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Crown FM1000A User Manual

Rf amplifier package
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FM1000A
RF 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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  • Page 1 ® FM1000A RF 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...

  • Page 2: Important Notices

    May 2005 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 any form by any means without the written permission of Crown International, Inc.

  • Page 3: Table Of Contents

    Contents Contents Contents Contents Contents Section 1—Getting Acquainted 1.1 Your Amplifier Package ..................1–2 1.2 Amplifier Package Specifications ................. 1–3 1.3 Safety Considerations ..................1–4 1.3.1 Dangers ......................1–4 1.3.2 Warnings ......................1–4 1.3.3 Cautions ......................1–4 Section 2—Installation 2.1 Operating Environment ..................2–2 2.2 Tools Required ....................
  • Page 4 4.2 PS1000 Power Supply ..................4–4 4.2.1 AC Input Board ..................... 4–5 4.2.2 PFC (Power Factor Correcting) Switching Board .......... 4–5 4.2.3 DC Output Board ..................4–6 4.2.4 Cooling Fans ....................4–6 Section 5—Troubleshooting 5.1 Troubleshooting Flow Chart Analysis ..............5–2 5.2 Digital Multimeter Parameters ................

  • Page 5: Section 1-Getting Acquainted

    I NFORMATION Section 1—Getting Acquainted This section provides a general description of the FM1000A power amplifier system and introduces you to safety conventions used within this document. Review this material before install- ing or operating the amplifier and power supply.

  • Page 6: Your Amplifier Package

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

  • Page 7: Amplifier Package Specifications

    5.25 x 17.25 x 23 inches (13.34 x 43.82 x 58.42 cm) exclusive of rack ears Weight: PA1000—40 pounds (18.1 kg) RF PA Modules—8 pounds (3.6 kg) each PS1000—43 pounds (19.5 kg) Note: System performance is specified using Crown Broadcast Model FM30 Exciter where applicable. Getting Acquainted 1–3...

  • Page 8: Safety Considerations

    1.3 Safety Considerations Crown Broadcast assumes the responsibility for providing you a safe product and safety guidelines during its use. “Safety” means protection to all individuals who install, operate, and service the transmitter as well as protection of the transmitter itself.

  • Page 9: Section 2-Installation

    Section 2—Installation This section provides important guidelines for installing your power amplifier and power supply. Review this information care- fully for proper installation. Installation 2–1...

  • Page 10: Operating Environment

    2.1 Operating Environment You can install the FM1000A amplifier system in a standard 19–inch component rack or on a suitable surface such as a bench or desk. In any case, the area should be as clean and well-ventillated as possible. The power supply must be installed directly above or below the power amplifier (for the included dressed cables to reach their respective connectors).

  • Page 11: Preinstallation

    2.4 Preinstallation 2.4.1 Power Amplifier Modules The PA1000 incorporates four power amplifiers (two each in two modules). Due to possible damage during shipment, the power modules have been removed. Follow these steps to install the modules: 1. Remove the front panel of the PA1000 (four screws). 2.

  • Page 12: Hubble Twist Lock® Connector Wiring

    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. WARNING Possible Electric Shock Hazard! Do not connect AC source until all other connections are made and installation is complete. 2–4 FM1000A User’s Manual...

  • Page 13: Installation

    2. Ensure that the PS1000 power switch is off, the circuit breakers of the 240 VAC 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 its instructions.

  • Page 14: Remote I/O Connection

    Remote/Local slide switch must be in the REMOTE position. Then the on-board remote RAISE and LOWER push buttons and any external remote switches attached to pins 4 and 15 of the I/O Connector can adjust Illustration 2–5 Local and Remote Functions 2–6 FM1000A User’s Manual...
  • Page 15 the level up to that limit and down to zero. When a specific output power level is set, the Metering and Control Board controls and maintains the setting to keep the power constant. The location of the Local Power Adjust (R62), the on-board Raise and Lower switches (SW3 &...
  • Page 16 PA Total Current Monitor (a buffered metering output with 1 V = 20 A) PA Volts (a buffered metering output with 1 V = 10 V) Note: PA = Power Amplifier Remote I/O Connector Pinout Table 2–8 FM1000A User’s Manual...

