MA 5002VZ Service Manual MA5002VZ - SM - 130446 1 - Original PDF

Macro-Tech®
POWER AMPLIFIER
SERVICE MANUAL
Models:
MA-5002VZ
Some models may be exported under the name Amcron®
© 2000 by Crown International, Inc., P.O. Box 1000, Elkhart, Indiana 46515-1000 U.S.A.
Telephone: 219-294-8000. Trademark Notice: Grounded Bridge™, PIP2™ and SmartAmp™ are
trademarks and Amcron®, Crown ®, IOC®, IQ System®, Macro-Tech,® ODEP® and VZ® are
registered trademarks of Crown International, Inc. Other trademarks are the property of their
respective owners.
130446-1
02-00
Rev. A
MA-5002VZ Service Manual 130446-1 Rev. A
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 46515-1000

Shipping: Plant 2 SW 1718 W. Mishawaka Road Elkhart IN 46517
Phone: (800) 342-6939 / (219) 294-8200
FAX: (219) 294-8301
CAUTION AVIS
TO PREVENT ELECTRIC SHOCK DO
NOT REMOVE TOP OR BOTTOM À PRÉVENIR LE CHOC
COVERS. NO USER SERVICEABLE ÉLECTRIQUE N’ENLEVEZ
PARTS INSIDE. REFER SERVICING PAS LES COUVERTURES.
TO QUALIFIED SERVICE RIEN DES PARTIES
PERSONNEL. DISCONNECT UTILES À L’INTÉRIEUR.
POWER CORD BEFORE REMOVING DÉBRANCHER LA BORNE
REAR INPUT MODULE TO ACCESS AVANT D’OUVRIR LA
GAIN SWITCH. MODULE EN ARRIÈRE.
WARNING
TO REDUCE THE RISK OF ELECTRIC
SHOCK, DO NOT EXPOSE THIS
EQUIPMENT TO RAIN OR MOISTURE!
The lightning bolt The exclamation point

triangle is used to triangle is used to alert the
alert the user to the user to important operating
risk of electric shock. or maintenance instructions.
II ©2000 Crown International, Inc.

130446-1 Rev. A MA-5002VZ Service Manual
Revision History
Revision Number Date Comments
Rev. A 02-2000 Initial Printing
©2000 Crown International, Inc. III

This page intentionally left blank
IV ©2000 Crown International, Inc.

Table of Contents
1 Introduction ............................................................................ 1-1
1.1 Introduction ................................................................................ 1-1
1.2 The MA “02” Series Amplifiers ................................................... 1-1
1.3 Scope ......................................................................................... 1-1
1.4 Warranty ..................................................................................... 1-1
2 Specifications ......................................................................... 2-1
3 Voltage Conversion ................................................................ 3-1
4 Circuit Theory ........................................................................ 4-1

4.1 Overview .................................................................................... 4-1
4.2 Grounded Bridge Theory ........................................................... 4-1
4.2.1 Grounded Bridge Operation ............................................. 4-2
4.2.2 Output Stage Circuitry ....................................................... 4-3
4.3 VZ Power Supply ........................................................................ 4-4
4.3.1 VZ Supply Operation ......................................................... 4-4
4.3.2 VZ Supply Circuitry ........................................................... 4-5
4.4 ODEP Theory ............................................................................. 4-6
4.4.1 ODEP Operation ................................................................ 4-6
4.4.2 ODEP Circuitry .................................................................. 4-7
4.5 Front End Theory ........................................................................ 4-8
4.5.1 Balanced Gain Stage ........................................................ 4-8
4.5.2 Variable Gain Stage .......................................................... 4-8
4.5.3 Error Amp .......................................................................... 4-8
4.5.4 Compessor ........................................................................ 4-9
4.5.5 Loudspeaker Offset Integration ........................................ 4-9
4.5.6 Voltage Translator and LVA Stages .................................. 4-9
4.5.7 Inverting Stages ................................................................ 4-9
4.6 Protection Systems .................................................................... 4-9
4.6.1 Soft Start ............................................................................ 4-9
4.6.2 Over-voltage .................................................................... 4-11
4.6.3 DC/LF .............................................................................. 4-11
4.6.4 Commom Mode Output Current ...................................... 4-12
4.6.5 Output Thermal ............................................................... 4-12
4.6.6 Transformer Thermal ....................................................... 4-12
4.6.7 FET Thermal .................................................................... 4-12
4.6.8 Power Loss ...................................................................... 4-13
4.6.9 Fan Control ...................................................................... 4-13
4.7 Display ..................................................................................... 4-13
4.8 Mono Modes ............................................................................ 4-13
4.8.1 Bridge Mono .................................................................... 4-13
4.8.2 Parallel Mono ................................................................... 4-14
©2000 Crown International, Inc. V

Table of Contents
5 Maintenance ........................................................................... 5-1
5.1 Cautions and Warnings .............................................................. 5-1
5.2 General Information ................................................................... 5-1
5.3 Troubleshooting ........................................................................ 5-1
5.3.1 Pre-AC-Checks ................................................................ 5-1
5.3.2 LED Checks ..................................................................... 5-2
5.4 Test Procedures ......................................................................... 5-4
5.4.1 Standard Initial Conditions ................................................ 5-4
5.4.2 Equipment Required ......................................................... 5-4
6 Parts ....................................................................................... 6-1

6.1 General Information .................................................................. 6-1
6.2 Ordering and Receiving Parts .................................................. 6-1
6.2.1 Terms ..................................................................................... 6-1
6.2.2 Shipment ................................................................................ 6-1
7 Exploded View Parts ............................................................ 7 -1
8 Module and Schematic Information .................................... 8 -1
9 Module Parts .......................................................................... 9-1
10 Schematics ........................................................................ 10-1
VI ©2000 Crown International, Inc.

phonic capability. The MA-5002VZ includes additional

1 Introduction features not found on other Macro-Tech series models
including switchable compression, switchable loud-
speaker offset integration (LOI), and ILOAD/ILIMIT indi-
1.1 Introduction cation.
This manual contains complete service information on
the Crown® MA-5002VZ power amplifier. It is designed 1.3 Scope
to be used in conjunction with the Reference Manual; This Service Manual in intended to apply to all ver-
however, some important information is duplicated in sions of the MA-5002VZ amplifier. The Parts Listings
this Service Manual in case the Reference Manual is include parts specific for the US version and the Euro-
not readily available. pean version (E13). For parts specific only to other
versions contact the Crown Technical Support Group
NOTE: THE INFORMATION IN THIS MANUAL IS for help in finding part numbers.
INTENDED FOR USE BY AN EXPERIENCED TECH-
NICIAN ONLY! 1.4 Warranty
Each Reference Manual contains basic policies as re-
1.2 The MA “02” Series Amplifiers lated to the customer. In addition, it should be stated
The Macro-Tech® series is a complete family of ampli- that this service documentation is meant to be used
fiers designed for pro sound reinforcement. Macro- only by properly trained personnel. Because most
Tech amplifiers are designed to provide enormous lev- Crown products carry a 3-Year Full Warranty (includ-
els of pure, undistorted power in a rugged low-profile ing round trip shipping within the United States), all
package, utilizing Crown's patented Grounded warranty service should be referred to the Crown Fac-
Bridge™ output topology. They also employ Crown's tory or Authorized Warranty Service Center. See the
patented ODEP® protection circuitry, which keeps the applicable Reference Manual for warranty details. To
amplifier working under extreme conditions that would find the location of the nearest Authorized Warranty
shut down a lesser amplifier. Crown's new Macro-Tech Service Center or to obtain instructions for receiving
“02” series amplifiers feature Crown's enhanced Crown Factory Service, please contact the Crown Tech-
PIP2™ (Programmable Input Processor) expansion nical Support Group (within North America), or your
system. The PIP2 expansion system makes it easy to Crown/Amcron Importer (outside North America). If you
tailor the amplifier to a specific application. Providing are an Authorized Warranty Service Center and have
high power amplification from 20 Hz to 20 kHz with questions regarding the warranty of a product, please
minimum distortion, Macro-Tech series amplifiers fea- contact the Field Service Manager or the Technical
ture balanced inputs with bridged and parallel mono- Support Group.
Crown Customer Service

Technical Support Group
Factory Service
Parts Department
Mailing Address: P.O. Box 1000, Elkhart IN 46515

Shipping Address: Plant 2 S. W.
1718 W. Mishawaka Rd., Elkhart IN 46517
Phone: (219) 294-8200
Toll Free: (800) 342-6939
Fax: (219) 294-8301
http://www.crownaudio.com
©2000 Crown International, Inc. Introduction 1-1

Figure 1.1 MA-5002VZ Front and Rear Views
1-2 Introduction ©2000 Crown International, Inc.

Controls
Compressor: A three-position back-panel switch is used to control
2 Specifications each channel’s input compressor. The “fast” setting provides an
attack time of 4 milliseconds and a release time of 300 millisec-
onds; the “slow” setting provides an attack time of 12 milliseconds
and a release time of 600 milliseconds; the “off” setting defeats
Specifications output-driven compression.
The following applies to 120-VAC, 60-Hz units in Stereo mode with 8-ohm loads and an Enable: A front-panel push button used to turn the amplifier on and
input sensitivity of 26-dB gain unless otherwise specified. Specifications for units
off.
supplied outside the U.S.A. may vary slightly at different AC voltages and frequencies.
Power Input Ground Lift: A two-position back-panel switch located on the
PIP2-FXQ used to isolate the input audio signal grounds from the
Output Power
AC (chassis) ground.
Level: A front-panel rotary potentiometer for each channel with 31
*1 kHz **20 Hz– 20 kHz
MA-5002VZ Power Power detents used to control the output level.
Loudspeaker Offset Integration: A two-position back-panel switch
2-ohm Dual (per ch.) 2,500W 2,155W
for each channel used to turn the loudspeaker protection circuitry
4-ohm Dual (per ch.) 2,000W 1,775W on and off. The circuitry protects against DC, off-center woofer
8-ohm Dual (per ch.) 1,300W 1,090W cone movement, and unwanted subsonic and ultrasonic frequen-
cies.
4-ohm Bridge-Mono 5,000W
Sensitivity: A three-position back-panel switch for each channel
8-ohm Bridge-Mono 4,000W 3,670W used to select input sensitivity: 0.775 volts or 1.4 volts for
*1 kHz Power: refers to maximum average power in watts
standard 1-kHz power, or a 26 dB voltage gain.
at 1 kHz with 0.1% THD.
Stereo/Mono: A three-position back-panel switch used to select
**20 Hz– 20 kHz Power: refers to maximum average power
in watts from 20 Hz to 20 kHz with 0.1% THD. Stereo, Bridge-Mono or Parallel-Mono mode.
VZ Mode: A four-position switch for each channel inside the front-
Load Impedance: Safe with all types of loads. Rated for 2 to 8 panel used to control the switching mode of the VZ power supplies.
ohms in Stereo, 4 to 16 ohms in Bridge-Mono and 1 to 4 ohms in Indicators
Parallel-Mono mode. Enable: An amber front-panel LED that shows the on/off status of
Voltage Gain to 1-kHz, 8-ohm rated output: the low-voltage power supply.
132:1 ±12% or 42 dB ±1 dB gain at 0.775 volt sensitivity; Signal/IOC: A green front-panel LED for each channel that flashes
71:1 ±12% or 37 dB ±1 dB gain at 1.4-volt sensitivity; to show amplifier output. If a channel’s output waveform differs
20:1 ±3% or 26 dB ±0.25 dB gain at the maximum level setting. from its input by 0.05% or more, the indicator flashes brightly to
Required AC Mains: 50 or 60 Hz; 100-, 120-, 200-, 208-, 230-, show distortion.
240- VAC (±10%).
ODEP: An amber front-panel LED for each channel that shows
AC Line Current, thermal-dynamic energy reserve. Normally, each ODEP indicator is
Current, voltage and frequency requirements are provided on the lit to show available reserve energy. In the rare event that a channel
unit’s back panel. has no reserve, its indicator will dim in proportion to ODEP
At Idle: All units draw 90 watts or less. limiting.
AC Line Connector: 10 AWG cordset with NEMA TT30P plug is ILoad/ILimit: A two-color (green/red) LED for each channel that
provided on 120-VAC, 60-Hz North American units. shows load current and limit current. They glow green to indicate
load current flowing out the amplifier, and they turn red when
Performance maximum current is being delivered to the load.
Frequency Response: ±0.1 dB from 20 Hz to 20 kHz at 1 watt (see
Input/Output
Figure 2.3).
Input Connectors: Balanced three-pin XLR and balanced ¼-inch
Phase Response: ±10 degrees from 10 Hz to 20 kHz at 1 watt (see (6.35-mm) TRS connectors are provided on the factory-installed
Figure 2.2). PIP2-FXQ module.
Signal-to-Noise Ratio,A-weighted: Input Impedance: Greater than 10 ohms, balanced. Greater than 5
Better than 105 dB below rated 1-kHz power. ohms, unbalanced.
Total Harmonic Distortion (THD): 1-kHz rated power, 0.05% or Input Sensitivity: Settings include 0.775 volts or 1.4 volts for
less true THD. standard 1 kHz power, or a 26-dB voltage gain.
Intermodulation Distortion (IMD): (60 Hz and 7 kHz at 4:1) Less Output Connectors: A multifunction, high-current output block is
than 0.05% from rated power to 35 dB below rated power at 8 provided. Crown output blocks include three pairs of connectors
ohms. for each channel (a total of 12 connectors). This allows multiple
Damping Factor: Greater than 1,000 from 10 Hz to 400 Hz (see loudspeakers to be easily connected to each channel. High current
Figure 2.4). screw terminals and banana jacks are provided which accept spade
lugs, banana plugs or bare wire.
Controlled Slew Rate: (Slew rates are limited to useful levels for
ultrasonic/RF protection.) Greater than 30 volts per microsecond. Output Impedance: Less than 10 milliohms in series with less than
2.5 microhenries(see Figure 2.5).
©2000 Crown International, Inc. Specifications 2-1

DC Output Offset: ±10 millivolts. And input overload protection is provided by the input compres-
Output Signal sors and current-limiting resistance at the input.
Stereo: Unbalanced, two-channel. Turn On: The four second turn-on delay prevents dangerous turn-
on transients. It also has “ soft start” to avoid tripping the AC circuit
Bridge-Mono: Balanced, single-channel. Channel 1 controls are
breaker by gradually bringing the supplies up to full voltage.
active; Channel 2 controls are removed from operation.
Accessories: Crown PIP and PIP2 modules including IQ-PIP
Parallel-Mono: Unbalanced, single-channel. Channel 1 controls are
modules.
active; Channel 2 controls are by passed.
Protection Construction
Steel chassis with durable black finish, aluminum front panel with
Macro-Tech amplifiers are protected against shorted, open or
Lexan overlay, and specially designed flow-through ventilation from
mismatched loads; overloaded power supplies; excessive
front to back panels.
temperature; chain destruction phenomena; input overload
damage; and high-frequency blowups.They also protect loud- Cooling: Internal heat sinks with on-demand, proportional forced-
speakers from input/output DC and turn-on/turn-off transients. air cooling controlled by ODEP. Includes custom heat diffusers and
patented circuitry to promote uniform dissipation.
If unreasonable operating conditions occur, the patented ODEP
circuitry will proportionally limit the drive level to protect the Dimensions: 19-inch (48.3-cm) standard rack mount width (EIA
output transistor stages, particularly in the case of elevated RS-310-B), 5.2-inch (13.3-cm) height, 15.875-inch (40.3-cm)
temperature. Transformer overheating will result in a temporary depth behind mounting surface, and 2.875 inches (7.3 cm) in front
shutdown of the affected channel; when it has cooled to a safe of mounting surface (see Figure 2.1). Allow 3 inches (7.6 cm)
temperature, the transformer will automatically reset itself. behind the back panel for adequate air flow.
Controlled slew rate voltage amplifiers protect against RF burnouts. Approximate Weight: 77 pounds, 9 ounces (35.2 kg) net; 88
pounds, 10 ounces (40.2 kg) shipping weight.
+45˚
0˚
–45˚
Figure 2.1 Dimensions

TEF ®
100 1K 10 K 20 K
FREQUENCY (Hz)
Figure 2.2 Typical Phase Response
2-2 Specifications ©2000 Crown International, Inc.

