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Power Base-2 & 800CSL Amplifier Service Manual

8

Theory

OVERVIEW

It should be noted from the outset that the PB-1 and
460CSL amplifiers are electrically and mechanically
identical products. The only differences, from a ser-
vice perspective, are cosmetic. For the purposes of
servicing the products, it should also be known that
the CSL version has been on the market since 1992.
Since the PB amplifiers have been in production since
the mid-1980’s there are a number of electrical and
mechanical parts associated with the older PB models
only. It is also important to realize that over time Crown
has introduced numerous improvements to PB/CSL
amplifiers. Though often changes are minor, and are
made for a variety of reasons, a few changes have had
a significant impact on the operation of the circuitry.
This manual is up to date as of the time of writing. For
additional information regarding these amplifiers, re-
fer to the applicable Technical Notes provided by
Crown for this product.

This section of the manual explains the general opera-
tion of a typical Crown power amplifier. Topics cov-
ered include Front End, Grounded Bridge, and ODEP.
Due to variations in design from vintage to vintage
(and similarities with other products Crown) the theory
of operation remains simplified.

FEATURES

Power Base/CSL amplifiers utilize numerous Crown
innovations including grounded bridge and ODEP
technologies. Cooling techniques make use of the
what is essentially air conditioner technology. Air flows
bottom to top, and front to side. Air flows a short
distance across a wide heatsink. This type of air flow
provides significantly better cooling than the “wind
tunnel” technology used by many other manufactur-
ers. Output transistors are of the metal can type rather
than plastic case. This allows for a significantly higher
thermal margin for the given voltage and current
ratings. All devices used are tested and graded to
ensure maximum reliability. Another electronic tech-
nique used is negative feedback. Almost all power
amplifiers utilize negative feedback to control gain
and provide stability, but Crown uses multiple nested
feedback loops for maximum stability and greatly
improved damping. Most Crown amplifiers have damp-
ing in excess of 1000 in the bass frequency range. This
feedback, along with our compensation and ultra-low
distortion output topology, make Crown amplifiers
superior.

Features specific to the Power Base/CSL Series’ in-

clude a single core transformer (one primary with two
independent ungrounded secondaries), a full time full
speed fan which also serves as the low voltage
transformer, slew rate limiting, and audio muting for
delay or protective action. This amplifier can operate
in either a Bridged or Parallel Mono mode as well as
dual (stereo). A sensitivity switch allows selection of
input voltage required for rated output. Level controls
are rear mounted. The only indicator provided tells the
operator that the low voltage supply is energized. In
general, the packaging of this model is designed for
maximum watt/price/weight/size value. It is the most
basic grounded bridge amplifier series now available
from Crown.

For additional details refer to the specification section,
or to the applicable Owner’s Manual.

FRONT END OPERATION

The front end is comprised of three stages:  Balanced
Gain Stage (BGS), Variable Gain Stage (VGS), and
the Error Amp. Figure 1 shows a simplified diagram of
a typical front end with voltage amplification stages.

Balanced Gain Stage (BGS)

Input to the amplifier is balanced. The shield may be
isolated from chassis ground by an RC network to
interrupt ground loops (early models did not have the
Ground Lift feature) via the Ground Lift Switch. The
non-inverting (hot) side of the balanced input is fed to
the non-inverting input of the first op-amp stage. The
inverting (negative) side of the balanced input is fed
to the inverting input of the first op-amp stage. A
potentiometer is provided for common mode rejection
adjustment. Electrically, the BGS is at unity gain.
(From an audio perspective, however, this stage
actually pr6dB gain if a fully balanced signal
is placed on its input.) The BGS is a non-inverting
stage. It’s output is delivered to the Variable Gain
Stage.

Variable Gain Stage (VGS)

Note:  Older models only had two front end stages.
The functions of this stage were combined, primarily,
with those of the third.

