Tait Orca 5000 Portable Radios Service Manual June 2003 IPN: M5000-00-105
Preface Contacting Tait Electronics Ltd The contact details for your nearest Tait Electronics regional office, can be found on the Tait Website: http://www.taitworld.com/ Enquiries and comments If you have any enquiries regarding this manual, or any comments, suggestions and notifications of errors, please contact Customer Support, Tait Electronics Ltd, Christchurch, New Zealand, or refer to the Tait Website.
Publication history Publication Date Product Code May 2001 M5000-00-100 June 2001 M5000-00-101 September 2001 M5000-00-102 May 2002 M5000-00-103 September 2002 M5000-00-104 June 2003 M5000-00-105 June 2003 IPN: M5000-00-105 iii
iv June 2003 IPN: M5000-00-105
Contents Part A: Introduction Servicing Tait Orca 5000 portable radios ................................................................................. A-3 WWW technical support ..................................................................................................................... A-3 What does this manual contain? .......................................................................................................... A-3 Calibration service kit .............................................
TOP-Jxxxx 806-870MHz radio specifications...................................................................................... B-11 TOP-Kxxxx 896-941MHz radio specifications .................................................................................... B-12 Circuit descriptions ................................................................................................................. B-13 Transmitter ..............................................................................................
Replacing the LCD display (Orca 5015/2x/35/40) .............................................................................. D-9 Replacing the shield, user interface PCB and polyester dome (Orca 5015/2x/35/40) ....................... D-12 Replacing the antenna connector, channel selector switch and volume control switch ..................... D-12 Replacing the microphone .................................................................................................................
Troubleshooting ..................................................................................................................................E-14 Multi-charger .......................................................................................................................... E-15 Multi-charger operation ......................................................................................................................E-15 Repairing the multi-charger ...........................................
PART A Introduction This part provides an introduction to servicing Tait Orca 5000 portable radios. It includes an outline of the Tait Orca 5000 range of products and precautions that should be taken before servicing Tait Orca 5000 portable radios. Detailed servicing instructions and information about spare parts are found in Part D: Servicing the radio. Contents Servicing Tait Orca 5000 portable radios ...................................................... A-3 WWW technical support .....................
IS PCB servicing requirements ............................................................................ A-11 FM approval ........................................................................................................ A-11 FM approved products ........................................................................................ A-11 FM approved accessories .....................................................................................
Servicing Tait Orca 5000 portable radios The Tait Orca 5000 series is a range of portable high performance, microprocessor-controlled radios manufactured using an RF-shielded PCB and high-density SMD components. Servicing of Tait Orca 5000 portable radios is limited to key mechanical and ancillary devices.
■ T6 driver bit and 8 mm socket (TOPA-SV011); ■ this manual; and ■ TOP Programming Utilities (TPU) CDROM (IPN 406-00003-xx). Other items required for calibration but not included as part of the service kit are: ■ RF communications test set (e.g. HP8920, MI2945/55, CMS52); ■ digital current meter capable of measuring current up to 3 A, accurate to two decimal places.; ■ DC power supply, 7.5 V, 3 A for portable radios; and ■ TOPA-SV-A07 if calibrating TOP-Axxxxxx 66 -88MHz product.
The Tait Orca 5000 series of portable radios There are eight Tait Orca 5000 series portable radio products: ■ Orca 5010/11 - low tier conventional technical support Website: http://www.taitworld.com/support ■ Orca 5030 - low tier trunked 2. In this manual, when the term TOP x is used (e.g. TOP A or TOP B), it indicates the specific frequency band. TOP A will therefore refer to an A band Orca, and TOP B to a B band Orca.
seal behind. Figure A-2 illustrates the difference. Radios factory fitted with the new chassis also have a product code with the format TOP-xxxxx-Bx. need to remove the rear accessory cover. Remove the battery, then insert the end of a key underneath the bottom edge of the accessory cover. Lift to remove the cover. Figure A-2: Changed chassis hole When attaching or removing an accessory, ensure that the lever is in the upright position.
