User`s Manual - Crown Broadcast
Contents
1. hae 4494496 E 6 15 SCH FM2K CONTROL amp METERING UNCONTROLLED Q43514 1 FM2000A User s Manual Reference Drawings 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 7 1 Service The product warranty see opposite page outlines our responsibility for defective pr2. EN 44 005 0002144 or L zi ano SEMI 0 0 9 9 mE in 32 n Fs E air oL 6 dv e Hr Ut A E __ lt 5 md ao L I 10 1o 4 gany N Te PSST SSS SS SES SSS SSS SSS SS SS PPS SS ce monum SSS SS SR m erm SS mmm 1 LL 19310 i 09 114100 Yd 08 1 Vd i 1 1 i 9 i MEI 1 bod wo wo 7 1 1 1 1 1 OU eae 1 1 wo wo 8600 1 i pl Ln 1 J i i i 1 1 Hd Lo no I p eun 11 mE i Li 1 1 1 D unio 1 i NM a i ache 1 i 010 i i 1 1 1 1 1 1 1 1 1 Moi 1 1 1 D 1 1 1 D 5m zu D 1 1 1 1 wz Ed 1 onn gun zel auo we T 82 ano __ 1 ee ano ees 2255 427217209 E iz 1 09 109110 Vd i TE Q8 LfidNI Vd 1 1 9 16 i 9 11 sum 1 1 1 1 100 100 nuo w sici a iF 1 ga Li
3. 1 Cc E crown FM2000A 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 Revision Control Revision Print Date Initial Release Rev 0 900415 1 November 1998 Second Printing 130319 1 November 1999 Third Printing April 2002 Fourth Printing May 2005 Important Notices 2005 Crown Broadcast a division of International Radio and Electronics Inc All rights reserved No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language in any form by any means without the written permission of Crown International Inc 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 Contents Section 1 Getting Acquainted 1 1 Your Amplifier Paekaug d HR e REL Oat 1 2 1 2 Amplifier Package Specifications 200 1 3 1 3 Safety Consider atto scs enr da 1 4 POS lE es 1 4 1 8 2 MMarniftss deae o 1 4
4. AUS 6 6 Illustration 3 7 Digital Multimeter eee eee eee 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 1096 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 FM2000A User s Manual 3 4 Fault Indicators Faults are indicated by illuminated red LED s when the following occurs Antenna Load SW
5. Me 006 4 i suo ES 1 1 1 1 i T w n 17044 o T 1 1 1 1 1 1 co 1 1 1 1 1 1 HNOS i an i 1 1 1 4 1 1 1 1 E 1 9 ano 1 1 1 1 250 1 1 r wo m wa 1 mm QNS 1 uuo 1 owy Pre 1 1 vii 1 1 QNS i GEMEINT i oi zo 4 1 ONS ONS ONS inovyvd Lnorvd 4 inorvd v anyos 852 ONS ONO Anoevd LNOEVd LNOEVd LNOEVd E 955 sdwv N Guo ror ONS ON 9 indevd indevd 1 ONS ONS LOOTYd 4 0 1 4 RF Output Combiner 6 11 Reference Drawings sped 21 6021 10210 6 0 0920 f aaiadlo3ds 3SIMH3HIO 13S AHOLOVJ SHION3T1 109 LOVX4A SSd INn 9 19114 Thy Z 21 90 92670 90211 10385 eu 20 amp 0 0211 3SIMH3H O SSIINN 968 e em
6. bi D2 5 135263 8 47PF NPO 8 c c c o D1 5 8 1N6263 R6 2 20K 3 R5 T 20K C6 d E e 8 7 01 C4 8 mE C5 001 001 R7 01 5 20K 0 L RF INPUT Back Panel J11 J12 AMPS 1 amp 2 AMPS 5 amp 6 BOARD 1 BOARD 3 PALIN PASIN PA1IN PALIN PALIN GND GND GND GND GND GND GND GND 444 AMPS 354 AMPS 7 amp 8 BOARD 2 BOARD 4 PA2IN NOTES PAAIN 1 ALL RESISTORS ARE IN OHMS PAZIN 1 4W 5 UNLESS OTHERWISE PASIN PA2IN SPECIFIED PAAIN 2 ALL CAPACITORS ARE IN PA2IN MICROFARADS UNLESS PA4IN OTHERWISE SPECIFIED GND 3 1201 1209 1217 are circuit board pads GND GND GND RF Input GND GND Reflectometer amp Splitter GND GND J0744 3m PA2000 RF Input Reference Drawings 6 9 100 100 ino vd 7031312395 ASIMYSHLO SS31Nn 5 NI SHOLIOVdVO Z Galdio3dS SS3TIND 6 Mtr NI SHOLSIS3H 821
7. Bin sozi SINHO NI SHV SHOLSISSY TIY H eu 90 amp 0 20211 SILON 0 vl 4520 102171 HLON31 SNun L qi EHE 3 001 L0 9121 100 9001 vizio 2 91219 11218 10 2 2 PT 929NI _ HOLINOW 38 ease OdNddZb 1 o e vIOZLO E _ _ _ _ M 050 re 34776 34686 6 Jasi 50210 70210 0219 20219 10210 506 60 19 ae poe 5 1ndlno NI dH Vd ME 4466 39981 ddz 901 1 80212 10219 90210 00219 11210 T ZHINZS2 zHW9Z1 zHWS61 RF OUTPUT FILTER amp REFLECTOMETER FM2000A User s Manual 6 12 J2 J1 COUPLER OUTPUT COUPLER DRIVE FWD j RF Fwn Es m GND GND 46 CONTROL METERING POWER DISTRIBUTION LI12vpc 8 PS PWR GND PAIB HI RE FWD MEM BATTERY AMP DC PWR 47 GND AMP4 PWR iod aie GND PA VOLTS SENS AMPI DC PWR DRIVE FWD AMPS DC ij 7 DC PWR AMPS DC PWR AMPS DC PWR ND GND E DC Em ED Em REM RF PWR
8. three fourths of the full output power 4 1 2 Power Combiner Board There are four Power Combiner Boards one attached to each of the four 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 acommon point junction on the Output Combiner Board User s Manual 4 1 3 Backplane Assembly The backplane assembly is located in the vertical center of the PA2000 behind the four 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 a 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 inter face 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 transfo
9. CM AS MILI CLE ps 04 3521 6 A CONTROLLED COPY COPIES OF THESE DOCUMENTS INCLUDING ASSOCIATED ELECTRONIC UR ORBE OE APPARSTUS REPRODUCTIONS ARE FOR REFERENCE ONLY UECEBSHISSION T 4 SCALE NONE PROJ NO SHEET 10 OF 10 Reference Drawings 6 5 NOT ON PWB BRIDGE BRIDGE J2 01 HFA25TB60 gt JUMPER QF1 QF4 IGBT 600V 50A FAST IGBT 600V 50A FAST R41 QF2 10K IGBT 600V 50A FAST C44 0033 250VAC 7 053 145818 054 R44 5 2W 5 Es 1N5818 10 OFS IGBT 600V 50A FAST IGBT 600V 50A FAST 0511 1N5818 C21 t 47 01 P E e E E in 10 1N5818 2N5P10 0512 osu 1N5818 1N5818 e 5 Ut LT1248 A Q2 2N5087 2N5087 Q3 Install R
10. FM technique for shifting the frequency of the main carrier at a Morse code rate Used in the on air identification of frequencies The process of reducing the gain of a given ampli fier Undesirable energy at integral multiples of a desired fundamental frequency High Frequency Frequencies in the 3 0 to 30 0 MHz range Frequencies affected by the pre emphasis Integrated Circuit Input Output Light Emitting Diode The process by which a carrier is varied to repre sent an information carrying signal Metal Oxide Semiconductor Field Effect Transistor a voltage controlled device with high input imped ance due to its electrically isolated gate A transmission within a localized geographic area ranging from a single room to a several kilome ters Power Amplifier PAV pilot pre emphasis processing receiver RF SCA S N spurious products stability stereo pilot stereo separation subcarrier suppression Power Amplifier Current Power Amplifier Voltage A 19 kHz signal used for stereo transmissions The deliberate accentuation of the higher audio frequencies made possible by a high pass filter The procedure and or circuits used to modify incoming audio keeping its level around 75 kHz deviation to make it suitable for transmission An option which adds incoming RF capability to an existing transmitter See also Translator Radio Frequency 1 A specific portion of the e