From the output of the BGS, the signal goes to the VGS
where gain is determined by the position of the Sen-
sitivity Switch, and level is determined by the level
control. VGS is an inverting stage with the input being
fed to its op-amp stage. Because gain after this stage
is fixed at 26dB (factor of 20), greater amplifier sensi-

Summary of Contents for 800 CSL

Page 1: ...IFIER SERVICE MANUAL K SVCPB2 1 95 CSL is a trademark and Power Base 2 ODEP and Crown are registered trademarks of Crown International Inc MailingAddress P O Box 1000 Elkhart IN U S A 46515 1000 ShippingAddress 57620 C R 105 Elkhart IN U S A 46517 1995 by CROWN INTERNATIONAL INC ...

Page 2: ...O ACCESS GAIN SWITCH CAUTION AVIS WARNING TO REDUCE THE RISK OF ELECTRIC SHOCK DO NOT EXPOSE THIS EQUIPMENT TO RAIN OR MOISTURE The information furnished in this manual does not include all of the details of design production or variations of the equipment Nor does it cover every possible situation which may arise during installation operation or maintenance If you need special assistance beyond t...

Page 3: ...Parts Listing 17 Module Information 20 Q42647 0 Output Module MT MA 21 Q42717 1 Output Module MT MA 2 22 Q42871 6 Output Module TO 3P MT MA 23 Q42966 4 Output Module TO 3P 2 24 Q43015 9 Output Module THC 25 Q43203 1 Output Module THC 2 26 Q42665 2 Main Module Original 27 Q42683 5 Main Module 2 29 Q42818 3 Main Module 3rd Gain 31 Q43059 7 Main Module THC 34 Table of Contents ...

Page 4: ...fic circuit board although an unpopulated circuit board may be built up with different parts to create different modules Note that Crown does not sell blank unpopulated circuit boards Each of the compact audio power amplifiers are designed for professional or commercial use Provid ing high power amplification from 20Hz to 20KHz with minimum distortion they feature balanced inputs with bridged and ...

Page 5: ...four character number after the prefix letter the space is considered a character The seventh character is usually a hy phen though it may be a letter to indicate a revision or specialnote Thelastcharacteriscalledacheck digit and is useful to Crown for internal tracking Crown is in the process of converting to a new part number system Length may vary from eight to twelve characters There is still ...

Page 6: ...ate 13V per microsecond Damping Factor 1000 from 10 Hz to 400 Hz DC Offset 10 millivolts Input Impedance Nominally 20K ohms balanced 10K ohms unbalanced Output Impedance 10 milliohms in series with 2 microhenries Protection Systems Output Device Emulation Protec tion ODEP limits drive in the event of dangerous dynamicthermalconditionswithoutinterruptingpower Current limiting for shorted load prote...

Page 7: ...40V Connections P10 to P16 P9 to P14 P8 to P13 For list of applicable transformer fuse F100 fanformer and power cord refer to voltage parts cross reference S1 Power Switch PB CSL Universal Fuse Board Specific parts are required for the PB 2 800CSL in order to be used at different international line volt ages Refer also to Mechanical Parts Lists 100 to 120V AC Mains 20A Fuse A10285 28 0 5A Low Volt...

Page 8: ...bassfrequencyrange This feedback along with our compensation and ultra low distortion output topology make Crown amplifiers superior Features specific to the Power Base CSL Series in clude a single core transformer one primary with two independent ungrounded secondaries a full time full speed fan which also serves as the low voltage transformer slew rate limiting and audio muting for delay or prot...

Page 9: ...r network splits the Error Signal ES into positive and negative drive signals for the bal ancedvoltagetranslatorstage Theseoffsetreference voltages drive the input to the Voltage Translator transistors A nested NFb loop from the output of the amplifier mixes with the inverted signal riding on the offset references This negative feedback fixes gain at the offset reference points and the output of t...

Page 10: ...stage is off Theory Vcc Positive Rail Vcc Negative Rail Load speaker Input signal HIGH SIDE LOW SIDE Inverting Op amp Figure 2 Crown Patented Grounded Bridge Topology The output of the LVA drives the base of predriver device Together the predriver and driver form the first two parts of the three deep Darlington and are biased class AB They provide output drive through the bias resistor bypassing t...