Figure 2.3 Typical Frequency Response
Figure 2.4 Typical Damping Factor
Figure 2.5 Typical Output Impedance
©2000 Crown International, Inc. Specifications 2-3

2-4 Specifications ©2000 Crown International, Inc.

INSTRUCTIONS
3 Voltage Conversion CAUTION: Because there is a risk of
electric shock, only a qualified technician
The MA-5002VZ power amplifier may easily be con- should change the line voltage configuration.
verted to a variety of AC mains voltages and may oper-
ate at 50 or 60 Hz. Complete directions to accomplish 1. Turn the amplifier off and disconnect it from the AC
line voltage and/or frequency changes are found on a power source. (The enable switch alone does not re-
label under the top cover of the unit. For convenience move lethal voltage from the line cord.) Wait at least 10
this information is duplicated here and on the following seconds before proceeding.
page.
2. Drain any remaining energy from the power supplies
Control Board Wiring for Different AC Voltages by shorting them as follows: Touch a 100 ohm, 10 watt
NO.** 100 V 120 V 200 V 208 V 230 V 240 V resistor across terminals A1 and A2 and across B1 and
P712 BLK BLK BLK BLK BLK BLK B2 as shown in the illustration. The resistor should be
P711 WHT WHT --NONE-- --NONE-- --NONE-- --NONE-- held across the terminals for 10 seconds. Be careful—
P724B BLU* BLU* BLU* BLU* BLU* BLU*
the resistor can become hot.
P707 BLK/GRN BLK/YEL BLK/GRN BLK/GRN BLK/YEL BLK/YEL
3. Locate the Control Board. It is the circuit board clos-
P704 --NONE-- --NONE-- BLK/YEL BLK/YEL WHT WHT
est to the front of the amplifier. It contains numerous
P705 --NONE-- --NONE-- WHT WHT BLK/GRN BLK/GRN
power supply connections which set the voltage and
P710 WHT/GRN WHT/YEL WHT/RED WHT/YEL WHT/YEL WHT/YEL
one jumper block which sets the frequency.
P709 WHT/RED WHT/RED WHT/GRN WHT/GRN WHT/GRN WHT/RED
P708 WHT/YEL WHT/GRN WHT/YEL WHT/RED WHT/RED WHT/GRN 4. Use the information in Figure 3.1 to connect the color-
P703 BLK/YEL BLK/GRN --NONE-- --NONE-- --NONE-- --NONE-- coded wiring harness correctly for the desired voltage.
P701 GRY GRY GRY GRY GRY GRY Configure each wire group one at a time so the wires
P700 GRY GRY GRY GRY GRY GRY are not confused. Do not mix wires between groups.
P702 GRN/YEL GRN/YEL GRN/YEL GRN/YEL GRN/YEL GRN/YEL This step may require you to cut one or more tie wraps.
P713 BLK/YEL BLK/GRN --NONE-- --NONE-- --NONE-- --NONE-- If you do, replace them to make sure no loose wires are
P714 WHT/YEL WHT/GRN WHT/YEL WHT/RED WHT/RED WHT/GRN able to prevent the fans from rotating.
P722 BRN* BRN* BRN* BRN* BRN* BRN*
P749 WHT/RED WHT/RED WHT/GRN WHT/GRN WHT/GRN WHT/RED 5. Locate the frequency jumper (JP1) and set it for ei-
P750 WHT/GRN WHT/YEL WHT/RED WHT/RED WHT/YEL WHT/YEL ther 60 Hz (left) or 50 Hz (right).
6. Locate the fan connector (P729/P730) and move it to
the appropriate voltage connector (left for 200-240 VAC
or right for 100-120 VAC).
P719 BLK BLK BLK BLK BLK BLK
P715 WHT WHT --NONE-- --NONE-- --NONE-- --NONE--
7. Double check that all connections are correct and
P724A BLU* BLU* BLU* BLU* BLU* BLU*
replace the top cover.
P736 GRN/YEL GRN/YEL GRN/YEL GRN/YEL GRN/YEL GRN/YEL
P735 GRY GRY GRY GRY GRY GRY
P734 GRY GRY GRY GRY GRY GRY
P742 BLK/YEL BLK/GRN --NONE-- --NONE-- --NONE-- --NONE--
P737 WHT/YEL WHT/GRN WHT/YEL WHT/RED WHT/RED WHT/GRN
P744 WHT/RED WHT/RED WHT/GRN WHT/GRN WHT/GRN WHT/RED
P743 WHT/GRN WHT/YEL WHT/RED WHT/YEL WHT/YEL WHT/YEL
P724C BLU* BLU* BLU* BLU* BLU* BLU*
P741 WHT WHT --NONE-- --NONE-- --NONE-- --NONE--
* Wire colors marked with a single asterisk connect to the power cord.
P740 BLK BLK BLK BLK BLK BLK ** The connector numbers are listed in clockwise order from left to right
P729*** as you face the front of the amplifier.
120 V Position 240 V Position
P730***
*** Connection P729 and P730 are combined on a single four-pin connec-
tor. It mates to a “120V” connector for 100V or 120V operation or a
Figure 3.1 Voltage/Frequency Conversion Chart “240V” connector for 200, 208, 230 or 240 volts.
©2000 Crown International, Inc. Voltage Conversion 3-1

CAUTION: To reduce the risk of fire,

replace F700, F701, & F702 with the
same type fuse. Use a 30 A fuse for F700
& F701 and a 1A fuse for F701 for ALL
voltage configurations.
ATTENTION: Utiliser un fusible de même

type (F700, F701 = 30A. F702 = 1A.)
pour toutes applications.
Figure 3.2 Voltage/Frequency Conversion Physical Layout
3-2 Voltage Conversion ©2000 Crown International, Inc.

is called Loudspeaker Offset Integration (LOI). The LOI

4 Circuit Theory circuit, when switched on, prevents excessive bass fre-
quency cone excursions below the audible frequency
range. It operates essentially as a band-pass filter. The
4.1 Overview low frequencies are rolled off at 18 dB/octave with a
–3 dB corner of 35 Hz (Butterworth response). Ultra-
It should be noted that over time Crown makes improve-
sonics are rolled off with a second order Bessel response
ments and changes to their products for various rea-
and –3 dB corner of 50 kHz.
sons. This manual is up to date as of the time of writing.
For additional information regarding these amplifiers, A compression circuit in each channel may be switched
refer to the applicable Technical Notes provided by off, on slow, or on fast by switches on the rear panel.
Crown for this product. Sketches have been added to This compressor is activated by either input overload
this section for clarification of the various concepts pre- or distortion (clipping). Input overload compression is
sented, as well as block diagrams for the amplifier and in fast speed when the compressor switch is in the off
specific portions of the amplifier. For detailed schemat- position. The compression ratio is infinite (it operates
ics refer to Section 6. as a peak limiter).
The Macro-Tech 5002VZ amplifier incorporates several The four-quadrant topology used in the grounded out-
new technological advancements, including real-time put stages is called the Grounded Bridge, and it makes
computer simulation of output transistor stress, low- full use of the power supplies. This patented topology
stress output stages, an advanced heat diffuser em- also makes peak-to-peak voltages available to the load
bodiment, a programmable input processor (PIP) ex- which are twice the voltage any output device is ever
pansion system, and articulated VZ power supplies. exposed to. The Grounded Bridge is covered in detail
in Section 4.2.
Custom circuitry is incorporated to limit temperature and
current to safe levels—making it highly reliable and tol- The two channels may be used together to double the
erant of faults. Unlike many lesser amplifiers, the Macro- voltage (bridged-mono) or the current (parallel-mono)
Tech 5002VZ can operate at its voltage and current lim- presented to the load. This feature gives the user flex-
its without self-destructing. ibility in maximizing the power available to the load.
Real-time computer simulation is used to create an ana- Macro-Tech amplifiers utilize a wide bandwidth multiloop
log reading of the junction temperature of the output feedback design with state of the art compensation tech-
transistors (herein referred to as the output devices). niques. This produces ideal behavior and results in ul-
Current is limited only when the device temperature be- tra-low distortion values.
comes excessive—and just by the minimum amount
necessary. This patented approach, called ODEP (Out- Aluminum extrusions have been widely used for
put Device Emulation Protection) maximizes the avail- heatsinks in power amplifiers due to their low cost and
able output power and eliminates overheating—the reasonable performance. However, measured on a
major cause of device failure. ODEP in the MA-5002VZ watts per pound or watts per volume basis, that extru-
also provides indication of amplifier thermal reserve sion technology doesn’t perform nearly as well as the
(front panel ODEP indicators) and may provide control cut fin radiator technology developed for the Macro-
of VZ mode when the VZ mode select switches are Tech 5002VZ power amplifier.
placed in the VZ-ODEP position. Our thermal diffusers are custom cut radiator fins on a
The amplifier is protected from all common hazards that solid heat sink block. They provide an extremely high
plague high-power amplifiers, including shorted, open ratio of area to volume, or area to weight. All power de-
or mismatched loads, overloaded power supplies, ex- vices are mounted directly to massive heat spreaders,
cessive temperature, chain-destruction phenomena, which are electrically hot. Making the heat spreaders
input-overload damage, and high-frequency blowups. electrically hot allows improved thermal performance
The unit protects loudspeakers from DC in the input by eliminating the insulating interface underneath the
signal and from turn-on and turn-off transients. It also power devices. The chassis itself is used as part of the
detects and prevents unwanted DC on the outputs. thermal circuit, and this maximizes utilization of the avail-
Additional protection features include input voltage able resources.
sense as well as overvoltage (AC mains).
4.2 Grounded Bridge Theory
A mode of protection which may be switched on or off The Grounded Bridge topology is ground-referenced
©2000 Crown International, Inc. Circuit Theory 4-1

Figure 4.1 Simplified Grounded Bridge
by the output stages rather than the power supply. ducts to deliver –Vcc to the load and the high side NPN
Composite devices are constructed to function as gi- stage is off.
gantic NPN and PNP devices since the available cur-
rents exceed the limits of existing individual devices. The low side operates quite differently. The power sup-
ply bridge rectifier is not ground referenced. This al-
The devices connected to the load are referred to as lows the power supply to deliver +Vcc and –Vcc from
“high-side NPN and PNP” and the devices connected the same bridge rectifier and filter as a total difference
to ground are referred to as “low-side NPN and PNP.” in potential, regardless of their voltages with respect to
Positive voltage is delivered to the load by increasing ground. The low side of bridge uses inverted feedback
conductance simultaneously in the high-side NPN and from the high side output to control the ground refer-
low-side PNP stage. At the same time, conductance of ence for the rails.
the high-side PNP and low-side NPN is being de-
creased. As the output swings positive, the output signal is fed
back to the low side and is inverted to drive the low
side with a negative signal. The negative signal causes
4.2.1 Grounded Bridge Operation the low side PNP to conduct (as the high side NPN con-
Figure 4.1 is a simplified example of Crown’s patented ducts) shifting the ground reference toward –Vcc until,
Grounded Bridge output topology (ignoring the articu- at the peak, –Vcc = 0V. At this time +Vcc equals the full
lating characteristics of the VZ supply). It consists of potential (from rail to rail, not rail to ground) of the power
four quadrants of three-deep Darlington (composite) supply with positive polarity. Since the high side is de-
emitter-follower stages per channel: one NPN and one livering +Vcc to the speaker load (which is ground ref-
PNP on the high side of the bridge (driving the load), erenced at all times), the speaker sees the full potential
and one NPN and one PNP on the low side of the bridge developed by the power supply with a positive polarity.
(controlling the ground reference for the rails). The out-
put stages are biased to operate class AB+B for ultra When the input drive signal is negative and the high
low distortion in the signal cross-over region. side PNP conducts to deliver a negative voltage to the
load, that output is again fed to the low side and in-
The high side of the bridge operates similar to a con- verted to cause the low side NPN to conduct. As the
ventional bipolar push-pull output configuration. As the low side NPN conducts, +Vcc swings toward the 0V
input drive voltage becomes more positive, the high side ground potential. At the peak: +Vcc = 0V. At this time
NPN conducts current and delivers positive voltage to –Vcc equals the full potential developed by the power
the speaker load. Eventually, full +Vcc is across the load. supply, but with negative polarity. Since the high side is
At this time the high side PNP is biased off. When the delivering –Vcc to the speaker load, the load sees the
drive signal is negative going, the high side PNP con-
4-2 Circuit Theory ©2000 Crown International, Inc.