  • Page 17: Section 3-Operation

    Section 3—Operation This section provides general operating parameters of your power amplifier system and a detailed description of the front panel display. Operation 3–1...

  • Page 18: Initial Power-Up Procedures

    PA1000 front panel Digital Multimeter, is between 0.4 and 0.8volts. This is not a drive dependent amplifier; therefore drive must be at a constant level regardless of main output power. Note: The unit will not operate until the exciter is active. 3–2 FM1000A User’s Manual...
  • Page 19 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 the output 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 is normally shipped with this setting.

  • Page 20: Power Switches

    This AC input circuit breaker must be in the “up” position (as shown below) for operation. AC Input Circuit Breaker Fans Power Control 240 VAC IN Illustration 3–4 AC Input Circuit Breaker 3–4 FM1000A User’s Manual...

  • Page 21: Dc Power Switch

    3.2.2 DC Power Switch The main on/off power switch located on the front panel of the power supply controls high voltage output. (The control circuit activates this voltage.) Power ® Power Switch Illustration 3–5 DC Power Switch 3.2.3 Interlock Switch This switch is located on the fan mounting bracket in the power supply.

  • Page 22: Digital Multimeter

    PA Temp—Highest temperature of all individual RF power amplifier heatsinks in degrees 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. 3–6 FM1000A User’s Manual...

  • Page 23: Fault Indicators

    3.4 Fault Indicators 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 reflected RF power. RF Drive—Lack of or insufficient RF drive. If the RF drive fault LED is lit, input drive must be increased.

  • Page 24: Fuse Indicators

    3 and 4 on the lower right power module. Fuses and Indicators Fault Fuses Power Out Antenna PA Temp RF Drive PA Voltage PA Temp Tot Current PA DC ® Illustration 3–9 Fuse Indicators 3–8 FM1000A User’s Manual...

  • Page 25: Section 4-Principles Of Operation

    ta ci n ha 'e n n ha ta ci 'e n n ha ta ci 'e n 'e n ta ci ta ci ta ci n ha 'e n ta ci Section 4—Principles of Operation This section discusses the circuit principles upon which the power amplifier and power supply function.

  • Page 26: Pa1000 Power Amplifier

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

  • Page 27: Backplane Assembly

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

  • Page 28: Metering And Control Board

    This board is fail-safe, like all the other circuit board components in the FM1000A and can be removed for repair/replacement if necessary.

  • Page 29: Ac Input Board

    4.2.1 AC Input Board The AC Input Board is located on the left side of the PS1000. AC power from the circuit breaker connects to the AC Input Board where it connects to a ±12 volt DC power supply and three relays. The ±12 volts is used to close the three relays when the DC Power Switch on the front panel is switched on.

  • Page 30: Dc Output Board

    The fans blow cool air through the heatsinks 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 power supply. 4–6 FM1000A User’s Manual...

  • Page 31: Section 5-Troubleshooting

    TROUBLE TROUBLE TROUBLE Section 5—Troubleshooting This section describes procedures for service personnel to diag- nose and troubleshoot potential fault conditions in the power amplifier and power supply. Troubleshooting 5–1...

  • Page 32: Troubleshooting Flow Chart Analysis

    PS2000. RF Drive: See Section 5.3.2 Ensure AC input circuit breaker is flipped up PA Temp: See Section 5.3.3 Ensure main power switch is turned on. PA DC: See Section 5.3.4 Call Support— See Section 8 5–2 FM1000A User’s Manual...

  • Page 33: Digital Multimeter Parameters

    5.2 Digital Multimeter Parameters The following procedures are general in nature; for in-depth service, and repair see the Service & Support section of this manual. W W ARNING ARNING Lethal voltages present! Only technically qualified individuals shoud attempt troubleshooting or service procedures If any abnormal readings are displayed for any of the following parameters on the Digital Multimeter, try troubleshooting in the following manner:...