Page 11: ...further from ground poten tial At the negative amplifier output peak Vcc 0V and Vcc equals the total power supply potential with Theory anegativepolarity Usingthesameexampleasabove a 70V supply would allow a negative output peak of 70V In summary a power supply which produces a total of 70VDC rail to rail or 35VDC statically is capable of producing 140V peak to peak at the ampli fier output when t...

Page 12: ...ic power level result in an accurate simulation of the actual thermal condi tion of the output transistors NEGATIVE LOW SIDE OUTPUT PNP STAGE POSITIVE LOW SIDE OUTPUT NPN STAGE NEGATIVE HIGH SIDE OUTPUT PNP STAGE POSITIVE HIGH SIDE OUTPUT NPN STAGE HIGH SIDE BIAS SERVO LVA 1 LVA 1 VOLTAGE TRANSLATOR VOLTAGE TRANSLATOR OUTPUT DEVICE EMULATION PROTECTION ERROR AMP VGS BGS BALANCED INPUTS INVERTING B...

Page 13: ...Initial Conditions Controls per standard heatsink tem perature less than 40 C Procedure Measure DC voltages on the output module across R02 adjust R26 if necessary Measure DC voltages on the output module across R21 adjust R23 if necessary Repeat for second channel TEST 3 ODEP VOLTAGE ADJUSTMENT Spec Cold Bias Per Charts Below 0 1V DC Initial Conditions Controls per standard heatsink at room tempe...

Page 14: ...hin 10 of each other TEST 8 LEVEL CONTROLS Spec Level controlled by level controls Initial Conditions Controls per standard Checkout Procedures Procedure No Load Inject a 1 kHz sine wave With level controls fully clockwise you should see full gain As controls are rotated counterclockwise observe similar gain reduction in each channel When com plete return level controls to fully clockwise position...

Page 15: ...r low frequency Initial Conditions Controls per standard Procedure No load Inject a 0 5 Hz 6 volt peak to peak square wave into each channel and verify that each channel cycles into mute TEST 16 SIGNAL TO NOISE RATIO Spec 100 dB 105 dB A weighted below rated 8 ohm power Initial Conditions Controls per standard Short inputs Procedure Load each channel to 8 ohms Measure less than 400 µV at the outpu...

Page 16: ...all tests are satisfactory the amplifier controls should be returned to the posi tions required by customer If conditions are unknown or unspecified factory settings are as follows Level Controls 9 to 11 O Clock Sensitivity Switch 0 775V U S 1 4V International Stereo Mono Switch Stereo Ground Lift Lift Power Off ...

Page 17: ...10426 8 Fuse Board International Only 1 P10125 6 Fuse Board U S Only 1 FANFORMER MECHANICAL ASSEMBLY CPN ITEM QTY C 7062 0 Screw 6 32 5 16 Flat Mach 2 C 9939 7 Fan Blade 4 inch CCW 1 D 8439 8 Fan Bracket 1 FILTER CAPACITOR MOUNTING ASSEMBLY ONE PER CHANNEL CPN ITEM QTY A10095 4 Washer 10 Ext Lock 2 A10098 5 Belleville Spring Washer 2 C 8433 2 C126 C226 10 000µF 110V 1 C 8752 5 D117 D217 35A 400V B...

Page 18: ...put Thru Hole Pad Insulator 1 D 8197 2 Paper Shroud 1 D 8264 0 PTC Thermal Sensor 1 F12019 0 Diode Heatsink Slug 1 M21324 5 Heatsink Aluminum 2 Output Module See Module List 1 BACK PANEL ASSEMBLY CPN ITEM QTY A10214 7 Strain Relief Power Cord 1 C 2823 0 Dual Binding Post Assembly 1 D 7074 4 Power Cord 3 14 15A USA 1 M21208J9 Back Panel 1 A10019 8 Nut 8 32 2 Captive 2 CHASSIS FRONT ASSEMBLY CPN ITE...

