Crown CE4000 Service Manual - PDF Versión 1

POWER AMPLIFIER
SERVICE MANUAL
CE Series
CE 4000
Some models may be exported under the name Amcron®
© 2002 by Crown Audio, Inc., P.O. Box 1000, Elkhart, Indiana 46515-1000 U.S.A. Telephone:
574-294-8000. Trademark Notice: Amcron® and Crown® are registered trademarks of Crown
International. Other trademarks are the property of their respective owners.
130485-1
11/02
Rev. B
CE 4000 Service Manual 130485-1 Rev. B
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: Crown Factory Service 1718 W. Mishawaka Road Elkhart IN 46517
Phone: (800) 342-6939 / (574) 294-8200
FAX: (574) 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 PERSON- RIEN DES PARTIES UTILES
NEL. DISCONNECT POWER CORD À L’INTÉRIEUR.
BEFORE REMOVING REAR INPUT DÉBRANCHER LA BORNE
MODULE TO ACCESS GAIN SWITCH. AVANT D’OUVRIR LA
MODULE EN ARRIÈRE.
WARNING
TO REDUCE THE RISK OF ELECTRIC
SHOCK, DO NOT EXPOSE THIS
EQUIPMENT TO RAIN OR MOISTURE!
The lightning bolt tri- The exclamation point trian-

angle is used to alert gle is used to alert the user to
the user to the risk of important operating or main-
electric shock. tenance instructions.
II
130485-1
130485-1 Rev.
Rev. BB CE 4000 Service Manual
Revision History
Revision Number Date Comments
Rev. A 05-2001 Initial Printing
Rev. B 11-2002 Added missing parts list on Page 5-76. Updated area code
and mailing address on Pages 1, 2 and 7. Updated sections
3.2.4, 4.3.3, 4.3.9, 4.4.5, 4.6.1, 4.6.8, 4.7.2, 4.7.3, Figure
4.16. Added notes to pages 5-39, 5-73, 5-97.
III
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IV
130485-1 Rev. B CE 4000 Service Manual
Table of Contents
1 Introduction........................................................................................1-1
1.1 Introduction ............................................................................................1-1
1.2 The CE 4000 Amplifier ...........................................................................1-1
1.3 Scope.....................................................................................................1-1
1.4 Warranty.................................................................................................1-1
2 Specifications ....................................................................................2-1
3 Theory of Operation ..........................................................................3-1
3.1 Audio Signal Path ..................................................................................3-1
3.1.1 Input Stage ...................................................................................3-1
3.1.2 Error Amplifier...............................................................................3-1
3.1.3 Modulator .....................................................................................3-1
3.1.4 Triangle Generator........................................................................3-2
3.1.5 Output...........................................................................................3-2
3.1.6 Output Filter..................................................................................3-3
3.2 Protection and Control Circuitry.............................................................3-3
3.2.1 Current Monitor.............................................................................3-3
3.2.2 Current Limiter..............................................................................3-4
3.2.3 Display Circuitry ...........................................................................3-4
3.2.4 Control Circuitry............................................................................3-4
3.3 Power Supply Operation........................................................................3-5
3.3.1 Power Entry and Filtering .............................................................3-5
3.3.2 Fuse..............................................................................................3-5
3.3.3 Low-Voltage Supplies (Flyback)...................................................3-5
3.3.4 Turn-On Control Circuitry..............................................................3-5
3.3.5 PFC Boost Stage ..........................................................................3-6
3.3.6 Bridge Isolation Stage ..................................................................3-6
4 Maintenance.......................................................................................4-1
4.1 Where to Begin ......................................................................................4-1
4.2 Surface Mount Technology ....................................................................4-1
4.3 Disassembly for Inspection & Service ...................................................4-1
4.3.1 Top Cover Removal ......................................................................4-1
4.3.2 Power Supply Discharge..............................................................4-1
4.3.3 Flyback Supply PWA Removal .....................................................4-3
4.3.4 Input Module (SST) Removal........................................................4-3
4.3.5 Output Panel Removal..................................................................4-3
4.3.6 Back Panel Assembly Removal...................................................4-3
4.3.7 Line Filter PWA Removal ..............................................................4-4
4.3.8 BFG PWA Removal.......................................................................4-4
4.3.9 Main PWA Removal ......................................................................4-4
4.4 Troubleshooting .....................................................................................4-4
4.4.1 Troubleshooting Flyback Power Supply........................................4-4
V
Table of Contents
4.4.2 Troubleshooting Trianglewave Generator and BCA
Output Stage. ...............................................................................4-5
4.4.3 Troubleshooting Power Supply, PFC PWA and Full Bridge
DC to DC Converter......................................................................4-6
4.4.4 Identifying Symptoms...................................................................4-6
4.4.5 Identifying and Repairing the Cause............................................4-7
4.5 Required Test Equipment.......................................................................4-8
4.6 Electrical Checkout Procedures ............................................................4-9
4.6.1 Quiescent AC Power Draw...........................................................4-9
4.6.2 Gain Switches...............................................................................4-9
4.6.3 Bridge Mono Operation................................................................4-9
4.6.4 Frequency Response ...................................................................4-9
4.6.5 Short Circuit Test ..........................................................................4-9
4.6.6 Output Power................................................................................4-9
4.6.7 Intermodulation Distortion ............................................................4-9
4.6.8 Signal to Noise Ratio ....................................................................4-9
4.6.9 Crosstalk at 20 kHz ....................................................................4-10
4.6.10 Post Test Settings .....................................................................4-10
4.7 Calibrations..........................................................................................4-10
4.7.1 Gaussian Filter Calibration .........................................................4-10
4.7.2 Overlap Correction and Adjustment...........................................4-10
4.7.3 Current Sensing Calibration .......................................................4-11
4.7.4 Output Filter Calibration .............................................................4-11
5 Parts....................................................................................................5-1
5.1 General Information ..............................................................................5-1
5.2 Ordering and Receiving Parts ..............................................................5-1
5.2.1 Terms ...........................................................................................5-1
5.2.2 Shipment .....................................................................................5-1
5.3 Mechanical Parts ...................................................................................5-1
5.3.1 CE4000 Amplifier Assembly.........................................................5-2
5.3.2 Back Panel Assembly...................................................................5-4
5.3.3 CE4000 PS Primary Heatsink Assembly ......................................5-5
5.3.4 CE4000 PS Diode Heatsink Assembly .........................................5-6
5.3.5 CE4000 PS Output Heatsink Assembly........................................5-7
5.3.6 CE4000 Standard Input Assembly ...............................................5-8
5.3.7 CE4000 Standard Domestic Ouput Assembly .............................5-9
5.3.8 CE4000 Power Switch Assembly ...............................................5-10
5.4 Circuit Board Parts...............................................................................5-11
5.4.1 Circuit Board and Schematic Part Numbers ..............................5-11
6 Schematics.........................................................................................6-1
VI
Speakon® plus 5-way barrier block, 5-way barrier

1 Introduction block plus binding strip, or dual Speakon.
1.3 Scope
1.1 Introduction This Service Manual in intended to apply to all
This manual contains complete service information on versions of the CE 4000 amplifier. The Parts Listings
the Crown® CE 4000 power amplifier. It is designed to include parts specific for the US version and the
be used in conjunction with the CE 4000 Reference European version. For parts specific only to other
Manual; however, some important information is versions contact the Crown Technical Support Group
duplicated in this Service Manual in case the CE 4000 for help in finding part numbers.
Reference Manual is not readily available.
1.4 Warranty
NOTE: THE INFORMATION IN THIS MANUAL Each Reference Manual contains basic policies as
IS INTENDED FOR USE BY AN EXPERIENCED related to the customer. In addition, it should be
TECHNICIAN ONLY! stated that this service documentation is meant to be
used only by properly trained personnel. Because
1.2 The CE 4000 Amplifier most Crown products carry a 3-Year Full Warranty
The Crown CE 4000 is a compact audio amplifier (including round trip shipping within the United
designed for professional use, providing high-power States), all warranty service should be referred to
amplification from 20 Hz–20 kHz with minimum the Crown Factory or Authorized Warranty Service
distortion. The CE 4000 features Crown’s patented, Center. See the applicable Reference Manual for
award-winning BCA® (Balanced Current Amplifier) warranty details. To find the location of the nearest
engineering, for superior power output, increased Authorized Warranty Service Center or to obtain
efficiency, legendary Crown sound and extraordinary instructions for receiving Crown Factory Service,
reliability. Crown’s enhanced, switch-mode power please contact the Crown Technical Support Group
supply with power factor correction allows the (within North America), or your Crown/Amcron
amplifier to be used worldwide without changing Importer (outside North America). If you are an
power supply components or settings. Other features Authorized Warranty Service Center and have ques-
include selectable on-board high-and low-pass tions regarding the warranty of a product, please
filter sets, SST (System Solution Topologies) module contact the Field Service Manager or the Technical
compatibility, and a choice of dual output connectors: Support Group.
Crown Customer Service

