Page 1
®
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
(574) 262-8900
i
Page 2
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.
Page 3
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
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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
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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
Page 6
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
Page 7
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
Page 8
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
Page 9
®
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
Page 10
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
Page 11
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
Page 12
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
Page 13
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
Page 14
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
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 & 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
Page 16
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
Page 17
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
Page 18
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
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. 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
Page 20
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
Page 21
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
I
O
®
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. When the
top cover of the power supply is removed, the Interlock Switch interrupts the
power supply control circuit disabling the high and low voltage supplies.
Lethal voltages are still present on the AC Input Board !
WWARNINGARNING
So, handle with care.
Interlock Switch
Illustration 3–6 Interlock Switch
3–5Operation
Page 22
3.3 Digital Multimeter
The 3–digit numeric display in the upper left corner of the front panel provides
information on the amplifier’s operation. Use the “up” and “down” push-buttons to
select one of the following parameters as indicated by a green LED.
Multimeter Metering Selection Buttons Metering Indicators
Metering
In Ref
SWR
ALC
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
Illustration 3–7 Digital Multimeter
In Ref—Input reference is a relative voltage level used to determine input RF
power level. This varies between frequency of operation and input power level.
SWR—Direct reading of the antenna Standing-Wave Ratio (the ratio of the actual
load impedance to the desired 50 ohm load impedance).
ALC—Automatic level control is DC gain control bias used to regulate PA supply
voltage. With the PA power supply at full output voltage, ALC will read about 6.0
volts. When the RF output is being regulated by the RF power control circuit, this
voltage will be reduced, typically reading 5.0 to 6.0 volts. The ALC voltage will be
reduced during PA DC overcurrent, SWR, or overtemperature conditions.
Power Out—Actually reads RF voltage squared, so the accuracy can be affected by
SWR. Tolerance of ± 10% is normal. For exact set-up on site, an external power
meter is recommended.
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
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. To achieve full output power, 30 watts of input drive is
required.
CAUTION
Possible equipment damage!
Do not exceed 40 watts of input drive.
Damage to the PA1000 will result if
this level is exceeded.
PA Temp—PA heatsink temperature is greater than 75°C (power foldback will
begin at this point).
PA DC—Power supply current for the PA (power amplifier) is at the preset limit, or
there 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 holds
the supply current to the preset limit.
Fault Indicators
Metering
In Ref
SWR
ALC
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
A4
PA7
PA8
Illustration 3–8 Fault Indicators
3–7Operation
Page 24
3.5 Fuse Indicators
The PA1000 consists of two field-replacable power modules with two amplifiers in
each module. Each of the paralleled amplifiers is protected by a 10 ampere
fast-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 8
represent amplifiers 3 and 4 on the lower right power module.
Fuses and Indicators
Power Out
PA Temp
PA Voltage
Tot Current
Fault
PA1
PA5
PA2
PA6
PA3
PA7
PA4
PA8
®
Antenna
RF Drive
PA Temp
PA DC
PA3
Fuses
PA4
PA7
PA8
Illustration 3–9 Fuse Indicators
3–8
FM1000A User’s Manual
Page 25
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Section 4—Principles of Operation
This section discusses the circuit principles upon which the
power amplifier and power supply function. This information is
not needed for day-to-day operation, but may be useful for advanced users and service personnel.
4–1Principles of Operation
Page 26
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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.
4.1 PA1000 Power Amplifier
The PA1000 power amplifier features adjustable output to deliver 500–1000 watts of
RF output power for broadcast transmission. The amplifier is broadband; no tuning
is required. The design, however, ensures efficient operation. Typical RF efficiency
is 75% to 85% across the FM band.
4.1.1 Power Modules
The primary components of the PA1000 are two, 500–watt power modules. These
power modules are mounted by stacking two in the right cavity of the chassis. The
two 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 as
those utilized in the Crown Broadcast 100, 250, and 500–watt transmitters.)
Power from the amplifiers is combined through a micro-strip combiner to convert
from 50 Ω output impedance for each amplifier to an intermediate impedance and
then return to the 50 Ω output at the Low Pass Filter. This technology eliminates
tuning and adjustments throughout the 88–108 FM band and enables each amplifier
to equally share the power load. The power combiner is also designed to allow a
module to be disconnected from the combiner and removed without adversely
affecting the impedance balance of the unit. With one module removed the impedance change allows the remaining module to continue operation at approximately
one-third of the full output power.
4.1.2 Power Combiner Board
There are two Power Combiner Boards; one attached to each of the two heatsinks
overlapping the amplifiers. Each board takes the power from two amplifiers and
combines it through a parallel quarter-wave transmission line transformer network.
The power is then summed in a common point junction on the Output Combiner
Board.
4–2
FM1000A User’s Manual
Page 27
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.
4.1.3.1 Backplane DC Interconnect Board
This board is located nearest the metal inner brace of the chassis. It distributes DC
power to each of the four MOSFET amplifiers, provides the interconnections for
control of the power supply, and enables connection to the remote control interface. The Backplane/DC Interconnect Board contains interconnections from the
Control and Metering Board to the DC Fuse and Power Distribution Board, as well
as 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 DC
Interconnect Board and the Output Combiner Board. It provides the power division
and impedance transformation needed to supply proper drive to each of the four
amplifiers (two modules).
4.1.3.3 Output Combiner Board
The Output Combiner Board is located nearest the Output Filter It consists of a
micro-strip transmission line that combines the output power from the four amplifiers (two modules) so that ultimately, all the power comes together at one common
point junction. Here the currents and voltages of all four power amplifiers are in
phase and producing equal RF output power. From this common point junction,
the Output Combiner Board uses a second quarter-wave transformer to convert the
output power to the 50–ohm impedance needed at the output of the unit.
4.1.4 Output Filter & Reflectometer
The Output Filter/Reflectometer is located behind the Backplane Assembly in the
center of the PA1000. See the accompanying schematic in Section 6 for more
information.
The ninth-order, elliptic, low-pass filter attenuates harmonics generated in the
power amplifier. The capacitors for the filter are circuit board pads. The reflectometer uses printed circuit board traces for micro-strip transmission lines. Transmission line segments (with an impedance of about 100 ohms) on either side of a
50–ohm conductor provide sample voltages representative of the square root of
forward and reverse power. DC voltages, representative of forward and reflected
power, go through a bulkhead Filter Board to the Backplane/DC Interconnect
Board, then to the Metering Board where they are processed for power control and
metering and for SWR metering and protection.
4–3Principles of Operation
Page 28
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4.1.5 Metering and Control Board
The Metering and Control Board is located above the upper left cavity. This board
supplies readings of voltages and currents, and provides information on the operation 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 of
the power level is activated within that limit by placing the Local/Remote slide
switch 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 power
constant. A long-life battery supplies power to retain the power setting after the
amplifier is turned off.
This board also takes samples from the RF amplifier boards and PS1000 power
supply and processes all the data. It provides SWR readings from the Output Filter
and folds back the amplifier power if the SWR exceeds safe operating limits. Protection circuitry for overcurrent and overtemperature conditions is designed into this
board as well, providing additional precaution against overheating. This board is
fail-safe, like all the other circuit board components in the FM1000A and can be
removed for repair/replacement if necessary.
