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Crown ce 4000, Service Manual

The Crown CE 4000 is a powerful amplifier designed for professional audio applications. From live concerts to recording studios, this reliable device delivers exceptional performance. For detailed instructions on operating the Crown CE 4000, simply visit our website and download the free operation manual.

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Parts 5-35

130485-1 Rev. B

CE 4000 Service Manual

©2002 Crown Audio, Inc.

Summary of Contents for ce 4000

Page 1: ... O Box 1000 Elkhart Indiana 46515 1000 U S A Telephone 574 294 8000 Trademark Notice Amcron and Crown are registered trademarks of Crown International Other trademarks are the property of their respective owners CE Series CE 4000 Some models may be exported under the name Amcron ...

Page 2: ...NT 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 the scope of this manual please contact the Crown Technical Support Group Mail P O Box 1000 Elkhart IN 465...

Page 3: ... Number Date Comments Rev A Rev B 05 2001 11 2002 Initial Printing Added missing parts list on Page 5 76 Updated area code and mailing address on Pages 1 2 and 7 Updated sections 3 2 4 4 3 3 4 3 9 4 4 5 4 6 1 4 6 8 4 7 2 4 7 3 Figure 4 16 Added notes to pages 5 39 5 73 5 97 130485 1 Rev B ...

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Page 5: ...ry 3 4 3 3 Power Supply Operation 3 5 3 3 1 Power Entry and Filtering 3 5 3 3 2 Fuse 3 5 3 3 3 Low Voltage Supplies Flyback 3 5 3 3 4 Turn On Control Circuitry 3 5 3 3 5 PFC Boost Stage 3 6 3 3 6 Bridge Isolation Stage 3 6 4 Maintenance 4 1 4 1 Where to Begin 4 1 4 2 Surface Mount Technology 4 1 4 3 Disassembly for Inspection Service 4 1 4 3 1 Top Cover Removal 4 1 4 3 2 Power Supply Discharge 4 1...

Page 6: ...alk at 20 kHz 4 10 4 6 10 Post Test Settings 4 10 4 7 Calibrations 4 10 4 7 1 Gaussian Filter Calibration 4 10 4 7 2 Overlap Correction and Adjustment 4 10 4 7 3 Current Sensing Calibration 4 11 4 7 4 Output Filter Calibration 4 11 5 Parts 5 1 5 1 General Information 5 1 5 2 Ordering and Receiving Parts 5 1 5 2 1 Terms 5 1 5 2 2 Shipment 5 1 5 3 Mechanical Parts 5 1 5 3 1 CE4000 Amplifier Assembly...

Page 7: ...settings Other features include selectable on board high and low pass filter sets SST System Solution Topologies module compatibility and a choice of dual output connectors Speakon plus 5 way barrier block 5 way barrier block plus binding strip or dual Speakon 1 3 Scope This Service Manual in intended to apply to all versions of the CE 4000 amplifier The Parts Listings include parts specific for t...

Page 8: ...CE 4000 Service Manual Introduction 1 2 130485 1 Rev B 2002 Crown Audio Inc Figure 1 1 CE 4000 Front and Rear Views ...

Page 9: ... Low Pass A three position switch for each channel located on the back panel below the input and output modules Switchable among settings for Flat 80 Hz and100 Hz Filter rolloff is 24 dB per octave High Pass A four position switch for each channel located on the back panel below the input and output modules Switchable among settings for Flat 30 Hz 40 Hz and 50 Hz Filter rolloff is 18 dB per octave...

Page 10: ... Nominally 20 k ohms balanced Nominally 10 k ohms unbalanced Input Sensitivity 0 775 volts or 1 4 volts for standard 1 kHz power or fixed 26 dB gain Output Connectors Three options available Four 4 Neutrik Speakon NL4MP mates with NL4FC output connectors 2 5 way binding posts in parallel with two 2 Speakon connectors or barrier strip outputs in parallel with two 2 5 way binding posts Output Signal...

Page 11: ...es of switch able filters that allow the signal to be low pass and high pass filtered at various frequencies The switches are located at the back panel The low pass filter is a fourth order Linkwitz Riley type and the high pass filter is a third order Butterworth type These switches S3 for the low pass and S5 for the high pass and their necessary circuitry are found on the BFG PWA Inherent in all ...