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

Shipping Address:
1718 W. Mishawaka Rd., Elkhart IN 46517
Phone: (574) 294-8200
Toll Free: (800) 342-6939
Fax: (574) 294-8301
http://www.crownaudio.com
Introduction 1-1
Figure 1.1 CE 4000 Front and Rear Views
Introduction 1-2
Total Harmonic Distortion (THD): 1-kHz rated

power, 0.5% or less THD.
2 Specifications Intermodulation Distortion (IMD): (60 Hz and 7 kHz
at 4:1) Less than 0.5% at rated power to 30 dB below
Note: All measurements are in Stereo mode with 8-ohm loads and an input sensitivity of rated power at 8 ohms.
26-dB gain at 1-kHz rated power unless otherwise specified.
Damping Factor: Greater than 700 from 10 Hz to
Power 400 Hz.**
Output Power: Crosstalk: Better than 50 dB below rated power,
20 Hz to 20 kHz.
Common Mode Rejection (CMR): Better than 70 dB
CE 4000 Power Chart from 20 Hz to 1 kHz.
Maximum power @ 1 kHz
DC Output Offset (Shorted Input): ±10 mV.
with 0.5% THD
2 ohm Dual 1800W
1
Controls & Connectors
4 ohm Dual 1200W Level: A 31-step detented rotary level control for
each channel located on the front panel.
8 ohm Dual 600W
Power: An on/off rocker switch located on the front
4 ohm Bridge-Mono 3600W panel.
8 ohm Bridge-Mono 2400W Mode: Turn power off before switching. A two-position
switch located on the back panel below the input
connectors which, when turned to stereo, operates
the amplifier as two independent channels. When
“Bridge-Mono” mode is selected, the amplifier
Load Impedance: Safe with all types of loads. Rated
bridges the two output channels for twice the output
for 2, 4 and 8 ohms in Stereo mode, 4 and 8 ohms
voltage.
in Bridge-Mono mode.
Sensitivity: A three-position switch located on the
Voltage Gain to 1-kHz, 8-ohm rated output:
back panel next to the Mode switch. Switchable
39.0-dB gain at 0.775-volt sensitivity; among 0.775 volts or 1.4 volts for full output into an
33.8-dB gain at 1.4-volt sensitivity; 8-ohm load (default setting), or 3.46 volts for a fixed
26-dB gain at 3.46-volt sensitivity. voltage gain of 26 dB.
Required AC Mains: 50/60Hz,100-240VAC (±10%). Fault Jack: A back-panel RJ-11 jack that may be
AC Line Current, remotely monitored to signal amplifier Fault condition.
An LED or other signalling device (not supplied)
100 Volts: 8.5 A;
may be used.
120 Volts: 7.1 A;
Filter Switches:
230-240 Volts: 3.7 A;
Low Pass: A three-position switch for each channel
At Idle: Amp draws no more than 155 watts. located on the back panel below the input and output
AC Line Connector: 15A IEC Connector with modules. Switchable among settings for Flat, 80 Hz
Country and100 Hz. Filter rolloff is 24-dB per octave.
Specific Cord and Plug. High Pass: A four-position switch for each channel
Inrush Current*: 50.86 A. located on the back panel below the input and output
modules. Switchable among settings for Flat, 30 Hz,
Performance 40 Hz and 50 Hz. Filter rolloff is 18-dB per octave.
Frequency Response: ±0.25 dB from 20 Hz to 20
kHz at 1 watt (See Figure 2.1). Indicators
Phase Response: ±15 degrees deviation from linear Signal: A green LED for each channel which flashes
phase from 20 Hz to 20 kHz at 1 watt. when a very low-level signal (>–40 dBm) is present
Signal to Noise Ratio, A-Weighted, 20 Hz to 20 kHz: at input. May be used for troubleshooting cable
Better than 100 dB below rated 1-kHz power; runs.
Clip: A red LED for each channel which turns on
* Per EN 55103-1: 1996 Annex B and Annex F. Highest reading from
a sample of 10 random readings.
when distortion becomes audible in the amplifier
** Measured using binding-post output connectors.
output.
Specifications 2-1
Fault: Normally off, this red indicator will blink under Output Connectors: Three options available: Four
five different conditions: (4) Neutrik® Speakon® NL4MP (mates with NL4FC)
1. When the amplifier is first powered up, until the output connectors; (2) 5-way binding posts in parallel
unit is ready for operation. with two (2) Speakon® connectors; or barrier strip
2. If the heatsinks reach a temperature above outputs in parallel with two (2) 5-way binding posts.
normal working limits. Output Signal,
3. If the transformer thermal protection circuit is Stereo: Unbalanced, two-channel;
activated. Bridge-Mono:Balanced, single-channel. Channel
4. If amplifier output wires develop a short-circuit. 1 controls are active; Channel 2 should be turned
5. If the amplifier output stage becomes non- down.
operational. Wiring Configuration: (see Figure: 2.2).
6. If there is a problem elsewhere in the amplifier. Protection
This circuit may be monitored remotely by plugging CE 4000 amplifiers are protected against shorted,
a simple switching circuit using an LED or other open or mismatched loads; overloaded power
signaling device into the back-panel RJ-11 (Fault) supplies; excessive temperature, chain destruction
jack. Under some conditions, the output of the phenomena, input overload damage and high-
amplifier will be muted. frequency blowups. They also protect loudspeakers
Power: A green LED that turns on when the amplifier from input/output DC, large or dangerous DC offsets
has been turned on and has power. and turn-on/turn-off transients.
Construction
Input/Output
Input Connector (standard module): One Neutrik® Rugged steel chassis is formed into a durable
Combo connector for each channel which features package any stagehand could love. Coated with
a balanced ¼-inch (6.35-mm) phone jack and a environmentally friendly powder for long life and
3-pin female XLR connector, in parallel with a barrier ease of maintenance.
strip termination. Cooling: Three-speed proportional speed fan.
Input Stage: Input is electronically balanced and Dimensions: EIA Standard 19-inch rack mount width
employs precision 1% resistors. (EIA RS-310-B), 5.25-inch (13.34-cm) height and
Input Impedance: Nominally 20 k ohms, balanced. 16.25-inch (36.56-cm) depth with additional 1-inch
Nominally 10 k ohms, unbalanced. rear rack ears.
Input Sensitivity: 0.775 volts or 1.4 volts for standard Weight: The CE 4000 net weight is 33.3 pounds (15.1
1-kHz power, or fixed 26-dB gain. kg). Shipping weight is 39.3 pounds.
Figure 2.2 Output Pin Assignments
Figure 2.1 Typical Frequency Response
Specifications 2-2
and high pass filtered at various frequencies. The

switches are located at the back panel. The low pass
3 Theory of Operation filter is a fourth-order Linkwitz-Riley type and the
high pass filter is a third-order Butterworth type.
These switches (S3 for the low pass and S5 for the
WARNING: All voltages on the primary side of the
high pass) and their necessary circuitry are found
flyback or bridge isolation transformers are not
on the BFG PWA.
referenced to ground. They are referenced to the
mains. When measuring these voltages with mains
voltage applied, always use an isolation transformer to Inherent in all PWM amplifiers is a rise in gain at
provide the mains voltage (and tie SMPSREF to signal higher frequencies. Because of this, a 32 kHz 7th-
ground) or use an isolated differential probe. order Gaussian low pass filter has been included in
the input stage of the CE4000 (on the main PWA). The
Gaussian filter-type is unique in that it has minimal
3.1 Audio Signal Path ringing and excellent phase response so even a
For the sake of simplicity, only channel one of the high-order filter such as this one does not adversely
audio signal path is described. affect the sonic excellence of the product. U111-A,
-B, -C and –D comprise this filter while U110-B and
3.1.1 Input Stage R178 form the gain calibration stage for this 7th
Signal is presented to the CE4000 through one of order filter.
three connectors when using the standard input
module. Each channel is outfitted with a balanced XLR 3.1.2 Error Amplifier
/ phone jack, and a barrier strip. These connectors The signal next enters the main amplifier error amp
are wired in parallel, which allows daisy chaining (U100-C) where it is mixed with a small portion of
when needed. The incoming shield is tied to ground the output voltage and current in such a way as to
through an 82-Ohm resistor (R607) in parallel with a control the amplifier’s overall output performance.
0.1uF cap (C605) for the purpose of inhibiting ground From the error amplifier, the signal is divided and
loop circulating currents and RFI protection. The fed to the modulator. Since the modulator circuit is
signal is then converted from balanced to unbalanced balanced, the drive signal for the positive modulator
in the Balanced Input Stage where it receives further is inverted by U100-D.
RFI protection. Input impedance is 20k Ohm balanced
and 10k Ohm unbalanced. Signal then flows into
the Variable Gain Stage where the front panel level 3.1.3 Modulator
controls are allowed to affect the gain. U101 and U103 are high-speed differential compara-
tors. U101 is the positive comparator and U103 is the
negative comparator. The comparator section has
The CE4000 amplifier comes with three input sensitiv- two outputs: inverting and non-inverting. The output
ity selections: 0.775V, 1.4V, and fixed 26dB gain set is therefore balanced. The audio signal is applied to
by a switch on the Bridge/Fault/Gain (BFG) PWA. the inverting input of both differential comparators
With the gain switch (S1) in the 0.775V position, R6 (with the positive modulator receiving the audio 180
sets the gain while in the 1.4V position R5 in parallel degrees out of phase from the negative modulator).
with R6 set the gain. In the 26dB position, R4 in The 250 kHz triangle wave (described below) is
parallel with R6 set the gain. The signal is then put applied to the non-inverting input of both differential
under the control of a full-time compressor circuit comparators. With no audio signal, the bipolar triangle
comprised of a symmetrical window detector, a buffer wave is therefore compared to a zero-volt signal
amplifier, and the gating op-amp which uses several and this results in a 250 kHz square wave pulse
small components to set the compressor’s attack and train that is passed to the NAND gate section of the
decay characteristics. These components are found differential comparator.
on the large main PWA. The actual compressing is
accomplished by an opto-isolator (U1) on the BFG
PWA that affects the gain in the signal path. Each NAND gate has two inputs: the modulated
signal from the high speed comparator section and
the current limiter detect signal from U106-A. In the
The signal then is passed through a series of switch- event of over-current, the current limiter signal is
able filters that allow the signal to be low pass shut off disabling the NAND gates. This results in no
Theory of Operation 3-1