Page 19: ...Pan Ph 2 A10192 1 Snap Bushing 5 4 C 1811 6 Tie Wrap 4 C 3163 0 Solder Lug 6 505 1 C 6487 0 Power Switch 22A Rocker 2 Pole 1 C 6912 7 Tension Retainer Board Support 2 C 6913 5 Spacer Nut 1 inch 2 C 6914 3 Spacer Nut 75 inch 2 C 8341 7 Ferrite Bead 2 C 9491 9 Screw 6 32 312 Taptite Pan 4 C 9953 8 Screw 6 20 312 Taptite Pan Black 6 D 7600 6 Ground Strap DBP to Chassis 1 D 7784 8 Label Sensitivity Sw...

Page 20: ...compensation Also im proved bias stability Q43203 1 THC 2 Output Module Replaces Q42967 2 only Electrically identical but larger screw head plates prevent shorting which could occur with the first THC output module MAIN MODULES Q42665 2 Original Main Module for PB 2 No longer available Q42683 5 Main 2 for PB 2 No longer available Q42818 7 Third Gain Main Module Same circuit board as the universal ...

Page 21: ... 5W R04 C 6486 2 2 5W R06 C 6486 2 2 5W R07 C 6486 2 2 5W R09 C 7779 9 22 flame proof R10 A10266 4711 470 R11 A10266 2R73 2 7 1W R12 A10266 2R73 2 7 1W R13 A10266 7501 75 R14 A10266 2R73 2 7 1W R16 C 6486 2 2 5W R17 C 6486 2 2 5W R19 C 6486 2 2 5W R20 C 6486 2 2 5W R21 C 7778 1 5 6 flame proof R22 C 7779 9 22 flame proof R23 C 6844 2 250 Pot LS Bias R24 A10266 1331 13K R25 A10266 2221 2 2K R26 C 6...

Page 22: ...79 9 22 5W Flame Proof R10 A10266 4711 470 R11 A10266 2R73 2 7 1W R12 A10266 1204 12 2W R13 A10266 7501 75 R14 A10266 1204 12 2W R15 C 6486 2 2 5W R16 C 6486 2 2 5W R17 C 6486 2 2 5W R18 C 6486 2 2 5W R19 C 6486 2 2 5W R20 C 6486 2 2 5W R21 C 7778 1 5 6 5W Flame Proof R22 C 7779 9 22 5W Flame Proof R23 C 6844 2 250 Pot LS Bias R24 A10266 1331 13K R25 A10266 2221 2 2K R26 C 6844 2 250 Pot HS Bias R...

Page 23: ...2R73 2 7 1W R12 A10266 1204 12 2W R13 A10266 7501 75 R14 A10266 1204 12 2W R15 C 6486 2 2 5W R16 C 6486 2 2 5W R17 C 6486 2 2 5W R18 C 6486 2 2 5W R19 C 6486 2 2 5W R20 C 6486 2 2 5W R21 C 7778 1 5 6 flame proof R22 C 7779 9 22 flame proof R23 C 6844 2 250 Pot LS Bias R24 A10266 1331 13K R25 A10266 2221 2 2K R26 C 6844 2 250 Pot HS Bias R27 A10266 3911 390 R28 A10266 1331 13K R29 A10266 5101 51 R3...

Page 24: ...e proof R10 A10266 4711 470 R11 A10266 2R73 2 7 1W R12 A10266 1204 12 2W R13 A10266 7501 75 R14 A10266 1204 12 2W R15 C 6486 2 2 5W R16 C 6486 2 2 5W R17 C 6486 2 2 5W R18 C 6486 2 2 5W R19 C 6486 2 2 5W R20 C 6486 2 2 5W R21 C 7778 1 5 6 flame proof R22 C 7779 9 22 flame proof R23 C 6844 2 250 Pot LS Bias R24 A10266 1331 13K R25 A10266 2221 2 2K R26 C 6844 2 250 Pot HS Bias R27 A10266 3911 390 R2...