Page 12: ... interface low current digital circuitry U119 and U123 with power MOSFETs also abbreviated FETs U120 and U121 are used to drive the gates of the output FETs Q106 Q113 In order to produce gate drive power to the drivers a floating supply is generated for the Vp side This supply uses U124 A and U124 B to divide the 500kHz clock down to 125 kHz The half bridge driver U22 uses this 125 kHz clock to co...

Page 13: ...present at the input of the amplifier the widths of the pulses at Vp and Vn change but the amplitude of the pulses stays at 2 Vcc Positive audio signals will cause the positive side of the output stage to be on more than 50 of the time while the negative side will be on less than 50 of the time The total on time will add to approximately 100 Also the on time of the two polarities will overlap so t...

Page 14: ...s a voltage greater than the window of 0 3V that is detected by U117 C and U117 B Depending on the polarity U117 C or U117 B will go low during an IOC event If this happens U125 D goes high and Q103 turns on Q103 turns on the compressor opto located on the BFG PWA which compresses the input signal and reduces the peak voltage the amplifier is required to produce U125 D going high will activate the...

Page 15: ...lifier and power supply The parts on the primary side of the power distribution circuitry including those on the EMI PWA have all met stringent regulatory safety requirements and if they fail must be replaced by the correct part as called out in the PWA documentation 3 3 2 Fuse In the rare event that a power supply failure draws excessive current from the mains and the power supply itself cannot r...

Page 16: ...62 500 times each second 3 3 6 Bridge Isolation Stage The 400VDC is then bucked down to the ground referenced rails Vcc and Vcc needed by the audio amplifier Controller U4 through gate drivers U17 U31 U29 and U32 and transformers T2 and T3 turns Q4 and Q7 on at the same time then turns Q4 and Q7 off and Q5 and Q6 on at the same time causing T1 to convert voltage and current to its secondary This p...

Page 17: ...makes the components and the solder joint more susceptible to damage 2 Rework of SMDs can often require specialized tools equipment or training 3 SMDs are very small and can be difficult to handle see and identify Remember that on the CE Series amplifiers the SMDs on the bottom side of the main module are GLUED Take care not to damage components while trying to remove them from the surface of the ...

Page 18: ...Crown Audio Inc Figure 4 1 CE 4000 Top View A Figure 4 2 CE 4000 Top View B Power Supply Discharge Line Filter PWA Back Panel Assembly Output Panel Assembly BFG PWA Input Panel Assembly Main PWA Flyback PWA PFC Coils J6 Fan Wire Jack J4 BFG PWA Line Filter PWA ...

Page 19: ...igure 4 5 2 Remove the four T15 screws that secure the output panel to the back panel 3 Slide the output panel up and out of the back of the amplifier Figure 4 5 Output Bus Bars 4 3 6 Back Panel Assembly Removal The back panel assembly is removed to access the BFG Main and Filter PWAs 1 Follow the instructions in Section 4 3 2 Supply discharge is necessary to avoid circuit damage 2 Remove the SST ...

Page 20: ...le shield to the chassis 5 Remove the two T15 screws that hold the shield to the Main PWA 6 Remove the metal shield out of the chassis 7 Remove the knobs from the front panel 8 Remove the nuts that secure the level controls to the front panel 9 Slide the level controls into the chassis 10 Remove the air shroud from the Main PWA heatsink 11 Unplug the power switch wires at J26 J27 J28 and J29 on th...

Page 21: ... Trianglewave Generator and BCA Output Stage 1 Using an oscilloscope check audio side triangle waveforms at TP102 with respect to TP105 see Figure 4 9 Figure 4 9 Output Signal of Triangle Wave Generator 2 Using an oscilloscope check audio side triangle waveforms at TP202 with respect to TP205 see Figure 4 9 3 Using an oscilloscope check BCA output stage gate switching see Figure 4 10 Probe at each...

Page 22: ...ure 4 13 PFC Gate Switching at 4VDC Figure 4 14 PFC Gate Switching at 60VDC 5 Using an external power supply apply 60VDC to J23 and verify that the frequency changes as shown in Figure 4 14 6 Using an oscilloscope check gate switching of the Full Bridge DC to DC Converter as shown in Figure 4 15 Verify the phase shift at startup Probe at TP 27 TP 29 TP 30 and TP 31 All measurements are with respec...