pulses exiting the comparators long enough to keep U120 and U121 are dual inverting high-speed
the current at an acceptable level. drivers designed to interface low current digital
circuitry (U119 and U123) with power MOSFETs (also
If there is no current-limiting action, the balanced abbreviated FETs). U120 and U121 are used to drive
output of U101 forms the positive portion of the the gates of the output FETs (Q106-Q113).
output waveform (Vp). The output of U103 is also
balanced and forms the negative portion of the In order to produce gate drive power to the drivers,
output waveform (Vn). These two balanced signal a floating supply is generated for the Vp side. This
lines are routed to the output stage drivers, U119 and supply uses U124-A and U124-B to divide the 500kHz
U123. If an audio signal is present at the inputs of the clock down to 125 kHz. The half-bridge driver U22
modulators, the triangle wave will be compared to uses this 125 kHz clock to control the high-side and
a varying signal at the comparators and the outputs low-side FETs in the dual FET IC U23 so that the
of the NAND gates will be a 250 kHz pulse train in output of U23 is alternately connected to +15VPS
which the widths of the pulses vary with the audio and ground . The rate of current rise is kept in control
amplitude. by the inductance of transformer T101. The end result
is that the output of U23 is a square wave of 15V
This operation is described as Pulse Width Modulation amplitude and approximately 50% duty cycle that is
(PWM), as used in the BCA amplifier. used as the primary excitation for the transformers.
The transformer provides the required isolation and
the secondary AC is converted back to DC by diodes
3.1.4 Triangle Generator D131 and D132 and filter capacitors C316-C319. The
The 250 kHz triangle wave has its origins from the Vn side receives gate driver power from the flyback
4MHz generator (clock generation is described in PWA (see below) and this power is referenced to
the power supply section). After U224-A divides the –Vcc rail.
the 500kHz square wave down to 250 kHz, U105
converts the signal from a 0V-5V square wave
We pause now for a qualitative description of output
to a –5V to +5V triangle wave that is extremely
stage operation (refer to Figure 4.1). All parts to the
accurate. R171, C159, C153, C154, R168, and R169
left of “Iout” are positive or “p” side parts and all
provide the feedback loop to the linear IC U105. The
parts to the right of “Iout” are negative or “n” side
potentiometer R170 allows the triangle wave to be
parts. The switches Swp and Swn are analogous to
DC offset in order to change the overlap/underlap
the FETs. Quiescent operation will be considered
characteristics of the output stage. Overlap/underlap
first. At the start of a switching cycle Swp and Swn
is analogous to the bias adjustment made in linear
are both turned on. Current flows from +Vcc, through
output stages but it does not require a temperature
Swp, through Lp, through Ln, through Swn, and down
sense to prevent thermal runaway. The output of
to –Vcc. The current rises at a controlled rate in the
U105 is routed to the non-inverting inputs of the
Lp and Ln inductors (see the current diagram to the
modulators.
right in Figure 4.1). Halfway through the cycle, the
switches turn off but the inductors have reached
A note on the triangle generator for channel two: a certain current flow (the peaks on the diagram)
Before the frequency is divided down by two, the and now must continue pushing current in the same
500 kHz clock is inverted by U106-B. This effectively direction. The current continues to flow in the same
shifts the channel two triangle wave 90 degrees from direction through the inductors but comes through the
that of channel one. diodes because the switches are open. Specifically,
current flows from –Vcc through D1, through Lp,
3.1.5 Output through Ln, through D2, and to +Vcc while ramping
The PWM modulated 250 kHz signals exit the modula- down. At quiescent, the Lp and Ln currents cancel
tors and enter the output stage via optocouplers so the net voltage developed at Iout across the
U119 (Vp) and U123 (Vn). These optocouplers give capacitor is zero. For positive voltage output, Swp
electrical isolation from the low voltage circuitry is left on longer than Swn and for a negative output
to the high voltage output circuitry. The output of voltage, the opposite occurs. Note that for any output
U119 and U123 are then sent to the output MOSFET voltage, the “on” time of both switches will overlap,
drivers. even if one is on longer than the other.

Figure 4.1 BCA Operation
Now back to the description of output circuit flow: of the time while the negative side will be on less
after the FETs, the signal is then routed to the BCA than 50% of the time. The total “on-time” will add to
filter inductors (Lp and Ln) and the current sense approximately 100%. Also, the on-time of the two
resistors (R383/R361 and R384/R362). The combining polarities will overlap so that when the negative side
point (B1) is then sent to the Output Filter. is on, the positive side is also. For negative-going
signals, the action is reversed (swap positive and
With no audio modulation, the PWM pulse train that is negative). The result at the summing junction B1 is an
sent to the gates of each set of FETs is the same and amplified version of the input signal, with some noise
the duty cycle is approximately 50%. This means that superimposed on it. The B1 signal is then routed
for no audio input, the positive FETs (Q106, Q107, to the Output Filter.
Q110 and Q111) turn on and off at the same time
as the negative FETs (Q108, Q109, Q112, Q113. As 3.1.6 Output Filter
mentioned before, the Lp and Ln inductors control The output filter is made up of three individual
the rate of rise of the current during this time so that filters: a 250 kHz filter (L101/C128), a 500 kHz
this does not act like a short during the couple of filter (L102/C131/C397), and a final 250 kHz filter
microseconds that they are on. The time that the FETs (L104/C136-C139). The signal passes through these
are on ramps current up in the inductors which stores three filters to eliminate both residual 500 kHz and
energy in them. This energy is released through the 250 kHz signals. The audio signal is then connected
diodes (D140-D143) when the FETs are turned off. to the output PWA through buss bars.
The Vp and Vn nodes swing between –Vcc and +Vcc
with a duty cycle of approximately 50%.
3.2 Protection and Control Circuitry
Operating the output stage in this way causes the 3.2.1 Current Monitor
current in the Lp and Ln inductors to completely Audio output current levels are monitored by the use
cancel at the B1 node. This drastically reduces the of transformer T100. A small primary winding is in
filtering requirements necessary after the output series with the output current and the secondary
stage. develops a voltage across R140 proportional to the
output current of the amplifier. This output current
information is used for two purposes:
If an audio signal is present at the input of the
1. Negative feedback
amplifier, the widths of the pulses at Vp and Vn
change but the amplitude of the pulses stays at 2 2. Current feedback information for the modulators.
* Vcc. Positive audio signals will cause the positive
side of the output stage to be on more than 50%

3.2.2 Current Limiter and Q103 turns on. Q103 turns on the compressor
To prevent excessive output current, the CE4000 opto (located on the BFG PWA) which compresses
amplifier incorporates a current limiting protection the input signal and reduces the peak voltage the
circuit. The current sense resistors (R383/R361 and amplifier is required to produce. U125-D going
R384/R362) in series with the Lp and Ln inductors high will activate the “Clip” LED, but only if the IOC
sense the output current. The voltage dropped condition occurs long enough to be audible. C312
across these two resistors is sent back to U108-A and R413 set the conditions at which the “Clip” LED
and U108-B. D109, R163, and R165 set the voltage illuminates. Details of the generation of the TLC signal
reference for U108-B. D109, R164, and R167 set are discussed in the next section.
the voltage reference for U108-A. Due to the circuit
configuration, only the reference at U108-5 will show The “Fault” LED indicates any condition when there
a voltage and it is set to 0.48VDC referenced to node is a reason for the modulators to be turned off. When
B1 with no signal input. activated, the Fault LED will flash at approximately
3Hz.
The outputs of the comparators are normally open
but since these two outputs are connected together The “Enable” LED is turned on by the presence of
and to U107-2 and through R161 to B1+15V, the level the +15V supply (see Section 4.3.3).
sits at one diode drop above B1 or +0.6VDC. Pin 3
of U107 is tied to B1. The output of U107 is inverting
so normally the output is low. U106-A inverts the 3.2.4 Control Circuitry
output and is used to turn the modulators on and After the low and high voltage rails are powered
off. Overall, if the outputs of U108 go low, the output up and stable, the C354 timing capacitor, along
of U106-A goes low to turn off the modulatorsU101 with U114-C and associated circuitry holds the
and U103. enable line (the net is called “Timing Cap 1”) low for
approximately four seconds. If Timing Cap 1 is low,
U115-A stays low which causes Q115 to be high.
The second input to U106-A is from the protection This is input to U106-A that is inverted on the output
circuitry and is used to turn off the modulators (U101 and holds the modulators off.
and U103) for various reasons (see Section 4.2.4).
Several detectors affect the status of Timing Cap 1.

3.2.3 Display Circuitry U114-A, along with scaling resistors R309 and R310
Just after the input signal is converted from balanced pull the line low if +Vcc rises beyond a safe limit.
to unbalanced, it is routed to the signal detection In a like fashion, U213-A, R315, and R316 look at
circuit. With a signal approximately 45-dB below that the –Vcc rail. U213-B with scaling resistors R320
required for full output, the Signal LED will illuminate. and R319 determine if the high voltage rails are
Note that this LED will indicate whether signal is high enough to ensure proper operation. If a large
present at the amplifier but not whether it is being amount of high frequency energy is being produced
output from the amplifier. by the output stage (such as during a shorted load
condition), U114-B with scaling resistors R311 and
The compressor circuit is initiated by either the Input- R312 and time delay cap C176 will pull Timing Cap
Output Comparator (IOC) circuit or by the Thermal 1 low. If the airflow is blocked or severely clogged
Limit Control (TLC) circuit. The IOC circuit, composed and even the fan on high speed can not keep the
of Q100, Q101, R121-R126, and D105-D106, uses amplifier cool, U115-D will pull Timing Cap 1 low. If
the error signal from the error amplifier (U100-C). If Timing Cap 1 goes low, it also turns on Q1 on the BFG
the error amplifier is unable to correct for non-linear PWA, which causes U5’s transistor to not conduct.
behavior in the amplifier, the error amplifier (U100-C) U5 is connected to pins 2 and 5 of the modular jack
will generate a voltage spike of approximately ±7V. J3 that allows for remote sensing of the amplifier’s
The IOC circuit clamps that voltage to the ±7V limit operating condition.
(normally it would go to the op-amp’s rails) and also
generates a voltage greater than the window of ±0.3V Special Negative Temperature Coefficient (NTC)
that is detected by U117-C and U117-B. Depending resistors are attached to three heatsinks and the
on the polarity, U117-C or U117-B will go low during power transformer to tell the amplifier if action needs
an IOC event. If this happens, U125-D goes high to be taken to reduce the temperature. RT1 and RT2