Table A-1: Tait Orca 5000 accessories Type of accessory Antennas Audio accessories * For use with TOPA-AA-005G Batteries June 2003 IPN: M5000-00-105 Product code Description TOPA-AN-101 130-230 MHz 3" helical TOPA-AN-102 336-540 MHz 3" helical TOPA-AN-201 136-340 MHz 6" helical TOPA-AN-212 400-940 MHz 6" wave whip TOPA-AN-203 896-941MHz 7" gain TOPA-AN-204 806-870M 1/2 wave gain TOPA-AN-205 896-941M 1/2 wave gain TOPA-AN-301 66-88MHz 10" helical TOPA-AA-001G Speaker microphone, -10 to
Type of accessory Battery chargers Plug packs (for TOPA-CH-200) Carrying accessories Product code Description TOPA-CH-100 Desktop trickle charger TOPA-CH-200 Desktop fast charger TOPA-CH-300 Six-way multi-charger T952-012 Australia, New Zealand and China (230 V 50 Hz input; plug configuration: T952-022 Singapore and Middle East (230 V 50 Hz input; plug configuration: T952-032 Mainland Europe (230 V 50 Hz input; plug configuration: ) T952-042 USA and Canada (115 V 60 Hz input; plug configu
Important information Basic servicing precautions Tait Orca 5000 portable radios require specialised servicing techniques and should only be serviced at an approved Tait service centre equipped with the necessary facilities. Standard anti-static procedures should be followed; a typical setup is shown in Figure A-5. If in doubt, contact Tait Electronics Ltd or your nearest Tait dealer.
Calibrating For information on calibrating Tait Orca 5000 portable radios, refer to: ■ the Tait Orca Calibration Application User’s Manual or the online help. The User’s Manual is on the TOP Programming Utilities (TPU) CD-ROM, which is included, together with this manual, as part of the calibration service kit. Test facilities Standard test facilities provide a way of testing the radio’s functions independently of normal radio operation.
Servicing Intrinsically Safe radios Intrinsically Safe radios ■ TOP-x25x0-B2 Intrinsically Safe (IS) radios are certified by a third party to be safe to use in particular hazardous locations. ■ TOP-x25x0-T2 Tait Orca 5000 IS portable radios can be identified by one or more of the following: ■ Yellow labels ■ IS circle logo ■ FM diamond logo ■ TOP-x26x0-B2 ■ TOP-x26x0-T2 For more information about the Tait Orca product code, refer to page page A-5.
Table A-3: FM ratings Approval Class Division Group Temperature Rating Intrinsically Safe: The unit is unable to cause ignition under normal or abnormal operating conditions. Class I: Gas or petroleum type environment. Division 1: Hazardous mixtures are normally present. Groups C & D: Ethylene and propane gases. T3C: 160°C Incentive: The unit is unable to cause ignition under normal operating conditions. Class I: Gas or petroleum type environment.
PART B Radio specifications and circuit descriptions This part outlines the radio specifications and circuit descriptions for Tait Orca portable radios. Contents Radio specifications ...................................................................................... B-3 General specifications ............................................................................................ B-3 Receiver performance ............................................................................................
B-2 June 2003 IPN: M5000-00-105
Radio specifications Tables B-1, B-2 and B-3 show information common to all the radios. For detailed information on each band, refer to the performance figures outlined in Tables B-4 to B-11. The performance figures are typical figures, unless otherwise stated, for equipment operating at standard room temperature. The test methods used to obtain these figures are those described in the European Telecommunication Standard ETS 300-086. Where applicable, the EIA figure is also given.
Table B-3: Transmitter performance Parameter Performance Duty cycle 20% (1 minute Tx, 4 minutes Rx at maximum temperature and voltage) Group delay variation ±50 µs (at mod audio output) bandwidth 300-3000 Hz Trunking data deviation (as per MPT1327) narrowband mediumband 1.5 kHz 2.
Table B-4: TOP-Axxxx 66-88MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 66-88MHz Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.
Table B-5: TOP-Bxxxx 136-174MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 136-174MHz Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.25kHz IF Bandwidth Universal Bandwidth (UB) 10kHz* Frequency Stability +/-2.5ppm (-30 to +60°C) Current Consumption (Receiver Squelched) 80mA 100mA Current Consumption (Standby with high economy duty cycle) 40mA N/A Current Consumption (Receiver Rated Audio) 300mA Transmitter current (Low/High power) 810mA/1.