11. 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 5 6 FM2000A User s Manual Section 6 Drawings The illustrations in this section may be useful for making adjustments taking measurements troubleshooting or understanding the circuitry of your RF power amplifier and power supply Reference Drawings 6 1 6 1 Views E wai 5 5 p peccet uL 5 UE 4 99000 broadcast Illustration 6 1 Front View RF Mpnitor Optional tion RF Input Remote I O ci RF Qutput Illustration 6 2 Back View FM2000A User s Manual 6 2 Diagrams and Schematics 2 kW RF Crown FM100 Power Output PA2000 Power Amplifier 50 70 watt exciter RF Input RF output To remote control and monitoring equipment Control DC input 240 volts AC Control DC output 50 60 Hz Input Power Single Phase PS2000 Power Supply Illustra
12. gs cne non ha la dispoziong o 6 fay e go con ta matita ci insegna a nop E 4 9 endo 79 due persone che a4 ner x n je non nulla nol me e gace che non ha la g ae matita ci insegn d vae ye che c e nulla 4 uM LU anaa non p fu seS conta ciinsega ano 7 P gode P m etl mma T N oe arg 0 go con ta mella ci insegna a no iv qe tita c insegn do con a igna a nop E we ondo due persone che ye wor os ha la dispozione po cne non c e nol mong gear ealo ay ci insegna nop T NS Par Lo tary 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 ad vanced users and service personnel Principles of Operation 4 1 Introduction The FM2000A is a solid state RF amplifier package designed to deliver 500 to 2000 watts The package consists of two separate compact units a power supply PS2000 and a power amplifier PA2000 In turn these units consist of modular components which provide for efficient operation as well as ease of service 4 1 PA20
13. 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 ou
14. 00 Power Amplifier The PA2000 power amplifier features adjustable output to deliver 500 2000 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 PA2000 are four 500 watt power modules These power modules are mounted by stacking two in the left cavity and two in the right cavity of the chassis The chassis of the power modules acts as a heat sink for the MOSFET amplifiers There aretwo power amplifiers mounted to spacer plates on each of the heat sinks for a total of eight power amplifiers in all The power amplifiers are the same as those utilized in the Crown Broadcast 100 250 500 and 1000 watt transmitters Power from the amplifiers is combined through a micro strip combiner to convert from 50 output impedance for each amplifier to an intermediate impedance and then return to the 50 Q 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 allowa module to be disconnected from the combiner and removed without adversely affecting the impedance balance of the unit With one module removed the imped ance change allows the remaining modules to continue operation at approximately
15. 1 4 77 MBR3100 3100 T1 i 4 4 R21 t 77 1 0K E 1 5 C19 R19 11 Lt 10 h 3W 77 0047 DI 13 14 cis D9 BYV44 300 E 0047 T R14 RIS 11 TO RF PA S 15 16 17 18 10 10 MUR130 AC y 1 D10 50V 24A 5 1 3W 89 uH 89 l D D13 77 ce 4 10047 0 130 D2 3300 T 3300 1 1920 i i 44 300 H3 Hg 9 10 2 14 CH BYV44 300 5 0047 R16 R17 4 13 11222 5678 10 10 I TO RF PA S 6 7 MUR130 PY WN 50V 24A 2 3W aW D12 89 uH 89 uH n cig _ C5 4 HEADER 44777 0047 MUR130 D4 MUR 3300 F 3300 34 4 4 220pF T BYV44 300 4 z R7 77 77 V 234K 7 RI R5 R13 ATI60V lt iK C8 IK SW ATI60V T 5W HD3 c R6 3 c 15K is a 77 INTEXT 12V gt 4 LOCAL ITT NOTES 51K CONTROL ILL 1N4004 e 1 pig UNLESS OTHERWISE SPECIFIED WE 1 ALL RESISTORS ARE IN OHMS 1 4W 5 TOL 7 2 ALL CAPACITORS ARE IN MICROFARADS HDI 77 da 215 ed 22 4 CONTROL _____ 3 ape 4 R18 R12 0 6VDC IN ADS lt 5 6 6 5 4 7 M 401K FOR 50V OUT 4 09 LM358 1 1 B CI2 B HEADER 5X2 R2 T o R8 5 11K 77 d 10K 2 0K 1 R3 1 77 1 77 77 T IM 1 77 77 FAN GND C10 R4 FAN 24VDC 6p EXER d n 510K APPROVALS ADIO AND ELECTRONICS COR
16. 16835 tente mutua 1 4 Section 2 Installation 2 1 Operating Environment 2 2 2 2 2 2 2 3 UNPACKING 2 2 UN NE Ic icr REPE 2 3 2 4 1 Power Amplifier MOUIUIBS 2 3 2 4 2 Hubble Twist Lock amp Connector Wiring ne 2 4 dede e e 2 5 2 6 1 repo e 2 6 Section 3 Operation 3 1 Initial Power up Procedures csset eat iu 3 2 3 2 Power Switcl s quei bl ada a dade de dus 3 4 3 2 1 AC Input Circuit eor t oe E ioa 3 4 32 3 5 222 o WHO ates seats et ae 3 5 222 Digital M ltiMeter i eoe qoot avoue 3 6 3 4 oh Said 3 7 3 5 Ue 3 8 Section 4 Principles of Operation 4 1 PA2000 Power Amplifier uet tet a FR bt ba iid 4 2 4 L1 Power Modules e t Ru 4 2 4 1 2 Power Combiner Board eu ie epe t cet E Ix 4 2 4 1 3 Backplane Assembly sion desee ttt tones umet 4 3 4 1 3 1 Backplane DC Interconnect Board see 4 3 4 1 3 2 Input Divider d 4 3 4 1 3 3 Output Combiner BOIS vis
17. 2 S S N Ratio 1 3 Safety 1 4 Schematics 6 3 service warranty 7 3 Service Instructions 7 5 Spurious Products 1 3 SWR 1 3 3 4 5 3 T Tot Current 5 4 transmitter package 1 2 Troubleshooting Flow Chart 5 2 U Unpacking 2 2 W Warranty 7 3 Weight 1 3 Index2