are attached to the amplifier output heatsinks (one met stringent regulatory safety requirements and,
per channel). R711 is attached to the primary side if they fail, must be replaced by the correct part as
power supply heatsink and R713 is attached to the called out in the PWA documentation.
power transformer. The NTC sensors feed the fan
control circuit. Normally, the fan runs at very low
3.3.2 Fuse
speed and R325, R42, R508, R509, R333, R334, and
In the rare event that a power supply failure draws
R86 limit the voltage applied to the fan. For medium
excessive current from the mains and the power
speed, Q105 conducts, shorting out R333, R334,
supply itself cannot reduce the current by shutting
and R86. For high speed, Q104 also conducts which
down the controllers, a fuse will blow on the EMI filter
shorts out the other dropping resistors.
PWA. This fuse is accessible through a slot in the filter
shield and is the same value regardless of the mains
“TLC” is a feature that allows the amplifier to decrease voltage that the amplifier is used with. Always replace
the amount of power it is dissipating if the power the fuse with the same type and rating!
devices or transformer are climbing towards an
unsafe temperature. This circuit uses the NTC-derived
voltage to control a varying power limiter. This circuit
3.3.3 Low-Voltage Supplies (Flyback)
Several things happen in parallel when the power
only comes into play if forcing the fan into high speed
switch is first turned on. The line current flows through
is not enough to keep the unit at a safe temperature.
PTCs R1 and R2 to prevent high inrush currents.
The TEMP IN signal is delivered to U125-A’s non-
The current is then rectified by D1 and flows through
inverting input while a reference voltage is sent to
L1 and D2 to charge energy reserve caps C1 and
its inverting input. U125-A scales and inverts the
C6. As soon as sufficient voltage is detected at the
temperature signal while U125-B inverts this new
“Vbulk” node, the low voltage “flyback PWA” supply
signal. U112-B and U112-C compare the temperature
starts running. It is a buck supply that self-starts by
information to the input signal amplitude. Normally,
free running (not synchronized to any clock) at about
the output of U112-B&C is open collector but if
80 kHz. This supply produces all of the required low
limiting is required, this output is forced low and is
voltage supplies except the Vp gate drive power
sent to the compressor circuit as TLC 1.
mentioned above in the “Output” section. All of the
secondary supplies are isolated from the primary by
The NTC voltages controlled by R339, R74, R712, a transformer. After the low voltage supplies are up
and R714 respectively are diode-OR’d to U115-D. and running, the clock circuitry runs and generates
U115-D compares this voltage to a reference formed a synchronizing signal for the flyback PWA that
by R337 and R336 to determine if, as a last line of overrides the free-running circuit and forces the
defense, Timing Cap 1 should be pulled low until flyback to run at 125 kHz.
the amplifier cools off.
3.3.4 Turn-On Control Circuitry
In the rare event that DC is produced by the output As mentioned in the previous section, while C1 and
stage, U113-C and U113-D form a window detector C6 are being charged through the PTCs, Q11 is
whose output goes low in that condition. This signal is held off and C47 charges up in approximately two
latched on permanently by U113-A and U113-B and seconds. U10-A’s output then goes high which turns
R304. This signal, which is high for a fault condition, Q8 on forcing U13-B’s output high which turns on the
is sent to U115-4 and will also turn off the modulators. relay via Q9 and shorts out the PTCs and allows full
To reset this latch, the power must by cycled to line voltage to get to C1 and C6. As Q8 is turning
the amplifier. on, Q3 turns off causesing C24 to discharge through
R9 and, after about 15mS, forces U13-A’s output low
which turns Q14 and Q15 off. When Q14 and Q15 are
3.3 Power Supply Operation on, they ground the soft-start pins of controllers U2
3.3.1 Power Entry and Filtering and U4 and this prevents them from running.
AC power enters the amplifier through a power cord
equipped with an IEC (unplugable) connector. It then
passes through the EMI filter to remove switching Three conditions can prevent the node at U10-A’s
noise caused by the amplifier and power supply. The output from going high. U24-A will hold this node
parts on the primary side of the power distribution low through D45 if there is a fault detected by the
circuitry (including those on the EMI PWA) have all audio output stage or if the power supply detects an

overcurrent condition. The circuit of U24-A and U24-B 3.3.6 Bridge Isolation Stage
will latch if either of these conditions is detected. The 400VDC is then “bucked” down to the ground
U11-B will hold the node low if U11-A detects a referenced rails (+Vcc and –Vcc) needed by the
low line voltage condition (about 60VAC) such as audio amplifier. Controller U4, through gate drivers
a brownout. U17, U31, U29, and U32 and transformers T2 and
T3, turns Q4 and Q7 on at the same time, then turns
3.3.5 PFC Boost Stage Q4 and Q7 off and Q5 and Q6 on at the same time,
After the relay closes and the soft-start pins are causing T1 to convert voltage and current to its
opened, the PFC controller, U2, starts to run. The secondary. This process is repeated so that any two
GDRV pin (20) on U2 controls gate drivers U9 and of the four FETs are on about 85% of the time. U4
U26 which drive the gates of Q1 and Q2 in a boost runs at 125kHz (the 250kHz sync signal is divided
mode configuration. Several inputs to the controller down within the IC). Diodes D3-D6 and capacitors
affect its operation. The controller uses feedback from C7-C8 rectify the secondary AC to DC. Transformer
the “V BULK” node, compensated by R24, C314, T1 provides isolation between primary (mains) and
and C14 and fed into U2-13 and U2-14 to maintain secondary (ground referenced) power for safety.
approximately 400VDC at this node. The feedback Controller U4 is called a “Phase-Shifted Bridge
loop is quite slow, in the “10’s of Hz” range, unlike Controller” because as its soft-start pin is released
that of a power amplifier, and so depends on the and U4-19 climbs in voltage (U4-19 is a current
large energy reserve capacitors to supply impulsive source), the controller slowly allows the power
power but overall, the voltage is regulated to 400VDC transfer to ramp up by phase-shifting the power FETs
regardless of the line voltage or the load current. Note properly. This stage is referred to as a “buck” stage
that 400VDC is higher than the highest expected (as mentioned previously), an “isolation” stage for its
peak line voltage so the PFC stage is always boosting transformer action, and a “bridge” stage since the
to a known voltage. The PFC controller also looks at four FETs form a full bridge topology.
the incoming “RECT AC+” voltage and makes sure
that the current the boost stage draws is in phase The AC primary current travelling through the
and shaped like the voltage. This makes the amplifier transformer is also passed through a small current
look like a resistor to the AC mains, and allows it to transformer in order to sense the current. This
pass certain regulatory requirements. Pin U2-3 looks AC signal is passed through diodes D9-D10 and
at the incoming line voltage to make sure it is within D12-D13 and cap C26 to convert it to DC. If the
safe limits and if not, shuts down the FETs. R36 sets bridge current is high and remains high for several
the current limit of the PFC stage to approximately seconds (such as when the amplifier is producing
47Amps peak. Using all of these inputs, U2 causes high voltage, high current sine waves), the average
the boost stage to take small amounts of current from power limiter will tell the audio amplifier to invoke the
the line 62,500 times each second. compressor and slowly reduce the power output. The
DC signal from C26 is also compared to a reference
in the Over Current Detect Circuit and will latch both
U2 and U4 off if currents above 50-55 Amps are
detected in the bridge primary. The power to the
amplifier must be cycled to reset this latch.

Of course, there are also things to watch out for with

SMT. (1) The placement of the components on the
4 Maintenance board, not through a hole, makes the components
and the solder joint more susceptible to damage. (2)
4.1 Where to Begin Rework of SMDs can often require specialized tools,
Effective repair involves three basic steps: equipment, or training. (3) SMDs are very small and
1) Determine the symptom(s) of the problem can be difficult to handle, see, and identify.
2) Identify the cause(s) of the symptom(s) Remember that on the CE-Series amplifiers, the SMDs
3) Repair the unit to eliminate the cause(s). on the bottom side of the main module are GLUED.
To determine the symptoms, you will want to get as Take care not to damage components while trying to
much information from the user as possible. Get remove them from the surface of the module.
as much information as you can about the system 4.3 Disassembly for Inspection & Service
and how the amplifier is used. There is always the The extent of disassembly required will depend upon
possibility that the problem will show up only if used the extent of inspection and service required.
in a specific way. Note: To avoid the risk of electric shock, turn off
Once you have all the information about the and unplug the amplifier from the ac power outlet
symptom(s), it is time to inspect the amplifier. A careful before disassembly or reassembly is attempted.
visual inspection is valuable for most problems, 4.3.1 Top Cover Removal
which you may encounter. To inspect the inside To remove the cover of the amplifier you will need
of the amplifier remove the cover as described in a #15 torx bit (TX15). After the cover is removed,
Section 4.3.1. and before any internal cables are disconnected,
Begin the inspection by looking for anything, which discharge the supplies. See Section 4.3.2.
appears abnormal, like loose connectors, broken 1. Turn the amplifier on its bottom on your workbench.
wires and burnt or visibly damaged components. The only access to the inside of the amplifier is the
Inspect the printed circuit assemblies for broken top cover.
traces and loose connections. Be thorough. The 2. Using the TX15 bit, Loosen the 8 screws around
time you spend visually inspecting the amp is time the perimeter of the cover.
well spent. 3. The cover lifts up and back after the screws are
4.2 Surface Mount Technology removed.
CE Series amplifiers use surface mount technology 4.3.2 Power Supply Discharge
in their design. There are several advantages to Before any connectors and PWAs (Printed Wire
using surface mount technology (SMT), including; Assemblies, or circuit boards) are removed, the
(1) surface mount devices (SMDs) are much smaller, Power Supplies need to be discharged. Follow these
and are mounted to the surface of the board, so simple steps.
more components can be placed on the board. (2) 1. Make sure the amplifier is unplugged from the
Components can be attached to both sides of the AC power source.
board, allowing the board size to be reduced. (3) 2. Locate L6 and L9 on the Main PWA (see Figure
SMT boards are lighter and provide better electrical 4.3).
performance and signal speed.
WARNING WARNING
Amplifier components are ESD sensitive. When Before unplugging or plugging in any connectors
servicing the amplifier, the technician must have or wires in the amplifier, discharge the power
approved ESD protection. Proper grounding straps supplies. See section 4.3.2 for instructions. Failure
and test equipment are required. Failure to use to do so will result in circuit failure.
proper protection will result in component failure.
Maintenance 4-1
J6
Main PWA
PFC Coils
Flyback PWA
Input Panel BFG PWA Output Panel Back Panel Power Supply Line Filter
Assembly Assembly Assembly Discharge PWA
Figure 4.1 CE 4000 Top View A
Line Filter
BFG PWA Fan Wire PWA
Jack (J4)
Figure 4.2 CE 4000 Top View B
Maintenance 4-2
3. Connect a 600 Ohm 10 watt resistor from L6 to L9. 4.3.4 Input Module (SST) Removal
Be careful not to touch the leads with your fingers, as 1. Remove the four Phillips-head screws that secure
±100V could be present at this point. the SST to the chassis.
4. Wait 30 seconds before removing the resistor. 2. Gently slide the SST out to expose the ribbon
Caution: the ten-watt resistor will become hot as cable connector.
the power supplies discharge. 3. Release the retention latch and disconnect the
ribbon cable from the SST Module and finish by
removing the SST from the chassis.
4.3.5 Output Panel Removal