Table B-6: TOP-Cxxxx 174-225MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 174-225MHz Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.25kHz IF Bandwidth Universal Bandwidth (UB) 10kHz* Frequency Stability +/-2.5ppm (-30 to +60°C) Current Consumption (Receiver Squelched) 80mA 100mA Current Consumption (Standby with high economy duty cycle) 40mA N/A Current Consumption (Receiver Rated Audio) 300mA Transmitter current (Low/High power) 800mA/1.
Table B-7: TOP-Gxxxx 336-400MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 336-400MHz Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.25kHz IF Bandwidth Universal Bandwidth (UB) 10kHz* Frequency Stability +/-2.5ppm (-30 to +60°C) Current Consumption (Receiver Squelched) 85mA 100mA Current Consumption (Standby with high economy duty cycle) 40mA N/A Current Consumption (Receiver Rated Audio) 300mA Transmitter current (Low/High power) 900mA/1.
Table B-8: TOP-Hxxxx 400-470MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 400-470MHz Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.25kHz IF Bandwidth Universal Bandwidth (UB) 10kHz* Frequency Stability +/-2.5ppm (-30 to +60°C) Current Consumption (Receiver Squelched) 80mA 100mA Current Consumption (Standby with high economy duty cycle) 40mA N/A Current Consumption (Receiver Rated Audio) 300mA Transmitter current (Low/High power) 780mA/1.
Table B-9: TOP-Ixxxx 450-530MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 450-530MHz Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.25kHz IF Bandwidth Universal Bandwidth (UB) 10kHz* Frequency Stability +/-2.5ppm (-30 to +60°C) Current Consumption (Receiver Squelched) 80mA 100mA Current Consumption (Standby with high economy duty cycle) 40mA N/A Current Consumption (Receiver Rated Audio) 300mA Transmitter current (Low/High power) 870mA/1.
Table B-10: TOP-Jxxxx 806-870MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 806-870MHz Transmit 851-870MHz Receive Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.25kHz IF Bandwidth Universal Bandwidth (UB) 10kHz* Frequency Stability +/-1.
Table B-11: TOP-Kxxxx 896-941MHz radio specifications General Orca 501x/2x Orca 503x/40 Frequency Range 896-941MHz Transmit 935-941MHz Receive Channel Spacing 12.5 / 20 / 25 kHz Frequency Increments 5 or 6.25kHz IF Bandwidth Universal Bandwidth (UB) 10kHz* Frequency Stability +/-1.
Circuit descriptions Circuit interface diagrams for the Tait Orca portable radios are shown in Figure A-1 (TOP B, C, G, H, I, J and K) and Figure A-2 (TOP A only). The Tait Orca portable radio has been designed to be totally electronically tuned using the Calibration Application. The titles of tests referred to below are tests available in the calibration system, e.g. Power Level test refers to the Power Level screen in the calibration system.
whose selection is controlled by a line from the microprocessor. The speaker output is always available on the accessory connector to drive an external speaker. Power supplies The unprocessed audio from the output of the demodulator IC (RX-DET-AF) is also available at the accessory connector. +5V-DIG The +5V-DIG supply provides a regulated 5 V to the microprocessor and its associated circuitry. It is controlled by the on/off switch and a line from the microprocessor.
+4V3-DEC The +4V3-DEC supply is derived from the +5V-AN voltage. It is used to power the transmit and receive VCOs in conjunction with the transmit control line from the processor. It also provides the loop filter reference in the synthesiser. Accessory connector interface The accessory connector interface is described in Part F: Accessories.
B - 16 Circuit descriptions June 2003 IPN: M5000-00-105
Interface PCB BATTERY- R1 C2 47N 2K2 470 R5 470 R2 BATTERY+ GND EXT-SPKR EXT+SPKR SENSE-1 SENSE-0 MOD-AUDIO EXT-MIC RX-DET-AF TXD RXD EXT-PTT +7V5-ACC 2 PL1 12 PL1 3 PL1 5 PL1 4 PL1 6 PL1 8 PL1 10 PL1 7 PL1 11 PL1 9 PL1 1 PL1 +7V5-ACC GND GND DGND P37 RESET SCLK SDAT KEY-D2 KEY-D1 KEY-D0 EXP-LATCH KEY-LATCH RX-DET-AF TX-AUDIO MOD-AUDIO S-DATA-READY MISO ON PTT VOL-MAX +5V-DIG 10 INTER 18 INTER 20 INTER 14 INTER 2 INTER 4 INTER 6 INTER 22 INTER 21 INTER 19 INTER 16
B - 18 Circuit diagrams June 2003 IPN: M5000-00-105
+7V5-BATT +7V5-BATT InterfacePCB PCB Interface Interface PCB BATTERY+ INTER BATTERY- BATTERY+ CCO 1616/006 AMENDMENTS DRAWN BRD BRD BRD BRD BRD 12 WAY SKT SP CHKD 246 246 CK D.O. APVD DW GND GND DATE 27-07-00 05-05-00 22-02-00 10-02-2K 24/11/99 RX-ANT RX-ANT RECEIVER RECEIVER June 2003 IPN: M5000-00-105 Figure B-2: Circuit interface diagram for Tait Orca portable radios (TOP A only) REV/ISS CCO NO.1616-011 CCO NO.
