Crown FM1000A User Manual

®

User's Manual

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

25166 Leer Drive, Elkhart, Indiana, 46514-5425 U.S.A.

FM1000A

RF Amplifier Package

[phone]

i

Revision Control

Revision Print Date

Initial Release (Rev. 0) 900413-1 November 1998
Revision 1April 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 any
form 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 the
following address:

ii

International Radio and Electronics

25166 Leer Drive, P.O. Box 2000

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

ContentsContents

Contents

ContentsContents

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..................................................................................................2–2

2.3 Unpacking.........................................................................................................2–2

2.4 Preinstallation...................................................................................................2–3

2.4.1 Power Amplifier Modules .............................................................................2–3

2.4.2 Hubble Twist Lock® Connector Wiring ........................................................2–4

2.5 Installation ........................................................................................................2–5

2.6 Remote I/O Connection.....................................................................................2–6

Section 3—Operation

3.1 Initial Power-up Procedures..............................................................................3–2

3.2 Power Switches ................................................................................................3–4

3.2.1 AC Input Circuit Breaker ...............................................................................3–4

3.2.2 DC Power Switch..........................................................................................3–5

3.2.3 Interlock Switch............................................................................................3–5

3.3 Digital Multimeter .............................................................................................3–6

3.4 Fault Indicators ................................................................................................. 3–7

3.5 Fuse Indicators .................................................................................................3–8

Section 4—Principles of Operation

4.1 PA1000 Power Amplifier...................................................................................4–2

4.1.1 Power Modules ............................................................................................4–2

4.1.2 Power Combiner Board ................................................................................4–2

4.1.3 Backplane Assembly.....................................................................................4–3

4.1.3.1 Backplane DC Interconnect Board ........................................................4–3

4.1.3.2 Input Divider Board...............................................................................4–3

4.1.3.3 Output Combiner Board........................................................................4–3

4.1.4 Output Filter & Reflectometer.......................................................................4–3

4.1.5 Metering and Control Board .........................................................................4–4

4.1.6 DC Fuse and Power Distribution Board ........................................................4–4

4.1.7 Cooling Fans.................................................................................................4–4

iii

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 ..........................................................................5–3

5.2.1 In Ref (Input Drive Reference)......................................................................5–3

5.2.2 SWR (Standing Wave Ratio) ........................................................................5–3

5.2.3 ALC (Automatic Level Control) .....................................................................5–3

5.2.4 Power Out ....................................................................................................5–3

5.2.5 PA Temp.......................................................................................................5–4

5.2.6 PA Voltage ....................................................................................................5–4

5.2.7 Tot Current ...................................................................................................5–4

5.2.8 PA1–8...........................................................................................................5–4

5.3 Fault Indicators .................................................................................................5–5

5.3.1 Antenna ........................................................................................................5–5

5.3.2 RF Drive........................................................................................................5–5

5.3.3 PA Temp.......................................................................................................5–5

5.3.3.1 Potential Causes for Non-functioning Cooling Fans..............................5–5

5.3.4 PA DC...........................................................................................................5–6

5.3.5 Multiple Indicators........................................................................................5–6

Section 6—Reference Drawings

6.1 Views ................................................................................................................6–2

6.2 Diagrams and Schematics ................................................................................6–3

Section 7—Service and Support

7.1 Service..............................................................................................................7–2

7.2 24–Hour Support..............................................................................................7–2

7.3 Spare Parts .......................................................................................................7–2

Glossary
Index

iv

I

INFORMATION

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.

Getting Acquainted

1–1

I

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 reliabil­ity. The FM1000A package includes a PA1000 amplifier, PS1000 power supply, and
an FM1K accessory pack.

The PA1000 broadband amplifier requires no tuning and typically provides 80% RF
efficiency across the band. The PS1000 power supply is power factor corrected and
90% efficient. Modern MOSFET technology ensures high AC to RF efficiency
(better than 70% overall) and long-term reliability. The unmatched efficiency of
this power amplifier significantly improves your bottom line by providing cooler
operation and lower power costs.

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

Economic long-term reliability is ensured through our carefully engineered solid­state 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 your
existing exciter or purchase the FM1000T which includes our award-winning FM30
exciter for an unbeatable 1 kW transmitter package.

Metering

In Ref
SWR
ALC

Power

I

O

Power Out
PA Temp
PA Voltage
Tot Current

PA1

PA5

PA2

PA6

PA3

PA7

PA4

PA8

®

®

Fault

Antenna
RF Drive
PA Temp
PA DC

PA3

Fuses

P

A

4 PA7

PA8

1–2

Illustration 1–1 FM1000A Amplifier Package

FM1000A User’s Manual

1.2 Amplifier Package Specifications

RF 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 at

400 Hz, no de-emphasis, no FM modulation
(typically > 60 dB)

Synchronous AM S/N Ratio: Better than –55 dB with 100% modulation at

400 Hz, no de-emphasis, FM
modulation=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 output

typical

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 x

58.42 cm) exclusive of rack ears, but inclu­sive of connectors

Power Supply Chassis: 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

I

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. To promote safety, we use standard hazard alert labeling on the product and
in this manual. Follow the associated guidelines to avoid potential hazard.