Page 23: ...y Wait for six seconds to see if the LED stops flashing 2 One or more of the power supplies are out of tolerance or missing Replace or troubleshoot the Flyback PWA If this does not correct the problem check for the 400 V Vboost by measuring from TP251 to TP50 If it is low then troubleshoot the PFC boost stage If 400 V is o k check the Vccs at L6 and L9 They should measure approximately 105 VDC to ...

Page 24: ...ion 1 Possible problem on the Main PWA and is likely a faulty U100 200 or a faulty MOSFET or diode in the output stage Troubleshoot and repair as necessary 2 Input PWA might be passing input signal DC components Check for short capacitors in the Input PWA 4 5 Required Test Equipment Due to the complex circuitry utilized the CE 4000 amplifier special calibration procedures and the correct test equi...

Page 25: ...easure the output voltage It should be the same as the 1 kHz reference voltage 0 25 dB Switch the frequency to 20 kHz and verify that the input voltage is still 0 1 Vrms Measure the output voltage and compare it to the 1 kHz reference voltage Tolerance is 0 25 dB Remove the load and signal Note Many oscillators need a frequency check at 20 kHz 4 6 5 Short Circuit Test Spec Amplifier will protect i...

Page 26: ...ter to 0 dB using the 1 kHz signal as a reference signal Increase the signal generator frequency to 20 kHz leaving the output level unchanged While measuring pin 14 of U111D adjust R178 for a reduction of level by 2 6 dB readout should be 2 6 dB Procedure 2 Obtain a multimeter with decibel measurement capabilities Set the meter to dB measurement mode Insert a 1 kHz signal into the input and measur...

Page 27: ... level until output voltage measures 40Vrms on one channel 3 Adjust R160 while observing TP 10 for channel 1 in order to achieve 1 0Vrms 10mVrms see Figure 4 21 4 Repeat the adjustment on R260 while observing TP 245 for channel 2 Figure 4 21 Current Sensing Calibration 4 7 4 Output Filter Calibration Output Filter Calibration is NOT field adjustable and should not need adjustment If you suspect th...

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Page 29: ...ocking fee and authorization from the Crown Parts Depart ment must be obtained before returning parts for credit 5 2 2 Shipment Shipment will normally be made via UPS or best other method unless you specify otherwise Ship ments are made to and from Elkhart Indiana USA only Established accounts with Crown will receive shipment freight prepaid and will be billed All others will receive shipment on a...

Page 30: ...00 FAN PLENUM SNAP 127777 1 10 1 PLENUM CE4000 FAN 127473 3 9 4 6 32 HEX NUT W BELLE A11056 1 8 16 SCREW 6 X 250 MACH TORX PNHD 103436 70604 7 2 5 X 136 X 02 NYLON WASHER A10101 5 6 1 SHEILD CE4000 MAIN BD RBN AP 128218 7 5 1 PWA CE4000 BFG See section 5 4 4 16 SEMS 6 32 X 31 TORX PNHD STAR 103433 70605 3 10 8 32 X 31 SERR FLTHD T15 BZ 102156 1 2 2 KNOB D350 D 8959 5 1 1 CHASSIS CE4000 WELD AP PC ...

Page 31: ...Parts 5 3 130485 1 Rev B CE 4000 Service Manual 2002 Crown Audio Inc Figure 5 1 Amplifier Assembly Exploded View ...

Page 32: ... 12 6 1 PWA CE EMI FILTER See section 5 4 5 1 WIRE 14 GRN YEL RING X 6 0 X FLAG A11544 GO60M 4 1 IEC SNAP IN 15A UL 10A VDE 102650 1 3 8 SCREW 6 32 X 250 MACH TORX PNHD 103436 70604 2 1 FAN 120 X 120 X 38mm 12VDC 140CFM 126992 2 1 1 PANEL CE4000 BACK AP PC PP 127227 12 ASM NUMBER 130251 2 RECOMMENDED ASSEMBLY TORQUES ITEM NO C P N TORQUE SETTINGS 3 103436 70604 13 15 IN LBS 12 A11056 2 10 12 IN LB...

Page 33: ... 1 9 9 8 32 X 312 TORX PNPH SEM 103415 10805 8 2 CLIP CE40002 FINGER 127182 1 7 1 CLIP CE4000 2 FINGER 127552 1 6 4 MOSFET 0 11 OHM 500V 126738 1 5 1 DIODE 30A 600V HYPERFAST 127457 1 4 2 MOSFET 0 08 OHM 500V TO 247 127456 1 3 1 RECT 50A 600V PC MNT BRIDGE 125427 1 2 2 5 WAFER 3 000 X 90X 04 CERAMIC 127204 1 1 1 EXTRU CE4000L FR HS MACHINED 127976 3 5 3 3 CE4000 PS Primary Heatsink Assembly Refer ...

