Crown Audio PA1000, FM1000A User Manual
®
FM1000A
RF Amplifier Package
User's Manual
©2005 Crown Broadcast, a division of International Radio and Electronics, Inc.
25166 Leer Drive, Elkhart, Indiana, 46514-5425 U.S.A.
(574) 262-8900
i
Revision Control
Revision 2
May 2005
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:
International Radio and Electronics
25166 Leer Drive, P.O. Box 2000
Elkhart, Indiana, 46515-2000 U.S.A.
ii
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
PA
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
Brass Screw
Brass/Black Screw
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.
Equipment grounding conductor
(green or green/yellow)
Hot circuit conductor, 240 VAC
(NOT white, NOT green)
Hot circuit conductor, 240 VAC
(NOT white, NOT green)
Conductor
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
25
Illustration 2–7 Remote I/O connector (back panel view)
View from Rear of Cabinet
14
The Remote I/O Connector Pinout Table on the next page summarizes the Remote
I/O pin connections.
Installation
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 Power (a momentary s witch, 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
Remote I/O Connector Pinout Table
2–8
FM1000A User’s Manual
Section 3—Operation
This section provides general operating parameters of your power
amplifier system and a detailed description of the front panel
display.
3–1Operation
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