  • Page 34: Pa Temp

    (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. 5–4 FM1000A User’s Manual...

  • Page 35: Fault Indicators

    5.3 Fault Indicators If one of the LED fault indicators is illuminated red, troubleshoot using the follow- ing suggestions: 5.3.1 Antenna Antenna mismatch. Effects from inclement weather conditions such as icing. Check for moisture in the feedline. Secure antenna connections. 5.3.2 RF Drive Denotes lack of or insufficient drive level.

  • Page 36: Pa Dc

    Also, check output power for proper current; the RF detection circuit could malfunction causing an overcurrent situation. 5.3.5 Multiple Indicators Call your Crown Broadcast service representative. See Section 7, Service and Support, for contact information. Fuses...

  • Page 37: Section 6-Reference Drawings

    Section 6—Reference Drawings The illustrations in this section may be useful for making adjustments, taking measurements, troubleshooting, or understanding the circuitry of your RF power amplifier and power supply. Reference Drawings 6–1...

  • Page 38: Views

    (Optional Connection) RF Input Ground Screws DC Input Air Intakes/Filters Remote I/O RF Output PA1000 Control Circuit Breakers + DC Output Fans Power Control DC Output PS1000 Air Exhaust Vents 240 VAC IN Illustration 6–2 Back View 6–2 FM1000A User’s Manual...

  • Page 39: Diagrams And Schematics

    RF Input Excitation PA1000 30 W Exciter Power Amplifier (Crown FM30) Remote I/O Connector Power Supply 0–50 VDC Control PA Supply PS1000 Power Supply 240 VAC 50/60 Hz Input Power Single Phase Illustration 6–3 FM1000A Block Diagram Reference Drawings 6–3...
  • Page 40 AC INPUT 360 VDC CIRCUIT 240 VAC BREAKER 220 VDC RECTIFIER + 0 to 50 VDC INPUT PFC & NEUTRAL 360 VDC CONTROL OUTPUT GROUND CONTROL RETURN +/ 12 VDC POWER SWITCH VOLTAGE BOOST INDUCTOR 9-PIN PS CONTROL DSUB Illustration 6–4 PS1000 Block Diagram...
  • Page 41 LM2586-ADJ 10.0K 1N4004 HEADER 5X2 NOTES : 330UH -12V _______ _______ +12V +12V ALL RESISTORS ARE IN OHMS, 1/4W, 5% UNLESS OTHERWISE 330UH SPECIFIED. ALL CAPACITORS ARE IN 1N4004 To DC OUTPUT BOARD MICROFARADS UNLESS OTHERWISE SPECIFIED. 1.10K 2N5822 2N5822 -12V GND CHASSIS GND EARTH...
  • Page 42 1N4148 1N4148 NOT ON PWB T2 80t 4.7K 1N4148 1N4148 2.74K BRIDGE- BRIDGE+ IND1 IND2 HFA25TB60 400VDC XFMR1 .001 JUMPER XFMR2 IGBT, 600V 50A FAST IGBT, 600V 50A FAST 630VDC .0047 XFMR IGBT, 600V 50A FAST GATE 0.04 .0033 250VAC .001 .001 1N5818...
  • Page 43 REVISION HISTORY APPROVALS E . C . N. DESCRIPTION DATE REDRAWN ON IREC FORMAT, AND ADDED U2,D16,L5,C20-21,R20-21 01/17/05 150uH +27V FAN +24VDC FAN FUSE ON/OFF FEEDBACK MUR420 MBR3100 MBR3100 18.7K 220/35V 470pF 220/35V LM2596T-ADJ MBR3100 MBR3100 1.0K .0047 13,14 BYV44-300 .0047 TO RF PA'S 15,16,17,18...
  • Page 44 Illustration 6–5 PA1000 Block Diagram...
  • Page 45 47PF NP0 BNC 1 OUTPUT 1N5263 47PF NP0 1N6263 .001 .001 RF INPUT (Back Panel) 1 2 3 4 5 RF IN NOTES : _______ _______ 1. ALL RESISTORS ARE IN OHMS, 1/4W, 5% UNLESS OTHERWISE SPECIFIED. 2. ALL CAPACITORS ARE IN MICROFARADS UNLESS OTHERWISE SPECIFIED.
  • Page 46 500 W Power Amp 6–10 FM1000A User’s Manual...
  • Page 47 RF Output Combiner Reference Drawings 6–11...
  • Page 48 RF OUTPUT FILTER & REFLECTOMETER 6–12 FM1000A User’s Manual...
  • Page 49 Note: All bypass capacitors are 0.01 mf Backplane Distribution Reference Drawings 6–13...
  • Page 50 Ribbon Cables and Connectors Ribbon Cables and Connectors 6–14 FM1000A User's Manual...
  • Page 51 +5.00 +12V POWER CAL TL074 49.9K R181 1N4004 1N4004 LM394 RF FWD MEM BATT REM PWR CTRL 1N4148 1N4148 +12V REM RF POWER R182 R108 100K C105 220K 3300UF/16V -12V 1N6263 LM394 MC33282 R177 R173 3.3K R179 240K 10.0K C103 U33B U29A TL074...
  • Page 52 Notes: 6–16 FM1000A User's Manual...