18. 58 _ DANGER Field Signal Reference is connected to one side of the AC power To co prevent serious injury or death do not touch this point UNCONTROLLED THESE DRAWINGS AND SPECIFICATIONS ARE THE DWG NO PROPERTY OF INTERNATIONAL RADIO AND nd unis 043522 4 REPRODUCED COPIED OR USED AS THE BASIS FOR THE MANUFACTURE OF DEVICES iW PERMISSION CALE NONE 103 6 6 FM2000A User s Manual 8 1 3 4 5 6 7 REVISION HISTORY APPROVALS E C N REV DESCRIPTION DATE DWN CHK CM PE C REDRAWN ON IREC FORMAT AND ADDED U2 D16 L5 C20 21 R20 21 01 17 05 DW DW F F J5 1 15 TO 150uH FAN FUSE 1 our 424VDC 5 J6 D5 D7 ON OFF 25216 4 1 1 eee MUR420 RO MBR3100 MBR3100 ecu un T 187 TS 22085v m Di 1 220 35V HH 77
19. P DWN DW OUS 465 WWW IR E CLCOM Loi 11 TITLE 5 CM DW SCH POWER SUPPLY DC OUTPUT LM358 UNCONTROLLED THESE DRAWINGS AND SPECIFICATIONS ARE THE PROPERTY OF PE DWG NO REV 77 UNLESS OTHERWISE MARKED IN RED INK BY CM AS A INTERNATIONAL RADIO AND ELECTRONICS CORP DISTRIBUTION B CONTROLLED COPY COPIES OF THESE DOCUMENTS AND ARE NOT TO BE REPRODUCED COPIED OR USED AS THE BASIS 200983 SCH INCLUDING ASSOCIATED ELECTRONIC REPRODUCTIONS FOR THE MANUFACTURE OR SALE OF APPARATUS OR ARE FOR REFERENCE ONLY DEVICES WITHOUT PERMISSION FILENAME 200983 5 SCALE NONE PROJ 533 SHEET OF I B_L_SHT1_A DOT REV A 1 3 4 5 6 7 8 Reference Drawings 6 7 8 9 enue 5 1950 00 EXCITER RF INPUT BE RF INPUT PA DC POWER Ribbon Cables 251 REMOTE PA Roun lt SUP ENTAL OsuB RF REFLECTOMETER SPLITTER SOOW MODULE 1 RF OUTPUT FILTER REFLECTOMETER BACKPLANE DISTRIBUTION DC DISTRIBUTION AND FUSE _ uu MODULE 4 METERING REMOTE amp CONTROL NPUT FWRD amp REV POWER PWA SUPPLY CNTRI CCA Illustration 6 5 PA2000 Block Diagram PA RF OUTPUT 7 R2 47PF NPO R4 82 m RF BNC 1 OUTPUT R3 R1 10 82 EL S
20. PA2000 10 Connect the DC input output cables between the PA2000 and the PS2000 as illustrated Illustration 2 4 The connector end with the ground lead con nects to the PA2000 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 PA2000 and the PS2000 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 connec tor into the female Hubble connector on the PS2000 and turn to the right until the connection locks 2 6 Remote I O Connection The Remote 1 0 Connector the back of the PA2000 allows remote control and monitoring of Certain transmitter functions There three basic control func tions 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 1 0 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 Thelimit 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
21. R 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 70 80 watts of input drive is CAUTION Possible equipment damage Do not exceed 80 watts of input drive Damage to the PA2000 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 X PowerOut PAS Antenna Pat PAS PAB PAT PAB B PATemp O PAB RF Drive SWR PAVoltage PAT PA Temp 3 PAB rm O ec 2000 Illustration 3 8 Fault Indicators Operation 3 7 3 5 Fuse Indicators The PA2000 consists of four field replacable power modules with two amplifiers in each module If a module fails it may bereplaced whilethe unit continues to opera
22. afety 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 A WARNING Severe shock hazard Type of Hazard Turn power off and Pictorial Indicatio wait approximately 1 Explanation of Hazard minute for capacitors of Hazard CF to discharge before handling them Illustration 1 3 Sample Hazard Alert 1 4 FM2000A User s Manual Section 2 Installation This section provides important guidelines for installing your power amplifier and power supply Review this information care fully for proper installation Installation 2 1 2 1 Operating Environment You can install the FM2000A ampli
23. d attempt troubleshooting 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 15 not between 0 8 and 1 2 volts then Check the exciter to ensure proper power input level of 70 80 watts 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 effects of inclement weather such as icing on the antenna and feed line for moisture in the feedline insecure antenna connections 5 2 3 ALC Automatic Level Control If this indication is not between 4 00 and 6 00 volts for 2 2 kW output then Check for overheating see PA Temp fault LED Check for overcurrent see DC fault LED Check for high SWR see Antenna fault LED 5 2 4 Power Out This reading is user adjustable but for full output should read 2 20 for 2 2 kW If lower than desired check for proper input drive and or proper adjustment of the Local Power Control see section 3 1 Troubleshooting 5 3 TROUBLE 5 2 5 Temp The meter should read between 35 50 with an ambient temperature of 25 If temperature is 75 C or above then check and do the following Ambient temperature higher than 50 reduce temperature Res
24. d 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 Expedite Shipment Other ENCLOSE WITH UNIT DO NOT M AIL SEPARATELY Service and Support 7 5 Glossary The following pages define terms and abbreviations used throughout this and other Crown Broadcast manuals Glossary G 1 ALC AM bandwidth BCD BFO BNC broadband carrier crosstalk density program deviation DIP distortion DPM EPROM ESD Audio Frequency the frequencies between 20 Hz and 20 kHz in the electromagnetic spectrum Automatic Level Control Amplitude Modulation the process of impressing information on a radio frequency signal by varying its amplitude The range of frequencies available for signalling Binary Coded Decimal a digital system that uses binary codes to represent decimal digits Beat Frequency Oscillator A bayonet locking connector for miniature coax said to be short for Bayonet Neill Concelman As used in the FM transmitter refers to the entire audio spectrum as opposed to the spectrum influ enced by the pre emphasis also called Wideband A continuous si