1.3.1 Dangers

DANGER represents the most severe hazard alert. Extreme bodily harm or death
will occur if DANGER guidelines are not followed.

1.3.2 Warnings

WARNING represents hazards which could result in severe injury or death.

1.3.3 Cautions

CAUTION indicates potential personal injury or equipment or property damage if
the associated guidelines are not followed. Particular cautions in this text also
indicate unauthorized radio-frequency operation.

Type of Hazard

WARNING

Severe shock hazard!

Pictorial Indication
of Hazard

Illustration 1–3 Sample Hazard Alert

Turn power off and
wait approximately 1
minute for capacitors
to discharge before
handling them.

Explanation of
Hazard

1–4

FM1000A User’s Manual

®

Section 2—Installation

This section provides important guidelines for installing your
power amplifier and power supply. Review this information care­fully for proper installation.

Installation

2–1

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).

2.2 Tools Required

To 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 Unpacking

Before handling any exposed printed circuit boards, ground yourself with an
antistatic strap and/or mat.

CAUTION

Possible equipment damage!
Guard against electrostatic discharge
through electronic components.

The power amplifier, power supply, and two power amplifier modules are packed
and shipped in individual boxes because of their modular nature. (The FM1K
accessory kit is packed inside one of the two power amplifier module boxes.) For
added protection, both the PA1000 amplifier and PS1000 supply are packed in an
inner box and then placed inside an outer box with styrofoam protective corners in
both boxes. You will need to unpack a total of four boxes (plus two inner boxes).

Note: Save the boxes and packaging material that the individual
units are packed in should you need to return them for factory
service.

2–2

FM1000A User’s Manual

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

Connector

Warning Label

Slide Rail

3. The warning labels on the front of the modules should all be positioned to the

4. Insert the two power modules, using their slide rails, into the built in chan-

Vacant Cavity

Illustration 2–1 Power Amplifier Module

center of the chassis, also note the position of the connector on the modules
and in the chassis.

nels of the right-side cavity as shown below. Note that the connectors and
warning labels are nearest the middle wall or partition of the PA1000.

Module A

(amps 3 & 4)

Module B

(amps 7 & 8)

Middle Partition

Illustration 2–2 Power Amplifier Module Placement

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

6. Replace the front panel of the PA1000.

Installation

2–3

2.4.2 Hubble Twist Lock® Connector Wiring

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

1. Use round cord with a diameter of 0.385–0.780 inches (10–20 mm), Type SJ
12/3 – 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 conductors
as shown in Illustration 2–3. Do not tin conductors.

1 Inch

(25 mm)

5/8 Inch
(16 mm)

Illustration 2–3 Cover, Cable & Conductors

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

Terminal

Green Hex Head Screw

Equipment grounding conductor

Conductor

(green or green/yellow)

Brass Screw

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

Brass/Black Screw

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

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.

WARNING

Possible Electric

Shock

Hazard!

2–4

Do not connect AC source until all
other connections are made and
installation is complete.

FM1000A User’s Manual

2.5 Installation

1. Mount the units in an appropriate 19–inch wide cabinet. The power supply
must be installed directly below the power amplifier for the included
cables to reach their respective connectors (see illustration 2–4 below).

Note: The PS1000 weighs approximately 40 pounds (18.1 kg); the
PA1000, approximately 43 pounds (19.5 kg). Use help to install.

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.

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

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

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

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

+ DC Input

DC Input

PA1000

+ DC Output

DC Output

PS1000

Ground Screws

RF Monitor

(Optional Connection)

Air Intakes/Filters

RF Output

Air Exhaust Vents

RF Input

Remote I/O

Control

Circuit Breakers

Fans

OFF

Power

Control

OFF

Installation

Illustration 2–4 Rear Panel Connections

240 VA C IN

2–5

8. Using the supplied connector, tie together pins 6 and 7 of the Remote I/O
connector. The amplifier will not operate without this connection or a
remote 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 to
the BNC connector on the PA1000.

10. Connect the DC input/output cables between the PA1000 and the PS1000 as
illustrated (Illustration 2–4). The connector end with the ground lead con­nects 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 using
hardware 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 connec­tor into the female Hubble connector on the PS1000 and turn to the right
until the connection locks.

2.6 Remote I/O Connection

The Remote I/O Connector on the back of the PA1000 allows remote control and
monitoring of Certain transmitter functions. There are three basic control func­tions—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/O
Connector, turns DC power to the PA on when the pin is grounded.

The RF power level adjustment remote control function has an internal maximum
limit set on the Metering and Control Board. The Local Power Adjust (R62) sets
the 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 to
your desired maximum limit (see illustrations 2–5 and 2–6). However, for any
remote operation to work, the 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

+5V

MAXIMUM

R62

LOCAL
POWER
ADJUST

MINIMUM

REMOTE

RAISE POWER

Pin 4

Remote I/O Conn.