4.1.6 DC Fuse and Power Distribution Board
This board is located above the right cavity over Power Modules A and B. The DC
Fuse and Power Distribution Board takes power direct from the power supply
through one 80–amp power line, divides it into four separate DC power lines, and
distributes it to the four power amplifiers. Metering resistors in each of the four
power lines monitor the current drawn by each of the four amplifiers to ensure
proper function for monitor and control of the unit.
4.1.7 Cooling Fans
There 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 is
drawn through the heatsinks where a flushing moves the air over the DC Distribution Fuse board, the Control and Metering Board, the Output Filter circuits, and
then out through the air vents on the side panel. If a fan fails, the amplifier will
fold back power to prevent overheating.
4.2 PS1000 Power Supply
The PS1000 supplies power to the PA1000 by converting single-phase 240
VAC 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 factor
corrected. The PS1000 consists of three printed circuit boards described below.
4–4
FM1000A User’s Manual
Page 29
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. In addition, the ±12 volts
are supplied to the PA1000 for use in the Control and Metering Board. The 240volt AC input to the power supply is connected through a Hubble Twist Lock
connector on the back panel to a 20–amp circuit breaker mounted inside the back
panel.
When the power supply is turned on and enabled, the AC power comes through
torroidal inductors which prevent harmonics and spurious products from feeding
back into the AC power lines. The current flows from the inductors to a bridge
rectifier that converts the current to DC Power, and from there to the PFC Switching Board where the rectified DC is filtered. The filtered DC power is then fed from
the PFC Switching Board through an 80–turn boost inductor and back to the PFC
Switching Board.
4.2.2 PFC (Power Factor Correcting) Switching Board
The PFC Switching Board is located directly behind the cooling fans (front panel) in
the PS1000. This board takes the voltage from the Torroidal Boost Inductor and
sends it to the Boost Switching Transistor. The switching transistor chops the DC
input power at a 25 kHz rate. The chopped voltage is then rectified, filtered, and
sent 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 chopped
DC power is fed through a blocking capacitor to a transformer on the DC Output
Board. The second switching stage controls the amount of power sent to the DC
Output Board. This ensures that the transformer output voltage and current are
correct for providing the selected RF output power to the amplifier.
4–5Principles of Operation
Page 30
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4.2.3 DC Output Board
The DC Output Board is located in the back of the unit directly behind the PFC
Switching Board. This board rectifies and filters the transformer output voltage
once again to produce the clean DC power required for the power modules. The DC
Output Board also provides the 24–volts that operate the cooling fans in both the
PS1000 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 come
together at the terminal in back of the unit providing the maximum output power
of 50 volts at 60 amperes.
4.2.4 Cooling Fans
There are two cooling fans located in the front section of the PS1000. Their primary function is to cool the semiconductors used in the switching and rectifying
process which are subject to high currents. 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
TROUBLE
TROUBLETROUBLE
Section 5—Troubleshooting
This section describes procedures for service personnel to diagnose and troubleshoot potential fault conditions in the power
amplifier and power supply.
5–1Troubleshooting
Page 32
TROUBLE
TROUBLETROUBLE
5.1 Troubleshooting Flow Chart Analysis
Does your
amplifier have
output power?
Are there any
fault
indicators?
Yes No
Is power
output at the
proper level?
Yes No
Yes No
Yes No
Is exciter delivering
sufficient RF drive?
(Check In Ref meter
reading.)
See Section 3.1
Initial Power-up
procedures.
See Section 3.1
Initial Power-up
procedures.
Do you have
power now?
Yes No
Is your exciter
turned on?
Yes No
Turn the
exciter on.
Antenna:
Section 5.3.1
RF Drive:
Section 5.3.2
PA Temp:
Section 5.3.3
PA DC:
Section 5.3.4
See
See
Secure all
connections to the
PS2000.
See
Ensure AC input
circuit breaker is
flipped up
See
Ensure main
power switc h is
turned on.
Call Support—
See Section 8
5–2
FM1000A User’s Manual
Page 33
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.
WWARNINGARNING
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:
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 Out
This 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 adjustment
of the Local Power Control (see section 3.1 #6).
5–3Troubleshooting
Page 34
TROUBLE
TROUBLETROUBLE
5.2.5 PA Temp
The meter should read between 35–50°C with an ambient temperature of 25°C. If
temperature 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 using
mild detergent and warm water.
❑ Possible antenna mismatch; check for icing, moisture in the feedline, and
secure antenna connections.
❑ Overcurrent: If PA DC fault indicator is flashing, monitor the current for a
proper level—the total current and the current of individual Power Amps.
5.2.6 PA Voltage
Supply 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 for
proper 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 Current
If 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 antenna
connections.
5.2.8 PA1–8
If 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.
5–4
FM1000A User’s Manual
Page 35
5.3 Fault Indicators
If one of the LED fault indicators is illuminated red, troubleshoot using the following 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.
❑ Ensure proper drive level of 25–30 watts input power.
❑ Check RF input cable for secure connection.
5.3.3 PA Temp
Temperature 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 using
mild detergent and warm water.
❑ Antenna mismatch; check for icing, moisture on the feedline, and secure
antenna connections.
❑ Overcurrent; check PA DC fault indicator, if flashing monitor current for
proper 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 malfunction
in 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 are
powered by the same circuit of the PS1000. There are two potential causes for a
non-functioning fan or fans:
1. If a single fan does not operate, the fan is faulty and must be replaced. (See
Section 7, Service & Support.)
2. If none of the fans operate, a blown circuit breaker, a short circuit in the
PS1000, or a damaged winding on the main transformer of the DC Output
Board (in the PS1000) is the cause. In this case, do one of the following:
5–5Troubleshooting
Page 36
TROUBLE
TROUBLETROUBLE
a. The circuit breaker is located on the rear panel of the power supply. If the
breaker has popped out, reset it by pushing it in. If the breaker continues
to trip, check for a short circuit.
b. Check each fan with a volt-ohm meter by disconnecting and testing it for a
short circuit. Replace the fan/fans as needed (see Section 7).
c.If none of the fans have short circuits, there is damage on the
winding of the transformer. It will have to be replaced (see Section 7).
5.3.4 PA DC
Discrepancy 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 the
4 individual amplifiers. This could occur as a result of a blown or faulty power
module, or a blown fuse; replace as appropriate (see Section 7, Service &
Support).
❑ There is too much total current—power foldback will occur above maximum
total amperage of 35 amps due to antenna mismatch. Examine the antenna
for arcing and moisture. 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.
®
etering
M
In Ref
R
SW
ALC
Power
I
O
Fault
Antenna
PA5
PA1
Power Out
RF Drive
PA6
PA2
p
PA Tem
PA Tem
PA7
PA3
PA Voltage
PA DC
PA8
PA4
Tot Current
®
®
Fuses
PA8
PA7
PA6
PA5
PA4
PA3
PA2
PA1
p
5–6
FM1000A User’s Manual
Page 37
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.