25. e units 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 PS2000 weighs approximately 43 pounds 19 5 kg the PA2000 approximately 57 5 pounds 26 1 Use help to install Ensurethat the PS2000 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 Install the exciter source such as a Crown Broadcast FM 100 according to its instructions Connect the RF input cable from the exciter source to the N connector on the back of the PA2000 Connect the RF output cable from the antenna to the 7 8 EIA or 7 16 DIN connector on the back of the PA2000 Connect one end of the supplied control cable to the 9 pin D sub connector on the PA2000 Connect the other end of the control cable to the 9 pin D sub connector on the PS2000 RF Mpnitor Optional Gonnection p bibl Illustration 2 4 Rear Panel Connections Installation 2 5 8 Using the supplied connector tie together pins 6 and 7 of the Remote 1 0 connector The amplifier will not operate without this connection or a remote switch on these pins See Section 2 6 for Remote 1 0 connection 9 If monitoring of the output signal is desired connect the RF monitor cable to the BNC connector on the
26. equirement RF Output I mpedance Maximum SWR Frequency Range RF Harmonics Spurious Products Asynchronous AM S N Ratio Synchronous AM S N Ratio Operating Environment Temperature Range Humidity Range AC Power Power Consumption Power F actor Overall Efficiency RF Output Connector Power Amplifier Chassis Power Supply Chassis Weight 200 to 2200 watts continuous with controlled power adjust with remote controlled power capability 50 70 watts for full output 50 watts unbalanced 1 7 1 With power foldback at high SWR 87 108 MHz Better than 80 dB Better than 55 dB with 10096 modulation 9 400 Hz no de emphasis no FM modulation typically gt 60 dB Better than 55 dB with 100 modulation 400 Hz no de emphasis FM modula tion 75 kHz 400 Hz typically gt 60 dB 0 50 C at sea level 0 80 at 20 C noncondensing 240 volts AC 10 15 50 60 Hz 2800 watts at 2000 watts RF output typical 96 typical 70 typical 7 8 inch EIA flange 7 16 inch DIN optional 7 17 25 x 23 inches 17 78 x 43 82 x 58 42 cm exclusive of rack ears but inclusive of connectors 5 25 x 17 25 x 23 inches 13 34 x 43 82 x 58 42 cm exclusive of rack ears PA2000 57 5 pounds 26 1 kg RF PA Modules 8 pounds 3 6 kg each PS2000 43 pounds 19 5 kg Note System performance is specified using Crown Broadcast Model FM100 Exciter where applicable Getting Acquainted 1 3 S
27. ere Moab ubt 4 3 4 1 4 Output Filter amp Reflectometer sss 4 8 4 1 5 Metering and Control Board ott ein 4 4 4 1 6 DC Fuse and Power Distribution Board sene 4 4 Io DET CPC 4 4 4 2 PS2000 Power 1 m to toi tte ente tui 4 5 421 AC Input Board ue e ar E al ah 4 5 422 Power Factor Correcting Switching 4 5 42 42 DO Board cuui so boston e 4 6 424 Cooling FANS 4 6 Section 5 Troubleshooting 5 1 Troubleshooting Flow Chart Analysis crs eie ee tne 5 2 5 2 1 In Ref Input DUva Hererenbel x sot coton diste potoit 5 3 5 2 2 SWR Standing Wave pto Pet 5 3 5 2 3 ALC Automatic Level 5 3 5244 POWOLOUI 5 3 5 2 Digital Multimeter Parameters osi duet 5 8 529 LINN 5 4 52D gee 5 4 AB uos ud dnd me uud olt qu bv ped E 5 4 R e E ua enum rando 5 4 5 5 531 ANNA PERPE 5 5 Dude STA TIVO ih ihe oka p puc leue e E 5 5 S E Nolte as 5 5 5 3 3 1 Potential Caus
28. ersonnel to diag nose and troubleshoot potential fault conditions in the power amplifier and power supply Troubleshooting 5 1 Troubleshooting Flow Chart Analysis Does your amplifier have output ja mower See Section 3 1 p Initial Power up output at the procedures proper level i d z Do you have Y No gt iid A power now Is exciter sufficient RF drive li Check In Ref meter reading Ves Is your exciter v y x See Section 3 1 fault Yes No gt Initial Power up indicators BN od procedures d 2 lt Yes gt Antenna See Section 5 3 1 RF Drive See m gt Section 5 3 2 PA Temp See gt Section 5 3 3 PA DC See L Section 5 3 4 5 2 T REA Turn the exciter on Secure all connections to the PS2000 Y Ensure AC input circuit breaker is flipped up Y Ensure main power switch is turned on Y Call Support See Section 8 FM2000A User s Manual 5 2 Digital Multimeter Parameters The following procedures are general in nature for in depth service and repair see the Service amp Support section of this manual WARNING Lethal voltages present Only technically qualified individuals shou
29. es for Non functioning Cooling Fans 5 5 ADU adu aU d 5 6 5 9 5 Indicalors eoe p epp a pp ui 5 6 Section 6 Reference Drawings OT VIO Aesopus ete asad eth bitin 6 2 6 2 Diagrams and Schematics 2 6 3 Section 7 Service and Support misc PEE 7 2 742 24 Hour 5 cuiu V o ob E e E b E RR 7 2 ue Nuit SN r 7 2 Glossary Index Section 1 Getting Acquainted This section provides a general description of the FM2000A 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 Your Amplifier Package The FM2000A is a highly efficient amplifier package designed to set a new standard in FM transmitter design offering modularity ease of use and long term reliabil ity The FM2000A package includes a PA2000 amplifier PS2000 power supply and an FM2K accessory pack The PA2000 broadband amplifier requires no tuning and typically provides 8096 RF efficiency across the band The PS2000 power supply is power factor corrected and 90 efficient Modern MOSFET technology ensures high AC to RF efficiency better than 7096 overall and long term reliability The unmatched efficiency of this power amplifier
30. etween 0 8 and 1 2 volts Thisis not a drive dependent amplifier therefore drive must be at a constant level regardless of main output power Note Theunit will not operate until the exciter is active and produces sufficient drive 3 2 FM2000A User s Manual 6 Before power up placethe Local Remote switch located on the Metering amp 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 amp 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 Local Remote Slide Switch ln ee On board Remote 22 Power Adjust Buttons Local Power Adjust Pot Illustration 3 2 Local Power Adjust 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 Air Intakes Filters zm mam crown 5 6 9 O0 5 Power Switch Illustration 3 3 PS2000 Front Panel Functions 8 Check the PA2000 parameters with the Digital Multimeter for a current Tot Current of 42 to 48 amps and a voltage PA Voltage of 32 to 36 volts If parameters are within range increase the Local Power Adjust to the maximum level of desired ope