full (negative) potential developed by the power sup- Q513, Q515, Q517, and Q536 are the HS NPN output
ply. devices. These devices are biased class B, in soft cut-
off. Together with driver and pre-driver, they function as
The total effect is to deliver a peak to peak voltage to a three-deep Darlington. The output devices work in
the speaker load which is twice the (static) voltage pro- parallel as a giant composite. The over-all bias topol-
duced by the power supply. Benefits include full utiliza- ogy is referred to as AB+B, originally conceived and
tion of the power supply (it conducts current during both patented by Crown engineers in 1966. This is still the
halves of the output signal; conventional designs re- most efficient, stable, and distortion free method used
quire two power supplies per channel, one positive and today in BJT output stages.
one negative), and never exposing any output device
to more than half of the peak to peak output voltage D506 is the flyback diode for the HS NPN output quad-
(which does occur in conventional designs). rant. In the event that a back EMF (flyback) pulse ex-
ceeds power supply voltage, the flyback diode will shunt
4.2.2 Output Stage Circuitry this voltage to the supply in order to protect the output
Circuitry on the positive and negative output modules devices.
include bias circuitry, current limit circuitry, last voltage
amplifiers (LVAs), pre-drivers, drivers, output devices, PNP pre-drivers, drivers, output devices, and flyback
and the Low Side error amp. Temperature sensors are diode D508 are a mirror image of the NPN side.
also mounted to the heatsinks via the output modules.
Overall, the High Side of the bridge operates much like
The positive LVAs (Q501, Q502, and Q503) convert the a conventional output stage, but the Low Side (LS) is
negative output of the voltage translator stage to a posi- quite unique.
tive drive voltage for the NPN High Side (HS) predriver.
The LS senses output voltage and common buss (0.04
There are three LVA transistors in parallel due to the
ohms above ground) potential. The audio output is in-
very high voltages (therefore higher current and ther-
verted by U503. Also in the U503 input circuitry are static
mal requirements) that are present when the power
and dynamic balance controls. These controls provide
supply is in high voltage mode. D522 prevents the +LVAs
a fine balance of the grounded bridge. Output of the
from producing a high negative output to the HS NPN
op-amp drives the LS pre-driver circuits through the LS
stage.
bias network.
Q507, Q508, and Q509 are the -LVAs and are arranged
LS bias is controlled in a fashion similar to that of the
in mirror image to the +LVAs, including D513.
HS. Two transistors, Q529 and Q530, fix LS bias volt-
On the positive side, D514, D515, and C506 via the age as measured from pin 15 (hot) to pin 13 of appli-
+LVAs act to limit slew rate. D514 and D515 also pre- cable ATE port TP1 or TP2. Potentiometer R556 adjusts
vent dangerously excessive current through the LVAs. bias in the LS.
D516, D517, and C507 are the negative HS mirror im-
Diodes D504 and D505 control polarity of applied LS
age.
drive signal. Via the bias transistors, signal is delivered
Q534 and Q540 provide two-speed current limiting in to the bases of the pre-drivers Q527 (NPN) and Q528
the output stage. Sense lines are arranged such that (PNP). Pre-drivers, drivers, and output devices in the
excessive current through any single HS output device LS operate class AB+B, exactly like the HS. The major
will result in current limit protection. Q535 and Q541 are difference is that rather than driving a load, the NPN
the negative side mirror image. and PNP stages control the ground reference for the
high voltage rails. As the HS NPNs conduct, LS PNPs
Q505 on the positive output module works in tandem conduct, and vice versa (as explained in section 4.2.1).
with Q505 on the negative output module as a Vbe
multiplier circuit. They produce and, with great stability, When the ODEP circuit senses that limiting drive is nec-
control bias for the High Side NPN and PNP devices. essary to prevent a dangerous thermal condition, it pro-
Potentiometer R505 is used to precisely set bias volt- vides an output which limits drive to the output stages.
age. Bias voltage is easily measured from pin 2 (hot) to For the HS, this limiting is accomplished on the main
pin 4 of ATE ports TP1 and TP2. Refer to Section 2 for module and is explained in section 4.4. For the LS, ODEP
appropriate test procedures. provides (via wires labeled ±LL) a signal which limits
bias feed to the LS output devices. This is accomplished
Q504 is the HS NPN pre-driver and Q511 is the HS through current mirrors Q532 and Q531 (LS NPN quad-
NPN driver. These devices are biased class AB for ul- rant), and Q542 and Q543 (LS PNP quadrant).
tra low distortion in the zero-crossing region.

4.3 VZ Power Supply The VZ supply is divided into segments to better match
VZ means Variable Impedance and is the name of the voltage and current requirements of the power tran-
Crown’s patented articulated power supply technology. sistors. Remember that audio signals like music are
It enables Crown to pack tremendous power into just complex waveforms. Refer to Figures 4.2 and 4.3.
5.25 inches of vertical rack space. For music the average level is always much less than
A power supply must be large enough to handle the the peak level. This means a power supply does not
maximum voltage and current necessary for the ampli- need to produce full voltage all the time.
fier to drive its maximum rated power into a specified The VZ supply is divided into two parts. When the volt-
load. In the process of fulfilling this requirement, con- age requirements are not high, it operates in a parallel
ventional power supply designs produce lots of heat, mode to produce less voltage and more current.
are heavy, and take up precious real estate. And it’s no
secret that heat is one of a power amplifiers worst en- The power transistors stay cooler and are not forced to
emies. needlessly dissipate heat. This is the normal operating
mode of the VZ power supply.
According to Ohm’s Law, the bigger the power supply,
the more heat the power transistors must dissipate. Also, When the voltage requirements are high, VZ switches
the lower the resistance of the power transistors, the to a series mode to produce higher voltage and less
more voltage you can deliver to the load. But at the current. The amplified output signal never misses a beat
same time that you lower the resistance of the transis- and gets full voltage only when it needs it.
tors, you increase the current passing through them, Sensing circuitry watches the voltage of the output sig-
and again increase the amount of heat they must dissi- nal to determine when to switch VZ modes. The switch-
pate. ing circuitry is designed to prevent audible switching
distortion to yield the highest dynamic transfer function
4.3.1 VZ Supply Operation — you hear only the music and not the amplifier. You
An articulated power supply, like VZ, can circumvent get not only the maximum power with the maximum
much of this problem by reducing the voltage applied safety, you also get the best power matching to your
to the transistors when less voltage is required. Reduc- load.
ing the voltage reduces the heat. Since the amplifier
runs cooler, you can safely pack more power into the In Figure 4.2, the individual components are
chassis. shown. Upstream of the toroid transformer,
though not shown, is where shutdown protec-
Toroid Bridge 1 tion and soft-start circuitry taps in to control AC
+VCC Buss mains input to the power supply. The VZ Control
circuitry senses audio level and switches the ar-
– + ticulating VZ supplies to either parallel (high cur-
rent) mode for lower level audio, or series (high
voltage) mode for high program peaks.
D 810
Figure 4.3 shows current flow with power supply
and grounded bridge operating to-
gether. Notice that the ungrounded
HI V HI I VZ supply operates much like a
VZ Control
Bridge 2 (MOSFETs) Circuitry battery. More exactly, it is a float-
ing DC supply made up of two in-
ternal batteries which operate in
– + either series or parallel.
In both examples it can be seen that when the
D 811
MOSFET switch is off, the dual supplies are
forced to operate in a parallel mode. Audio level
is sensed via a line tapping off the NFb loop.
When audio level is rising and at about 80% of
-VCC Buss the parallel mode supply voltage, the MOSFETs
(the switch is actually a three-device compos-
Figure 4.2 Simplified VZ Supply

VZ Power Supply & Grounded Bridge Output Topology
+ (+Vcc)
+Vcc (Positive Rail)
R R
Input
signal
Load
+ S1 + (speaker)
V1 V2 Inverting Op-amp
– –
HIGH SIDE -Vcc (Negative Rail) LOW SIDE
Parallel =
Series =
– (-Vcc)
R = Switch Resistance
Figure 4.3 Simplified VZ Supply in Operation
ite switch) are turned on. No current will flow through 4.3.2 VZ Supply Circuitry
either of the control diodes (D810 and D811, as shown For simplicity, only channel 1 circuitry will be covered
for channel 1) because reverse polarity is applied unless noted otherwise. The actual VZ switch circuit is
through the MOSFET switch. Since this happens to both located on the VZ switch assembly. This assembly con-
rectifier sources at the same time, and the negative side tains the filter capacitors, MOSFET switches, and con-
of Bridge 1 is then shorted to the positive side of Bridge trol diodes (D810 and D811). Three MOSFETs are used
2, the supplies are forced to operate in series mode. in parallel for sharing the high current supplied to the
Like two batteries, the supplies will provide double volt- rails. Operation of this section was covered in detail,
age in series mode, double current in parallel mode. minus circuit designations, in Section 4.3.1.
Although shipped from the factory in VZ-ODEP mode, WARNING: From a service standpoint, it is critical
the user may switch modes to Lock Low voltage (high to note that VZ switch control circuitry is NOT ground
current), or operate the supply in VZ-AUTO mode. VZ- referenced. Any attempt to take voltage measure-
ODEP is similar to VZ-AUTO mode, except that in AUTO ments using a ground reference when voltage is
mode, in the event ODEP is activated to protect the applied will not only be unreliable, but may be ex-
amplifier, the VZ will automatically lock into low voltage tremely dangerous. Serious damage to equipment
(high current) mode. While this mode of operation will or personnel may occur if this is attempted.
cool the amplifier more quickly in the event that the ther-
mal reserve is exhausted, it may cause voltage clip- The output of a 555 timer (U703) on the control module
ping rather than ODEP limiting. Seldom will the ampli- determines whether the MOSFETs are switched on
fier be operated locked in high current mode unless a (high) or off (low). This 555 device and the various
very low impedance is being driven. sources that feed the 555 are the things that make the
articulation work.
The master 555 trigger is controlled by the output of

U702A. S700, physically accessible from behind the The ODEP circuitry actually comes in two parts, one
front grille, determines the VZ operating mode. In high positive and the other negative. For the purposes of
voltage mode (Q42930-0 Control Module only) the out- this discussion, only the channel 1 ODEP circuitry is
put of U702A is held low. This in turn keeps the 555 covered here, and the focus will primarily be on the
output high and the MOSFETs are kept on. In the high positive half.
current mode, U702A is held in the opposite polarity,
keeping the output of the 555 low and the MOSFETs off. An LM-334Z thermal sensor provides a calibrated out-
In the AUTO position of S700, the audio level sense put from the output modules. At 25° C its output is 2.98V,
circuitry controls the threshold and reset inputs to the with a 10 mV increase per every 1° C rise in heatsink
555. The 555 will then switch states to high voltage when temperature.
the audio level is sufficient and will switch back down This thermal sensor output, from the positive sensor,
automatically when level has dropped sufficiently. Ca- goes to three destinations. First is a buffer which drives
pacitors in the U705 circuitry control the speed of the the calibrated temperature test point at pin 7 of TP1/
down-shift. In the VZ-ODEP mode, the switch operates TP2. Second is an over-temperature limit trip (thermal
as it would in AUTO mode unless ODEP limiting is in limit amplifier, as shown below). This will cause both
progress. When ODEP limiting occurs, optic coupler the positive and the negative ODEP circuit to go into,
U704 pulls the reset control low to the 555 to turn the and remain in, hard ODEP until the heatsinks cool. Third,
MOSFET switches off, and keep them off (low voltage/ it goes down into a circuit which combines thermal and
high current mode) until the ODEP limiting condition output power information.
clears.
The thermal sensor from the negative output module
Upstream of the toroids are the soft-start and protec- only performs this last function.
tion mechanisms used to power down the amplifier.
Although tied into the power supply primary, these cir- A pair of sense lines from the Low Side emitter resistors
cuits are covered in Section 4.6, Protection Systems. provide current information. Combined with VCC infor-
mation, actual instantaneous power is calculated. A
The low voltage power supply utilizes a separate trans- combining circuit determines the net thermal condition
former. The front panel power switch and a 1A fuse based on the power being delivered for the existing
(F702) are the only components upstream of this trans- heat level. The ODEP amplifier accepts this input infor-
former. The output of the rectifier produces ±24VDC mation and, using an RC model of the heat transfer
unregulated. U715 and U716 produce regulated characteristics of the output devices (as mounted in
±15VDC respectively. (A separate fullwave rectifier pro- the heatsinks), creates a complex output proportional
duces pulsed DC for Over-voltage sense and Soft-start to the thermal reserve of the output devices.
control.)
Output from the positive ODEP amplifier ranges from
– 12V (cold) to +9V (hard ODEP). This output drives the
4.4 ODEP Theory positive LS bias feed control circuit (see Section 4.2.2)
To protect the output stages from adverse thermal con- and the negative HS Voltage Translator feed control cir-
ditions, a specially developed “ODEP” (Output Device cuit (see Section 4.5.2). Also, this circuit provides test
Emulator Protection) circuit is used. It produces a com- point monitoring information and VZ-ODEP VZ mode
plex analog output signal proportional to the always control information.
changing safe-operating-area (SOA) margin of the out-
put transistors. This output signal controls the Voltage Output from the negative ODEP amplifier ranges from
Translator stage and Low Side output stage bias. This +12V (cold) to – 9V (hard ODEP). This output drives the
action removes only the drive that may exceed the safe- negative LS bias feed control circuit (see Section 4.2.2)
operating-area of the output stage. and the positive HS Voltage Translator feed control cir-
cuit (see Section 4.5.2). Also, this circuit provides test
Thermal sensors give the ODEP circuitry vital informa- point monitoring information, VZ-ODEP control informa-
tion on the operating temperature of the heat sinks on tion, and front panel ODEP (thermal reserve) LED con-
which the output devices are mounted. This tempera- trol information.
ture signal combines with the complex ODEP signal to
form the heart of our patented ODEP protection scheme. Also tapping into the ODEP output control of LS bias
feed and Voltage Translator feed are signals from the
fault, power (turn-on delay), and power loss (brown-
4.4.1 ODEP Operation
out) circuits. By using the output of ODEP for ±LL and
Refer to Figure 4.4 for a diagram of the basic operation
±LH control, these sources can mute the audio to the
of the ODEP system.

Channel 1 ODEP Circuitry shown

ODEP Inputs: ODEP Outputs:
Temperature Calibrated Temperature, for monitoring
±VCC ±ODEP Level, for monitoring
Output Current ±ODEP Level, for Bi-ODEP control of VZ Supply
±ODEP Level, to limit drive at ±Voltage Translators (±LH)
±ODEP Level, to limit Low Side Bias (±LL)
ODEP Indication (front panel LEDs)
Off Main On Main Module

Module
+Temp 1 Calibrated Temperature Output
LM-334Z Buffer Amplifier Hot
+9V
Thermal Sensor Thermal Limit Amplifier Cold
(+2.98V at 25˚C,
-12V
+10mV/˚C Rise) +ODEP Output
+VCC
+VCC -LH 1
Q519 LS +ODEP Amplifier
Output
+IC 1 +LL 1
Re
+ICOM 1 RC Network
Thermal Model FAULT 1
Common Output Buss PWR 1
PWR LOSS
-ICOM 1
-ODEP Amplifier
Re
-IC 1 +LH 1
Q524 LS
Output RC Network
-VCC -LL 1
Thermal Model
-VCC
-ODEP Output
-Temp 1 +12V
LM-334Z Cold Hot
Thermal Sensor -9V
Figure 4.4 Simplified ODEP Circuitry

output stage: a. until power-up delay has timed out; b. ing. When the thermal condition clears, this limiting con-
immediately upon indication of any failure mode; c. im- dition will also clear.
mediately upon loss of AC mains (power-down or ac-
tual loss of AC service). +VCC enters via dual PNP transistor pack U116.
Positive ODEP bias is adjusted by R182. The voltage at
that point controls the static balance of the U116 de-
4.4.2 ODEP Circuitry vice. U116 combines the VCC and output current sense
±TEMP signals are produced by U500 and U501 on information, the output of which represents output power
the output modules. U108, on the main module, is a level. The common output is brought into RN101 where
buffer which drives the temperature sense test point. it provides the reference for temperature and power.
U117A has a fixed window voltage of 6.2V via Zener U112B is the active device and, together with the power
D129. If heatsink temperature level exceeds about signal, drives the ODEP amplifier U112A. The RC net-
130° C, U117A output will cause both the positive and work in the feedback path of U112A models the ther-
negative ODEP amplifiers to go into hard ODEP limit- mal junctions from output device die to housing, hous-