6–1Reference Drawings
Page 38
6.1 Views
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
Illustration 6–1 Front View
+ 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
OFF
Fans
OFF
Power
Control
240 VA C IN
6–2
Illustration 6–2 Back View
FM1000A User’s Manual
Page 39
6.2 Diagrams and Schematics
30 W Exciter
(Crown FM30)
RF Input
Excitation
1 kW RF
Power Output
PA1000
Power Amplifier
Remote I/O
Connector
Power Supply
Control
0–50 VDC
PA Supply
PS1000
Power Supply
240 VAC
50/60 Hz Input Power
Single Phase
Illustration 6–3 FM1000A Block Diagram
6–3Reference Drawings
Page 40
6–4
FM1000A User’s Manual
Illustration 6–4 PS1000 Block Diagram
240 VAC
AC
CIRCUIT
BREAKER
AC INPUT
NEUTRAL
GROUND
AC
INPUT
CCA
POWER
SWITCH
RECTIFIER
PFC &
CONTROL
CCA
DC
OUTPUT
CCA
+ 0 to 50 VDC
RETURN
PS CONTROL
9-PIN
DSUB
220 VDC
+/ 12 VDC
VOLTAGE
BOOST
INDUCTOR
360 VDC
360 VDC
CONTROL
Page 41
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 OTHERWISE
SPECIFIED.
2. ALL CAPACITORS ARE IN
MICROFARADS UNLESS
OTHERWISE SPECIFIED.
220-240
VAC IN
REV
Q43521-6
DWG. NO.
PROJ NO.SCALE: NONE
TITLE:
SIZE
B
UNCONTROLLED
UNLESS OTHERWISE MARKED IN RED INK BY CM AS
A CONTROLLED COPY, COPIES OF THESE
DOCUMENTS INCLUDING ASSOCIATED ELECTRONIC
REPRODUCTIONS ARE FOR REFERENCE ONLY.
SCH, FM2K POWER SUPPLY AC INPUT
SHEET 10 OF 10
J
103
THESE DRAWINGS AND SPECIFICATIONS ARE THE
PROPERTY OF INTERNATIONAL RADIO AND
ELECTRONICS CORP., AND SHALL NOT BE
REPRODUCED, COPIED, OR USED AS THE BASIS
FOR THE MANUFACTURE OR SALE OF APPARATUS
OR DEVICES WITHOUT PERMISSION.
-12V
-12V
+12V +12V
POWER OFF/ON
+12V
-12V
C3
1.5UF/630V
HD3
HEADER 5X2
1 2
3 4
5 6
7 8
9 10
CB1A
15A
CB1B
15A
J1
C1
.0033
250VAC
C2
.0033
250VAC
K1
RELAY 24V
K2
RELAY 24V
D1
1N4004
D2
1N4004
SW1
DC Power
SW2
AC Power
R1
PTC
D3
1N4004
D4
1N4004
C11
220
50V
VR1
LM2586-ADJ
12345
R9
1.10K
D5
2N5822
R10
10.0K
C15
1.0
C16
1.0
C14
220
50V
C13
220
50V
L4
330UH
L5
330UH
C12
47
20V
D6
2N5822
Q1
IRFD9113
C10
.001
R7
1K
R5
1K
U1
4N37N
Q2
IRFD9113
R8
10K
HD2
1
2
R2
5 PTCR35 PTC
K3
RELAY 24V
R100
.04 OHM
D1
BDF01
- +
C9
1.5
630v
C7
.0033
250VAC
C8
.0033
250VAC
L2
100UH
L3
100UH
R4
5.6
3W
C6
.47
250VAC
C5
.0033
250VAC
C4
.0033
250VAC
MOV1
V217HA40
MOV2
V271HA40
MOV3
V271HA40
MOV4
V271HA40
Page 42
GND CHASSIS
GND SIGNAL
GND FIELD SIGNAL
15VDC
+-
(25KHZ)
(22.5KHZ)
25V
R58 for AC current foldback.
Install R58.
*
*
*
NOTES :
_______
_______
1. ALL RESISTORS ARE IN OHMS,
1/4W, 1% UNLESS OTHERWISE
SPECIFIED.
2. ALL CAPACITORS ARE IN
MICROFARADS UNLESS
OTHERWISE SPECIFIED.
T2 80t
5t
1
2
3
4
5
6
T2
XFMR
GATE
T3
1
2
3
4
5
6
T1
XFMR
GATE
4 1N5818
THESE DRAWINGS AND SPECIFICATIONS ARE THE
PROPERTY OF INTERNATIONAL RADIO AND
ELECTRONICS CORP., AND SHALL NO BE
REPRODUCED, COPIED, OR USED AS THE BASIS
FOR THE MANUFACTURE OF DEVICES WITHOUT
PERMISSION.
REV
DWG. NO.
SHEET 10 0F 10
L
UNCONTROLLED
UNLESS OTHERWISE MARKED IN RED INK BY CM AS
A CONTROLLED COPY, COPIES OF THESE
DOCUMENTS INCLUDING ASSOCIATED ELECTRONIC
REPRODUCTIONS ARE FOR REFERENCE ONLY. SCALE: NONE PROJ NO.
TITLE:
SIZE
C
103
SCH, FM2K PWR SUP PFC SWITCHER
Q43522-4
NOT ON PWB
D1
HFA25TB60
J3
IND1
J4
IND2
J6
XFMR2
J2
BRIDGE+
J1
BRIDGE-
J5
XFMR1
C46
.001
C18
.001
DS1
1N5818
Q1
2N5210
R1
0.04
3%
15W
C13
.01
C12
.0039
C11
.01
C10
1.0
C20
10
C5
10
C6
1.0
C4
.01
C15
.0047
3KV
C44
.0033
250VAC
HD1
1
2
DS3
1N5818
DS4
1N5818
C9
.47
C8
.047
U1
LT1248
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
D10
1N4148
C49
10
35V
C14
4.7
C17
47
D4
1N4004
R33
4.7K
5%
C50
1.5
630VDC
C26
470
C25
470
C24
470
C23
470
VR1
7815CT
IN
2
C
1
OUT
3
C19
1000
D2
1N4004
R23
15K
5%3W
R24
15K
5%3W
DZ2
24V
R34
4.7K
5%
HD2
1
2
QF1
IGBT, 600V 50A FAST
DL1
LED
DS2
1N5822
QF4
IGBT, 600V 50A FAST
QF5
IGBT, 600V 50A FAST
C38
.001
6KV
C39
.001
6KV
C36
.01
C35
.0015
R62
4.7K
5%
DL2
LED
DS14
1N5818
DS13
1N5818
DS12
1N5818
DS11
1N5818
U2
UC3875
10
10
9
9
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
C42
.01
R16
4.3K
5%
D3
1N4004
C40
4.7
400VDC
D6
1N4148
D8
1N4148
C37
1.0
D7
1N4148
D9
1N4148
R51
20
1%
QF2
IGBT, 600V 50A FAST
QF3
IGBT, 600V 50A FAST
U3
4N37
B
6
C
5
E4NC
3
K
2
A
1
U4
4N37
B
6
C
5
E4NC
3
K
2
A
1
HD3
1
2
3
4
5
6
C2147C43
.01
C34
330PF
C33
1.0
C41
.01
C32
.001
C45
.001
DS7
DS9
DS10
DS8
C29
.001
C31
47
C30
.01
C27
0.1
C28
0.1
R9
20K
R17
OPEN
R22
2K
R28
10K
R29
10K
R21
15K
R36
3.01K
R37
75K
R35
6.81K
R45
3.01K
R14
1K
R27
20.5K
R20
20K
R55
22.1K
R58
10K
R4
4.02K
R3
4.02K
R7
100
R10
1K
R56
100K
R57
100K
R12
75K
75K
R19
10
R31
10
R30
5.11K
R39
75K
R40
5.11K
R38
10
R48
10
R47
10K
R49
10K
R44
10
R43
10K
R41
10K
R42
10
R18
10
R46
10
R50
1K
R52
33
5%2W
R53
33
5%2W
R32
22
5%3W
R15
330K
5%
R11
4.3K
5%
R8
300
5%
Q3
2N5087
HD4
1
2
HD5
1
2
HD6
1
2
DL3
AMBER
C22
.001
C47
.001
C48
.001
Q2
2N5087
R59
3.32K
R54
4.99K
C1
.001
C7
.001
C2
.001
C3
.001
D5 OPEN
C16
.001
6KV
R2
1.50K
R5
511K
.5W
R6
511K
.5W
R25
511K
.5W
R26
511K
.5W
C51
.001
D12
0 OHM
D11
0 OHM
R60
2.74K
L1
JUMPER
Page 43
DWG. NO. REV.