1. Remove the four nuts on the Main PWA that hold
the output buss bars to the Main PWA (see Figure
4.5).
2. Remove the four T15 screws that secure the output
panel to the back panel.
3. Slide the output panel up and out of the back
of the amplifier.
Figure 4.3 Power Supply Discharge
4.3.3 Flyback Supply PWA Removal

1. Follow the instructions in Section 4.3.2. Supply
discharge is necessary to avoid circuit damage.
2. Remove the two screws and two plastic washers
securing the Flyback PWA to the Chassis (see Figure
4.4).
3. Release the retention latches on the connectors
located at the bottom of the Flyback PWA.
4. Lift the Flyback PWA straight up and out of the
chassis. Figure 4.5 Output Bus Bars
4.3.6 Back Panel Assembly Removal

The back panel assembly is removed to access the
BFG, Main and Filter PWAs.
1. Follow the instructions in Section 4.3.2. Supply
discharge is necessary to avoid circuit damage.
2. Remove the SST module (Section 4.3.4).
3. Remove the output panel (Section 4.3.5).
4. Disconnect the Brown and Blue primary wires from
the Main PWA. Slide both wires out from underneath
Flyback PWA.
5. Remove the 8 Flathead T15 screws on the side
and bottom of chassis that secure the back panel to
Figure 4.4 Flyback PWA and PFC Coils the chassis. Slide the back panel partially out and
away from the amplifier, then unplug the fan wires
from the Main PWA at J4 (see Figure 4.3).
Maintenance 4-3
6. Disconnect the safety ground wire attaching the 13. Remove the seven orange- or blue-painted
back panel to the chassis. screws that secure the Main PWA assembly to the
7. Pull the back panel assembly the rest of the way chassis.
out of the back of the amplifier. 14. Holding the heatsinks, lift and slide the Main PWA
4.3.7 Line Filter PWA Removal straight up and backwards out of the chassis.
1. Remove the back panel assembly (see Section 4.4 Troubleshooting
4.3.6). As mentioned earlier, the three steps to effective
2. Remove the four T15 screws that secure the repair are: Determine the symptoms; identify the
shield. cause of the symptoms; repair the unit to eliminate
3. Disconnect the faston connectors before removing the cause.
the PWA. Please troubleshoot based on the order listed below.
4. Remove the four standoffs that hold the Line Filter 4.4.1 Troubleshooting Flyback Power Supply.
PWA to the back panel assembly. 1. Nulls off the error amplifier output of channel 1 by
5. Remove the Line Filter PWA. placing a jumper between TP100 and TP104 (Jumper
4.3.8 BFG PWA Removal 1 in Figure 4.6).
1. Remove the back panel assembly (see Section 2. Nulls off the error amplifier output of channel 2 by
4.3.6). placing a jumper between TP200 and TP204 (Jumper
2. Remove the T15 flathead screw that holds the 2 in Figure 4.6).
metal cable shield to the chassis. 3. Defeat Undervoltage protection circuitry on BCA
3. Remove the two T15 screws that hold the shield side by pulling TP248 to +15V (TP254) (Jumper 3
to the Main PWA.
4. Remove the metal shield out of the chassis.
5. Disconnect the ribbon cable from the Main PWA 1
at J6. (see Figure 4.2)
6. Remove the tie-wraps securing the ribbon cables.
7. Remove the two T15 screws securing the BFG 2
PWA to the chassis.
8. Lift the BFG PWA straight up from the chassis.
4.3.9 Main PWA Removal 3
1. Remove the FlyBack PWA (see Section 4.3.3).
2. Remove the back panel assembly (see Section
4.3.6).
3. Disconnect the PFC coils and remove them from Figure 4.6 Shorting Jumpers
the side panel of the chassis.
4. Remove the T15 flathead screw that holds the in Figure 4.6).
metal cable shield to the chassis. 4. Defeat Brown-out effect protection circuitry by
5. Remove the two T15 screws that hold the shield pulling TP249 to +15V (TP-6) with a jumper, as shown
to the Main PWA.
6. Remove the metal shield out of the chassis.
7. Remove the knobs from the front panel.
8. Remove the nuts that secure the level controls
to the front panel.
9. Slide the level controls into the chassis.
10. Remove the air shroud from the Main PWA Jumper
heatsink.
11. Unplug the power switch wires at J26, J27, J28
and J29 on the Main PWA.
12. Remove the seven screws that secure the heatsink
assembly and coil assembly to the chassis. Figure 4.7 Brown-Out Jumper
Maintenance 4-4
5. Connect half wave rectified AC power flyback and 2. Using an oscilloscope check audio side triangle
power it up through an isolation transformer as waveforms at TP202 with respect to TP205 (see
shown in Figure 4. Figure 4.9).
Warning: NOT using an isolation transformer in 3. Using an oscilloscope check BCA output stage
Step 5 can result in test equipment damage. gate switching (see Figure 4.10). Probe at each gate
drive resistor.
R360 for Q107 and Q110 (Figure 4.10) while R357 for
Q108 and Q111 (Figure 4.11) of Vp Channel 1.
Q109 and Q113 (Figure 4.11) of Vn Channel 1.
Q208 and Q211 (Figure 4.11) of Vp Channel 2.
Q209 and Q213 (Figure 4.11) of Vn Channel 2.
A total of four measurements for each channel, 2 for
each Vp and Vn sides.
Figure 4.8 Half-Wave Rectified Flyback
6. Using a multimeter check DC supplies on power

supply side. Confirm TP6, TP7 and TP8 = +15V, TP46
= +7.5V, TP252 =19.0V, U2 pin 11 = 5.1V, and TP256
and U14 pin 1 = 5.0V. All measurements should be
made with respect to SMPS reference (TP2).
7. Using a multimeter check DC supplies on audio
side. Confirm TP254 is +15V, TP255 is -15V and
TP257 is 5.0V. All measurements should be made
with respect to AGND (TP-105).
4.4.2 Troubleshooting Trianglewave Generator and
BCA Output Stage.
1. Using an oscilloscope check audio side triangle
waveforms at TP102 with respect to TP105 Figure 4.10 Gate Switching, View A
(see Figure 4.9).
Figure 4.9 Output Signal of Triangle-Wave Generator

Figure 4.11 Gate Switching, View B
Maintenance 4-5
4.4.3 Troubleshooting Power Supply, PFC PWA and

Full Bridge DC to DC Converter
1. Using an oscilloscope check power supply clocks
at TP-253 and TP-12, as shown in Figure 4.12. All
measurements are with respect to SMPS reference.
Figure 4.14 PFC Gate Switching at 60VDC
6. Using an oscilloscope check gate switching of the

Full Bridge DC to DC Converter, as shown in Figure
4.15. Verify the phase shift at startup. Probe at TP-27,
Figure 4.12 Power Supply Clock TP-29, TP-30 and TP-31. All measurements are with
respect to SMPS reference.
2. Place jumper between J28 and J29 to simulate
front panel switch on.
3. Remove/ bypass boost inductor L1 and using an
external power supply apply 4VDC at J23.
4. Using an oscilloscope check PFC gate switching
at TP-5 with respect to TP-2, as shown in Figure
4.13.
Figure 4.15 Full-Bridge DC to DC Converter