31. fier 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 Q 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 Ooo 2 3 Unpacking Before handling any exposed printed circuit boards ground yourself with antistatic strap and or mat CAUTION Possible equipment damage 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 FM2K accessory kit is packed inside one of the two power amplifier module boxes For added protection both the PA2000 amplifier and PS2000 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 Savethe boxes and packaging material that the individual units are packed i
32. frequencies in the 30 to 300 MHz range Voltage Standing Wave Ratio see SWR See broadband 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 B Backplane Assembly 4 3 Backplane DC Interconnect Board 4 3 Board Layouts 6 3 Circuit Breaker 3 4 Combiner Board 4 2 Connections 2 5 Connectors Hubble Twist Lock amp 2 4 Hubble Twist Lock 2 6 connectors 2 5 D DC Fuse and Power Distribution Board 4 4 DC Output Board 4 6 DC Power Switch 3 5 Digital Multimeter 3 6 5 3 E Efficiency 1 3 efficiency 1 2 exciter 1 2 F Fans 4 4 4 6 5 5 Fault Indicators 3 7 5 5 Frequency Range 1 3 Fuse Indicators 3 8 H Humidity Range 1 3 In Ref 3 4 5 3 Input Divider Board 4 3 Installation 2 5 Interlock Switch 3 5 L labels 1 4 M Metering and Control Board 4 4 multimeter display 3 4 0 operation 3 2 Output Combiner Board 4 3 Output Filter amp Reflectometer 4 3 P DC 5 6 PA Temp 3 4 5 4 PA Voltage 5 4 parts spares 7 2 PFC Power Factor Correcting Switching Board 4 5 power adjust 3 3 3 4 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 remote 1 0 2 7 repair warranty 7 3 RF Drive Requirement 1 3 RF Harmonics 1 3 Index 1 RF Output Impedance 1 3 RF output power 1 2 RF Power Output 1 3 RF power output 1 2 RU spaces 1
33. gnal which is modulated with a second information carrying signal 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 A high average of modulation over time The amount by which the carrier frequency changes either side of the center frequency Dual In line Package term used to describe an IC or socket that has two parallel rows of pins The unwanted changes in signal wave shape that occur during transmission between two points Digital Panel Meter Erasable Programmable Read Only Memory Electrostatic Discharge a discharge that is potentially distructive to sensitive electronic components FM2000A User s Manual exciter FET frequency synthesizer FM FSK gain reduction harmonics HF Highband IC I O LED modulation MOSFET nearcast PA Glossary 1 A circuit that supplies the initial oscillator used in the driver stage 2 A transmitter con figuration which excludes stereo generation and audio processing Field Effect Transistor A circuit that generates precise frequency signals by means of a single crystal oscillator in conjunc tion with frequency dividers and multipliers Frequency Modulation the process of impressing information on a radio signal by varying its fre quency Frequency Shift Keying an
34. he same circuit of the PS2000 There are two potential causes for a non function ing fan or fans 1 Ifa single fan does not operate the fan is faulty and must be replaced See Section 7 Service amp Support 2 If none of the fans operate a blown circuit breaker a short circuit in the PS2000 or a damaged winding on the main transformer of the DC Output Board in the PS2000 is the cause In this case do one of the following Troubleshooting 5 5 TROUBLE a 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 Discrepancy in current between the individual amplifiers or in total current Thereis 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 amp Support Thereistoo much total current power foldback will occur above maximum total amperage of 65 amps due to some malfunction For antenna mismatch check for arcing
35. ight cavity over Power Modules A and B TheDC Fuse and Power Distribution Board takes power direct from the power supply through one 80 amp power line divides it into eight separate DC power lines and distributes it to the eight power amplifiers Metering resistors in each of the eight power lines monitor the current drawn by each of the eight amplifiers to ensure proper function for monitor and control of the unit 4 1 7 Cooling Fans two cooling fans located in the back of the PA2000 powered by the PS2000 Thefans operate 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 F ilter cir cuits and then out through the air vents on the side panels If a fan fails the amplifier will fold back power to prevent overheating 2000 User s Manual 4 2 PS2000 Power Supply The PS2000 supplies power to the PA2000 by converting single phase 240 VAC into 50 VDC The PS2000 is protected by a 20 A double pole circuit breaker This highly efficient power supply utilizes switching technology and is power factor corrected The PS2000 consists of three printed circuit boards described below 4 2 1 AC Input Board The AC Input Board is located on the left side of the 52000 AC power from the circuit breaker connects to the AC Input Board where it connectsto a 12 volt DC powe
36. king 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 ensuresthat the transformer output voltage and current are correct for providing the selected RF output power to the amplifier Principles of Operation 4 5 4 2 3 DC Output Board The DC Output Board 15 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 PS2000 and the PA2000 Therearetwo parallel paths from the DC Output Board with half the power going through each set of output cables These cables come together at theterminal in back of the unit providing the maximum output power of 50 volts at 60 amperes 4 2 4 Cooling Fans There aretwo cooling fans located in the front section of the PS2000 Their pri mary 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 PS2000 The fans have a dedicated circuit breaker located on the back panel of the power supply FM2000A Users Manual Section 5 Troubleshooting This section describes procedures for service p