ing to case, and case to heatsink under both static and 4.5.1 Balanced Gain Stage
dynamic conditions. The Balanced Gain Stage (BGS) amplifier U100A con-
verts the input audio from a balanced configuration to
The output of the positive ODEP amplifier drives +ODEP
single-ended with (electrical) unity gain. The compres-
test point pin 11. It also drives U114A and U114B which
sion device is essentially a resistive shunt across the
in turn drive – LH and +LL respectively. The output of
balanced BGS input. The BGS drives the Variable Gain
the negative ODEP amplifier drives the ODEP indica-
Stage and provides information to the compressor con-
tion circuitry and – ODEP test point pin 9. Negative ODEP
trol circuit and to the PIP connector.
also drives U114C and U114D which in turn drive +LH
and – LL respectively.
4.5.2 Variable Gain Stage
Also entering the U114 comparator networks are the The Variable Gain Stage (U100B) taps signal from the
PWR (power relay engage), PWRLOSS (brown-out), and wiper of the front panel level control (R120). Gain of the
FAULT (any protection which shuts down the amplifier) front-end is set by the gain of this stage. The sensitivity
signals via blocking diodes. If any of these signals drop switch (S100, located on the rear panel) selects the
low, the feed to the LS bias and Voltage Translator drive amount of gain in this stage. Overall amplifier sensitivity
will be shut down via ±LL and ±LH. This action mutes may be set for 26 dB fixed gain (about 5.1Vrms), 1.4V,
all audio in the event of a dramatic failure. or 0.775V. Since overall amplifier gain after this stage is
26 dB, this stage will have a fixed gain of 0 dB (26 dB
4.5 Front End Theory setting), about +12 dB (1.4V setting), or about +16 dB
Figure 4.5 explodes the front-end portion of the overall (0.775V setting). The output of this stage drives the Er-
block diagram. Once again, only channel 1 will be dis- ror Amp.
cussed in detail.
4.5.3 Error Amp
Input to the amplifier is only via a PIP module. The stan- The Error Amp (U105) input comes from the Variable
dard module shipped with the MA-5002VZ is the PIP2- Gain Stage with or without Loudspeaker Offset Integra-
FXQ. Whether this, or any other module is used, the tion (LOI), and is summed with amplifier output in a nega-
amplifier senses a balanced input from the installed tive feedback (NFb) configuration. Output of the Error
module. Amp drives the Voltage Translators and provides error
Figure 4.5 Front End Circuitry Block Diagram

signal information. An error signal (spike) is produced 4.5.7 Inverting Stages

any time the shape of the output waveform differs from Overall, the amplifier is non-inverting. Four stages within
the output of the Variable Gain Stage and LOI by more the amplifier, however, do invert the audio signal for a
than 0.05%. This error signal drives the error signal (ES) net non-inversion. The individual stages are: the BGS,
input to the PIP connector, the error signal sense test which inverts the audio; the Variable Gain Stage, which
point, and the compression control circuit. inverts it back; the input side of U106 and U107 (which
drives the Voltage Translators) re-inverts the audio (the
4.5.4 Compressor Voltage Translators are a common-base configuration
The compression circuitry senses error signal and BGS for high voltage gain); and finally, the LVAs invert the
level. If the BGS overloads, or an error signal is present, audio for the last time for a net non-inversion through
the compression control circuit (U101) produces a com- the amplifier.
pression drive pulse. A switch on the rear panel selects
the speed of the integrator circuit to follow. In the off 4.6 Protection Systems
position, the error driven compression is disabled, but The MA-5002VZ has several protection mechanisms to
the input overload compression remains on (in fast limit drive or shutdown the amplifier completely in the
speed) to protect the front end. The compression drive event of a fault of almost any kind. Mechanisms include:
pulse also drives the IOC Integrator (U102). The IOC ODEP (covered in depth in Section 4.4), current limit
integrator not only tells the IOC indicator circuit when to (covered in Section 4.2.2), over-voltage (on AC mains),
turn on, but ensures that the indicator will remain on DC/LFI, common mode output current, output thermal,
long enough to be visible to the human eye. transformer thermal, FET thermal, loss of AC mains,
The compression integrator (U102, Q100) sets com- compression (covered in Section 4.5.4), LOI (covered
pression speed and produces an output pulse which in Section 4.5.5), and slew rate limit (covered in Section
controls attack and decay times. An optic device (U103) 4.2.2). After any non-latching fault which has shut down
provides a resistive shunt to the input audio according the amplifier clears, the amplifier will automatically power
to the degree of compression required and the dura- back up via soft-start. Because the fans within the MA-
tion of that compression. The amplifier input impedance 5002VZ cool the amplifier (under normal conditions) to
is not affected by compressor operation. prevent thermal shutdowns and ODEP limiting, the fan
control circuit is also covered in this section.
4.5.5 Loudspeaker Offset Integration Refer to Figures 4.6, 4.7, and 4.8. Figure 4.6 shows soft-
LOI (U104A/B) senses amplifier feedback and prevents start and fan control. Figure 4.7 shows the soft-start con-
dynamic DC offset. It operates essentially as a dual fil- trol signals. Figure 4.8 shows the over-all protection
ter system with band pass from about 35 Hz to about scheme of the MA-5002VZ. Each augments the others,
50 kHz. The upper roll-off has a second order Bessel and explode the basic block diagram of the unit (Fig-
response while the lower roll-off has a third order ure 4.9).
Butterworth response.
4.6.1 Soft-start
4.5.6 Voltage Translator and LVA Stages Soft-start circuitry controls the rate at which power is
The Voltage Translator stages (Q104, Q104) channel initially applied to the primary of the toroid transformers
the signal to the Last Voltage Amplifiers (LVAs, located for the high-voltage power supplies. For ease of expla-
on the output modules), depending on the signal polar- nation, assume the amplifier is operating properly and
ity, from the error amp U105. The ±LVAs, with their push- is just being turned on from the front panel power switch.
pull effect through the High Side bias servo devices,
drive the fully complementary output stage. For more Before the power switch push-button is depressed, the
information on the LVAs, refer to Section 4.2. input to the low voltage supply is open. The high volt-
age supply is isolated via input relay K700 and triac
U106 and U107 bring in feedback information and pro- Q701 (which is in parallel with K700).
tection muting to the Voltage Translator stages. The feed-
back controls gain from the Voltage Translators to the Several things occur immediately at turn-on. First, the
output jacks. The protection inputs (±LH) pull off feed low voltage supply powers up and produces its main
to the Voltage Translators in proportion to ODEP limit- unregulated ±24VDC and regulated ±15VDC. It also
ing, and completely shut down the feed in the event of immediately produces pulsed DC via full-wave rectifier
power-down or a Fault. D709/D714.

POWER
XFMR
Portion of POWER
Main Module ON
+10.4V - RELAY RELAY
+ DRIVE K700
+15V
FAULT
VOLTAGE
DC/LFI
DIVIDER
OV/TSW
WITH C120 POSITOR
PWRLOSS
STANDBY 5.0 OHM
DRIVER SOFT-START
DRIVER
-15V
-
+
POWER
SWITCH DC PULSE
WIDTH TO CH 2 SOFT-START DRIVER
CONTROL
LOW +15V CH 1 FAN

VOLTAGE -15V CONTROL
POWER +24V TEMPERATURE CH 1
SUPPLY -24V
FAN ODEP CH 1
DRIVERS
+
TEMPERATURE CH 2
-
ODEP CH 2
CH 2 FAN
TSW1 CONTROL
FANS
TSW2
Figure 4.6 Soft-start and Fan Control
As this occurs, all op-amps in the amplifier receive Note: Any protection signal within the amplifier which is
power, including front-end stages, relay power control used to shut it down will discharge this capacitor (C120),
U111C, and standby control U111B. The output of immediately causing the relay (K700) to open. Upon
U111C powers relay K700 via relay drive transistor clearance of such a shut-down protection signal, the
Q700. When the output of this op-amp goes high, Q700 charge will begin again with the same ramp effect and
turns on and the relay closes. The output of U111C is same delay.
held low until the amplifier delay times out by compar-
The ramped voltage on the capacitor C120 is also
ing a high voltage on its inverting input to an RC net-
sensed by Standby amplifier U111B. Its unity gain out-
work voltage on its non-inverting input. R329 and R330
put is non-inverting. It drives the Soft-start op-amp
fix a window at about +10.4VDC. At turn-on, C220 (a
(U701A) inverting input with its ramp to control the rate
10 µF cap) is fully discharged. In that first instant, it keeps
at which the field develops in the toroid. On the non-
– 15V on the non-inverting input of U111C, keeping its
inverting input to U701A is the pulsed DC drive from
output low. As the capacitor charges it produces a
the U701B/Q708 pulse circuit. Jumper JP1 may be set
ramped rise in voltage as it charges through R327. Af-
to 50 or 60 Hz, but must be set properly to have the
ter about 4 seconds, the voltage between R327 and
correct pulse width for soft-start. Pulse width is deter-
R328 exceeds the window voltage and U111C output
mined by C717 and either R777 (50 Hz) or R777 in par-
goes high, in turn causing relay K700 to close.
allel with R806 (60 Hz).

The output of U701A controls the Soft-start. Refer to fields have built up in the high voltage supply, and the
Figure 4.6 for a graphic of Soft-start operation. main relay closes. At time 3 a protective action occurs;
note that the DC supply remains. At time 4 the condi-
When the output of U701A goes low, the opto-triac de- tion clears and the restart begins. Time 5 is akin to time
vice U700 turns on. While on, the input triac Q700 con- 2, and time 6 is another protective action. The lower
ducts. Positor R702 limits peak input current to the tor- graph shows Q701 operation (high = on).
oid to a maximum of 22A peak (with 120VAC mains).
U701A combines the sloped input from the C120 cir- Any time a protection mechanism has acted and the
cuitry on the main module with the pulsed DC. As the condition then clears, this entire process repeats.
portion of time which the output of U701A goes low in-
creases, the amount of time where AC mains conduct 4.6.2 Over-voltage
to the transformer (via Q700 and R702) increases until One mode of amplifier protection is a shutdown in the
it remains on. When the U111C PWR circuit times out, event of over-voltage on the AC mains. This is sensed
the relay closes, bypassing the current limiting soft-start by the pulsed DC signal produced by the full-wave rec-
circuit. Soft-start control signals are shown in Figure 4.7. tifier in the low voltage supply.
The upper signal is that produced by C120. At time 0
the amplifier is off. At time 1 the power switch is pressed R780 picks off the pulsed DC, and U707D will, if the
(on). At time 2 C120 has fully charged, the magnetic voltage is too high, shift its output to a low. When this
happens, the over-volt/therm red LED on the control
module lights and signal OV1 goes low
to the main module.
A low (over-voltage condition) on
OV1 causes U211C to shift to a
C120
low output. This low, through D1,
CHARGE
causes C120 to discharge im-
VOLTAGE
mediately. This in turn causes the
main relay to drop out, soft-start
to reset, and the ±LL and ±LH
0 1 2 3 4 5 6 to clamp audio drive. Over-volt-
age is a non-latching fault con-
dition.
4.6.3 DC/LF
The amplifier senses its own out-
PULSED put for DC or very low frequency
DC FROM and will interrupt the amplifier
LVPS channel in the event of DC or low
frequency.
The feedback loop is sensed for
0 1 2 3 4 5 6 voltage and the current sense
signal provides current informa-
tion. An RC network at the input
to U109C/D will prevent the LF
circuit from activating with nor-
mal audio frequency material,
SOFT-START and will ensure activation with
TRIAC high level subsonic currents or
CONTROL voltages.
If U109C/D sense a DC (or LF)
level, it will output a low, which
0 1 2 3 4 5 6
will, through D102, discharge
Figure 4.7 Soft-start Signal C120 and initiate power supply

shutdown. A low will also cause the DC/LF red LED on

the main module to light. DC/LF is a non-latching pro- DC PULSE
WIDTH
tection mechanism. CONTROL
+15V SOFT-START
CONTROL
4.6.4 Common Mode Output Current + SOFT-
- START
Common mode current in the output stage
V
can only be due to an output stage failure STANDBY
or full power output of RF energy. Com- 0 1
PWR
mon mode current occurs when a high - MAIN
current level exists in both the positive and + RELAY
C120 +10.4V
the negative halves of the output stage.
U115 is a specialty device. It serves as ±LL & ±LH
both an Opto-SCR, and as a conventional -15V
FOR LS BIAS &
V XLTR FEED
SCR. It must have both an optic gate and CONTROL
conventional gate firing at the same time
in order to latch. The conventional gate is DC/LF
DC VOLTAGE &
fired by current sense of the output stage CURRENT SENSE
Low-side. The optic gate is fired by the
DC/LF
High-side current sense. If high currents RED
exist in both sides simultaneously, the SCR
FAULT
will latch on, and remain on until the unit is
FAULT LS NPN CURRENT
turned off. SENSE HS NPN CURRENT
OUTPUT
When the SCR latches, low voltage causes MODULE
the red LED (labeled Output Module) to RED
light, and places a low on the FAULT sig-

PWR LOSS ±15VDC
nal line. A low on the FAULT line is sensed, SENSE
via D112, by C120. Once again, a low here
discharges C120 and shuts down the am- To Ch 2
To Ch 2
plifier. FAULT is a latching protection x1 BUFFER
OV/TSW OVER-VOLTAGE
mechanism (the only one in the amplifier).
+
TOROID
- THERMAL
4.6.5 Output Thermal SWITCH
OV/TSW
Output over-temperature protection has RED
been covered, to a degree, in Section
REMOTE
4.4.2, ODEP Circuitry. The calibrated tem- STANDBY
perature sense from the positive half of the FROM PIP
output stage drives an over-temperature STBY
amp, U117A. If heatsink temperature ex- RED
ceeds a limit of about 130° C, the amplifier

will go into hard ODEP. This does not shut Figure 4.8 Over-all Protection Scheme
down the amplifier, but does clamp the au-
dio. Refer to Section 4.4.2. results in amplifier shutdown by way of shared over-
voltage circuitry. Refer to Section 4.6.2.
4.6.6 Transformer Thermal
The main power transformers have built-in thermal 4.6.7 FET Thermal
switches which open in the event of transformer over- A special circuit has been designed into the MA-5002VZ
temperature. In the event that the thermal switch opens to protect the MOSFET switches in the VZ supply. The
in the channel 1 toroid, Q709 turns on, causing U707D voltage drop across the FETs (while conducting) is pro-
to go low. When it does, the over-voltage/thermal switch portional to device temperature. Control circuitry senses
LED on the control module is energized and the OV1 the voltage and, if necessary, the supply will be forced
signal is tripped; the fans are also forced to high speed. into low voltage (high current) mode to allow the FET
Transformer thermal protection is self-resetting. This devices to cool.