Gate Switching
4.4.4 Identifying Symptoms

Why was the amplifier brought in for repair? Can you
get it to malfunction again? Some problems can be
Figure 4.13 PFC Gate Switching at 4VDC intermittent and difficult to find.
Once you have identified and verified the symptoms,
5. Using an external power supply apply 60VDC you can look for helpful information in Section 4.4.5 as
to J23 and verify that the frequency changes, as to where the cause of the problem is located.
shown in Figure 4.14.
Maintenance 4-6
If you don’t observe anything wrong with the amplifier, ground. If Vcc is low or missing, troubleshoot the Full
tactfully inquire how the owner used it and try to Bridge DC to DC converter stage.
determine if it was misused or some other component 3. ±15 V supply is too low. Check the Flyback PWA.
in their system could have been at fault. Remember 4. DC is present on the Channel 1 or Channel 2
that the protection circuits in this amplifier will protect output terminals, usually caused by a bad MOSFET
loudspeakers from problems caused upstream from or diode in the amplifier’s output stage.
the amplifier (DC protect).
5. The channel one heatsink is too hot. Verify the
If you lack sufficient information about the problem, heatsink temperature is less than 80°C. The output
and there aren’t any obvious problems with the heatsinks should be at earth ground. The SMPS
amplifier, skip to Section 4.6, the Electrical Checkout reference heatsink is above ground, so do not touch
Procedures. amplifier ground and the SMPS reference heatsink
4.4.5 Identifying and Repairing the Cause at the same time.
The first step in identifying the cause of the problem 6. The overvoltage sensor has been tripped. Measure
is always a visual inspection. Once the top cover the ±Vccs at L6 and L9. They should read less than
is removed, and the supplies are discharged, look 120 VDC referenced to ground.
for loose connectors, broken wires, loose hardware,
7. Transformer T1 has exceeded its thermal limit.
burnt components, or bad solder joints on the PC
Replace T1. Replace R713.
boards. Check both sides of the board.
Signal LED is off and the Clip LED is on for either
Once the visual inspection is complete you may
channel.
power up the unit. The best way to positively locate
which PWA is at fault is to have a working PWA of each 1. Troubleshoot the appropriate channel. A Clip LED
type on hand and plug them into the amplifier one at on generally means an output stage failure.
a time to see when the problem goes away. Signal LED is on and the Clip LED is on for either
The following Symptoms and Causes may help you channel.
determine which corrective action to take. We realize 1. The amplifier channel is clipping. Reduce the
that this list is limited. Please read through the Theory input signal level
chapter in this manual to better understand the 2. A short is present at the output. Check the output
function of each PWA. This will help you come to your wiring.
own conclusion as to the location of the problem. Output sounds distorted. Clip LED is off.
Amp does not appear to power up. No Enable 1. The input stage is being overdriven. Reduce the
LED. input signal level.
First, check the power supply fuse (located on the 2. There is a problem in the Input PWA. Replace or
Line Filter PWA). Check for faulty switch or faulty troubleshoot the Input PWA.
inductor connection in the EMI and Filter module. Amplifier does not meet Output Power specifica-
Also, make sure the AC line voltage is correct for the tion.
amplifier you are working on. Severely low AC line
1. The amplifier has reached thermal limits. Check
voltage could cause the amp to not power up. If
for proper fan operation.
both check out, then the amplifier is in a fault mode.
Viper could be dead. The most likely trouble area 2. PFC boost stage is not functioning properly.
is the Flyback PWA. Check for 400 VDC at TP-251 with respect to TP-50.
Troubleshoot PFC boost stage if measurement is
The Fault LEDs on one or both channels are
nonconforming.
flashing.
Amplifier does not meet Frequency Response
1. The Fault LEDs normally flash during turn-on
specification.
delay. Wait for six seconds to see if the LED stops
flashing. 1. Make sure the output voltage does not exceed
45Vrms.
2. One or more of the power supplies are out of
tolerance or missing. Replace or troubleshoot the 2. Check back panel filter switch positions.
Flyback PWA. If this does not correct the problem, 3. Check BFG PWA highpass and lowpass circuitry.
check for the 400 V Vboost by measuring from TP251 4. Possible problem in the 32-kHz 7th-order Gaussian
to TP50. If it is low, then troubleshoot the PFC boost filter. Readjust R178 and R278 for channel 1 and 2
stage. If 400 V is o.k., check the ±Vccs at L6 and
L9. They should measure approximately 105 VDC to
Maintenance 4-7
filter. Readjust R178 and R278 for channel 1 and 2 a faulty U100/200 or a faulty MOSFET or diode
respectively to get the frequency response in spec. in the output stage. Troubleshoot and repair as
Troubleshoot and repair filter as necessary. necessary.
Amplifier does not meet Voltage Gain specifica- 2. Input PWA might be passing input signal DC
tion. components. Check for short capacitors in the Input
1. The gain of the amplifier is determined by the BFG PWA.
PWA. Check the optocoupler for proper operation or 4.5 Required Test Equipment
replace the BFG PWA. Due to the complex circuitry utilized the CE 4000
2. Check residual resistance of gain level potentiom- amplifier, special calibration procedures and the
eters. correct test equipment are necessary to insure
Amplifier does not meet DC Output Offset speci- original factory specifications are achieved.
fication. Figure 4.16 is list of test equipment needed to
1. Possible problem on the Main PWA, and is likely successfully service the amplifier. Recommended
models are those used by Crown.
Alternate oscilloscope choices: Tektronix TDS360 and HP HP54610B. The latter is a 500 MHz
scope, which is needed to test newer BCA power supplies.
Figure 4.16 Required Test Equipment
Maintenance 4-8
4.6 Electrical Checkout Procedures output voltage and compare it to the 1 kHz reference
The test procedures in this section are used to verify voltage. Tolerance is ±0.25 dB. Remove the load
the operation of the amplifier. You may, however, find and signal. Note: Many oscillators need a frequency
these tests helpful in troubleshooting a problem if the check at 20 kHz.
problem is not easily identified. 4.6.5 Short Circuit Test
All tests assume that AC power is from 100-240 Spec: Amplifier will protect itself
VAC ±10%. Procedure: Inject a 1kHz, 1Vrms sine wave into the
During each test, it is assumed that the following input of channel 1. Short the output of channel 1 to
conditions are set on the amplifier unless otherwise ground for 10 seconds. The amplifier should cycle
noted: into fault mode. Every four to six seconds the Clip
LEDs will flash, indicating that it is checking to see if
• Level controls fully clockwise.
the short is still there. Remove the short and perform
• Bridge Output switch off. the test on channel 2.
• Input Sensitivity of both channels set at 26 dB.
4.6.6 Output Power
• Filter settings in the back panel are set to FLAT. Spec: Each channel
4.6.1 Quiescent AC Power Draw 600 watts into 8 ohms
Spec:130 watts maximum quiescent. 1,200 watts into 4 ohms
Procedure: With no load connected to the amplifier, 1,800 watts into 2 ohms (at ≥200V line voltage).
turn on the amplifier. Measure AC power draw. It
Spec: less than 0.5% THD.
should be less than 130 watts.
Procedure 8 ohm: Load the channel under test to 8
4.6.2 Gain Switches ohms. Inject a 1kHz sine wave and bring the level up
Spec: 0.775V, 1.4 V, 26 dB
until the output reaches 0.5% THD. Measure at least
Procedure: No Load. With the level controls at full 69.3 Vrms at the output.
gain and the input sensitivity switches set to 1.4 V,
Procedure 4 ohm: Load the channel under test to 4
inject a 1 kHz, 0.775 Vrms, into each channel. At
ohms. Inject a 1kHz sine wave and bring the level up
the output of each channel measure 38.3 Vrms, ±3.8
until the output reaches 0.5% THD. Measure at least
Vrms. Switch the Input Sensitivity switches to 26 dB.
69.3 Vrms at the output.
At the output of each channel measure 15.5 Vrms,
±0.5 Vrms. Switch the Input Sensitivity switches to Procedure 2 ohm: When testing 2-ohm power at
0.775 V, At the output of each channel measure 69.3 line voltages under 200 VAC, test one channel at a
Vrms, ±6.9 Vrms. time. Load the channel under test to 2 ohms. Inject
a 1kHz sine wave and bring the level up until the
4.6.3 Bridge Mono Operation output reaches 0.5% THD. Measure at least 60.0
Spec: Same voltage out both channels, channel 2 Vrms at the output.
out of phase.
4.6.7 Intermodulation Distortion
Procedure: No load. Switch the Bridge Mono switch
Spec: Less than 0.5% from 0 dB to -30 dB.
on and inject a 1 kHz sine wave into channel 1 only.
Monitor both outputs of the amplifier. They should be Procedure: Load the channel under test to 8 ohms.
the same voltage and 180 degrees out of phase with Inject a SMPTE standard IM signal (60 Hz and 7 kHz
each other. Remove the signal and turn the Bridge mixed at 4:1). Adjust the output voltage for a peak
Mono switch off. equivalent voltage of 69.3 volts. This is your 0-dB
reference. Measure less than 0.5% IMD from 0 dB to
4.6.4 Frequency Response -30 dB in 5- dB steps.
Spec: ±0.25 dB from 20 Hz to 20 kHz.
4.6.8 Signal to Noise Ratio
Procedure: Load the channel under test to 4 ohms.
Spec: Greater than 100 dB below rated 8 ohm power,
Inject a 0.1Vrms, 1kHz sine wave into the input.
A weighted.
Measure the output voltage. It should be 2.0 Vrms.
This is now your 1 kHz reference voltage. Switch the Procedure: Load the channel under test to 8 ohms.
frequency to 20 Hz and verify that the input voltage Terminate the input with 600 ohms. Verify that the
is still 0.1 Vrms. Measure the output voltage. It should gain switch is set at 26 dB and level control is at full
be the same as the 1 kHz reference voltage ±0.25 volume. Measure less than 550 µVrms at the output
dB. Switch the frequency to 20 kHz and verify that using an A-weighted filter.
the input voltage is still 0.1 Vrms. Measure the
Maintenance 4-9
4.6.9 Crosstalk at 20 kHz Procedure: Monitor TP37 found on the Main PWA.
Spec: Greater that 50 dB. Center oscilloscope to view lower right portion of
Procedure: Load each channel to 8 ohms. Verify that waveform (see Figure 4.17). Adjust R170 for the
both gain switches are set at 26 dB and both level sharpest-possible squarewave rising edges, with a
controls are at full volume. Inject a 2.0 Vrms, 20 kHz, transition curve less than 10.0V. Figure 4.18 shows a
sine wave into channel 1 and terminate channel 2 correct transition curve, Figure 4.19 shows “underlap”
with 600 ohms. Measure less than 126.5 mV at the (under adjustment), where the transition curve
output of channel 2. Now remove the signal from exceeds 10.0V. Figure 4.20 shows “overlap” (over
channel one and inject it into channel 2. Terminate adjustment), where the transition curve is not
channel 1 with 600 ohms. Measure less than 126.5 “smooth.”
mV at the output of channel 1. Repeat for channel 2, monitoring TP244 and adjusting
4.6.10 Post Test Settings R270.
After completion of testing, if all tests are satisfactory,
the amplifier controls should be returned to the
positions required by the customer. If the conditions
are unknown or unspecified, the factory settings
are as follows:
• Gain switches set to 1.4 V
• Bridge Mono switch turned off
• Level controls set fully counterclockwise
• Power switch turned off
• All filter switches set to the flat position
4.7 Calibrations
4.7.1 Gaussian Filter Calibration
Procedure 1: Obtain a multimeter with decibel
measurement capabilities. Set the multimeter to dB
measurement mode. Insert a 1 kHz signal into the Figure 4.17 Overlap Adjustment
input and measure at pin 14 of U111D. Reset the
meter to 0 dB using the 1 kHz signal as a reference
signal. Increase the signal generator frequency
to 20 kHz, leaving the output level unchanged.
While measuring pin 14 of U111D adjust R178 for
a reduction of level by 2.6 dB (readout should be
–2.6 dB).
Procedure 2: Obtain a multimeter with decibel Transition
measurement capabilities. Set the meter to dB
measurement mode. Insert a 1 kHz signal into the 10V
input and measure at the speaker output (no load).
Reset the meter to 0 dB using the 1 kHz signal as
a reference signal. Increase the signal generator
frequency to 12.5 kHz, leaving the output level
unchanged. Adjust R178 for a meter reading of 0 db.
This second test method is an alternative to the first
and should give the desired results: a flat frequency
response throughout the audio bandwidth.
4.7.2 Overlap Correction and Adjustment Figure 4.18 Correct Overlap Adjustment
Conditions: (Less than 10V)
• Amplifier output assembly MUST be room tem-
perature (72 degrees F/21 degrees C)
• No input signal
• No load
Maintenance 4-10
Transition
10V
Figure 4.19 Underlap Figure 4.21 Current Sensing Calibration