37. l power amplifier fuses 1 8 replace as indicated by red LED Reduced power output check all fault indicators and troubleshoot accord ingly FM2000A User s Manual 5 3 Fault Indicators If one of the LED fault indicators is illuminated red troubleshoot using the follow ing suggestions 5 3 1 Antenna Antenna mismatch Effects from inclement weather conditions such as icing Check for moisture in the feedline Secure antenna connections 5 3 2 RF Drive Denotes lack of or insufficient drive level Ensure proper drive level of 70 80 watts input power Check RF input cable for secure connection 5 3 3 Temp Temperature has reached the internal preset limit for safe operation 75 C Ambient temperature higher than 50 C reduce temperature Q Restricted air flow remove any obstructions clean dirty air filters by using mild detergent and warm water Q 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 amp 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 PA2000 and the PS2000 have two cooling fans each All fans are powered by t
38. laims 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 Notes 7 4 FM2000A User s Manual Factory Service 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 an
39. lectromagnetic spectrum between audio fre quency and the infrared portion 2 A frequency useful for radio transmission roughly 10 kHz and 100 000 MHz Subsidiary Communications Authorization see subcarrier Signal to Noise Unintended signals present on the transmission output terminal A tolerance or measure of how well a component circuit or system maintains constant operating conditions over a period of time See pilot The amount of left channel information that bleeds into the right channel or vice versa A carrier signal which operates at a lower fre quency than the main carrier frequency and which modulates the main carrier The process used to hold back or stop certain frequencies FM2000A User s Manual SWR THD translator satellator UHF VCO VHF VSWR Wideband Glossary 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 Total Harmonic Distortion A transmitter designed to internally change an FM signal from one frequency to another for retransmission Used in conjunction with terres trial fed networks A transmitter equipped with an FSK ID option for rebroadcasting a satellite fed signal Ultra High Frequency frequencies in the 300 to 3000 MHz range Voltage Controlled Oscillator Very High Frequency
40. llation 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 Useround 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 Slidethe cover onto the cord Remove insulation from cable and conductors as shown in Illustration 2 3 Do not tin conductors 1 Inch lt 25 gt gt 16 Illustration 2 3 Cover Cable amp Conductors 4 Loosen terminal screws Insert conductors fully into proper terminals ac cording to the table below Take caution that there are no stray wire strands Terminal Green Hex Head Screw Equipment grounding 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 of torque 6 Tighten assembly screws to 10 pound inches 1 1 of torque 7 Tighten cord clamp screws to 10 pound inches 1 1 of torque A WARNING Possible Electric Shock Hazard Do not connect AC source until all other connections are made and installation is complete 2 4 2000 User s Manual 2 5 Installation gt e Mount th
41. m LO E 27V0C 12 A E REM SWR ou SPARE n In i AMP2 PWR PAIS LO EE DER Pror T 25 27VDC AMP D PAI7 LO AMP2 DC PWR 15 Pu e m AMPS DC PWR 17 sa AMPE DC PWR PAI4 LO AMPG DC PWR REM PA VOLTS REM PA ALC REM 1 REM EWR REM _ PAM LO wn b T sls AMP PWR J3 REMOTE REM RF PWR REM PWR aeu sur TUETM DC PWR PAI6 LO HI PWR ne c ETT ME ETE j ALI 22 02 REM RF DRIVE 25 AMPI Dc PWR err E quem cem cu EE ITE Cr ____ 2 aeu ews m PHT j gor mre REM ALC Q d n REM 132 a a 59 ame cM SEE m PA VOLTS SENSE K ames oc ecw ean Ege gs E REM PAIS MEM BATTERY 71 error EET 4 4l Note All bypass capacitors are 0 01 mf Backplane Distribution 6 13 FM2000A User s Manual Reference Drawings Ribbon Cables and Connectors Lr MEL M REMOTE PA8 Current Monitor Input Power Reference 14 PA7 Cu
42. mmary the voltage from this pin goes to 5 V if any fault occurs and drops below 2V when the fault goes away Em Ground 10 ALC the voltage from this pin is a direct reading of automatic level control voltage not buffered 11 PA Temperature a buffered metering output with 1 V 2 20 C 12 SWR a buffered metering output with a calculated reading of standing wave ratio in VDC 13 RF Output Power a buffered metering output with a calculated reading of output power of 1 V 2 1000 W 14 Input Power Reference a buffered metering output with a DC voltage representing input power Remote LOWER Power a momentary switch on this pin when held low will lower the power level 10 watts every 0 5 seconds 16 PA 6 Current Monitor a buffered metering output with 1 V 2 A 17 PA 5 Current Monitor a buffered metering output with 1 V 2 A 18 Ground 19 PA 4 Current Monitor a buffered metering output with 1 V 2 A Current Monitor a buffered metering output with 1 V 2 A 21 Ground PA 2 Current Monitor a buffered metering output with 1 V 2 A PA 1 Current Monitor a buffered metering output with 1 V 2 A PA Total Current Monitor a buffered metering output with 1 V 2 20 A PA Volts a buffered metering output with 1 V 2 10 V Note Power Amplifier Remote 1 0 Connector Pinout Table 2 8 FM2000A User s Manual Section 3 Operation This section provides general operating parameters of you