Page 25: ...711 470 R11 A10266 2R73 2 7 1W R12 A10266 1204 12 2W R13 A10266 7501 75 R14 A10266 1204 12 2W R16 C 6486 2 2 5W R17 C 6486 2 2 5W R19 C 6486 2 2 5W R20 C 6486 2 2 5W R21 C 7778 1 5 6 5W Flame Proof R22 C 7779 9 22 5W Flame Proof R23 C 6844 2 250 Pot LS Bias R24 A10266 1331 13K R25 A10266 2221 2 2K R26 C 6844 2 250 Pot HS Bias R27 A10266 3911 390 R28 A10266 1331 13K R29 A10266 5101 51 R30 A10265 10...

Page 26: ...1 A10266 2R73 2 7 1W R12 A10266 1204 12 2W R13 A10266 7501 75 R14 A10266 1204 12 2W R16 C 6486 2 2 5W R17 C 6486 2 2 5W R19 C 6486 2 2 5W R20 C 6486 2 2 5W R21 C 7778 1 5 6 5W Flame Proof R22 C 7779 9 22 5W Flame Proof R23 C 6844 2 250 Pot LS Bias R24 A10266 1331 13K R25 A10266 2221 2 2K R26 C 6844 2 250 Pot HS Bias R27 A10266 3911 390 R28 A10266 1331 13K R29 A10266 5101 51 R30 A10265 10201 102 R3...

Page 27: ... D207 C 2851 1 1N4004 D108 D208 C 3181 2 1N4148 D109 D209 C 3181 2 1N4148 D110 D210 C 3181 2 1N4148 D111 D211 C 5061 4 1N3070 D112 D212 C 3181 2 1N4148 D113 D213 C 3181 2 1N4148 D114 D214 C 3181 2 1N4148 D115 D215 C 3181 2 1N4148 D120 D220 C 3181 2 1N4148 D121 D221 C 3181 2 1N4148 D122 D222 C 3181 2 1N4148 D123 D223 C 5061 4 1N3070 NETWORK RESISTORS N100 N200 D 4669 4 Balanced Input Trim N101 N201...

Page 28: ...0266 2721 2 7K R149 R249 C 7781 5 200 OHM R150 R250 A10266 2721 2 7K R151 R251 A10266 1031 10K R152 R252 A10266 1231 12K R154 R254 A10266 1011 100 OHM R156 R256 A10266 1321 1 3K R157 R257 A10266 1321 1 3K R158 R258 A10266 9121 9 1K R159 R259 A10266 1031 10K R161 R261 A10266 4701 47 OHM R162 R262 A10266 4701 47 OHM R165 R265 A10265 53611 5 36K 1 R146 R246 A10265 53611 5 36K 1 R167 R267 A10266 1021 ...

Page 29: ...uF DIODES D1 C 2851 1 1N4004 D2 C 2851 1 1N4004 D3 C 2851 1 1N4004 D4 C 2851 1 1N4004 D5 C 2851 1 1N4004 D6 C 2851 1 1N4004 D7 C 2851 1 1N4004 D104 D204 C 2851 1 1N4004 D105 D205 C 2851 1 1N4004 D106 D206 C 2851 1 1N4004 D107 D207 C 2851 1 1N4004 D108 D208 C 3181 2 1N4148 D109 D209 C 3181 2 1N4148 D110 D210 C 3181 2 1N4148 D111 D211 C 5061 4 1N3070 D112 D212 C 3181 2 1N4148 D113 D213 C 3181 2 1N41...

Page 30: ...266 1031 10K R147 R247 C 7781 5 200 OHM R148 R248 A10266 2721 2 7K R149 R249 C 7781 5 200 OHM R150 R250 A10266 2721 2 7K R151 R251 A10266 1031 10K R152 R252 A10266 1231 12K R153 R253 C 5869 2 ZERO OHM R156 R256 A10266 1321 1 3K R157 R257 A10266 1321 1 3K R158 R258 A10266 9121 9 1K R159 R259 A10266 1031 10K R161 R261 A10266 4701 47 OHM R162 R262 A10266 4701 47 OHM R167 R267 A10266 1021 1K R168 R268...