4.6.8 Power Loss fier thermal reserve. The LEDs are amber (although they
The MA-5002VZ has the ability to sense a “brown-out” may have a reddish appearance) and are normally on.
condition on the AC service. This is accomplished by They dim and/or extinguish in the event that the
sensing the low-voltage power supply at U111A. Local amplifier’s thermal reserve is exhausted. ODEP indica-
capacitors on the ±15VDC keep this chip powered for tors will also extinguish whenever the main supply re-
a short time after the low voltage supply drops out on lays are open (such as a protection action being acti-
power-down/loss. vated, or during Soft-start time-out).
An RC network, consisting of C1 and R6, will cause the Green SPI/IOC LEDs show signal presence (SPI) and
output of U111A to shift low the instant low voltage is any form of distortion (IOC). They flash dimly with the
lost. This negative potential discharges C120 causing audio to show signal. In the event of an IOC condition
immediate opening of the main relay, and reset of the (output waveform differs from input by >0.05%, or input
Soft-start circuitry. It is essential that C120 be discharged overload) the light will be on brightly. An occasional flash
immediately in the event that power is restored before of IOC usually indicates clipping. If the IOC light locks
C120 would otherwise discharge. The power-loss cir- in, it usually indicates a protective action, or “hard” ODEP
cuit is common to both channels. Its output goes to limiting.
±LL and ±LH to immediately mute audio upon power-
ILOAD/ILIMIT LEDs flash green with the audio when pro-
down or power-loss, thus preventing turn-off audio noise.
gram material is being delivered to a load. Its function
is similar to that of the SPI, except that SPI is voltage
4.6.9 Fan Control driven and does not require a load. ILOAD comes on
The MA-5002VZ, unlike other members of the Macro- when the amplifier is loaded, and its brightness is in
Tech family, has two onboard fans. They are mounted proportion to the output current. This is the ILOAD func-
to the chassis divider assembly and pull cool air from tion. In the event of current limiting action, the light will
the front and discharge it across the output stage flash to red. This is the ILIMIT function.
heatsinks to the rear of the amplifier. Also unlike the other
Macro-Techs, the fans are fully ODEP proportional (they
operate in proportion to output stage temperature and 4.8 Mono Modes
calibrated ODEP control voltage). The MA-5002VZ has three main operating modes,
namely dual (stereo), bridge mono, and parallel mono.
U713B combines channel 1 temperature and ODEP
level, U713A for channel 2. D706 and D707 form a di- There are a number of precautions which should be
ode OR gate. The output of the OR gate drives one taken when operating the amplifier in either of the mono
input to U707B. The other input to U707B is from the modes. The VZ mode switches for each channel must
DC pulse width control circuit (U701B). U707B oper- be set to the same setting. Sensitivity, LOI, and Com-
ates in a fashion similar to that of U707A, the Soft-start pressor switches for channel 2 make no difference. The
control amplifier. A graphic example of the fan control input must be to channel 1 only. The input to channel 2
waveforms would look a good deal like those in Figure and controls for channel 2 are NOT defeated in either
4.7, except that the thermal drive would be unique from mono mode, therefore no connection to channel 2 may
that of the Soft-start ramp. be made in either of the mono modes. The channel 2
level control should be turned down (counterclockwise)
The fans will also be forced to operate at full speed in fully in either mono mode.
the event a toroid transformer thermal switch trips open.
Monaural amplifier operating modes are covered in
detail in the MA-5002VZ Reference Manual. The dis-
4.7 Display cussion below primarily aids in understanding how the
Amplifier front panel indication includes a total of 7 LEDs. mono modes work for testing purposes.
These include Enable, ODEP, SPI/IOC, and ILOAD/ILIMIT.
The Enable indicator is an amber light which indicates 4.8.1 Bridge Mono
presence of the low voltage supply. It is powered by the Bridge mono is intended for loads of 4 ohms or greater.
unregulated +24VDC supply. It will be on any time the The feedback loop for channel 1 also drives the input
power switch is depressed (unless the low voltage fuse to channel 2 in this mono mode. The input to channel 2
blows). is, however, inverted. This causes the output of chan-
nel 2 to be of equal magnitude and opposite polarity
ODEP indicators provide an on-line indication of ampli- (for double voltage output). The output of the amplifier

is balanced, and channel 1 hot output is connected to The channel 1 and 2 amplifier hot outputs must be
load hot (+), channel 2 hot output is connected to load shorted by an external shorting buss (10 AWG or larger).
return (– ). The amplifier output to the load(s) is taken from either
channel’s hot output to load hot, and either channel’s
4.8.2 Parallel Mono negative output to the load return (– ). The shorting buss
Parallel mono is intended for loads less than 4 ohms must be removed prior to changing from parallel mono
(as low as 1 ohm) in a monaural amplifier configuration. to either other mode.
Figure 4.9 Macro-Tech 5002VZ Amplifier Block Diagram

toms. After troubleshooting and repair (or as a part of),

the final step is to thoroughly test the amplifier to be
5 Maintenance certain that it meets the factory specifications. Test pro-
cedures in Section 5.4 will help you do this as well as
aid you in locating the cause of problem(s).
5.1 Cautions and Warnings
DANGER: The outputs of this amplifier can produce 5.3 Troubleshooting
LETHAL energy levels! Be very careful when making
connections. Do not attempt to change output wiring 5.3.1 Pre-AC-Checks
until the amplifier has been off at least 10 seconds. A number of checks can be made prior to powering up
WARNING: This unit is capable of producing high sound the unit. These should be done in order to prevent an
pressure levels. Continued exposure to high sound pres- unwanted disaster when turning the unit on. Once these
sure levels can cause permanent hearing impairment checks are made power may be applied for further
or loss. User caution is advised and ear protection is checks. Note: It will be necessary to remove top, rear,
recommended when using at high levels. and bottom panels for complete access to all modules.
WARNING: Do not expose this unit to rain or moisture.
WARNING: Only properly trained and qualified techni- Step 1: Acquire all information possible from the
cians should attempt to service this unit. There are no person(s) having the problem to determine the nature
user serviceable parts inside. of the complaint. Ask questions like “Why was the am-
WARNING: When performing service checks with the plifier brought in for repair?” “Does it do this right at turn
power off, discharge the main power supply filter ca- on, does it take a while, or does it only happen some-
pacitors fully before taking any measurements or touch- times?” If you observe nothing wrong, inquire tactfully
ing any electrical components. A 300-ohm 10-W resis- how the unit was being used when the malfunction oc-
tor is recommended for this. Hold the resistor with pli- curred to determine if it may have been misused, if the
ers, as the resistor may become extremely hot. user misunderstood what happened, or if another sys-
WARNING: Under load, with a sine wave signal at full tem component may be at fault.
power into both channels, the amplifier may draw in Step 2: Always do a complete visual inspection. A prob-
excess of 30 amperes from the AC service mains. lem may be obvious just by looking. Things to look for
WARNING: Do not change the position of the Mode include burned components, wires not connected, fan
Switch when the amplifier is turned on. If the position of obstructions, loose hardware or connections, and sol-
this switch is changed while the amplifier is powered, dering. Dirty air filters or plugged heatsinks greatly re-
transients may damage your speakers. duce amplifier efficiency and result in pre-mature ODEP
WARNING: Heatsinks are not at ground potential. Si- limiting. The fan blades should spin freely. Burns and
multaneously touching either heatsink and ground, or other physical damage should be repaired and com-
both heatsinks will cause electrical shock. ponents in the affected circuit areas should be checked
CAUTION: Eye protection should be worn at all times carefully before continuing.
when protective covers are removed and the amplifier
is plugged in. Whether a problem is identified by visual inspection or
CAUTION: Disconnect the power cord before install- not, several checks should be performed prior to turn-
ing or removing any cover or panel. ing the amplifier on. These should be performed if cata-
strophic failure has been reported, no signal output with
5.2 General Information constant IOC is reported, or the condition of the ampli-
In most cases you will be using the test procedures in fier is otherwise unknown but failure is suspected.
Section 5.4 after conducting your repairs. Before ini-
Channel 1 uses 100/300 series numbering and chan-
tially powering up the amplifier you should review Sec-
nel 2 uses 200/400 series numbering on the main mod-
tion 5.1 and take appropriate steps for personal and
ule. 500 series numbering is used on the output and
equipment safety. Section 5.3 will help to determine
emitter modules, regardless of the channel. 700 and
whether the amplifier should be safe to turn on.This
800 series numbers are used on control, current sense,
section also includes some additional checks that
and terminator modules.
should be made prior to starting the actual check-out.
Italicized print in the test procedures (Section 5.4) in- The third item on the “to do” list involves a number of
cludes basic troubleshooting hints to augment proce- electrical checks. Due to the protection features of the
dures in Section 5.3. These hints do not cover every MA-5002VZ, it should be safe to turn-on under all cir-
possibility, but should be helpful for a variety of symp- cumstances, but these preliminary checks may allow a
©2000 Crown International, Inc. Maintenance 5-1

partial, if not complete, repair before power is ever ap- d.) If a failure is found in any LVAs, checks
plied. These checks are designed to find problems in should continue up onto the main module in the volt-
the output stages. The ultimate guide should always be age translator stage.
common sense.
e.) Failure within the power supply itself is very
To access all of the modules, simply remove the top rare, however a cursory check of major items is always
cover, rear panel, and bottom cover. The main module prudent. A 30A fuse should not blow unless a cata-
will slide up and back for access to output module com- strophic failure has occurred in the output stage or
ponents by loosening four screws. The main module power supply. The low voltage fuse should not blow
tray need not be removed in order to remove an output unless a failure has occurred, probably in the supply
assembly, however, to perform component replacement itself. If a failure has occurred in the output stages, check
on the main module the tray should be removed com- the MOSFET switches and other VZ control components,
pletely and the module removed from the tray. Note that such as bridge rectifiers.
the current sense module is actually comprised of two
separate boards, connected by dual ribbon cables, 5.3.2 LED Checks
hardwired at both ends. The smaller board is called When power-off checks are complete and any defects
current sense, the larger is, by itself, referred to as the found are corrected during that phase, the next step is
terminator. Either name, however, may be applied to to apply power. The MA-5002VZ includes several LED
the pair. In Section 8 they are covered as a single part, indicators to assist you in troubleshooting an amplifier
D 7994-3. malfunction.
a.) Locate the flyback diodes D506, D507, All indicators on the amplifier, both front panel and in-
D508, and D509 on the emitter modules and check for ternal, are important. External indicators include Enable,
indications of a short. If a short is indicated, this means ODEP, SPI/IOC, and ILOAD/ILIMIT. Internal indicators in-
that an output device or driver transistor in parallel with clude DC/LF, Fault (output module), Standby, and Over-
that diode is shorted, usually not the diode itself. If a voltage/Transformer Thermal.
faulty output device is found, the entire output assem-
bly may be replaced, or only the affected components. A chart on the following pages lists likely LED combina-
If an output device is found to be defective, emitter re- tions and likely causes. In each case it is assumed that
sistors should also be checked. If no output device is the LED circuit itself is operating properly. If a failure is
found defective, perform a quick check of driver, pre- suspected, compare amplifier indicators with the chart.
driver, and bias transistors. Then, if no problem is found,
In order to ensure that the problems are assessed cor-
move to power-on checks.
rectly, perform the LED checks under the following con-
b.) Check driver and pre-driver transistors for ditions: Before power is applied, ensure that the Ste-
shorts or opens. If a fault is found, do an in-circuit static reo/Mono switch is in the STEREO position. Do NOT
check of all semiconductors on the output modules. If connect any signal source or load to the amplifier. Turn
no output device and nothing upstream is found defec- the amplifier on. After approximately 4 seconds the turn-
tive, move to power-on checks. Otherwise continue. on delay should time out. During the delay, IOC indica-
tors will usually be on and ODEP indicators should be
c.) If a failure has occurred anywhere in the off. After the delay times out, relays click on, IOC indi-
output stages, check bias servo transistors on each cation should go off, and ODEP indicators should come
(positive and negative) output module. Any failure as- on. If this does not occur, definitely refer to the chart
sociated with bias transistors may result in repeat fail- that follows. Although this chart contains most likely fail-
ure of the affected channel even if all other defective ures, it does not cover every possibility. Common sense
components have been found and replaced. and a study of schematics and circuit theory (provided
in Section 4) should ultimately lead to a proper repair.
5-2 Maintenance ©2000 Crown International, Inc.

Indicator Condition Cause

ODEP One OFF At any time the main relay is off (open), the ODEP indicator is also
SPI/IOC Both OFF held off. Any protective action which will result in amplifier shut-
ILOAD/ILIMIT Both OFF down will cause the ODEP indicator on the affected channel to be
STBY Both OFF off. The ODEP indicator will also be off when the amplifier is into
OV/THERM Both OFF “full ODEP” limiting. Under the initial conditions described, the
DC/LF Both OFF conditions in the left column will only occur when there is a failure
OUTPUT MOD Both OFF in one relay or relay control circuit, in the ODEP circuit itself, or in
a thermal sensor for the ODEP circuit.
ODEP One OFF An ODEP indicator off coupled with one or both internal STBY
SPI/IOC Both OFF indicators lit is most often caused by low line voltage. It may also
ILOAD/ILIMIT Both OFF be caused by placing a logical low on a RS (remote standby func-
STBY One/Both ON tion) connection to the PIP module. First, verify AC mains voltage
OV/THERM Both OFF and check the amplifier to ensure it is wired for the appropriate
DC/LF Both OFF AC mains. The RS port from the PIP module is not likely to be at
OUTPUT MOD Both OFF fault, but if an IQ-PIP is installed, it may be necessary to replace it
with a blank module (such as the PIP2-FXQ) for testing purposes.
ODEP Both OFF Both ODEP indicators off coupled with both internal OV/THERM
SPI/IOC Both OFF indicators lit is most often caused by high line voltage (>10% above
ILOAD/ILIMIT Both OFF what the amplifier is wired for). It is extremely unlikely that the
STBY Both OFF thermal switches in both amplifier channels will be activated. First,
OV/THERM Both ON verify AC mains voltage and check the amplifier to ensure it is
DC/LF Both OFF wired for the appropriate AC mains. If fans are running at full speed,
OUTPUT MOD Both OFF a transformer thermal condition is probably being stimulated by a
failed IC such as U707.
ODEP One OFF One ODEP indicator off coupled with one internal OV/THERM in-
SPI/IOC Both OFF dicator lit will result from an open thermal switch in the toroid of
ILOAD/ILIMIT Both OFF the affected channel. Except for very early units with control mod-
STBY Both OFF ule Q42930-0, fans should both be operating at high speed. If
OV/THERM One ON they are, a thermal switch is in fact open. If fans are off or nearly
DC/LF Both OFF off (and control module is Q43096-9 or later), the problem is more
OUTPUT MOD Both OFF likely a failed Q709 (Ch 1) or Q707 (Ch 2).
ODEP One OFF One ODEP indicator off coupled with IOC and DC/LF indications
SPI/IOC One ON indicates a DC offset at the amplifier's output. The amplifier may
ILOAD/ILIMIT Both OFF attempt to cycle if a small offset is being caused by a malfunction.
STBY Both OFF This may not be the direct result of an output device failure. It may
OV/THERM Both OFF rather be caused by a grossly maladjusted or faulty balance con-
DC/LF One ON trol within the amplifier. It may also be caused by any number of
OUTPUT MOD Both OFF minor components failing in an unexpected manner. It could also
be the result of an unbalanced ODEP circuit (±ODEP bias poten-
tials unequal). If the DC/LF indication remains locked in, the OUT-
PUT MOD Fault circuit may be activated, but on occasion the DC/
LF circuit will trigger faster causing this indication. Observe the
output with a scope to determine if cycling action is in fact occur-
ring.

