B Parts 5-29 ©2002 Crown Audio, Inc.
  • Page 58 130485-1 Rev. B CE 4000 Service Manual Parts 5-30 ©2002 Crown Audio, Inc.
  • Page 59 CE 4000 Service Manual 130485-1 Rev. B Parts 5-31 ©2002 Crown Audio, Inc.
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  • Page 61 CE 4000 Service Manual 130485-1 Rev. B Parts 5-33 ©2002 Crown Audio, Inc.
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  • Page 63 CE 4000 Service Manual 130485-1 Rev. B Parts 5-35 ©2002 Crown Audio, Inc.
  • Page 64 130485-1 Rev. B CE 4000 Service Manual Parts 5-36 ©2002 Crown Audio, Inc.
  • Page 65 CE 4000 Service Manual 130485-1 Rev. B Parts 5-37 ©2002 Crown Audio, Inc.
  • Page 66 130485-1 Rev. B CE 4000 Service Manual Parts 5-38 ©2002 Crown Audio, Inc.
  • Page 67 CE 4000 Service Manual 130485-1 Rev. B Parts 5-39 ©2002 Crown Audio, Inc.
  • Page 68 130485-1 Rev. B CE 4000 Service Manual Parts 5-40 ©2002 Crown Audio, Inc.
  • Page 69 CE 4000 Service Manual 130485-1 Rev. B Parts 5-41 ©2002 Crown Audio, Inc.
  • Page 70 130485-1 Rev. B CE 4000 Service Manual Parts 5-42 ©2002 Crown Audio, Inc.
  • Page 71 CE 4000 Service Manual 130485-1 Rev. B CE4000 MAIN PWA NUMBER: 126218-13 DRAWING SHEET: 41 Parts 5-43 ©2002 Crown Audio, Inc.
  • Page 72 130485-1 Rev. B CE 4000 Service Manual CE4000 MAIN PWA NUMBER: 126218-13 DRAWING SHEET: 41 Parts 5-44 ©2002 Crown Audio, Inc.
  • Page 73 CE 4000 Service Manual 130485-1 Rev. B Parts 5-45 ©2002 Crown Audio, Inc.
  • Page 74 130485-1 Rev. B CE 4000 Service Manual Parts 5-46 ©2002 Crown Audio, Inc.
  • Page 75 CE 4000 Service Manual 130485-1 Rev. B Parts 5-47 ©2002 Crown Audio, Inc.
  • Page 76 130485-1 Rev. B CE 4000 Service Manual Parts 5-48 ©2002 Crown Audio, Inc.
  • Page 77 CE 4000 Service Manual 130485-1 Rev. B Parts 5-49 ©2002 Crown Audio, Inc.
  • Page 78 130485-1 Rev. B CE 4000 Service Manual Parts 5-50 ©2002 Crown Audio, Inc.
  • Page 79 CE 4000 Service Manual 130485-1 Rev. B Parts 5-51 ©2002 Crown Audio, Inc.
  • Page 80 130485-1 Rev. B CE 4000 Service Manual Parts 5-52 ©2002 Crown Audio, Inc.
  • Page 81 CE 4000 Service Manual 130485-1 Rev. B Parts 5-53 ©2002 Crown Audio, Inc.
  • Page 82 130485-1 Rev. B CE 4000 Service Manual Parts 5-54 ©2002 Crown Audio, Inc.
  • Page 83 CE 4000 Service Manual 130485-1 Rev. B Parts 5-55 ©2002 Crown Audio, Inc.
  • Page 84 130485-1 Rev. B CE 4000 Service Manual Parts 5-56 ©2002 Crown Audio, Inc.
  • Page 85 CE 4000 Service Manual 130485-1 Rev. B Parts 5-57 ©2002 Crown Audio, Inc.
  • Page 86 130485-1 Rev. B CE 4000 Service Manual Parts 5-58 ©2002 Crown Audio, Inc.
  • Page 87 CE 4000 Service Manual 130485-1 Rev. B Parts 5-59 ©2002 Crown Audio, Inc.