43. n should you need to return them for factory service 2 2 FM2000A User s Manual 2 4 Preinstallation 2 4 1 Power Amplifier Modules The PA2000 incorporates four power amplifiers two each in two modules Dueto possible damage during shipment the power modules have been removed Follow these steps to install the modules 1 Remove the front panel of the PA2000 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 Slide Rail Illustration 2 1 Power Amplifier Module 3 The warning labels on the front of the modules should all be positioned to the center of the chassis also note the position of the connector on the modules and in the chassis 4 Insert the four power modules using their slide rails into the built in chan nels of the right side cavity and two upside down in the left cavity as shown below Note that the connectors and warning labels are nearest the middle wall or partition of the PA2000 n n ry ry y s e 3 Module A amps 3 amp 4 Module C amps 5 amp 6 Module D am ps 7 amp 8 Middle Partition Illustration 2 2 Power Amplifier Module Placement 5 Besurethe modules are pushed in completely so that the connector makes proper contact 6 Replace the front panel of the PA2000 Insta
44. oducts Before returning a product for repair or replacement our choice call our Customer Service department using the following telephone number 866 262 8915 Our Customer Service Representative will give you further instructions regarding the return of your product Usethe original shipping carton or a new one obtained from Crown Place shipping spacers between the slide out power amplifier assem bly 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 8915 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 8915 You may also writeto the following address Service Manger International Radio and Electronics Company Inc 25166 Leer Drive Elkhart Indiana U S A 46514 5425 7 2 FM2000A User s Manual Crown Broadcast Three Year Limited Product Warranty SUMMARY OF WARRANTY Crown Broadcast IREC warrants its broadcast products
45. 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 PA2000 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 1 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 PA2000 1 Connector on the power amplifier is described in the following diagram 13 1 0000000000000 000000000000 25 14 Illustration 2 7 Remote I O connector back panel view The Remote 1 0 Connector Pinout Table on the next page summarizes the Remote pin connections Installation 2 7 Function 8 Current Monitor a buffered metering output with 1 V 2 A 7 Current Monitor a buffered metering output with 1 V 2 A Ground 4 Remote RAISE Power a momentary switch on this pin when held low will raise the power level 10 watts every 0 5 seconds power output level below internal limits See Section 2 6 page 2 7 6 Ground 7 Remote AC Power On a latching switch on this pin when held low will turn the AC power supply on Remote RF Power Control a resistor to ground on this pin reduces RF Fault Su
46. r power amplifier system and a detailed description of the front panel display Operation 3 1 Initial Power up Procedures These steps summarizethe operating procedures you should usefor the initial operation of the power amplifier and power supply of the FM2000A 1 Ensurethat the external remote control unit is properly connected See Section 2 6 and the pin out description table on page 2 8 for proper pin configuration If not using a remote control unit pin 7 must betied to ground pin 6 2 Connect Antenna 3 If using an external remote control enable the power supply via the remote 1 0 connector 4 Turn on set to 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 Fan AC Input PA1000 Circuit Breaker Circuit Breaker 19 GOD DC O tp t PS2000 Air Exhaust Vents 240 VAC IN Illustration 3 1 PS2000 Back Panel Functions 5 Turn on the exciter a Crown FM100 or equivalent and adjust its RF power output level until theIn Reference In Ref voltage as indicated on the PA2000 front panel Digital Multimeter is b
47. r 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 disc
48. r supply and three relays The 12 volts is used to closethethree relays when the DC Power Switch on the front panel is switched on In addition the 12 volts are supplied to the PA2000 for use in the Control and Metering Board The 240 volt 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 inductorsto a bridge rectifier that converts the current to DC Power and from thereto the PFC Switch ing 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 PS2000 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 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 bloc
49. ration Note TheLocal Power Adjust pot is unconventional CW lowers power Operation 3 3 9 Place Local Remote switch see Illustration 3 2 in the Remote position and using an external remote control unit connected to the Remote 1 0 connector or the on board remote Raise Lower buttons adjust the PA2000 to the maximum power set by the Local Power Adjust This prevents adjusting to higher than permitted power levels 10 Verify that thefollowing conditions are present as indicated by the PA2000 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 ALC Should read between 4 00 and 6 00 volts for 2 2 kW output less for lower output or danger conditions i e high SWR Power Out Should read 2 20 for 2 2 kW output PA Temp Should read 35 to 50 C with ambient temperature of 25 Theremainder of this section describes the functions of the front and rear panel indicators and switches of the PA2000 and PS2000 3 2 Power Switches 3 2 1 Input Circuit Breaker The PS2000 supplies power to the PA2000 by converting single phase 220 240 VAC into 50 VDC The PS2000 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 L rgs Power fo
50. rethey are processed for power control and metering and for SWR metering and protection Principles of Operation 4 3 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 opera tion 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 Protec tion 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 F M2000A and can be removed for repair replacement if necessary 4 1 6 DC Fuse and Power Distribution Board This board is located above the r