200983-SCH
C
1 2 3 4 7 8
A
B
C
D
E
F
1 2 3 4 6 7 8
A
B
C
E
F
5
THESE DRAWINGS AND SPECIFICATIONS ARE THE PROPERTY OF
INTERNATIONAL RADIO AND ELECTRONICS CORP.
AND ARE NOT TO BE REPRODUCED, COPIED OR USED AS THE BASIS
FOR THE MANUFACTURE OR SALE OF APPARATUS OR
DEVICES WITHOUT PERMISSION.
1 1
SHEET
OFSCALE : NONE
PROJ NO.
FILENAME:
DWG . NO .
REV.
C
200983-SCH
TITLE:
UNCONTROLLED
UNLESS OTHERWISE MARKED IN RED INK BY CM AS A
CONTROLLED COPY, COPIES OF THESE DOCUMENTS
INCLUDING ASSOCIATED ELECTRONIC REPRODUCTIONS
ARE FOR REFERENCE ONLY.
APPROVALS
DWN
CHK
CM
PE
DISTRIBUTION
E . C . N. REV DESCRIPTION
APPROVALS
PECHK CMDATE DWN
REVISION HISTORY
65
SIZE
B
B_L_SHT1_A.DOT REV. A
INTERNATIONAL RADIO AND ELECTRONICS CORP.
25166 LEER DRIVE ELKHART, IN. 46514
574-262-8900
WWW.IREC1.COM
IREC
DZ1
16V
L5
150uH
+
C21
220/35V
Vin
1
ON/OFF
5
FEEDBACK
4
OUT
2
GND
3
U2
LM2596T-ADJ
D16
MUR420
2
3
1
84
U1A
LM358
1%
1%
R20
18.7K
R21
1.0K
T1
C19
.0047
R19
10
3W
D5
MBR3100
D6
MBR3100
D7
MBR3100
D8
MBR3100
C13
1
+
C14
220/35V
+27V
C20
470pF
D9
MUR130
D10
MUR130
D1
BYV44-300
D2
BYV44-300
D11
MUR130
D12
MUR130
D3
BYV44-300
D4
BYV44-300
D13
MUR130
D14
MUR130
L1
89 uH
L3
89 uH
+
C7
.47/160V
R1
1K
5W
D15
1N4004
1 2
3 4
5 6
7 8
9 10
HD1
HEADER 5X2
+
C8
.47/160V
R5
1K
5W
R6
15K
1/2W
C9
0.1
+12V
R10
10K
R9
51K
1%
123
HD3
HEADER 3
R13
100K
R7
234K
C11
220pF
1%
L2
89 uH
L4
89 uH
+
C1
3300
+
C4
3300
+
C2
3300
+
C5
3300
C3
1
C6
1
1
2
3
4
J3
4 HEADER
1
2
3
4
J4
4 HEADER
1
2
3
4
5
6
HD2
HEADER 6
R2
5.11K
1% R3
1M
1%
R4
510K
C10
.1
R18
5.11K
1%
C12
.01
R8
10K
1%
ALC
FAN +24VDC
FAN +24VDC
FAN GND
R12
3.01K
R11
2.0K
1%
1%
CONTROL
0-6VDC IN
(5V FOR 50V OUT)
ALC
INT/EXT
LOCAL
CONTROL
R14
10
3W
R15
10
3W
C15
.0047
C16
.0047
R16
10
3W
R17
10
3W
C17
.0047
C18
.0047
TO RF PA'S
50V 24A
TO RF PA'S
50V 24A
1
J5
1
J6
1
J1
1
J2
TO
FAN FUSE
NOTES:
UNLESS OTHERWISE SPECIFIED:
1. ALL RESISTORS ARE IN OHMS, 1/4W, 5% TOL.
2. ALL CAPACITORS ARE IN MICROFARADS.
5
6
7
U1B
LM358
SCH, 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
Page 44
6–8
FM1000A User’s Manual
Illustration 6–5 PA1000 Block Diagram
Page 45
BNC 1
C2
R2
82
47PF NP0
R4
10
RF
OUTPUT
RF INPUT
(Back Panel)
Coaxual Cable Connection
D1
1N6263
C3
.001
R5
20K
R3
10
C1
47PF NP0
R7
20K
R1
82
D2
1N5263
R6
20K
C6
R8
.01
C5
.01
R
F
E
W
F
L
D
1 2 3 4 5
HD1
20K
RF IN
C4
.001
Coaxual Cable Connection
NOTES :
_______
_______
1. ALL RESISTORS ARE IN OHMS,
1/4W, 5% UNLESS OTHERWISE
SPECIFIED.
2. ALL CAPACITORS ARE IN
MICROFARADS UNLESS
OTHERWISE SPECIFIED.
3. C1201-1209A,1217 are circuit board pads.
RF Input
Reflectometer & Splitter
J0744-3m
PA1000 RF Input
6–9Reference Drawings
Page 46
RFOUT
PA OUT
PA OUT
L24
PA OUT
PA OUT
GND
L28
GND
GND
GND
RFOUT
NOTES :
1. ALL RESISTORS ARE IN OHMS,
_______
_______
1/4W, 5% UNLESS OTHERWISE
SPECIFIED.
MICROFARADS UNLESS
OTHERWISE SPECIFIED.
2. ALL CAPACITORS ARE IN
b
REV
J0746-8
ELKHART, IN. 46517 PHONE (219) 294-8000
VPWR
L1121
R1101
50NH
C1125
60PF
1718 WEST MISHAWAKA ROAD
500W RF POWER MODULE CCA
CROWN INTERNATIONAL, INC.
C1124
C1123
T1121
0.01
0.01
PA OUTPUT BD
C1138
0.068
C1122
C1121
60PF
C1125
C1124
C1123
T1121
0.01
0.01
DISC
0.01
50NH
L1122
PA OUTPUT BD
DISC
0.01
C1138
0.068
L1121
50NH
C1122
C1121
DISC
0.01
50NH
L1122
DISC
0.01
VPWR
15K
Q1101
BLF278
250W RF POWER AMP A
C1110
R1120
R1110
DZ1110
1N4735
0.01
2.7K
10K
10K
POT V
R1111
0.01
C1111
6.2V
R1113
R1112
C1113
0.01
5.6
2W
24
3W
R1117
C1112
0.01
2W
5.6
10
R1116
T1111P
C1116
R1119
T11S
27PF
3W
200
C1115
C1114
2W
0.01
5.6
R1115
2W
0.01
5.6
R1114
PA INPUT BD
R1101
15K
C1110
R1120
R1110
DZ1110
2.7K
10K
1N4735
THESE DRAWINGS AND SPECIFICATIONS ARE THE
SHALL NOT BE REPRODUCED, COPIED, OR USED
AS THE BASIS FOR THE MANUFACTURE OR SALE
OF APPARATUS OR DEVICES WITHOUT PERMISSION.