B - 20 Circuit diagrams June 2003 IPN: M5000-00-105
PART C Diagnostics and fault finding This part provides information on diagnosing faults in Tait Orca 5000 portable radios. The information in the fault finding charts should be used in combination with the test facilities, and it may also be helpful to examine the radio programming software data using the programming system for Tait Orca 5000 conventional or trunked radios. Contents Test facilities .................................................................................................
C-2 June 2003 IPN: M5000-00-105
Test facilities Standard test facilities provide a way of testing the radio’s functions independently of normal radio operation. A series of test commands can be sent to a radio in two ways: {C01} An invalid command code has been received. Try sending the command again. ■ using the TOP calibration application; or {C02} A (valid) command code has been received but with invalid parameters. Check the parameters and try sending the command again. ■ using a terminal program.
{X04} The DSP is not responding. Check the DSP for pin connections. If the error persists, the DSP needs to be replaced. Contact your Tait dealer. {X05} The DSP version number is incorrect. The radio software and DSP software are incompatible. The DSP needs to be replaced with a later version. Contact your Tait dealer. {X06} The MCU internal configuration is incorrect. Contact your Tait dealer. {X09} The prototype timer has expired.
Table C-1: Test commands Function Description Signalling Set modem to send zeros Set modem to send ones Set modem to send preamble Disable modem signalling Read modem receive string (continuous) Disable all signalling Enable subaudible signalling Read subaudible signalling decode status 10 11 12 13 14 15 16 17 Mute Force Rx audio muted Force Rx audio unmuted Mute DSP input Unmute DSP input Let squelch control Rx audio Read RX_BUSY status 20 21 22 23 24 25 Relax Rx mute control Inhibit PA (transmit m
Table C-1: Test commands (continued) Function Description Radio info Read radio serial number Read radio software version number Read radio type 94/131 96 130 Read DSP software version number Read radio hardware version number Read main database version Read calibration database version Read last system error Load absolute synth frequency Load synth reference divider Load synth prescaler 132 133 160 160 204 101 102 103 Set volume pot Set transistor gate bias Set TCXO mod Set VCO mod Set Tx power leve
Table C-2: Calculating the parameters required for test command 101 Calculating parameters for test command 101 Example 1: Calculating tttttt for an H band radio Enter the parameters in the format tttttt T rrrrrr R F ■ tttttt represents the transmit frequency tttttt = See Example 1 ■ T and R represent channel spacing 0 = 5 kHz 1 = 6.25 kHz ■ rrrrrr represents the receive frequency transmit frequency (MHz) channel spacing (MHz) = 461.025 MHz 6.25 kHz = 461.025 x 106 Hz 6.
Fault finding charts The fault finding charts in Figures C-1 to C-6 address the faults you are most likely to find. If you experience other faults that do not fall into these categories, contact your Tait dealer. They are: ■ Radio cannot be switched on; ■ Cannot change channel; ■ No serial communication; ■ Receive faults; ■ Cannot transmit; and ■ No transmit audio.
Figure C-1: Radio cannot be switched on Radio cannot be switched on Is the battery charged? NO Charge the battery. NO Clean battery contacts using the graphite tip of a 4H (#4) or harder pencil. YES Battery contacts clean and unobstructed? YES Check on/off/volume control switch. Function for pins 1 to 4 OK? After charging battery, can radio be switched on? NO NO Replace battery contacts. Replace on/off/volume control switch.
Figure C-2: Cannot change channel Cannot change channel Using the truth table below, is channel selector operation OK? Replace channel selector switch.