51. rmation needed to supply proper drive to each of the eight amplifiers 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 power amplifier modules so that ultimately all the power comes together at one common point junction Here the currents and voltages of all four power amplifier modules arein 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 amp Reflectometer The Output Filter Reflectometer is located behind the Backplane Assembly in the center of the PA2000 Seethe accompanying schematic in Section 6 for more information Theninth order elliptic low pass filter attenuates harmonics generated in the power amplifier The capacitors for the filter are circuit board pads reflecto meter uses printed circuit board traces for micro strip transmission lines Trans mission 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 whe
52. ro 240 VAC IN Illustration 3 4 AC Input Circuit Breaker 3 4 FM2000A User s Manual 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 etl Broadcast M EE 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 WARNING Interlock Switch Illustration 3 6 Interlock Switch Operation 3 5 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 PowerOu PAS Antenna Multimeter Metering Selection Buttons Metering Indicators 5 PA Temp RFDrive SWR PAVoltage PAT PATemp PAB
53. rrent Monitor Lower Power iround ent Monito PA ent Monito RF Power Control 4 Current Monitor AC Power ON Current Monitor Fault Summa b 2 Current Monitor ALC gt PA1 Current Monitor lempera PA Total Current Monitor SWR PA Volts H 000 W DB CONNECTORS VIEWED FROM INSIDE CHASSIS FEMALE DB9 10 CONDUCTOR PWR SUP CONTROL RIBBON gt 12 REMOTE DON FM2000 BACKPLANE BOARO VIEWED FROM CHASSIS FRONT 5 7 9 1 i3 9 9 9 23 3 0099209 899 22 29 29 PWR SUP ON_FMLOOO BACKPLANE BOARD VIEWED FROM CHASSIS FRONT CHASSIS LEFT Ribbon Cables and Connectors Tu lv 1 DM ies
54. 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 Installa tion is made simple with just three interconnections between the amplifier and power supply In addition built in digital metering and status indicator capabili ties enable intuitive operation to further augment the user friendly design Economic long term reliability is ensured through our carefully engineered solid state design The PA2000 features four field replaceable 500 watt power modules This power amplifier delivers 500 to over 2000 watts of RF power output Use your existing exciter or purchase the FM2000T which includes our award winning FM100 exciter for an unbeatable 2 kW transmitter package E D Dive x Oo Oo Oo Oo Oo esee e reour oasen ESU een PA20 C ro urn e e e e e PA2000 o 2820000 Illustration 1 1 FM2000A Amplifier Package 1 2 FM2000A User s Manual 1 2 Amplifier Package Specifications RF Power Output RF Drive R
55. 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 1 0 Connector can adjust 5V R62 MAXIMUM LOCAL E 9 POWER ADJUST MINIMUM REMOTE RAISE POWER Electro LOCAL TANSMITTER Pin4 Control CONTROL Remote I O Conn SW3 1 Circuit SW5 RAISE REMOTE NU REMOTE LOWER POWER 15 Remote I O Conn sw4 LOWER Illustration 2 5 Local and Remote Functions 2 6 FM2000A 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 amp SW4 and the Local Remote slide switch SW5 are shown below Local Remote Slide Switch On board Remote p Power Adjust Buttons Local Power Adjust Pot Illustration 2 6 On board Remote Power amp Related Controls Another remote control function available at pin 5 of the Remote 1 0 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
56. te at a reduction in output power Each of the paralleled amplifiers is protected by a 10 ampere fast acting fuse When a fuse opens the indicator light next to it comes illuminates and built in redundancy allows the unit to continue operation The fuse can be replaced while the unit is operating Fuses 1 and 2 represent amplifiers 1 and 2 on thetop left module Fuses 3 and 4 represent amplifiers 3 and 4 on thetop right module Fuses 5 and 6 represent amplifiers 5 and 6 on the lower left power module Fuses 7 and 8 represent amplifiers 7 and 8 on the lower right power module Fuses and Indicators PAS Antenna PAS PAT PAB np PP o PAB RFDrive rer US Go 6 irrent PAS PAB 1 st o FM POWER AMPLIFIER Illustration 3 9 Fuse Indicators 3 8 FM2000A User s Manual due pers ndo che ci insegn ol con 8 egna E qe joe che non ha la dispoziong due persone ondo ero che a E d c e nulla yes wet aede LL ee
57. tion 6 3 FM2000A Block Diagram Reference Drawings 6 3 7 9 enue N sasn 00 AC INPUT AC 240 VAC CIRCUIT BREAKER NEUTRAL GROUND DSUB PS CONTROL AC INPUT CCA SWITCH 220 12 VDC VOLTAGE BOOST INDUCTOR Illustration 6 4 PS2000 Block Diagram 360 VDC 360 VDC CONTROL DC OUTPUT CCA 0 to 50 VDC RETURN 215 Eu VR1 LM2586 ADJ D3 1N4004 HD3 HEADER 5X2 1 RESISTORS ARE IN OHMS 1 4W 5 UNLESS OTHERWISE D4 1N4004 2 ALL CAPACITORS ARE D5 To DC OUTPUT BOARD MICROFARADS UN 2N5822 OTHERWISE SPECI i POWER 2 From Switcher Board R8 10K Q2 Q1 5 IRFD9113 DC Power IRFD9113 FRONT PANEL 4 xk 4 MOV1 m V217HA40 K1 RELAY 24V C6 47 RELAY 24V 250VAC e 2 0033 MOV2 250VAC V271HA40 V271HA40 V271HA40 C3 K2 1 5UF 630V RELAY 24V D1 D2 1N4004 1N4004 INTERNA TINAL ADIT AND ELE gt S586 LES Ove SLR GS _ REAR PANEL SCH FM2K POWER SUPPLY AC INPUT es THESE DRAWINGS AND SPECIFICATIONS ARE THE UNCONTROLLED PROPERTY OF INTERNATIONAL RADIO AND UNLESS OTHERWISE MARKED IN RED INK BY
58. tricted 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 Voltage Supply voltage to the RF power amplifiers should be 50 V If itis not check drive level to ensure proper power level input of 70 80 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 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 65 amperes then check or do the following Reduce power output check all fault indicators and troubleshoot accordingly If one or more of the 500 watt power modules has failed replace High SWR check for icing moisture in the feedline and secure antenna connections 5 2 8 1 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 individua
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