  • Page 53: Section 7-Service And Support

    Section 7—Service and Support We understand that you may need various levels of support or that the product could require servicing at some point in time. This section provides information for both of these scenarios. Service and Support 7–1...

  • Page 54: Service

    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 Sales at the following number. (866) 262-891 You may also write to the following address: Service Manger International Radio and Electronics Company, Inc.
  • Page 55 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.
  • Page 56 Notes: 7–4 FM1000A User's Manual...
  • Page 57 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:...

  • Page 58: Glossary

    Glossary The following pages define terms and abbreviations used throughout this and other Crown Broadcast manuals. Glossary G–1...
  • Page 59 The unwanted changes in signal wave shape that occur during transmission between two points. Digital Panel Meter EPROM Erasable Programmable Read Only Memory Electrostatic Discharge; a discharge that is poten- tially distructive to sensitive electronic compo- nents. G–2 FM1000A User's Manual...
  • Page 60 exciter (1) A circuit that supplies the initial oscillator used in the driver stage. (2) A transmitter configuration which excludes stereo generation and audio processing. Field-Effect Transistor frequency synthesizer A circuit that generates precise frequency signals by means of a single crystal oscillator in conjunc- tion with frequency dividers and multipliers.
  • Page 61 (or vice versa). subcarrier A carrier signal which operates at a lower fre- quency than the main carrier frequency and which modulates the main carrier. suppression The process used to hold back or stop certain frequencies. G–4 FM1000A User's Manual...
  • Page 62 Standing-Wave Ratio; on a transmission line, the ratio of the maximum voltage to the minimum voltage or maximum current to the minimum current; also the ratio of load impedance to in- tended (50 ohms) load impedance. Total Harmonic Distortion translator A transmitter designed to internally change an FM signal from one frequency to another for retrans- mission.

  • Page 63: Index

    Index H H H H H A A A A A Humidity Range 1–3 AC Input Board 4–5 AC Power 1–3 I I I I I AC power 2–4 ALC 3–4, 5–3 In Ref 3–4, 5–3 Antenna 3–7 Input Divider Board 4–3 mismatch 5–5 Installation 2–5 antenna 2–5...
  • Page 64 R R R R R T T T T T remote I/O 2–7 Tot Current 5–4 RF Drive Requirement 1–3 transmitter package 1–2 RF Harmonics 1–3 Troubleshooting Flow Chart 5–2 RF Output Impedance 1–3 U U U U U RF output power 1–2 RF Power Output 1–3 Unpacking 2–2 RF power output 1–2...

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