(Greater than 10V)
4.7.4 Output Filter Calibration
Output Filter Calibration is NOT field adjustable and
should not need adjustment. If you suspect the
slugs ( L101, L102 for Channel 1 while L201 and
L201 for Channel 2) have been moved, the amplifier
should be sent to CROWN Factory Service for proper
adjustment.
Transition
10V
Figure 4.20 Excessive Overlap

(No Smooth Transition)
4.7.3 Current Sensing Calibration

Drive and test one channel at a time.
1. Connect output to 8 Ohms load and apply 1kHz
Sinewave input signal.
2. Adjust output gain level until output voltage
measures 40Vrms on one channel.
3. Adjust R160 while observing TP-10 for channel
1 in order to achieve 1.0Vrms +/-10mVrms (see
Figure 4.21).
4. Repeat the adjustment on R260 while observing
TP-245 for channel 2.
Maintenance 4-11
This Page Intentionally Left Blank
Maintenance 4-12
established, after which an amount due will be issued

and shipment made upon receipt of payment. New
5 Parts parts returned for credit are subject to a restocking
fee, and authorization from the Crown Parts Depart-
ment must be obtained before returning parts for
5.1 General Information credit.
Replacement parts for this Crown amplifier can be
ordered from the Crown Parts Department.
5.2.2 Shipment
Shipment will normally be made via UPS, or best
PART PRICES AND AVAILABILITY ARE SUBJECT
other method unless you specify otherwise. Ship-
TO CHANGE WITHOUT NOTICE.
ments are made to and from Elkhart, Indiana USA,
only. Established accounts with Crown will receive
5.2 Ordering and Receiving Parts shipment freight prepaid and will be billed. All others
When ordering parts, be sure to give the product will receive shipment on a C.O.D. or prepayment
model, and include a description and part number (check or credit card) basis.
from the parts listing. Price quotes are available
on request. 5.3 Mechanical Parts
This section includes a mechanical part list for
5.2.1 Terms this product. All serviceable parts and assemblies
Normal terms are prepaid. Net-30 Days applies to will have a Crown Part Number (CPN) listed in this
only those having pre-established accounts with chapter. The parts listed are current as of the date
Crown. The Crown Parts Department does accept printed. Crown reserves the right to modify and
Visa or Master Card. If prepaying, the order must improve its products for the benefit of its customers.
be packed and weighed before a total bill can be
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
Parts 5-1
5.3.1 CE4000 Amplifier Assembly

Refer to Figure 5.1 for Exploded View
Item Quantity Description Part # (CPN)

28 1 ASM, CE4000 BACK PANEL See section 5.2.2
27 1 ASM, CE4000 POWER SWITCH See section 5.2.8
26 1 COVER, CE4000 TOP PC 126223-4
25 3 4” CABLE TIE C 1811-1-6
24 1 8-32 HEX NUT W/BELLE A11056-2
23 2 TIE, 5.625” CABLE 127330-1
22 1 SUB-FRONT, CE4000 FP PC 130526-1
21 7 CAP, CE400 PEM STANDOFF 128119-2
20 1 PWA, CE4000 MAIN See section 5.4
19 1 INDUCTOR,PFC 127399-6
18 1 PWA, CE4000 FLYBACK See section 5.4
17 2 RIVET, CE4000 INS RET PLASTIC 128130-1
16 2 INSULATOR, CE4000 HS NOMEX 126923-4
15 1 COILS, CE4000 L/PLN MATCHED 127401-3
14 7 WASHER, CE4000 HEATSINK SHLDR 128120-1
13 7 #10 BELLVILLE WASHER SS A10098-4
12 7 MSCREW, 10-32 X 3.50 TORX PNHD Z 128345-1
11 2 RIVET, CE4000 FAN PLENUM SNAP 127777-1
10 1 PLENUM, CE4000 FAN 127473-3
9 4 6-32 HEX NUT W/BELLE A11056-1
8 16 SCREW, #6 X .250 MACH TORX PNHD 103436-70604
7 2 .5 X .136 X .02 NYLON WASHER A10101-5
6 1 SHEILD, CE4000 MAIN BD RBN AP 128218-7
5 1 PWA, CE4000 BFG See section 5.4
4 16 SEMS, 6-32 X .31 TORX PNHD STAR 103433-70605
3 10 8-32 X .31 SERR FLTHD T15 BZ 102156-1
2 2 KNOB, D350 D 8959-5
1 1 CHASSIS, CE4000 WELD/AP/PC 126222-11
ASM, NUMBER:
127390-4
NOTES: RECOMMENDED ASSEMBLY TORQUES

1) THESE 8 SCREWS ARE USED TO FASTEN INPUT
ITEM NO. C.P.N. TORQUE SETTINGS
AND OUTPUT MODULES TO BACK PANEL.
3 102156-1 12-14 IN LBS.
2) THESE 4 NUTS ARE USED TO FASTEN OUTPUT
4 103433-70605 16-18 IN LBS.
MODULE BUSS BARS TO MAIN PWA.
8 103436-70604 10-12 IN LBS.
3) SLIDE CABLE TIES (ITEM 25) THRU LANCES
IN CHASSIS, PLACE RIBBON CABLE (PART OF 9 A11056-1 10-12 IN LBS.
ITEM 5) AGAINST CHASSIS SIDE PANEL BETWEEN 12 128345-1 16-18 IN LBS
LANCES, THEN SECURE CABLE TIES AROUND 24 A11056-2 10-12 INLBS
RIBBON CABLE.
Parts 5-2
Figure 5.1 Amplifier Assembly (Exploded View)
Parts 5-3
5.3.2 Back Panel Assembly


13 1 LABEL, VDE EARTH GROUND D 7037-1
12 2 8-32 HEX NUT W/BELLE A11056-2
11 1 WIRE, 14 GRN/YEL RING X 6.0 X RING A11544-G060G
10 1 SHIELD, CE400EMI FILTER 128229-7
9 1 WIRE, 14 BLU FAST X 21 X FLAG A11386-HZ10M
8 1 WIRE, 14 BRN FAST X 21 X FLAG 103448-A21OM
7 4 STAND, 6-32 X 1.9375 HEX MALE/FEM A12095-12
6 1 PWA, CE EMI FILTER See section 5.4
5 1 WIRE, 14 GRN/YEL RING X 6.0 X FLAG A11544-GO60M
4 1 IEC SNAP IN 15A UL/10A VDE 102650-1
3 8 SCREW, 6-32 X .250 MACH TORX PNHD 103436-70604
2 1 FAN, 120 X 120 X 38mm 12VDC 140CFM 126992-2
1 1 PANEL, CE4000 BACK AP/PC/PP 127227-12
ASM. NUMBER:
130251-2
NOTES:
RECOMMENDED ASSEMBLY TORQUES
1) CONNECT ITEM 8 TO “J9” & ITEM 9 TO “J10”
ON ITEM 6 PWA PRIOR TO ASSEMBLING ITEM
3 103436-70604 13-15 IN LBS.
10.
12 A11056-2 10-12 IN LBS.
Figure 5.2 CE4000 Back Panel Assembly (Exploded View)
Parts 5-4
5.3.3 CE4000 PS Primary Heatsink Assembly


11 X TYPE 340HEATSINK COMPOUND S2162-6
10 1 SHIM, CE4000 BRIDGE RECTIFIER 128246-1
9 9 8-32 X .312 TORX PNPH SEM 103415-10805
8 2 CLIP, CE40002 FINGER 127182-1
7 1 CLIP, CE4000 2 FINGER 127552-1
6 4 MOSFET, 0.11 OHM 500V 126738-1
5 1 DIODE, 30A 600V HYPERFAST 127457-1
4 2 MOSFET, 0.08 OHM 500V TO-247 127456-1
3 1 RECT, 50A 600V PC MNT BRIDGE 125427-1
2 2.5 WAFER, 3.000 X .90X.04 CERAMIC 127204-1
1 1 EXTRU, CE4000L-FR HS MACHINED 127976-3
ASM. NUMBER:
128009-1
9 103415-10805 22-24 IN LBS.
Figure 5.3 CE4000 PS Primary Heatsink Assembly (Exploded View)
Parts 5-5
5.3.4 CE4000 PS Diode Heatsink Assembly


5 4 8-32 X .312 TORX PNPH SEM 103415-10805
4 1 CLIP, CE4000 4 FINGER SS .040 127182-1
3 4 DIODE, 30A 600V HYPERFAST 127457-1
2 1 WAFER, 3.00 X.90 X .04 CERAMIC 127204-1
1 1 EXTRU,CE4000 L-RR HS MACHINED 127977-3
ASM. NUMBER:
128010-1