Q1101
BLF278
PROPERTY OF CROWN INTERNATIONAL, INC. AND
250W RF POWER AMP B
0.01
10K
POT V
R1111
0.01
C1111
6.2V
R1113
R1112
C1113
0.01
2W
5.6
24
3W
R1117
C1112
0.01
2W
5.6
10
R1116
T1111P
C1116
R1119
T11S
27PF
3W
200
C1115
C1114
2W
0.01
5.6
R1115
1.0
2W
0.01
5.6
R1114
PA INPUT BD
C6
TEMPERATURE
SENSE
U1
LM35DZ
1.0
C5
1.0
C4
RFIN
1.0
C2
GND
GND
GND
AMPA DC PWR
AMPA DC PWR
AMPA DC PWR
6–10
PA IN
PA IN
C3
GND
GND
TEMP AMP A&B
1.0
GND
GND
RFIN
1.0
C1
L18
L14
AMPB DC PWR
AMPB DC PWR
AMPB DC PWR
TEMP V+
PA IN
GND
GND
GND
PA IN
GND
500 W Power Amp
FM1000A User’s Manual
Page 47
RF Output Combiner
6–11Reference Drawings
Page 48
PA RF
OUTPUT
D1211
1N5263
C1216
.001
R1212100.50 W
C1211
47PF NP0
R1211
1-10 PF
200
0.50 W
R1214
R1213100.50 W
1PF
C1209A
200
0.5 W
C1210
82PF SM
C1212
47PF NP0
R1218
D1201
1N6263
1K
C1215
1K
R1215
R1216
100K
R1217
.01
C1214
C1213
100
FWD
REF
.01
R1216
.001
100K
RF Output
Filter & Reflectometer
J0750-0
1 2 3 4 5
HD1202
L
HEADER 5
1. ALL RESISTORS ARE IN OHMS,
NOTES :
_______
_______
1/4W, 5% UNLESS OTHERWISE
SPECIFIED.
MICROFARADS UNLESS
OTHERWISE SPECIFIED.
3. C1201-1209A,1217 are circuit board pads.
2. ALL CAPACITORS ARE IN
(195MHz) (176MHz) (252MHz)
(455MHz)
C1208
5.13PF
C1207
9.3PF
C1206
7.1PF
C1200
1.35PF
RF IN
L1205
77.9NH
L1204
87.5NH
L1203
94.1NH
L1202
90.5NH
C1205
14.1PF
C1204
37.7PF
C1203
38.9PF
C1202
40.9PF
C1201
15.4PF
L1201
250NH
10PF
C1201A
RF MONITOR
GUAGE
#17
#12
#12
#12
#12
0.7"
LENGTH
14
I.D. TURNS
0.25"
L1201
INDUCTORS
0.6"
333
0.5"
L1202
0.5"
0.5"
L1203
0.7"
0.5"
L1204
0.6"
3
0.4375"
L1205
RF OUTPUT FILTER & REFLECTOMETER
EXACT COIL LENGTHS ARE FACTORY-SET.
6–12
FM1000A User’s Manual
Page 49
6–13
Reference Drawings
Backplane Distribution
Note: All bypass capacitors are 0.01 mf
Page 50
6–14
FM1000A User's Manual
Ribbon Cables and Connectors
Ribbon Cables and Connectors
Page 51
J2-12
10mv per degree C.
(0.2VDC at 2000W)
SWR CAL
DENOM
NUMER
POWER CAL
SWR clamp @ <200W
(1.5:1)
49.9K FOR 2:1
100uA/A
.5V/A
.5V/A
100uA/A
100uA/A
100uA/A
100uA/A
100uA/A
100uA/A
100uA/A
PA LIMIT
INPUT FWD
INPUT REV
OUTPUT FWD
OUTPUT REV
(0.1V at 1.00)
(.35VDC at 35 degrees)
(.48V at 48 volts)
(.5VDC at 50 amps)
.05V/A
.5V/A
.5V/A
.5V/A
.5V/A
.5V/A
.5V/A
1N4148'S
*
*
POWER RANGE
U1,3,5,6,8,24,25 U2,4,26,29 U27 U28
4
1184
1,8
4,574
(40mv/A)
(DETERMINED BY DIR. CPLR. SENSITIVITY.)
DIFFERENTIAL PA ERROR CURRENT SENSE.
R158 = OPEN: HIGHEST-LOWEST = 2.4 AMP.
R158 = 240K: HIGHEST-LOWEST = 1.2 AMP.
(LOWEST PAI)
(HIGHEST PAI)
123
4 72
7169
70
Metering Card Edge Connector
Viewed from front panel
NO PIN
NO PIN
NO PIN
NO PIN
NO PIN
NO PIN
NO PIN
NO PIN
(SPARE)
(SPARE)
(SPARE)
UNITSTENS100's
SWR
ALC19.99
19.99
199.9
199.9
F.S.
DECIMAL POINT
199.9
POWER SET
J2-12
(0.2VDC at 2000W)
PA1
PA2
PA3
PA4
PA6
PA7
19.99
19.99
19.99
19.99
19.99
19.99
19.99
19.99
19.99
SWR
ALC
PA DC VOLTS
PA DC AMPS
19.99
19.99
199.9
199.9
199.9PA TEMPERATURE
19.99
PA1
PA2
PA3
PA4
PA5
PA6
PA7
PA8
19.99
19.99
19.99
19.99
19.99
19.99
19.99
19.99
(0.1V at 1.00)
(0.6v at 6v)
(.35VDC at 35 degrees)
(.48V at 48 volts)
(.5VDC at 50 amps)
(1.999V reads "1999" FULL SCALE)
POWER OUT
PA TEMP
PA VOLTS
PA AMPS
19.99 PA8
19.99
KW OUT
DRIVE
19.99 DRIVE
U16-23U7,14U13
7
4
1
26
14716
U15
8167,8
MSB
LSB
U11,12U9,10
16
7 8
LOCAL ONLY
.5V PER AMP
.5V PER AMP
.5V PER AMP
.5V PER AMP
.5V PER AMP
.5V PER AMP
.5V PER AMP
.5V PER AMP
RF output power is limited by the lower of:
Front panel OUTPUT control.
Remote RAISE/LOWER step circuit, or
Remote PWR CTRL analog input, or
ALL GRN
NOTES :
_______
_______
1. ALL RESISTORS ARE IN OHMS,
2. ALL CAPACITORS ARE IN
PA5
THESE DRAWINGS AND SPECIFICATIONS ARE THE
SHALL NOT BE REPRODUCED, COPIED, OR USED
AS THE BASIS FOR THE MANUFACTURE OR SALE
OF APPARATUS OR DEVICES WITHOUT PERMISSION.
PROPERTY OF CROWN INTERNATIONAL, INC. AND
SCALE NONE
DWG. NO.
102120
MFM2000
SCH, FM1K CONTROL & METERING
PROJ NO.
SHEET 1 OF 1
F
REV
TITLE:
SIZE
D
UNCONTROLLED
UNLESS OTHERWISE MARKED IN RED INK BY CM AS
A CONTROLLED COPY, COPIES OF THESE
DOCUMENTS INCLUDING ASSOCIATED ELECTRONIC
REPRODUCTIONS ARE FOR REFERENCE ONLY.