Indicator Condition Cause

ODEP Both OFF Both ODEP indicators off coupled with both IOC and DC/LF indi-
SPI/IOC Both ON cations indicates a DC offset at both outputs. If possible, inquire if
ILOAD/ILIMIT Both OFF the user was operating the amplifier in a mono mode when the
STBY Both OFF failure occurred. If so, then it is likely that output stage damage
OV/THERM Both OFF has occurred in both channels. If not, two unique problems may
DC/LF Both ON have occurred, or there may be an unexpected short on the ter-
OUTPUT MOD Both OFF minator/current sense module. Other unexpected shorts may be
possible. Mechanical integrity should be carefully checked.
ODEP One OFF An ODEP indicator off coupled with one internal OUTPUT MOD
SPI/IOC Either OFF/ON indicator lit may be accompanied with IOC and ILOAD/ILIMIT for the
ILOAD/ILIMIT Either OFF/ON affected channel. Such a fault is latching and keeps the high volt-
STBY Both OFF age rails off. This type of fault is caused by conduction in both the
OV/THERM Both OFF positive and negative half of the output stage simultaneously.
DC/LF Both OFF Under normal conditions this cannot occur at levels much above
OUTPUT MOD One ON 100mW, assuming the amplifier is properly biased. A fault like this
is usually the result of a failed output device, or possibly a failed
bias network. It may also be caused by operating the amplifier at
extremely high levels with ultra-sonics.
ODEP Both OFF Both ODEP indicators off with no other abnormal indication is al-
SPI/IOC Both OFF most impossible unless both relays fail, or the Power Loss IC
ILOAD/ILIMIT Both OFF (U111A) circuit has failed.
STBY Both OFF
OV/THERM Both OFF
DC/LF Both OFF
OUTPUT MOD Both OFF
5.4 Test Procedures 5.4.1 Standard Initial Conditions

The following test procedures are to be used to verify The start of each step assumes all switches are pre-set
operation of this amplifier. DO NOT connect a load or to the following positions:
inject a signal unless directed to do so by the proce- Dual Mono Switch: STEREO position.
dure. These tests, though meant for verification and Sensitivity Switches: Both to 0.775V position.
alignment of the amplifier, may also be very helpful in Compressor Switches: Both to OFF position.
troubleshooting. For best results, tests should be per- LOI Switches: Both to OFF position.
formed in order. VZ Mode Switches: Both to VZ position.
All tests assume that AC power is from a regulated 120 Level Controls: Both up (clockwise) fully.
VAC source. Test equipment includes an oscilloscope, 5.4.2 Equipment Required
a DMM, a signal generator, loads, and I.M.D. and T.H.D. The following is a list of standard equipment needed to
noise test equipment. perform all the tests listed in Section 2.3.3:
WARNING! Most adjustments are made with the cov- Line Voltage Variac: 5 kW or larger.
ers removed. Prior to any AC power off testing, dis- Oscilloscope: 2 Channel, 10 MHz or better.
charge all power supply capacitors. Also, use ex- Digital Multimeter: Various measurements.
treme caution when making internal adjustments Watt Meter: For AC line draw.
when the unit is powered. ACVM: Peak reading RMS calibrated (all AC line
voltage and amplifier output voltage checks).
I.M.D. Analyzer: 60 Hz/7 kHz in 4:1 ratio, accurate to
0.001% I.M.D.
T.H.D. Analyzer: Accurate to 0.001%.
Loads: 3000 W continuous at 1 ohm.

WARNING: Do not connect any load to the MA-5002VZ power amplifier during these tests
until specifically instructed to do so.
Type of Test Input Signal and Comments

or Adjustment Load Parameters
1. Turn-on Delay No Signal Check for a delay of approximately 4 seconds from
No Load the time the power push button is pressed until the
IOC indication clears and ODEP indicators come on.
If the IOC fails to clear in one channel, check for pres-
ence of rail voltages and for a DC offset. Also check
circuit board LED for indication of a fault - DC/LF,
Output Module, and OV/TSW. Turn unit off, discon-
nect the power cord, discharge power supplies, and
check for a failure in the output stage of the affected
channel, or other applicable circuit area. If the fans
lock in high speed after delay times out, check fan
control components, ODEP output, and LM334Z de-
vices on the output modules.
2. DC Output Offset No Signal With the input level controls turned fully clockwise,
No Load the DC offset for both channels should be less than
±15 millivolts. Note: There are no output offset adjust-
ments for the MA-5002VZ. A small DC offset may in-
dicate an ODEP failure. A large DC offset usually indi-
cates a failure in the output stage, though such an
offset should have shut down the amplifier on a DC/
LFI signal.
3. Quiescent Power No Signal While there is no published specification on quies-

No Load cent power, it should be checked. A power draw with
the fans off or operating slowly will normally be less
than 150 W (<1.5 A). If quiescent power greatly ex-
ceeds expectation then turn the amplifier off immedi-
ately and search for power supply or output failure. If
quiescent draw exceeds expectation by a “small”
amount check bias immediately.
4. High Side Bias No Signal Bias voltage is set while the amplifier is at room tem-
No Load perature. If the amplifier is hot from prior testing for
repair or other purposes, it should be set aside until it
has cooled before continuing with this check. Bias,
once factory set, normally will not require adjustment.
For channel 1: Measure the voltage at TP1 pin 2 with
respect to pin 4 (DO NOT measure from ground refer-
ence). The bias voltage should equal .330VDC ± 10
millivolts. If the bias voltage needs to be adjusted,
adjust R505 on the channel 1 output assembly for the
correct bias voltage. For channel 2: Measure the volt-
age at TP2 pin 2 with respect to pin 4 (DO NOT mea-
sure from ground reference). The bias voltage should
equal .330VDC ± 10 millivolts. If the bias voltage needs
to be adjusted, adjust R505 on the channel 2 output
assembly for the correct bias voltage.


5. Low Side Bias No Signal Bias voltage is set while the amplifier is at room tem-
No Load perature. If the amplifier is hot from prior testing for
repair or other purposes, it should be set aside until it
has cooled before continuing with this check. Bias,
once factory set, normally will not require adjustment.
For channel 1: Measure the voltage at TP1 pin 15 with
respect to pin 13 (DO NOT measure from ground ref-
erence). The bias voltage should equal .330VDC ±
10 millivolts. If the bias voltage needs to be adjusted,
adjust R556 on the channel 1 output assembly for the
correct bias voltage. For channel 2: Measure the volt-
age at TP2 pin 15 with respect to pin 13 (DO NOT
measure from ground reference). The bias voltage
should equal .330VDC ± 10 millivolts. If the bias volt-
age needs to be adjusted, adjust R556 on the chan-
nel 2 output assembly for the correct bias voltage.
6. O.D.E.P Null No Signal ODEP Nulls are based on heatsink temperatures. A

No Load reference voltage is supplied at TP1/TP2 which is pro-
portional to the heatsink temperature. For positive
ODEP: Measure TP1/TP2 pin 18 with respect to
ground. Refer to the chart (Figure 5.1) below. If mea-
sured voltage falls outside the listed range, the am-
plifier is too hot or too cold. Now measure TP1/TP2
pin 11 and adjust, if necessary, R182/R282 for the set
voltage on the chart, ±0.1 V. For negative ODEP: Mea-
sure TP1/TP2 pin 17 with respect to ground. Refer to
the chart (Figure 5.1) below. If measured voltage falls
outside the listed range, the amplifier is too hot or too
cold. Now measure TP1/TP2 pin 9 and adjust, if nec-
essary, R191/R291 for the set voltage on the chart,
±0.1 V. Note that the negative ODEP set voltage is a
negative voltage with respect to ground.
Voltage ODEP Set Voltage ODEP Set

Measured Voltage Measured Voltage
2.90 V 12.96 V 3.00 V 11.76 V
2.91 V 12.64 V 3.01 V 11.64 V
2.92 V 12.72 V 3.02 V 11.52 V
2.93 V 12.60 V 3.03 V 11.40 V
2.94 V 12.48 V 3.04 V 11.28 V
2.95 V 12.36 V 3.05 V 11.16 V
2.96 V 12.24 V 3.06 V 11.04 V
2.97 V 12.12 V 3.07 V 10.92 V
2.98 V 12.00 V 3.08 V 10.80 V
2.99 V 11.88 V 3.09 V 10.68 V
Figure 5.1 ODEP Set Voltage Chart

WARNING: Many of the following checks are done by connecting a resistive load to the output of the
amplifier. Use caution and follow check-out procedures carefully to ensure correct results. These
tests require a resistive load capable of over 3000 W continuous into as low as 1 ohm.
WARNING: The MA-5002VZ is capable of drawing in excess of 80 Amperes of current from 120VAC
Mains when loaded to 2 ohms per channel and with both channels driven by a 1 kHz sine wave.
CAUTION: 30 A fuses should be replaced after completion of tests, as they will be stessed during high
power tests. Special 30 A test fuses may be used during testing if they are replaced with the stock
fuses after the tests. 30 A fuse part number is A10285-30.

7. CMR Null 0.775V (0 dBu), With the sensitivity switch in the high gain position
1-kHz Sq. Wave (0.775V), insert a common mode 1-kHz 0 dBu square
No Load wave into channel 1 (phono tip & ring shorted or XLR
pins 2 and 3 shorted). At the output jacks measure
less than 25 mV. If necessary adjust R105. Repeat
test for channel 2, adjust R205 if necessary. This ad-
justment is easiest when done with an oscilloscope
at the output and adjusting the square wave for a flat
line. (Set scope for high vertical sensitivity.)
8. Sensitivity (Gain) 1-kHz Sine Wave Set the sensitivity switches to the 26-dB position,
No Load check both level controls full clockwise. Insert a .775V
1-kHz sine wave and measure 14.8V–16.1V at the out-
put of each channel. Set sensitivity to the 0.775V po-
sition and measure 95V–104V at the output of each
channel. Set the sensitivity switches to 1.4V position
and measure 51.8V–57.2V at the output of each chan-
nel.
9. Bridge Mono 1kHz Sine Wave
No Load Note: Always turn power to the amplifier off prior to
changing the position of the Stereo/Mono Switch. With
the dual/mono switch in the bridge mono position, set
the channel two input level control to full CCW. Insert
a .775 Vrms 1-kHz signal into channel one input. There
should be signal present on both channel outputs,
equal in amplitude, with channel two 180 degrees out
of polarity from channel one (see Figure 5.2). Chan-
nel one input level control should control the output
level for both channels. Return the amplifier to stereo
operation.


10. Parallel Mono 1-kHz Sine Wave Note: Always turn power to the amplifier off prior to
No Load changing the position of the Stereo/Mono Switch. With
the dual/mono switch in the parallel mono position,
insert a .775 Vrms 1-kHz signal into channel one. There
should be two signals with the same polarity present,
equal in amplitude, at the outputs of channels one
and two. Both of these signals will be controlled by
the channel one input level control. Switch the stereo/
mono switch to stereo. There should be signal present
only on the channel one output.
11. Current Sense Balance No Signal Place the Stereo/Mono switch in the PARALLEL MONO
No Load position. Measure VDC of the channel 1 + output with
respect to the channel 2 + output. Verify null of less
than ±10 mVDC. If necessary adjust null via R2 cur-
rent sense balance pot on the Main Module.
12. Static Balance No Signal Place the VZ Mode switches in the VZ-ODEP position
No Load (see Figure 5.4). Measure ±VCC with respect to
ground for channel 1 (P852 & P851 on Control board).
Values should be of equal magnitude and opposite
polarity. If magnitudes vary by more than 500mV, ad-
just static balance pot R568 on the output module for
null (no difference in magnitude). Switch to VZ (AUTO)
position and verify null is maintained. Re-adjust only
if necessary. Repeat check for channel 2 (P854 & P853
on Control board), adjust R568 if necessary.
13. Dynamic Balance 1-kHz Sine Wave With no load on the amplifier, increase the input to
No Load achieve 125.0 Vrms, ±.3 Vrms, at the output of the
channel under test. Measure TP1/TP2 pin 16 and ad-
just R566 on the output module for 3.500 Vrms, ±.200
Vrms.
Figure 5.2 Bridge MONO


14. Over-voltage No Signal With the amplifier powered from a variac, increase
No Load AC mains line voltage to 12% above the line voltage
for which the amplifier is wired. The amplifier should
trip off at 10.5% to 11% above the line voltage for
which it is wired. If it does not, then set line voltage to
10.5% high and slowly adjust R780 on the control
module until the amplifier trips into protect mode. If
adjustment is performed, retest new adjustment.
15. LOI Sine Wave Place sensitivity switches in 26 dB position; check or

8-ohm Load place LOI (EPS) switches to OFF (BYPASS) position.
Insert a 1-kHz sine wave and adjust for 2.8 Vrms
(1 W) output into 8 ohms. Adjust to 30 Hz then to
20 Hz, level should remain constant. Switch LOI (EPS)
to ON (ENABLE). Check output at 30 Hz at –2 dB ±
0.1 dB. Adjust frequency to 20 Hz and measure out-
put level at –11 dB ± 0.1 dB. Return LOI/ESP and
sensitivity switches to initial condition (Section 5.4.1).
16. Compressor 1-kHz Sine Wave With each channel loaded to 8 ohms, insert a 1-kHz
8-ohm Load sine wave and increase level until the amplifier is well
into clip. Place the compressor switches in SLOW po-
sition and check for non-clipped output. Move
switches to FAST position and again verify non-clipped
output. Return switches to OFF position.
17. Parallel Balance 1-kHz Sine Wave Place the Stereo/Mono switch in the PARALLEL MONO
8-ohm Load position. Load each channel to 8 ohms separately,
(loads must be precisely equal) and insert a 1 kHz
sine wave. Adjust for 60 Vrms output. Measure VAC
of the channel 1 + output with respect to the channel
2 + output. Verify null of less than 100 mVrms with
signal applied. If necessary adjust null via R4 parallel
balance pot on the Main Module. Make sure the Ste-
reo/Mono switch is returned to STEREO upon test
completion.
18. Current Sense Cal. 1-kHz Sine Wave
1-ohm Load Factory set adjustment normally will not require
recalibration. Perform this check as a verification,
adjust only if the measurement is out of tolerance. With
channel 1 loaded to 1 ohm, insert a 1 kHz sine wave
and adjust for an output of 10.00 Vrms, ±20 mV. Mea-
sure TP1 pin 1 with respect to ground. Value should
be 2.00 Vrms ±10 mV. If necessary adjust V/A cal pot
R759 on the current sense module. Repeat test for
channel 2 measuring TP2 pin 1; adjust R859 if neces-
sary.


19. LED Check, 1-kHz Sine/Sq Wave Turn the amplifier on after being off at least 10 sec-
Current Limit Check Various Loads onds. Observe that the ODEP lights come on after
about 4 seconds. The SPI/IOC lights should go off (if
on during delay) at this time. Input a 1-kHz 2 Vrms
sine wave into each channel and observe that the SPI/
IOC lights are on bright. Turn down the input level to
about 0.5 Vrms and observe that the SPI/IOC lights
remain on, but dimly. Remove the input signal and
load the amplifier to 8 ohms/Ch. Insert the 0.5 Vrms
signal again and note that the ILOAD/ILIMIT indicators
come on green. Change the load to 1 ohm/Ch, switch
to a square wave (20% Duty Cycle), and increase in-
put level to 2 Vrms. Note that the ILOAD/ILIMIT indicators
turn red. This check also constitutes the Current Limit
Check.
20. 10 kHz Square Wave 10-kHz Sq. Wave

Slew Rate Test 8 ohm Load With an 8-ohm load on each channel, insert a 10-kHz
square wave and adjust amplitude to produce an
output 10V below clipping (see Figure 5.3). Observe
a 30V/µS (or higher) slew rate. The output waveform
should be stable with no ringing or over-shoot.
21. DC/LF Protect 4-Hz Sq. Wave
8-ohm Load Insert a 5Vpp 4-Hz square wave with an 8-ohm load
on the output. The protection relay should cycle.
Figure 5.3 10-kHz Square Wave


22. 1 kHz Power + THD 1-kHz Sine Wave Note: Operation with a sine wave into a low imped-
Various Loads ance load, when operating at AC voltages of less than
200VAC, will cause the 30 A fuses to blow after 30 to
60 seconds. 30 A Fuse = Part Number A10285-30.
AC Mains of 120 VAC, 60 Hz; or 230/240 VAC, 50 Hz:

8-ohm Load: Minimum voltage is 102.0 Vrms
(1,300 W) with <0.1% THD.