Figure C-3: No serial communication No serial communication Are the physical connections correct, e.g. battery charged, comms lead inserted correctly into the correct port on the PC, flexible loom contacts clean, etc.? NO Make sure physical connections are intact. YES Is the software using the correct serial port? NO Change the ‘COMM Port’ using Edit|Preferences or Tools|Options. YES Leads OK? NO Replace or repair leads. NO Set Tx/Rx switch to Rx.
Figure C-4: Receive faults Receive faults Is the radio in lock (command 72)? NO NO YES Is the radio programmed correctly? Check programming. Are YES channels programmed correctly? NO Is the frequency/band information correct? NO YES Reprogram radio. YES Is receive sense > -117 dBm NO YES Is squelch operating normally? 16 dB city, 12 dB country NO Recalibrate squelch. NO Replace speaker. NO Replace speaker contacts. NO Replace on/off/volume control switch.
Figure C-5: Cannot transmit Cannot transmit Is the radio in lock (command 72)? NO Check programming. Are channels and frequency/band information programmed correctly? YES YES NO Is the radio programmed correctly? NO Reprogram radio. YES Is current greater than 1.5 A (high YES power) or 700 mA (low power)? NO NO Is the transmit current less than 400 mA? Is RF switch functioning? YES Check PTT switch. YES Is RF out assembly OK? YES NO Replace RF out assembly.
Figure C-6: No transmit audio No transmit audio Is the flexible loom inserted correctly? When an external accessory is NO plugged in, is there microphone audio for the accessory? NO Ensure loom is properly fitted into the socket on the PCB. YES Is the flexible loom damaged? YES Replace flexible loom. NO YES Is the internal microphone working? NO Replace internal microphone.
PART D Servicing the radio This part describes the disassembly and reassembly of Tait Orca 5000 portable radios and the servicing of some key mechanical and ancillary devices. Information is also provided on ordering spare parts for servicing portable radios. Contents Servicing the radio ........................................................................................D-3 ........................................................................................ D-3 Screw head types .................
Reassembling the radio .............................................................................. D-14 Rear panel reassembly and replacing the auxiliary flexible PCB ..........................D-14 Fitting the PCB to the chassis and replacing the RF out assembly .......................D-15 Fitting the shield to the chassis ............................................................................D-15 Fitting the front panel to the chassis ................................................................
Servicing the radio Servicing of Tait Orca 5000 portable radios is limited to key mechanical and ancillary devices.
Disassembling the radio Removing the front panel from the chassis ■ the front panel assembly; Unscrew the antenna and detach the battery pack. ■ the speaker; The channel selector and on/off/volume control knobs need to removed before separating the front panel and the chassis. To remove the knobs, insert a side cutter at the base of each knob, flat side down (Figure D-2), making sure not to damage the knob label and the switch shaft. Squeeze lightly; the knobs should pop off. Discard the knobs.
Figure D-3: Removing the front panel from the chassis, using the battery as leverage 1 battery pack 5 microphone grommet protruding from the shield 2 front panel 6 grip battery here, gently pull away from the front panel 3 chassis 7 pull radio out and away from the front panel at this point 4 shield the chassis. Removing the shield sub-assembly from the chassis Maintain pressure and insert a flat bladed screwdriver (approximately 4 mm) in the gap between the shield and the chassis.
Repeat this on the other side. Remove the microphone grommet by pulling upward (Figure D-5). You can now see the bottom surface of the PCB. The basic layout of the PCB is shown in Figures D-8 and D-9. Refer to these diagrams for the placement of parts. Note that on Orca 5015, Orca 502x, Orca 5035 and Orca 5040 radios, the user interface loom must be detached from the main PCB before the shield can be separated from the main PCB and chassis.
Removing the rear panel Follow the disassembly instructions and disassemble the radio to the PCB level. Refer to Figure D-10 for the details of the rear panel assembly. Insert a small flat bladed screw driver under the auxiliary dummy rear cover and apply pressure to push the dummy rear cover lugs free of the holes in the rear panel. To remove the rear panel, insert a small flat-bladed screwdriver just under the notch in the base and twist. Remove the rear panel seal.