5 103415-10805 22-24 IN LBS.
Figure 5.4 CE4000 PS Diode Heatsink Assembly (Exploded View)
Parts 5-6
5.3.5 CE4000 PS Output Heatsink Assembly


6 6 8-32 X .312 TORX PNPH SEM 103415-10805
5 6 CLIP, CE4000 2 FINGER 127552-1
4 4 DIODE, 300V ULTRAFAST APT15D30K D9053-6
3 8 MOSFET, 250V 16A MTP16N25E C10207-6
2 2 WAFER, 2.7000 X .90 X .04 CERAMIC 127564-1
1 1 EXTRU, CE4000 R-HALF HS MACHINED 127978-3
ASM. NUMBER:
128011-3

6 103415-10805 22-24 IN LBS.
Figure 5.5 CE4000 PS Output Heatsink Assembly (Exploded View)
Parts 5-7
5.3.6 CE4000 Standard Input Assembly


3 4 SCREW, #4 X .5 PNHD PH AB BZ A10111-70408
2 1 PWA, CE INPUT EC See section 5.4
1 1 PANEL, CE INPUT CHARCOAL 126787-5
ASM. NUMBER:
127049-1

3 A10111-70408 4-5 IN LBS.
2 (REF) 103435-70608 13-15 IN LBS.
Figure 5.6 CE4000 Standard Input Assembly (Exploded View)
Parts 5-8
5.3.7 CE4000 Standard Domestic Ouput Assembly


5 4 SCREW, 6-32 X .250 MACH TORX PNHD 103436-70604
4 1 SHEILD, CE4000 OTPT BUSS BAR 128203-1
3 1 INSULATOR, CE4000 OTPTBUSS BAR 128202-1
2 4 BAR, CE4000 OUTPUT BUSS AP 127672-2
1 1 PWA, CE4000 SPEAKON/BDG POST OTPT See section 5.4
ASM. NUMBER:
127831-1

5 103436-70604 13-15 IN LBS
Figure 5.7 CE4000 Standard Domestic Output Assembly (Exploded View)
Parts 5-9
5.3.8 CE4000 Power Switch Assembly


3 2 WIRE, 16 WHT FAST X 4 X FLAG A11518-K040P
2 2 WIRE, 16 BLK FAST X 4 X FLAG A11608-EO30R
1 1 SWITCH, ROCKER PNL MNT DPST 16A 127455-1
ASM. NUMBER:
128425-1
NOTES:
1) MARKINGS 1, ID, 2, 2D ARE IDENTIFIED ON
SWITCH HOUSING.
2) J26, J27, J28, J29 ARE CORRESPONDING LOCA-
TIONS ON PWA.
Figure 5.8 CE4000 Power Switch Assembly (Exploded View)
Parts 5-10
5.4 Circuit Board Parts

This section includes electrical parts lists for this CE4000 POT BOARD
product. All serviceable parts and assemblies will PWA NUMBER: 127563-3
have a Crown Part Number (CPN) listed in this
section. The parts listed are current as of the date CE 4K SPEAKON/BDG POST OTPT
printed. Crown reserves the right to modify and PWA NUMBER: 127820-3
improve its products for the benefit of its customers. Drawing Sheet: 5
Please note: where reference designations are listed
as “installed on next assembly,” the CPN (Crown Part CE4000 EMI FILTER
Number) for the associated part may be found in PWA NUMBER: 128243-6
Section 6.2, Mechanical Parts.
5.4.1 Circuit Board and Schematic Part Numbers

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.
Note on circuit board designations: Crown circuit

boards are referenced with a PWA and/or PWB part
number. PWA stands for Printed Wire Assembly. This
is the completed circuit board with all components
assembled. PWB stands for Printed Wire Board. This
is the circuit board only, without components.
CE4000 MAIN
PWA NUMBER: 126218-13
Drawing Sheet:
41
42

Drawing Sheet:
41
42
CE4000 BFG
PWA NUMBER: 126828-12 (REV.2)
PWA NUMBER: 126828-12 (REV.A)
CE4000 INPUT CE
Drawing Sheet:
4
CE4000 FLYBACK
Parts 5-11
Parts 5-12
Parts 5-13
Parts 5-14
Parts 5-15
Parts 5-16
Parts 5-17
Parts 5-18
Parts 5-19
Parts 5-20
Parts 5-21
Parts 5-22
Parts 5-23
Parts 5-24
Parts 5-25
Parts 5-26
Parts 5-27
Parts 5-28
Parts 5-29
Parts 5-30
Parts 5-31
Parts 5-32
Parts 5-33
Parts 5-34
Parts 5-35
Parts 5-36
Parts 5-37
Parts 5-38
Parts 5-39
Parts 5-40
Parts 5-41
Parts 5-42
CE4000 MAIN PWA NUMBER: 126218-13

DRAWING SHEET: 41
Parts 5-43

DRAWING SHEET: 41
Parts 5-44
Parts 5-45
Parts 5-46
Parts 5-47
Parts 5-48
Parts 5-49
Parts 5-50
Parts 5-51
Parts 5-52
Parts 5-53
Parts 5-54
Parts 5-55
Parts 5-56
Parts 5-57
Parts 5-58
Parts 5-59
Parts 5-60
Parts 5-61
Parts 5-62
Parts 5-63
Parts 5-64
Parts 5-65
Parts 5-66
Parts 5-67
Parts 5-68
Parts 5-69
Parts 5-70
Parts 5-71
Parts 5-72
Parts 5-73
Parts 5-74
Parts 5-75
Parts 5-76

DRAWING SHEET: 41
Parts 5-77

DRAWING SHEET: 42
Parts 5-78
Parts 5-79
Parts 5-80
Parts 5-81
Parts 5-82
Parts 5-83
Parts 5-84
Parts 5-85
Parts 5-86
Parts 5-87
Parts 5-88
Parts 5-89
Parts 5-90
Parts 5-91
Parts 5-92
Parts 5-93
Parts 5-94
Parts 5-95
Parts 5-96
Parts 5-97
Parts 5-98
Parts 5-99
Parts 5-100
Parts 5-101
Parts 5-102
Parts 5-103
Parts 5-104
Parts 5-105
Parts 5-106
Parts 5-107
Parts 5-108
Parts 5-109
Parts 5-110
CE4000 BFG
6 Schematics Schematic Sheet:
8
The schematics provided are representative only.
There may be slight variations between amplifier to
amplifier. These schematics are intended to be used
for troubleshooting purposes only. Schematic Sheet:
8
CE4000 MAIN
PWA NUMBER: 126218-13 PWA NUMBER: 126828-13 (REV.A)
Schematic Sheet: Schematic Sheet:
43 9
44
45 CE4000 INPUT CE
46
Schematic Sheet:
47
5
48
PWA NUMBER: 126218-14 CE4000 FLYBACK

Schematic Sheet:
Schematic Sheet:
43
6
44
45
CE4000 POT BOARD
46
47
Schematic Sheet:
48
5

Schematic Sheet:
Schematic Sheet:
1
5
2
3
CE 4K SPEAKON/BDG POST OTPT
4
5
Schematic Sheet:
6
6
7
8
CE4000 EMI FILTER
Schematic Sheet:
5
Schematics 6-1
Schematics 6-2

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POWER AMPLIFIER

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

The lightning bolt tri- The exclamation point trian-

Revision Number Date Comments

Rev. A 05-2001 Initial Printing

This page intentionally left blank

Speakon® plus 5-way barrier block, 5-way barrier

Crown Customer Service

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

Figure 1.1 CE 4000 Front and Rear Views

Total Harmonic Distortion (THD): 1-kHz rated

Figure 2.2 Output Pin Assignments

Figure 2.1 Typical Frequency Response

and high pass filtered at various frequencies. The

Theory of Operation 3-1

Theory of Operation 3-2

Figure 4.1 BCA Operation

Theory of Operation 3-3

Several detectors affect the status of Timing Cap 1.

Theory of Operation 3-4

Theory of Operation 3-5

Theory of Operation 3-6

Of course, there are also things to watch out for with

Figure 4.1 CE 4000 Top View A

Figure 4.2 CE 4000 Top View B

4.3.5 Output Panel Removal

Figure 4.3 Power Supply Discharge

4.3.3 Flyback Supply PWA Removal

4.3.6 Back Panel Assembly Removal

Figure 4.8 Half-Wave Rectified Flyback

6. Using a multimeter check DC supplies on power

Figure 4.9 Output Signal of Triangle-Wave Generator

4.4.3 Troubleshooting Power Supply, PFC PWA and

Figure 4.14 PFC Gate Switching at 60VDC

6. Using an oscilloscope check gate switching of the

Figure 4.15 Full-Bridge DC to DC Converter

4.4.4 Identifying Symptoms

Figure 4.16 Required Test Equipment

Figure 4.19 Underlap Figure 4.21 Current Sensing Calibration

Figure 4.20 Excessive Overlap

4.7.3 Current Sensing Calibration

This Page Intentionally Left Blank

established, after which an amount due will be issued

Crown Customer Service

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

5.3.1 CE4000 Amplifier Assembly

Item Quantity Description Part # (CPN)

NOTES: RECOMMENDED ASSEMBLY TORQUES

Figure 5.1 Amplifier Assembly (Exploded View)

5.3.2 Back Panel Assembly

Item Quantity Description Part # (CPN)

Figure 5.2 CE4000 Back Panel Assembly (Exploded View)

5.3.3 CE4000 PS Primary Heatsink Assembly

Item Quantity Description Part # (CPN)

Figure 5.3 CE4000 PS Primary Heatsink Assembly (Exploded View)

5.3.4 CE4000 PS Diode Heatsink Assembly

Item Quantity Description Part # (CPN)

RECOMMENDED ASSEMBLY TORQUES

Figure 5.4 CE4000 PS Diode Heatsink Assembly (Exploded View)