  • Page 88 130485-1 Rev. B CE 4000 Service Manual Parts 5-60 ©2002 Crown Audio, Inc.
  • Page 89 CE 4000 Service Manual 130485-1 Rev. B Parts 5-61 ©2002 Crown Audio, Inc.
  • Page 90 130485-1 Rev. B CE 4000 Service Manual Parts 5-62 ©2002 Crown Audio, Inc.
  • Page 91 CE 4000 Service Manual 130485-1 Rev. B Parts 5-63 ©2002 Crown Audio, Inc.
  • Page 92 130485-1 Rev. B CE 4000 Service Manual Parts 5-64 ©2002 Crown Audio, Inc.
  • Page 93 CE 4000 Service Manual 130485-1 Rev. B Parts 5-65 ©2002 Crown Audio, Inc.
  • Page 94 130485-1 Rev. B CE 4000 Service Manual Parts 5-66 ©2002 Crown Audio, Inc.
  • Page 95 CE 4000 Service Manual 130485-1 Rev. B Parts 5-67 ©2002 Crown Audio, Inc.
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  • Page 97 CE 4000 Service Manual 130485-1 Rev. B Parts 5-69 ©2002 Crown Audio, Inc.
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  • Page 99 CE 4000 Service Manual 130485-1 Rev. B Parts 5-71 ©2002 Crown Audio, Inc.
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  • Page 101 CE 4000 Service Manual 130485-1 Rev. B Parts 5-73 ©2002 Crown Audio, Inc.
  • Page 102 130485-1 Rev. B CE 4000 Service Manual Parts 5-74 ©2002 Crown Audio, Inc.
  • Page 103 CE 4000 Service Manual 130485-1 Rev. B Parts 5-75 ©2002 Crown Audio, Inc.
  • Page 104 130485-1 Rev. B 130485-1 Rev. B CE 4000 Service Manual Parts 5-76 ©2002 Crown Audio, Inc.
  • Page 105 CE 4000 Service Manual 130485-1 Rev. B CE4000 MAIN PWA NUMBER: 126218-14 DRAWING SHEET: 41 Parts 5-77 ©2002 Crown Audio, Inc.
  • Page 106 130485-1 Rev. B CE 4000 Service Manual CE4000 MAIN PWA NUMBER: 126218-14 DRAWING SHEET: 42 Parts 5-78 ©2002 Crown Audio, Inc.
  • Page 107 CE 4000 Service Manual 130485-1 Rev. B Parts 5-79 ©2002 Crown Audio, Inc.
  • Page 108 130485-1 Rev. B CE 4000 Service Manual Parts 5-80 ©2002 Crown Audio, Inc.
  • Page 109 CE 4000 Service Manual 130485-1 Rev. B Parts 5-81 ©2002 Crown Audio, Inc.
  • Page 110 130485-1 Rev. B CE 4000 Service Manual Parts 5-82 ©2002 Crown Audio, Inc.
  • Page 111 CE 4000 Service Manual 130485-1 Rev. B Parts 5-83 ©2002 Crown Audio, Inc.
  • Page 112 130485-1 Rev. B CE 4000 Service Manual Parts 5-84 ©2002 Crown Audio, Inc.
  • Page 113 CE 4000 Service Manual 130485-1 Rev. B Parts 5-85 ©2002 Crown Audio, Inc.
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  • Page 138 130485-1 Rev. B CE 4000 Service Manual This Page Intentionally Left Blank Parts 5-110 ©2002 Crown Audio, Inc.
  • Page 139 PWA NUMBER: 127563-3 Schematic Sheet: PWA NUMBER: 126218-16 PWA NUMBER: 127563-4 (REV.A) Schematic Sheet: Schematic Sheet: CE 4K SPEAKON/BDG POST OTPT PWA NUMBER: 127820-3 Schematic Sheet: CE4000 EMI FILTER PWA NUMBER: 128243-6 Schematic Sheet: Schematics 6-1 ©2002 Crown Audio, Inc.
  • Page 140 130485-1 Rev. B CE 4000 Service Manual This Page Intentionally Left Blank Schematics 6-2 ©2002 Crown Audio, Inc.

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