(1,985 W) with <0.1% THD.

(2,500 W) with <0.1% THD.
AC Mains of 100-220 VAC, 50Hz:

(1,250 W) with <0.1% THD.

(1,865 W) with <0.1% THD.

(2,375 W) with <0.1% THD.
23. Functional 60-Hz Sine Wave For these tests, the cooling fan blade must be stopped.
ODEP & VZ-ODEP 2-ohm Load To stop the fans, turn off and unplug the amplifier. Lift
operation the fan wire connector from P729/P730 on the control
module. Turn the amplifier back on and perform these
tests. At the end of these tests, turn the amplifier off,
unplug it, and return the fan wires to the appropriate
position (P729 or P730).
Place the VZ mode switches in the AUTO position (see

Figure 5.4; remove top filter to access switches). With
a 2-ohm load per channel and output voltage of 60
Vrms 60 Hz to both channels, allow the heatsinks to
heat up until the ODEP protection circuit starts to limit
the output signal (this should take a few minutes). A
waveform like that shown in Figure 5.5 should be ob-
served. Note: In VZ AUTO mode the flattened portion
of the wave will probably not have the “clean” ap-
pearance of Figure 5.5, but should still resemble it.
Check to see that the IOC LED is lit and that the ODEP
LED dims and extinguishes when ODEP is activated.
While ODEP limiting is taking place, switch the VZ
mode switches to the VZ-ODEP position and verify
that the amplifier locks into low voltage mode (the
ODEP waveform should appear much more “clean”).


Next configure the amp for parallel mono operation.

With the input signal now present on channel one only,
load channel one output with 8 ohms and channel
two with 2 ohms. Observe that channel two ODEP
protection circuit is limiting both channel one and
channel two outputs. Next load channel one with 2
ohms and channel two with 8 ohms. Observe that
channel one ODEP protection circuit is limiting both
channel one and channel two outputs.
Return the cooling fan blade to normal operation af-

ter these tests have been completed, and allow a few
minutes for the amplifier to cool with no signal input.
Return all controls to initial conditions per Section
5.4.1.
Correct operation of the ODEP circuit is dependent

upon correct ODEP null settings (Step 6).
24. Intermodulation I.M. Signal Source
Distortion (I.M.D.) 8-ohm Load Place the sensitivity switches in the 26 dB position.
Use a 60-Hz/7-kHz (standard SMPTE IM signal) input
signal summed in a 4:1 ratio. Set the 60-Hz portion
for 73.8 Vrms at the output of the channel under test.
This is your 0 dB reference. Measure the I.M. distor-
tion. Check in –5 dB (power) steps until –35 dB is
reached (range is 1,065 W down to 0.34 W). Read-
ings should be less than .05% at each level.
CH 1 VZ MODE SWITCH CH 2 VZ MODE SWITCH
LEVEL
15
12 18
9 21
l 0
6 24
3 27
CH2 0 30 ENABLE
VZ-ODEP *On Original Control Module VZ (AUTO)*

LOCK LOW Q42930-0 this was the VZ (AUTO)
VZ (AUTO) LOCK HIGH position. LOCK LOW
VZ (AUTO)* VZ-ODEP
Figure 5.4 VZ Mode Switch Locations Figure 5.5 ODEP Protection


25. Noise No Signal Make sure the sensitivity switches are in the 26-dB
No Load position and the level controls are fully clockwise. Ter-
minate the input with a 600-ohm load. Using a 20 Hz–
20 kHz bandpass filter, measure the noise on the out-
put of the channel under test. Noise should be less
than 574 µVrms (105 dB down from 1300 watts into 8
ohms).
26. Crosstalk Check 20-kHz Sine Wave Make sure the sensitivity switches are set in the
8-ohm Load 26-dB position. Load each channel to 8 ohms. Insert
a 20-kHz sine wave into channel 1 and adjust for 45
Vrms output. Terminate channel 2 input with 600 ohms.
Measure less than 80 mVrms at the output of channel
2. (Greater than 55 dB down at 20 kHz)
Move the input signal from channel 1 to channel 2

and the 600-ohm termination from channel 2 to chan-
nel 1. Ensure there is 45 Vrms at the output of chan-
nel 2. Measure less than 80 mVrms at the output of
channel 1.
27. VZ Modes 1-kHz Sine Wave Note: VZ-ODEP mode was checked during the ODEP
8-ohm Load test, Step 23. I.M.D. and 1-kHz power checks ad-
equately tested the VZ (AUTO) mode. LOCK HIGH (if
present) was checked adequately in the static bal-
ance adjustment check, Step 12. Place the VZ Mode
Switches in LOCK LOW (see Figure 5.4). With an
8-ohm load on each channel, insert a 1-kHz sine wave
into each channel. Clipping should occur at approxi-
mately 36 Vrms (410 W).
Post-testing Procedure:
At the completion of testing, replace the 30 A fuses (if
testing was done at 100–120VAC), and set all switches
per customer request. If none are specified by the
customer, the following are standard factory settings
for original shipment:
Dual Mono Switch: STEREO position.

Sensitivity Switches: Both to 1.4V position.
Compressor Switches: Both to FAST position.
LOI Switches: Both to ON position.
VZ Mode Switches: Both to VZ–ODEP position.
Level Controls: Both down (counter-clockwise) fully.
In most applications, VZ–ODEP is the VZ Mode to use

for best thermal performance.


6.2.1 Terms
6 Parts Normal terms are prepaid. Net-30 Days only applies to
those having pre-established accounts with Crown. The
Crown Parts Department does accept Visa or Master
Card. If prepaying, the order must be packed and
6.1 General Information weighed before a total bill can be established, after
Replacement parts for this Crown amplifier can be or- which an amount due will be issued and shipment made
dered from the Crown parts department. upon receipt of payment. New parts returned for credit
are subject to a restocking fee, and authorization from
PART PRICES AND AVAILABILITY ARE SUBJECT the Crown Parts Department must be obtained before
TO CHANGE WITHOUT NOTICE. returning parts for credit.
6.2 Ordering and Receiving Parts 6.2.2 Shipment

Shipment will normally be made via UPS, or best other
When ordering parts, be sure to give the product model,
method unless you specify otherwise. Shipments are
and include a description and part number from the
made to and from Elkhart, Indiana USA, only. Estab-
parts listing. Price quotes are available on request.
lished accounts with Crown will receive shipment freight
prepaid and will be billed. All others will receive ship-
ment on a C.O.D. or prepayment (check or credit card)
basis.
Crown Customer Service

Technical Support Group
Factory Service
Parts Department
Mailing Address: P.O. Box 1000, Elkhart IN 46515

Shipping Address: Plant 2 S. W.
1718 W. Mishawaka Rd., Elkhart IN 46517
Phone: (219) 294-8200
Toll Free: (800) 342-6939
Fax: (219) 294-8301
http://www.crownaudio.com
©2000 Crown International, Inc. Parts 6-1

6-2 Parts ©2000 Crown International, Inc.

130446-1 Rev A MA-5002VZ Service Manual
7 Exploded View Parts
7.1 General Information

This chapter includes a mechanical part list for this
product. All serviceable parts and assemblies will have
a Crown Part Number (CPN) listed in this chapter.
The parts listed are current as of the date printed.
Crown reserves the right to modify and improve its
products for the benefit of its customers.
©2000 Crown International, Inc. Exploded View Parts 7-1

MA-5002VZ Service Manual 130446-1 Rev A
Figure 7.1 Main Chassis Exploded View
7-2 Exploded View Parts ©2000 Crown International, Inc.

7.1 Main Chassis Assembly
Item # QTY Part Number Description Notes
1 1 --- Front Chassis Assembly See Section 7.2
2 1 --- Transformer Assembly See Section 7.6
3 1 F12701-3 Chassis
4 1 --- Ch 1 Capacitor Assembly See Section 7.7
5 1 F12567J7 Bottom Cover
6 1 --- Terminator Assembly See Section 7.9
7 1 --- Output Assembly See Section 7.12
8 1 --- Back Panel See Section 7.4
9 1 F12302J9 Output Cover
10 1 102745-1 PIP2-FXQ
11 1 --- Main Board Tray Assembly See Section 7.11
12 1 F12176J7 Top Cover
13 1 --- Chassis Divider Assembly See Section 7.5
14 1 --- Ch 2 Capacitor Assembly See Section 7.8

Figure 7.2 Front Chassis Assembly

7.2 Front Chassis Assembly
2 4 A10089-11032 Screw, 10-32 X 2
3 4 A10094-8 Washer, #10 Int. Tooth
4 4 A10094-5 Washer, #8 Int. Tooth
5 4 C 8874-7 Screw, 8-18 X .375 Sht mtl
6 3 A10092-10607 Screw, 6-32 X .437 Socket
7 1 --- Transformer Bracket See Transformer Assembly, Section 7.6
8 2 C 8507-3 Screw, 8-32 X 1 Flat Hd
9 1 F12888-8 Front Panel
10 1 128304-1 MA-5002VZ Lexan Overlay
11 2 C 8776J3 Handle
12 2 D 6265-9 Knob
13 2 C 6005-0 Set Screw, 6-32 X .18
14 2 --- Nut Part of item 23
15 2 --- Washer Part of item 23
16 7 D 7937-2 LED Collar
17 1 D 7872-1 Pushbutton
18 1 D 4108-3 Pushbutton Collar
19 5 D 7696-4 Foam Filter
20 20 B 5796-6 Velcro .5" x .25"
21 4 C 7965-4 Screw, 8-32 X .37 Flat Hd
22 1 D 7791J2 Grille Extrusion
23 2 C 7280-8 5K ohm Level Pots Includes hardware items 14 and 15
24 2 D 7792J0 Panel Cap
25 2 D 7793J8 End Cap

Figure 7.3 Middle Chassis Assembly

7.3 Middle Chassis Assembly
2 1 --- Divider Assembly See Section 7.5
3 2 D 7927-3 Capacitor Holder, Inner
4 2 D 7928-1 Capacitor Holder, Outer
5 1 M46664-5 Ch 2 Bi-Level Switch Assby See Section 7.8
6 2 D 7870-5 Valox Washer
7 6 A10100-10 Flat Washer, #8
8 6 A10094-6 Lock Washer, #8 Int Star
9 2 A10089-70820 Screw, 8-32 X 1.25
10 1 M46665-2 Ch 1 Bi-Level Switch Assby See Section 7.7
11 2 A10089-10808 Screw, 8-32 X .5
12 4 D 7871-3 Valox Spacer
13 2 D 7818-4 Output Slide Guide
14 1 --- PIP Terminator Assembly See Section 7.9
15 1 --- Ch 1 Output Assembly See Section 7.12 (Ch 1 & 2 are identical)
16 2 A10089-10612 Screw, 6-32 X .75
17 2 A10094-4 Lock Washer, #6 Int Star
18 2 A10100-4 Flat Washer, #6
19 1 --- Ch 2 Output Assembly See Section 7.12 (Ch 1 & 2 are identical)
20 13 C 8874-7 Screw, 8-18 X .375 sht mtl
21 15 A10094-5 Lock Washer, #8 Int Str Blk
22 15 F12567J7 Bottom Cover
23 4 A10109-70604 Screw , 6-32 X .25 Black
24 2 A10089-70844 Screw, 8-32 X 2.75
25 2 A10100-12 Washer, 3/16 X 9/16 X 1/16

Figure 7.4 Rear Chassis Assembly

7.4 Rear Chassis Assembly
1 1 F12176J7 Top Cover
2 - --- Main Board Tray Assembly See Section 7.11
3 1 128302-1 Back Panel
4 1 F12302J9 Box Shield Output post protective cover
5 1 102745-1 PIP2-FXQ
6 4 C 8874-7 Screw, 8-18 X .375 Sht Mtl
7 13 A10089-70806 Screw, 8-32 X .375
8 17 A10094-5 Lock Washer, #8 Int Str Blk

OW
FL
AIR
4
Figure 7.5 Chassis Divider (Fan) Assembly

7.5 Chassis Divider (Fan) Assembly
1 1 100111-1 Divider Plate
2 2 C 7858-1 Fan
3 1 D 7883-8 Transformer Low Voltage Transformer
4 1 C 9069-3 Bushing, Universal 0.875
5 8 A10106-70806 Screw, #8 X .37 Hex Washer Head

15
2
14
13
1
12
11
3
10
6 6
16
8
9
Figure 7.6 Transformer Assembly

7.6 Transformer Assembly
1 4 C10332-2 Bridge Rectifier, 50A EDI
2 1 Control Module See Section 8.
3 1 Q42929-2 Display Module See Section 8.
4 3 C 8852-3 0.5" PC Board Support
5 1 F12813-6 XFMR/Sub-front Bracket
6 2 D 9019-7 Main Power Toroid XFMR
7 2 C 8919-0 0.5" Steel Bolt
8 2 A10095-7 0.5" Ext. Lockwasher
9 2 A10102-21 0.5" Hex Nut
10 1 C10180-5 DPST 6A Pushbutton Switch
11 2 C 5961-5 4-40 X .375 Taptite
12 7 A10094-4 #6 Int. Star Washer
13 7 A10086-10608 6-32x.5 Machine Screw
14 4 A10098-3 #8 HDS-4 Saftey Washer
15 4 A10102-6 8x32 Hex Nut
16 2 A10100-25 0.5" Plain Steel Washer

Figure 7.7 Channel 1 Bi-Level Switch Assembly

7.7 Ch 1 Bi-Level Switch Assembly (M46665-2)
1 2 D 7882-0 15000µF Capacitor C810, C812

2 1 P10357-5 Insulator: Ch 1 & 2 #1
3 1 M21070-4 Plate: Ch 1 -Vcc #1
4 1 D 7821-8 Insulator: Ch 1 #2
5 3 C 6541-4 Torque Spreader
6 3 C 9927-2 MOSFETs Q810, Q811, Q812
7 3 A11397-003 Lead Insulation Tube
8 3 C 8341-7 Ferrite Bead FB1, FB2, FB3
9 1 M21071-2 Plate: Ch 1 FET #2
10 - --- Wires
11 1 D 7825-9 Insulator: Ch 1 & 2 #3
12 1 M21072-0 Plate: Ch 1 Diode #3
13 1 D 7822-6 Insulator: Ch 1 #4
14 1 M21073-8 Plate: Ch 1 +Vcc #4
15 1 A10086-11008 Screw, 10-32 X .5
16 1 D 2934-4 Solder Lug
17 11 A10094-4 Lock Washer, #6
18 9 A10086-10604 Screw, 6-32 X .25
19 1 A10086-11006 Screw, 10-32 X .375
20 1 A10086-11005 Screw, 10-32 X .315
21 2 C 8855-6 Dual Diode D810, D811
22 2 A10102-5 Hex Nut, 6-32
23 1 H43479-7 Header (with wires)
24 1 D 7843-2 Switch Board Ch 1 (Ch 1 half of blank part D 7843-2)
25 1 D 7880-4 Insulator: Ch 1 & 2 #5
26 1 A10086-11009 Screw, 10-32 X .562
27 4 A10094-8 Lock Washer, #10
28 6 A10101-26 Nylon Washer