Page 34: ...IODE 30A 600V HYPERFAST 127457 1 2 1 WAFER 3 00 X 90 X 04 CERAMIC 127204 1 1 1 EXTRU CE4000 L RR HS MACHINED 127977 3 ASM NUMBER 128010 1 RECOMMENDED ASSEMBLY TORQUES ITEM NO C P N TORQUE SETTINGS 5 103415 10805 22 24 IN LBS Figure 5 4 CE4000 PS Diode Heatsink Assembly Exploded View 5 3 4 CE4000 PS Diode Heatsink Assembly Refer to Figure 5 4 for Exploded View Item Quantity Description Part CPN ...

Page 35: ...K D9053 6 3 8 MOSFET 250V 16A MTP16N25E C10207 6 2 2 WAFER 2 7000 X 90 X 04 CERAMIC 127564 1 1 1 EXTRU CE4000 R HALF HS MACHINED 127978 3 ASM NUMBER 128011 3 RECOMMENDED ASSEMBLY TORQUES ITEM NO C P N TORQUE SETTINGS 6 103415 10805 22 24 IN LBS Figure 5 5 CE4000 PS Output Heatsink Assembly Exploded View 5 3 5 CE4000 PS Output Heatsink Assembly Refer to Figure 5 5 for Exploded View Item Quantity De...

Page 36: ...INGS 3 A10111 70408 4 5 IN LBS 2 REF 103435 70608 13 15 IN LBS Item Quantity Description Part CPN 3 4 SCREW 4 X 5 PNHD PH AB BZ A10111 70408 2 1 PWA CE INPUT EC See section 5 4 1 1 PANEL CE INPUT CHARCOAL 126787 5 Figure 5 6 CE4000 Standard Input Assembly Exploded View 5 3 6 CE4000 Standard Input Assembly Refer to Figure 5 6 for Exploded View ...

Page 37: ...scription Part CPN 5 4 SCREW 6 32 X 250 MACH TORX PNHD 103436 70604 4 1 SHEILD CE4000 OTPT BUSS BAR 128203 1 3 1 INSULATOR CE4000 OTPTBUSS BAR 128202 1 2 4 BAR CE4000 OUTPUT BUSS AP 127672 2 1 1 PWA CE4000 SPEAKON BDG POST OTPT See section 5 4 5 3 7 CE4000 Standard Domestic Ouput Assembly Refer to Figure 5 7 for Exploded View Figure 5 7 CE4000 Standard Domestic Output Assembly Exploded View ...

Page 38: ... X FLAG A11518 K040P 2 2 WIRE 16 BLK FAST X 4 X FLAG A11608 EO30R 1 1 SWITCH ROCKER PNL MNT DPST 16A 127455 1 NOTES 1 MARKINGS 1 ID 2 2D ARE IDENTIFIED ON SWITCH HOUSING 2 J26 J27 J28 J29 ARE CORRESPONDING LOCA TIONS ON PWA Figure 5 8 CE4000 Power Switch Assembly Exploded View 5 3 8 CE4000 Power Switch Assembly Refer to Figure 5 8 for Exploded View ...

Page 39: ... are repre sentative only There may be slight variations between amplifier to amplifier These schematics are intended to be used for troubleshooting purposes only Note on circuit board designations Crown circuit boards are referenced with a PWA and or PWB part number PWA stands for Printed Wire Assembly This is the completed circuit board with all components assembled PWB stands for Printed Wire B...

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Page 139: ... Schematic Sheet 43 44 45 46 47 48 PWA NUMBER 126218 16 Schematic Sheet 1 2 3 4 5 6 7 8 CE4000 BFG PWA NUMBER 126828 7 REV A Schematic Sheet 8 PWA NUMBER 126828 12 REV A Schematic Sheet 8 PWA NUMBER 126828 13 REV A Schematic Sheet 9 CE4000 INPUT CE PWA NUMBER 126883 4 Schematic Sheet 5 CE4000 FLYBACK PWA NUMBER 127027 6 Schematic Sheet 6 CE4000 POT BOARD PWA NUMBER 127563 3 Schematic Sheet 5 PWA N...

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