1/4W, 5% TOL.
MICROFARADS.
UNLESS OTHERWISE
SPECIFIED:
FOLDBACK
CAL.
RF FWD MEM BATT REM PWR CTRL
REM RF POWER
REM /PWR RAISE
RF REV
REM /PWR LOWER DP10
DP100
REM SWR
DRIVE REV
DRIVE FWD
REM RF DRIVE
REM ALC
DPM REF
ALC
PATEMP 1-2
FAULT SUM
+50V
PATEMP 3-4
REM PAV
PAV SENSE SWR LAMP
REM PA TEMP
PATEMP 5-6
DRIVE LAMP
PATEMP 7-8
+12V IN +12V
SH HI 1
PATEMP LAMP
SH LO 1
PS /POWER ON RF FWD
RF REV PADC LAMP
ALC DRIVE FWD -12V IN -12V
-12V IN DRIVE REV SH HI 2
GND REM RF POWER
+12V IN REM SWR
REM PA TEMP REM PAV
REM ALC REM PAIT
FAULT SUM REM PAI1 SH LO 2
REM /PWR ON REM PAI2
REM PWR CTRL REM PAI3 DP10
REM /PWR RAISE REM PAI4
REM /PWR LOWER REM PAI5 DP100
REM PAI6
REM RF DRIVE REM PAI7 SH HI 3
GND REM PAI8
GND GND
GND GND SH LO 3
REM PAIT
GND SH LO 1
SH HI 1
PATEMP 7-8 SH LO 2
PATEMP 5-6 SH HI 2 SH HI 4
PATEMP 1-2 SH LO 3
TEMP V+ SH HI 3
PATEMP 3-4 SH LO 4
SH HI 4 SH LO 5
SH HI 5 SH LO 6 SH LO 4
SH HI 6 SH LO 7
SH HI 7 SH LO 8
SH HI 8 +50V
PAV SENSE IN'LK 1
MEM BATT IN'LK 2
SH HI 5
SH LO 5
REM PAI1
REM PAI2
REM PAI3
REM PAI4
REM PAI5
SH HI 6 REM PAI6
REM PAI7
REM PAI8
SH LO 6
IN'LK 2PS /POWER ON
IN'LK 1REM /PWR ON SH HI 7
+12V IN TEMP V+ SH LO 7
GND
SH HI 8
SH LO 8
DPM IN
+5V
+12V
+12V
+12V
+12V
PA+5V
+12V
+12v
+5.00
+12V
+5.00
+12V
+12V
+12V
+12V
PA+5V
PA+5V
PA+5V
+5V
+5V
+5V
+12V
PAV+6
+5.00
+5.00
+12V
+12V
+12V
-12V
-12V
-12V
-12V
-12V
-12V
PA-5V
-12V
-5V
-12V
-12V
-12V
-12V
-12V
-12V
-12V
PA-5V
PA-5V
PA-5V
PAV-6
+5.00
-12V
-5V
-12V
+12V
+12V
+5V
-5V
-12V
+5V
PA-5V
PA+5V
-5V
+5.00
+5.00
+5V
-5V
VCC
VDD
-12V
+5V
VEE
+5V
+5V
+5V
VSS
+5V
+5V
+5V
D26
1N4148
C33
100PF
DZ1
6.2V
DZ2
6.2V
D24
1N5822
D25
1N5822
U28
REF02
IN
2
TEMP
3
TRIM
5
OUT
6
D21
C65
100UF/63V
C98
.01
C101
1nF
U14C
74HC132
9
10
8
U7B
74HC14
3 4
U7C
74HC14
5 6
U7A
74HC14
1 2
U14D
74HC132
12
13
11
DL20
DL19
DL18
DL17
DL16
DL15
DL14
DL13
DL12
DL11
DL10
DL9
DL8
DL7
DL6
R201
OPEN
R202
OPEN
R203
OPEN
R204
OPEN
R205
100 1%
R206
100 1%
R207
100 1%
R208
100 1%
R209
OPEN
R210
OPEN
R216
100 1%
R215
100 1%
R214
100 1%
R213
100 1%
R212
OPEN
R211
OPEN
R144
100 1%
R143
100 1%
R140
100 1%
R139
100 1%
R137
OPEN
R136
OPEN
R134
OPEN
R133
OPEN
R131
100 1%
R130
100 1%
R128
100 1%
R127
100 1%
R125
OPEN
R124
OPEN
R122
OPEN
R121
OPEN
U16A
OPEN
2
3
1
8 4
U16B
OPEN
6
5
7
U17A
MC33282
2
3
1
8 4
U17B
MC33282
6
5
7
U18A
OPEN
2
3
1
8 4
U18B
OPEN
6
5
7
U19A
MC33282
2
3
1
8 4
U19B
MC33282
6
5
7
C63
.01
Q13
2N5087
Q12
2N5087
Q11
OPEN
Q10
OPEN
Q9
2N5087
Q8
2N5087
Q7
OPEN
Q6
OPEN
R145
4.99K
R141
4.99K
R138
OPEN
R135
OPEN
R132
4.99K
R129
4.99K
R126
OPEN
R123
OPEN
U25D
TL074
+
-
13
12
14
U25C
TL074
+
-
9
10
8
U25B
TL074
+
-
6
5
7
U25A
TL074
+
-
2
3
1
4 11
U24D
TL074
+
-
13
12
14
U24C
TL074
+
-
9
10
8
U24A
TL074
+
-
2
3
1
4 11
D44 OPEN
D45 OPEN
D46
D47
D48
OPEN
D49
OPEN
D50
D51
D27 OPEN
D28 OPEN
D30
D31OPEN
D29
D32
OPEN
D33
D34
R156
4.3K
R157
10K
R158
OPEN
U8D
TL074
+
-
13
12
14
U26A
MC33282
2
3
1
8 4
U26B
MC33282
6
5
7
R146
1.0K
R148
10K 1%
C22
100PF
R147
20K
1%
R168 100
R167 OPEN
R166 OPEN
R165 100
R164 100
R163 OPEN
R162 OPEN
R169 100
R154
220K
C19
1nF
U5D
TL074
+
-
13
12
14
U5C
TL074
+
-
9
10
8
C20
1nF
R49
10K
R47
OPEN
U5B
TL074
+
-
6
5
7
D9
1N4148
D8
OPEN
D7
1N4148
R45
10K
D6
OPEN
R43
OPEN
C14
1nF
U5A
TL074
+
-
2
3
1
4 11
C16
1nF
R42
OPEN
R112
220K
C13
OPEN
R113
220K
R44
1K
C15
1nF
C18
1nF
R153
220K
R46
OPEN
R48
1K
U3D
TL074
+
-
13
12
14
C70
1nF
R53
100
R52
100K 1%
R108
220K
C1
1nF
C2
1nF
R5
62K
R3
100K
U1A
TL074
+
-
2
3
1
4 11
R4
10k
R1
1K
R12
1K
R109
220KC41nF
U1B
TL074
+
-
6
5
7
C5
1nF
R15
510
R14
100K
U1C
TL074
+
-
9
10
8
C10
1nF
R37
100K
C9
1nF
R110
220K
R36
1K
R39
1K
R111
220K
C11
1nF
U1D
TL074
+
-
13
12
14
C12
1nF
R41
100K
R8
49.9K
U2B
MC33282
6
5
7
D10
1N4148
R7
49.9K
R6
3.3K
D11
1N4148
C3
.01
U2A
MC33282
2
3
1
8 4
R16
10K
U3A
TL074
+
-
2
3
1
4 11
R19
10K
R17
10K
R23
10K
R21
1K
U4A
MC33282
2
3
1
8 4
C6
.01
R20
3.3K
R28
49.9K
R25
10K
R22
10K
R24
10K
Q14
2N5210
R26
100K
D5
1N4148
Q4
LM394
1
1
2
2
3
3
4
4
8
8
7
7
6
6
5
5
R31
12K
U4B
MC33282
6
5
7
C7
.01
R27
3.3K
U3C
TL074
+
-
9
10
8
U3B
TL074
+
-
6
5
7
C8
1nF
R33
10.0K
R35
100
R29
10K
R30
5.1K
R9
10.0K
R11
100
C34
1nF
R174
10K
SW3
RAISE
R176
10K
R173
51K
U29A
74HC132
1
2
3
U29D
74HC132
12
13
11
U29C
74HC132
9
10
8
U29B
74HC132
4
5
6
R175
51K
C95
1UF
SW4
LOWER
R178
3.3K
D37
1N4148
D38
1N4148
R177
240K
R61
ZERO
R180
4.99K
D53
1N4148
D52
1N4148
R179
10K
R59
1K
D40
1N4004
D39
1N4004
R181
1K
R183
4.99K
U33B
TL074
+
-
6
5
7
D41
1N4148
C100
1nF
U33C
TL074
+
-
9
10
8
U33A