REMOTE

LOWER POWER

Pin 15

Remote I/O Conn.

SW3

RAISE

SW4

LOWER

Electro­Control
Circuit

SW5

LOCAL

REMOTE

TANSMITTER

CONTROL

2–6

Illustration 2–5 Local and Remote Functions

FM1000A User’s Manual

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 & SW4), and the Local/Remote slide switch (SW5) are
shown below.

Local/Remote
Slide Switch

On-board Remote

Power Adjust

Buttons

Local Power Adjust

Pot

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

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 the
RF power output level of the amplifier to be reduced below the internal limit set by
the Local Power Adjust pot or the remote Raise/Lower settings. However, some
drive power, less than one watt, may still be present at the antenna. Depending on
the resistor used, this pin can serve as a control for optional low power operation.

The remaining remote functions are for monitoring the various
parameters of the PA1000. They are either buffered metering outputs, direct
reading, or latched high/low indications. Further details of these functions are
described 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.).

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

13

1

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

Installation

25

Illustration 2–7 Remote I/O connector (back panel view)

View from Rear of Cabinet

14

2–7

Pin # Function

1 PA#8 Current Monitor (a b uff ered metering output with 1 V = 2 A)
2 PA#7 Current Monitor (a b uff ered metering output with 1 V = 2 A)
3 Ground
4 Remote RAISE Po wer (a momentary switch, on this pin, when held lo w will

raise the power le vel 10 watts ev ery 0.5 seconds)

5 Remote RF Po wer Control (a resistor to g round on this pin reduces RF

power output lev el below internal limits. See Section 2.6, page 2–7)
6 Ground
7 Remote AC P o w er On (a latching switch, on this pin, when held low will turn

the AC power supply on)
8 Fault Summary (the voltage from this pin goes to +5 V if any f ault occurs and

drops below 2V when the fault goes aw ay)
9 Ground

10 ALC (the voltage from this pin is a direct reading of automatic level control

voltage, not b uffered)

11 P A Temperature (a buffered metering output with 1 V = 20° C)
12 SWR (a buffered metering output with a calculated reading of standing wave

ratio in VDC)

13 RF Output Power (a buff ered metering output with a calculated reading of

output power of 1 V = 1000 W)

14 Input Power Ref erence (a buff ered metering output with a DC voltage

representing input power)

15 Remote LOWER Pow er (a momentary switch, on this pin, when held low will

lower the power le vel 10 watts ev ery 0.5 seconds)

16 P A#6 Current Monitor (a b uff ered metering output with 1 V = 2 A)
17 P A#5 Current Monitor (a b uff ered metering output with 1 V = 2 A)
18 Ground
19 P A#4 Current Monitor (a b uff ered metering output with 1 V = 2 A)
20 P A#3 Current Monitor (a b uff ered metering output with 1 V = 2 A)
21 Ground
22 P A#2 Current Monitor (a b uff ered metering output with 1 V = 2 A)
23 P A#1 Current Monitor (a b uff ered metering output with 1 V = 2 A)
24 P A Total Current Monitor (a buffered metering output with 1 V = 20 A)
25 P A Volts (a buffered metering output with 1 V = 10 V)

Note: PA = Power Amplifier

2–8

Remote I/O Connector Pinout Table

FM1000A User’s Manual

This section provides general operating parameters of your power
amplifier system and a detailed description of the front panel
display.

Section 3—Operation

3–1Operation

3.1 Initial Power-up Procedures

These steps summarize the operating procedures you should use for the initial
operation of the power amplifier and power supply. More detailed information
follows.

1. Ensure that the external remote control unit is properly connected (See the
Pin Out Description Table, Section 2.6, page 2–8 for proper pin configura­tion). 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 remote
I/O connector.

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

Outputs to

PA1000

+ DC Output

DC Output

PS1000

Fan

Circuit Breaker

Fans

Air Exhaust Vents

AC Input

Circuit Breaker

OFF

OFF

Power

Control

240 V AC IN

Illustration 3–1 PS1000 Back Panel Functions

5. Turn on the exciter (a Crown FM30 or equivalent) and adjust its RF power
output level until the In Reference (In Ref) voltage, as indicated on the
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

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. See Section 2.6 for setting up remote
operation and using the on-board remote buttons and other controls.

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

Local/Remote
Slide Switch

On-board Remote

Power Adjust

Buttons

Local Power Adjust

Pot

Illustration 3–2 Local Power Adjust and Other Controls

Power

I

O

Power Switch

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

Air Intakes/Filters

®

Illustration 3–3 PS1000 Front Panel Functions

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.)

3–3Operation

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

a. In Ref—Should read between 0.4 and 0.8 volts (0.5 nominal, dependent

upon 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 panel
indicators and switches of the PA1000 and PS1000.

3.2 Power Switches

3.2.1 AC Input Circuit Breaker

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

AC Input

Circuit Breaker

Fans

Control

240 V AC IN

Illustration 3–4 AC Input Circuit Breaker

ONON

Power

3–4

FM1000A User’s Manual