Figure 7.8 Channel 2 Bi-Level Switch Assembly

7.8 Ch 2 Bi-Level Switch Assembly (M46664-5)
1 2 D 7882-0 15000µF Capacitor C800, C802

2 1 P10357-5 Insulator: Ch 1 & 2 #1
3 1 M21074-6 Plate: Ch 2 -Vcc #1
4 1 D 7824-2 Insulator: Ch 2 #2
5 3 C 6541-4 Torque Spreader
6 3 C 9927-2 MOSFETs Q800, Q801, Q802
7 3 A11397-003 Lead Insulation Tube
8 3 C 8341-7 Ferrite Bead FB4, FB5, FB6
9 1 M21075-3 Plate: Ch 2 FET #2
10 - --- Wires
11 1 D 7825-9 Insulator: Ch 1 & 2 #3
12 1 M21076-1 Plate: Ch 2 Diode #3
13 1 D 7820-0 Insulator: Ch 2 #4
14 1 M21077-9 Plate: Ch 2 +Vcc #4
15 1 A10086-11008 Screw, 10-32 X .5
16 1 D 2934-4 Solder Lug
17 11 A10094-4 Lock Washer, #6
18 9 A10086-10604 Screw, 6-32 X .25
19 1 A10086-11006 Screw, 10-32 X .375
20 1 A10086-11005 Screw, 10-32 X .312
21 2 C 8855-6 Dual Diode D800, D801
22 2 A10102-5 Hex Nut, 6-32
23 1 H43479-7 Header (with wires)
24 1 D 7843-2 Switch Board Ch 2 (Ch 2 half of blank part D 7843-2)
25 1 D 7880-4 Insulator: Ch 1 & 2 #5
26 1 A10086-11009 Screw, 10-32 X .562
27 4 A10094-8 Lock Washer, #10
28 8 A10101-26 Nylon Washer

Figure 7.9 PIP Terminator Shelf Assembly

7.9 PIP Terminator Shelf Assembly
1 3 A10086-10604 6-32-.25 Machine Screw Phillips, round-head
3 1 --- Current Sense Module See Section 8
4 1 C 7705-4 Cable Clamp
5 1 --- Current Sense Module See Section 8
6 3 C 8823-4 0.125” PC Board Support
7 2 D 5903-6 8-32x.5 Screw Phillips, flat-head, taptite
8 1 F11160-3 Strain Relief For Power Cord D 7890-3
9 1 D 7890-3 Power Cord 30A 10/3 TT-30P Plug (No. America)
10 1 A10111-10806 #8x.375 Sheetmetal Screw Pan-head
11 1 A10095-2 #8 Ext. Star Washer
12 1 D 7817-6 Center Output Slide Guide
13 1 A10109-7064 6-20x.25 Screw Phillips, pan-head, black
14 1 F12699-9 Terminator/PIP Shelf Bracket
15 1 H43430-0 Output Flex Bar Ch 1 Includes Insulating Sleeve

1 H43431-8 Output Flex Bar Ch 2 Includes Insulating Sleeve
16 1 --- Line Filter PWA See Section 8 (Export Only)

7.10 PIP Terminator Shelf Assembly, View "A"

(USA Units only)
1 16 C 8835-8 .25-32 Nut
2 12 A10094-9 Lockwasher, .25 Int. Star
3 4 M21078-7 Terminator Bar
4 4 D 7924-0 Bushing, Steel
5 1 D 7816-8 Terminator Panel
6 8 C 8794-7 Un-insulated Banana Jack
7 4 A10170-12516 .25-20x1 Machine Screw Output, slot hex-washer head
Figure 7.10 PIP Terminator Shelf Assembly, View "A"

7.11 Main Board Tray Assembly
1 1 100110-1 Main Board Tray
2 1 See Section 8 Main Module See Section 8.
4 6 A10086-10604 6-32x.25 Machine Screw Phillips, round-head
Figure 7.11 Main Module Tray Assembly

Figure 7.12 Output Assembly

7.12 Output Assembly

(Channels 1 & 2 Identical)
1 8 C 8187-4 NPN Outputs,

8 C 8188-2 PNP Outputs,
2 1 F12154-5 Heatsink
3 1 M21188-4 Flex Bar Fastener
4 1 --- Negative Emitter Module See Section 8.
5 1 --- Negative Output Module See Section 8.
6 1 D 7922-4 Insulator
7 4 A10224-9 Rubber Grommets
8 1 --- Positive Output Module See Section 8.
9 2 C 8789-7 Flex Bar Spacers
10 1 --- Positive Emitter Module See Section 8.
11 2 D 7870-5 Valox Washer
12 3 A10100-16 Washer, 7/16OD X ,203ID
13 2 A10098-4 Belleville Washer, #10
14 2 A10086-10810 Screw, 8-32 X .62
15 3 A10094-6 Lock Washer, #8 Int. Star
16 1 A10089-10612 Screw, 6-32 X .75
17 32 A10110-10606 Screw, 6-32 X .375
18 1 A10089-10808 Screw, 8-32 X .5
19 1 A10089-70820 Screw, 8-32 X 1.25
20 4 A10086-10406 Screw, 4-40 X .37
21 4 A10098-1 Washer, .394OD X .126ID
22 6 A10086-10604 Screw, 6-32 X .25
23 4 A10094-4 Washer, #6 Int Star
24 4 C 6541-4 Predriver Torque Spreader
25 2 C 5453A1 PNP, 2SA1006BR
2 C 6436-7 NPN, 2SC2336BR
26 2 C10223-3 PNP, MJL1302A
2 C10224-1 NPN, MJL3281A
27 1 D 7871-3 Valox Spacer

Figure 7.13 Wiring Diagram #1



Interconnect Cables
Designation Part Number Description Notes
J2A D 9236-7 20 Wire Ribbon Cable PIP2
J2B D 9235-9 18 Wire Ribbon Cable PIP2
J35 D 7886-1 16 Wire Ribbon Cable Main to Control to Display
J500 D 7889-5 16 Wire Ribbon Cable Main to Ch 1 Output P500 (top)
J501 D 7885-3 16 Wire Ribbon Cable Main to Ch 1 Output P501 (bottom)
J600 D 7885-3 16 Wire Ribbon Cable Main to Ch 2 Output P500 (bottom)
J601 D 7964-6 16 Wire Ribbon Cable Main to Ch 2 Output P501 (top)
J700 D 7887-9 16 Wire Ribbon Cable Main to Current Sense
J732 J832 D 7888-7 16 Wire Ribbon Cable Main to Control

D 8542-9 16 Wire Ribbon Cable Main to Control, Part of Control Mod.
J733 J833 H43479-7 Bi-Level Control Wires Control to Bi-Level Switches
R120 R220 H43551-3 Level Controls With Wires Also includes hardware


8.2.6 Control PWA

8 Module and Schematic 127488-2
Information Control PWA on 127917-1 PWB.
8.1 General Information 8.2.7 Display PWA
Q42929-2
The schematics referenced and provided are repre-
Display PWA on D7845-7 PWB.
sentative only. There may be slight variations between
amplifier to amplifier. These schematics are intended
to be used for troubleshooting purposes only.
8.2.8 Current Sense PWA:
Note on circuit board designations: Crown circuit boards
are referenced with a PWA and/or PWB part number. 102397-2
PWA stands for Printed Wire Assembly. This is the com- Current Sense PWA on 102395-2 PWB.
pleted circuit board with all components assembled.
PWB stands for Printed Wire Board. This is the circuit
board only, without components. 8.2.9 Line Filter PWA (CE Models Only):
128273-2
Line Filter PWA on 128272-2 PWB.
8.2 Modules
8.2.1 Main PWA 8.3 Schematic Diagrams:
125903-4
Main PWA on 125902-4 PWB. 8.3.1 Main PWA
125901
8.2.2 Positive Output PWA: (left and right are identical) 8.3.2 Positive Output PWA
J0488-7
Q43293-2
Positive Output PWA on D8526-2 PWB. 8.3.3 Negative Output PWA
J0488-7
8.2.3 Negative Output PWA: (left and right are identical) 8.3.4 Positive Emitter PWA
J0488-7
Q43294-0
Negative Output PWA on D8527-0 PWB. 8.3.5 Negative Emitter PWA
J0488-7
8.2.4 Positive Emitter PWA: (left and right are identical) 8.3.6 Control PWA
128112-2
Q42935-9
Positive Emitter PWA on P10336-9 PWB. 8.3.7 Display PWA
J0491-1
8.2.5 Negative Emitter PWA: (left and right are identical) 8.3.8 Terminator PWA
102396
Q42934-2
Negative Emitter PWA on P10342-7 PWB. 8.3.9 Line Filter PWA
128273-2
©2000 Crown International, Inc. Module and Schematic Information 8-1

8-2 Module and Schematic Information ©2000 Crown International, Inc.

9 Module Parts
9.1 General Information

This chapter includes electrical parts lists for this prod-
uct. All serviceable parts and assemblies will have a
Crown Part Number (CPN) listed in this chapter. The
parts listed are current as of the date printed. Crown
reserves the right to modify and improve its products
for the benefit of its customers. Please note: where ref-
erence designations are listed as “installed on next as-
sembly,” the CPN (Crown Part Number) for the associ-
ated part may be found in Section 7, Exploded View
Parts.
102397-2
125903-4
127488-2
128273-2
Q42929-2
Q42934-2
Q42935-9
Q43293-2
Q43294-0
©2000 Crown International, Inc Module Parts 9-1

9-2 Module Parts ©2000 Crown International, Inc.



























125903-4 PWA Component Map

(Component Side)
©2000 Crown International, Inc. Module Parts 9-29

This Page Intentionally Left Blank









127488-2 PWA Component Map

(Component Side)










Q42929-2 PWA Component Map

(Component Side)


Q42934-2 Negative Emitter PWA
PWB: P10342-7, Schematic: J0488-7

Circuit Component Part Applicability
Designation Description Number & Notes
Capacitors
C513 0.022 µfd C 5671-0
C521 0.022 µfd C 5671-0
Diodes
D508 MR822 C 8383-9
D509 MR822 C 8383-9
Resistors
R523 0.33 ohm 5 W C 8787-1
R525 0.33 ohm 5 W C 8787-1
R527 0.33 ohm 5 W C 8787-1
R529 12 ohm 12 W A10266-1204
R535 12 ohm 12 W A10266-1204
R537 0.33 ohm 5 W C 8787-1
R539 0.33 ohm 5 W C 8787-1
R541 0.33 ohm 5 W C 8787-1
R581 0.33 ohm 5 W C 8787-1
R583 0.33 ohm 5 W C 8787-1

PWA Q42934-2 Component Map (Component Side)

Q42935-9 Positive Emitter PWA
PWB: P10336-9, Schematic: J0488-7

Circuit Component Part Applicability
Designation Description Number & Notes
Capacitors
C512 0.022 µfd C 5671-0
C520 0.022 µfd C 5671-0
Diodes
D506 MR822 C 8383-9
D507 MR822 C 8383-9
Resistors
R522 0.33 ohm 5W C 8787-1
R524 0.33 ohm 5 W C 8787-1
R526 0.33 ohm 5 W C 8787-1
R528 12 ohm 12 W A10266-1204
R534 12 ohm 12 W A10266-1204
R536 0.33 ohm 5 W C 8787-1
R538 0.33 ohm 5 W C 8787-1
R540 0.33 ohm 5W C 8787-1
R580 0.33 ohm 5 W C 8787-1
R582 0.33 ohm 5 W C 8787-1












10 Schematics
The schematics referenced and provided are repre-

sentative only. There may be slight variations between
amplifier to amplifier. These schematics are intended
to be used for troubleshooting purposes only.
102396
125901
128112
128273
J0488-7
J0491-1
©2000 Crown International, Inc Schematics 10-1

10-2 Schematics ©2000 Crown International, Inc.

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Macro-Tech®

Mail: P.O. Box 1000 Elkhart IN 46515-1000

The lightning bolt The exclamation point

II ©2000 Crown International, Inc.

Revision Number Date Comments

Rev. A 02-2000 Initial Printing

©2000 Crown International, Inc. III

This page intentionally left blank

IV ©2000 Crown International, Inc.

2 Specifications ......................................................................... 2-1

3 Voltage Conversion ................................................................ 3-1

4 Circuit Theory ........................................................................ 4-1

©2000 Crown International, Inc. V

6 Parts ....................................................................................... 6-1

7 Exploded View Parts ............................................................ 7 -1

8 Module and Schematic Information .................................... 8 -1

9 Module Parts .......................................................................... 9-1

10 Schematics ........................................................................ 10-1

VI ©2000 Crown International, Inc.

phonic capability. The MA-5002VZ includes additional

Crown Customer Service

Mailing Address: P.O. Box 1000, Elkhart IN 46515

©2000 Crown International, Inc. Introduction 1-1

Figure 1.1 MA-5002VZ Front and Rear Views

1-2 Introduction ©2000 Crown International, Inc.

©2000 Crown International, Inc. Specifications 2-1

Figure 2.1 Dimensions

Figure 2.2 Typical Phase Response

2-2 Specifications ©2000 Crown International, Inc.

Figure 2.3 Typical Frequency Response

Figure 2.4 Typical Damping Factor

Figure 2.5 Typical Output Impedance

©2000 Crown International, Inc. Specifications 2-3

This page intentionally left blank

2-4 Specifications ©2000 Crown International, Inc.

©2000 Crown International, Inc. Voltage Conversion 3-1

CAUTION: To reduce the risk of fire,

ATTENTION: Utiliser un fusible de même

Figure 3.2 Voltage/Frequency Conversion Physical Layout

3-2 Voltage Conversion ©2000 Crown International, Inc.

is called Loudspeaker Offset Integration (LOI). The LOI

©2000 Crown International, Inc. Circuit Theory 4-1

Figure 4.1 Simplified Grounded Bridge

4-2 Circuit Theory ©2000 Crown International, Inc.

©2000 Crown International, Inc. Circuit Theory 4-3

4-4 Circuit Theory ©2000 Crown International, Inc.

VZ Power Supply & Grounded Bridge Output Topology

+Vcc (Positive Rail)

Figure 4.3 Simplified VZ Supply in Operation

©2000 Crown International, Inc. Circuit Theory 4-5

4-6 Circuit Theory ©2000 Crown International, Inc.

Channel 1 ODEP Circuitry shown

Off Main On Main Module

Figure 4.4 Simplified ODEP Circuitry

©2000 Crown International, Inc. Circuit Theory 4-7

Figure 4.5 Front End Circuitry Block Diagram

4-8 Circuit Theory ©2000 Crown International, Inc.

signal information. An error signal (spike) is produced 4.5.7 Inverting Stages

©2000 Crown International, Inc. Circuit Theory 4-9

VZ-ODEP On Original Control Module VZ (AUTO)