Page 31: ...148 C248 C 6810 3 180pF C 149 C249 C 6808 7 470pF C152 C252 C 6809 5 220pF C153 C253 C 6804 6 1uF DIODES D1 C 2851 1 1N4004 D2 C 2851 1 1N4004 D3 C 2851 1 1N4004 D4 C 2851 1 1N4004 D5 C 2851 1 1N4004 D6 C 2851 1 1N4004 D7 C 2851 1 1N4004 D8 C 3181 2 1N4148 D9 C 3549 0 1N916B 10V D104 D204 C 2851 1 1N4004 D105 D205 C 2851 1 1N4004 D106 D206 C 2851 1 1N4004 D107 D207 C 2851 1 1N4004 D108 D208 C 3181...

Page 32: ... R129 R229 A10266 1041 100K R130 R230 A10266 1041 100K R131 R231 A10266 1031 10K R132 R232 C 5062 2 100K TRIMMER R133 R233 A10266 2741 270K R134 R234 A10266 1231 12K R135 R235 C 7782 3 100 OHM R136 R236 A10266 6821 6 8K R137 R237 C 7782 3 100 OHM R138 R238 A10266 6821 6 8K R139 R239 A10266 1021 1K R140 R240 A10266 8201 82 OHM R141 R241 A10266 1541 150K R142 R242 A10266 1541 150K R146 R246 A10266 1...

Page 33: ...J100 J200 C 6777 4 PHONE JACK J500 J800 D 6619 7 10 RIBBON ASSY J600 J700 D 6620 5 6 RIBBON ASSY MISC BOARD D 7251 8 MOUNTS U1 U2 2 C 1889 2 6 32 NUT 2 C 2176 3 6 32 X 5 SCREW 2 C 5341 0 HEATSINK 2 C 5594 4 STAR WASHER MOUNTS U104 U204 2 C 3450 1 14 PIN SOCKET COVERS FOR J100 J200 2 C 6778 2 Phone Jack Cover STRAIN RELIEF 4 C 1811 6 CABLE TIE Q42818 7 Main Module Parts List D 7251 8 Board ...

Page 34: ...10 3 180pF C149 C249 C 6808 7 470pF C150 C250 C 6806 1 01µF Q43059 7 Main Module Parts List D 7993 5 Board C151 C251 C 6806 1 01µF C152 C252 C 6950 7 82pF 5 C153 C253 C 8897 8 1µF C154 C254 C 8426 6 1µF 250V C155 C255 C 8897 8 1µF C156 C256 C 8897 8 1µF C157 C257 C 6806 1 01µF DIODES D1 C 2851 1 1N4004 D2 C 2851 1 1N4004 D3 C 2851 1 1N4004 D4 C 2851 1 1N4004 D5 C 2851 1 1N4004 D6 C 2851 1 1N4004 D...

Page 35: ...4 R234 A10266 1232 12K 5W R135 R235 C 7782 3 100 Flame Proof R136 R236 A10266 6821 6 8K R137 R237 C 7782 3 100 Flame Proof R138 R238 A10266 6821 6 8K R139 R239 A10266 8211 820 R140 R240 A10266 6801 68 R141 R241 A10266 1541 150K R142 R242 A10266 1541 150K R143 R243 A10266 1041 100K R144 R244 A10266 1041 100K R145 R245 A10266 1851 1 8M R146 R246 A10266 1031 10K R147 R247 C 7781 5 200 5W Flame Prf R1...

Page 36: ...21 10K R919 R1019 A10266 10021 10K R920 R1020 A10266 10021 10K R921 R1021 C 9079 2 200 Pot CMR Null SWITCHES S2 C 7325 1 Ground Lift S3 C 7960 5 Sensitivity S4 C 6781 6 Stereo Mono IC S U1 C 5095 2 UA7815 U2 C 5096 0 UA7915 U100 U200 C 6911 9 UPA75 U101 U201 C 4345 2 LM339 U102 U202 C 4345 2 LM339 U103 U203 C 6910 1 UPA76 U104 U204 C 7558 7 MC33079P MISC Board D 7993 5 Socket C 3450 1 14 Pin Nut A...

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