TL074
+
-
2
3
1
4 11
R186
3.3K
D43
1N4148
C35
0.1
U9
74HC4051
X0
13
X1
14
X2
15
X3
12
X4
1
X5
5
X6
2
X7
4
INH
6
A
11
B
10
C
9
X
3
D13
1N4148
R67
51K
R70
100K
R69
10K
C23
0.1
U8B
TL074
+
-
6
5
7
R68
200K
R72
100
R71
100
R73
10.0K
U8A
TL074
+
-
2
3
1
4 11
U6B
TL074
+
-
6
5
7
R75
100K
R77
1M
C26
0.1
C25
0.1
R65
20K
R78
1K
R66
1M
R79
1K
R81
OPEN
U6C
TL074
+
-
9
10
8
R82
7.5K
R83
120K
U6A
TL074
+
-
2
3
1
4 11
C27
1nF
R85
1M
R149
100K
R86
5.1K
U6D
TL074
+
-
13
12
14
R18
200K
D35
1N4148
D36
6.2V
C28
.01
R88
OPEN
R97
10K
U7E
74HC14
11 10
DL1
RED
D14
1N4148
D15
1N4148
D16
1N4148
R89
120K
R91
120K
R93
120K
R94
100K
R92
100K
R90
100K
DL2
RED
D19
1N4148
D20
1N4148
D18
1N4148
U7D
74HC14
9 8
R96
100K
R95
56K
D17
1N4148
R98
220K
DL4
RED
DL3
RED
U7F
74HC14
13 12
R99
510
R161
56K
C37
.01
R116
100K
R114
10K
SW2
DOWN
U14A
74HC132
1
2
3
C38
.01
R117
100K
U14B
74HC132
4
5
6
R115
510K
R118
3.3K
SW1
UP
D23
1N4148
D22
1N4148
C32
0.1
C30
0.1
R101
470K
C31
0.1
R104
10.0K
R170
510
R171
510
RFC3
33UH
RFC4
33UH
VR1
7805
IN
2
C
1
OUT
3
VR2
79L05
IN
2
C
1
OUT
3
U11
74HC4051
X0
13
X1
14
X2
15
X3
12
X4
1
X5
5
X6
2
X7
4
INH
6
A
11
B
10
C
9
X
3
U12
74HC4051
X0
13
X1
14
X2
15
X3
12
X4
1
X5
5
X6
2
X7
4
INH
6
A
11
B
10
C
9
X
3
RFC1
33UH
R152
10K
R56
10.0K
U8C
TL074
+
-
9
10
8
R58
100
R106
10K
C71
1nF
R54
49.9K
R76
24.9K
D12
1N4148
Q2
LM394
1
1
2
2
3
3
4
4
8
8
7
7
6
6
5
5
D1
1N6263
D4
1N6263
R151
100
R160
4.3K
C99
1nF
D42
1N4148
RFC2
470UH
SW5
Switch
1
2
3
PL1
HDR 72
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
35 36
37 38
39 40
41 42
43 44
45 46
47 48
49 50
51 52
53 54
55 56
57 58
59 60
61 62
63 64
65 66
67 68
69 70
71 72
R142
100
R200
100
R159
100K
R63
510
R62
1K
R182
1K
C103
1nF
R102
100K
R100
100K
C68
47UF/20V
C67
47UF/20V
C17
OPEN
C60
.01
C57
OPEN
C54
OPEN
C51
.01
C48
.01
C45
OPEN
C42
OPEN
R60
100
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R225
OPEN
R226
0
R218
OPEN
R219
OPEN
R220
OPEN
R221
OPEN
U24B
TL074
+
-
6
5
7
U10
74HC4051
X0
13
X1
14
X2
15
X3
12
X4
1
X5
5
X6
2
X7
4
INH
6
A
11
B
10
C
9
X
3
R222 OPEN
R155
OPEN
C75
OPEN
R50
470
C44
OPEN
U30
74HCT193
A
15
B
1
C
10
D
9
UP
5
DN
4
LOAD
11
CLR
14
QA
3
QB
2
QC
6
QD
7
CO
12
BO
13
C74
OPEN
C76
1nF
C77
1nF
Q1
LM394
1
1
2
2
3
3
4
4
8
8
7
7
6
6
5
5
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R57
1.15K
C78
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C87
1UF
R103
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2
6
7
1
8
4
5
R223
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C79
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U33D
TL074
+
-
13
12
14
C90
1UF
R32
510
R64
10K
C94
1UF
C81
1nF
C97
3300UF/16V
C83
47UF/20V
R119
150
C80
1nF
R84
20K
C96
47UF
C86
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C102
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D2
1N6263
C29
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C66
100UF
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C85
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C64
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R120
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C73
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C36
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B
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10
D
9
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5
DN
4
LOAD
11
CLR
14
QA
3
QB
2
QC
6
QD
7
CO
12
BO
13
R105
2.49K
Q3
LM394
1
1
2
2
3
3
4
4
8
8
7
7
6
6
5
5
C92
1UF
D3
1N6263
C88
1UF
R2
22K
C56
OPEN
C61
1nF
R224
0
C49
1nF
C46
1nF
C59
1nF
R107
1.15K
DZ4
ICTE-12
DZ5
ICTE-12
C82
47UF
20v
R227
OPEN
R80
10K
C69
1nF
R87
50K
C89
1UF
R40
22K
C62
1nF
C53
OPEN
C47
1nF
C50
1nF
R150
OPEN
C43
OPEN
R38
22K
C72
1nF
C39
1UF
R34
1.15K
U32
DAC0800
B8
12
B7
11
B6
10
B5
9
B4
8
B3
7
B2
6
B1
5
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VR-
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CLR
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QA
3
QB
2
QC
6
QD
7
CO
12
BO
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C104
1nF
DZ3
6.2V
R74
1.15K
R10
1.15K
R13
22K
R172
24.9K
C41
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C84
1UF
C21
1nF
C40
OPEN
C24
1nF
C91
1UF
C55
OPEN
C58
1nF
C52
OPEN
R51
24.9K
R217
1K
Page 52
6–16
FM1000A User's Manual
Notes:
Page 53
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
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 returned 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 Sales at the following number.
(866) 262-891
You may also write to the following address:
Service Manger
International Radio and Electronics Company, Inc.
25166 Leer Drive
Elkhart, Indiana, U.S.A. 46514-5425
7–2
FM1000A User's Manual
Page 55
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
Service and support 7 – 3
Page 56
Notes:
7–4
FM1000A User's Manual
Page 57
Factory Ser vice Instructions
To obtain factory service, complete the bottom half of this page, include it with the unit, and ship to:
International Radio and Electronics Company, Inc.
25166 Leer Drive
Elkhart, Indiana, U.S.A. 46514-5425
For units in warranty (within 3 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 ship freight collect (COD for cost of freight) or 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:
Telecphon: (574) 262-8900
Fax: (574) 262-5399
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 COD
Please Quote before servicing
Card Number: Exp. Date: Signature:
Return Shipment Preference if other than UPS Ground:
ENCLOSE WITH UNIT—DO NOT MAIL SEPARATELY
Service and Support
Expedite Shipment Other
7–5
Page 58
A B C
Glossary
The following pages define terms and abbreviations used
throughout this and other Crown Broadcast manuals.
Glossary
G–1
Page 59
A B C
AF Audio Frequency; the frequencies between 20 Hz
and 20 kHz in the electromagnetic spectrum.
ALC Automatic Level Control
AM Amplitude Modulation; the process of impressing
information on a radio-frequency signal by varying
its amplitude.
bandwidth The range of frequencies available for signalling.
BCD Binary-Coded Decimal; a digital system that uses
binary 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 entire
audio spectrum as opposed to the spectrum influenced by the pre-emphasis; also called "Wideband."
carrier A continuous signal which is modulated with a
second, information-carrying signal.
crosstalk In FM broadcasting, this term generally refers to
the interaction between the main (L+R) and the
subcarrier (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 frequency
changes either side of the center frequency.
DIP Dual In-line Package; term used to describe an IC
or socket that has two parallel rows of pins.
distortion The unwanted changes in signal wave shape that
occur during transmission between two points.
DPM Digital Panel Meter
EPROM Erasable Programmable Read Only Memory
ESD Electrostatic Discharge; a discharge that is poten-
G–2
tially distructive to sensitive electronic components.
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.
FET Field-Effect Transistor
frequency synthesizer A circuit that generates precise frequency signals
by means of a single crystal oscillator in conjunction with frequency dividers and multipliers.
FM Frequency Modulation; the process of impressing
information on a radio signal by varying its frequency.
FSK Frequency Shift Keying; an FM technique for
shifting the frequency of the main carrier at a
Morse code rate. Used in the on-air identification
of frequencies.
gain reduction The process of reducing the gain of a given ampli-
fier.
harmonics Undesirable energy at integral multiples of a
desired, fundamental frequency.
HF High Frequency; Frequencies in the 3.0 to 30.0
MHz 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 impedance due to its electrically isolated gate.
nearcast A transmission within a localized geographic area
(ranging from a single room to a several kilometers).
PA Power Amplifier
Glossary
G–3
Page 61
A B C
PAI Power Amplifier Current
PAV Power Amplifier Voltage
pilot A 19–kHz signal used for stereo transmissions.
pre-emphasis The deliberate accentuation of the higher audio
frequencies; made possible by a high-pass filter.
processing The procedure and/or circuits used to modify
incoming audio (keeping its level around 75 kHz
deviation) to make it suitable for transmission.
receiver An option which adds incoming RF capability to an
existing transmitter. See also "Translator."
RF Radio Frequency; (1) A specific portion of the
electromagnetic spectrum between audio-frequency and the infrared portion. (2) A frequency
useful for radio transmission (roughly 10 kHz and
100,000 MHz).
SCA Subsidiary Communications Authorization; see
"subcarrier."
S/N Signal to Noise
spurious products Unintended signals present on the transmission
output terminal.
stability A tolerance or measure of how well a component,
circuit, or system maintains constant operating
conditions over a period of time.
stereo pilot See "pilot."
stereo separation The amount of left-channel information that bleeds
into the right channel (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
SWR 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 intended (50 ohms) load impedance.
THD Total Harmonic Distortion
translator A transmitter designed to internally change an FM
signal from one frequency to another for retransmission. Used in conjunction with terrestrial-fed
networks.
satellator A transmitter equipped with an FSK ID option for
rebroadcasting a satellite-fed signal.
UHF Ultra High Frequency; frequencies in the 300 to
3000 MHz range.
VCO Voltage-Controlled Oscillator
VHF Very High Frequency; frequencies in the 30 to 300
MHz range.
VSWR Voltage Standing-Wave Ratio; see "SWR."
Wideband See "broadband."
Glossary
G–5
Page 63
Index
AA
A
AA
HH
H
HH
AC Input Board 4–5
AC Power 1–3
AC power 2–4
ALC 3–4, 5–3
Antenna 3–7
mismatch 5–5
antenna 2–5
BB
B
BB
Backplane Assembly 4–3
Backplane DC Interconnect Board 4–3
Board Layouts 6–3
CC
C
CC
Circuit Breaker 3–4
Combiner Board 4–2
Connections 2–5
Connectors
Hubble Twist Lock® 2–4
Hubble Twist-Lock 2–6
connectors 2–5
DD
D
DD
DC Fuse and Power Distribution Board
4–4
DC Output Board 4–6
DC Power Switch 3–5
Digital Multimeter 3–6, 5–3
EE
E
EE
Efficiency 1–3
efficiency 1–2
exciter 1–2
FF
F
FF
Humidity Range 1–3
II
I
II
In Ref 3–4, 5–3
Input Divider Board 4–3
Installation 2–5
Interlock Switch 3–5
LL
L
LL
labels 1–4
MM
M
MM
Metering and Control Board 4–4
multimeter display 3–4
OO
O
OO
operation 3–2
Output Combiner Board 4–3
Output Filter & Reflectometer 4–3
PP
P
PP
PA DC 5–6
PA Temp 3–4, 5–4
PA Voltage 5–4
PFC (Power Factor Correcting)
Switching Board 4–5
power adjust 3–3
Power Consumption 1–3
Power Factor 1–3
Power Module 4–2
Power Out 3–4, 5–3
Power Switch 3–4
power switch 3–3
Power-up 3–2
Fans 4–4, 4–6, 5–5
Fault Indicators 3–7, 5–5
Frequency Range 1–3
Fuse Indicators 3–8
Index-i
Page 64
RR
R
RR
TT
T
TT
remote I/O 2–7
RF Drive Requirement 1–3
RF Harmonics 1–3
RF Output Impedance 1–3
RF output power 1–2
RF Power Output 1–3
RF power output 1–2
RU spaces 1–2
SS
S
SS
S/N Ratio 1–3
Safety 1–4
Schematics 6–3
Spurious Products 1–3
SWR 1–3, 3–4, 5–3
Tot Current 5–4
transmitter package 1–2
Troubleshooting Flow Chart 5–2
UU
U
UU
Unpacking 2–2
WW
W
WW
Weight 1–3
Index-ii
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