Replacing key mechanical and ancillary devices This section describes the replacement of key mechanical and ancillary devices. These include: Press firmly into position, then remove the piece of clear plastic from the front of the lens.
the hole at the top of the PTT recess. Be sure not to split or otherwise damage it. Replacing the LCD display (Orca 5015/2x/35/40) Replacing the speaker Following the disassembly instructions, remove the shield from the front panel and unplug the user interface loom from the main PCB. Following the disassembly instructions, remove the front panel from the chassis. The speakers sits in the inside of the front panel (see Figure D-7).
Figure D-8: Bottom surface of the PCB, which is visible when the shield has been removed from the chassis 1 2 3 7 5 4 5 6 1 antenna connector 2 channel selector switch 3 on/off/volume control switch 8 4 antenna connector pin placement (5 pins) 9 5 speaker contact pin placement 10 6 channel selector pin placement (6 pins) 7 on/off/volume control pin placement (5 pins) 8 PTT tact switch 9 PA can 10 PA screw 11 microphone placement 12 microphone grommet placement 13 user interface loom connector
Figure D-9: Top surface of PCB, which is visible only when the PCB has been removed from the chassis 3 2 1 4 5 7 6 1 antenna connector 2 channel selector switch 8 3 on/off/volume control switch 4 RF assembly placement 5 auxiliary flex socket 6 PTT tact pin placement (4 pins) 7 battery contact placement 8 battery contact seal placement 9 microphone pin placement (2 pins) 9 June 2003 IPN: M5000-00-105 Replacing key mechanical and ancillary devices D - 11
Replacing the shield, user interface PCB and polyester dome (Orca 5015/2x/35/40) On Orca 5015/2x/35/40 radios the shield, user interface PCB and polyester dome are replaced as one complete assembly. Following the disassembly instructions, remove the shield from the front panel and unplug the user interface loom from the user interface PCB. Remove the LCD display assembly from the discarded shield, and fit to the replacement shield according to the instructions on page D9.
Replacing the chassis Following the disassembly instructions, fully disassemble the radio. Discard both the chassis and main seal. Inspect a new main seal to determine orientation and top/bottom surfaces. The tab is located at the top of the radio. Note that the seal is not flat. Ensure that the orientation is such that the bends follow the groove on the new chassis. Locate the tab in the hole at the top of the chassis groove. Place top corners. Smooth seal into position across the top of the chassis.
Reassembling the radio This section describes the reassembly of the radio once the required units have been serviced. Additional instructions for replacing the following mechanical and ancillary devices are also included: The rubber must sit flush with the back of the chassis or the rear panel will not sit properly and the battery will not fit correctly. Fold the flexible PCB over and fit the contact area on the chassis; it should fit snugly in place.
Fitting the PCB to the chassis and replacing the RF out assembly socket driver set to 10in.lb (1.1Nm). Then tighten the PA screw to 2in.lb (0.23Nm). Put the battery contact seal over the battery contacts rather than into the chassis. If you put the seal on the chassis, the contacts will squash the seal. Using a heavy-tip soldering iron (e.g. Weller 2PTCC8 tip), solder the antenna connector and two switches in place, if required, taking care not to damage the surrounding components.
Figure D-12: Assembly of the switches 9 1 shield 7 8 8 2 chassis 3 antenna connector 4 channel selector switch 6 6 6 5 on/off/volume control switch 6 ribbed lock washer (M6x10x0.7 mm) 7 SMA connector nut (¼x7.9x3 mm) 4 5 3 2 8 channel/volume control nut (M6x7.9x3 mm) 9 knob seal 1 Fitting the front panel to the chassis Place the radio into the front panel top first, inserting the antenna connector and knob switches through the holes.
Spares kits The following table shows a list of spares kits which are currently available for servicing Tait Orca 5000 portable radios. Spares kits are designed to service 100 radios, and can be ordered from your local Tait dealer. TOPA-SP-401G Tait Orca 5000 main PCBs are available on an exchange basis from Technical Support at Tait Electronics Ltd. When ordering, use the following naming convention TOP-XXXXX-KS.
Table D-2: Orca 5010/11/30 spares kit (TOPA-SP-401G) IPN 040-05500-08 219-50029-00 220-01414-03 231-00010-45 232-00010-42 240-02156-01 252-00010-77 252-00010-56 303-10053-00 303-30072-00 308-01015-00 311-01049-xx 311-03108-00 316-06763-00 316-06765-02 316-85133-00 319-01026-00 345-00020-09 345-00020-11 352-00010-52 352-01053-00 353-00010-42 360-01060-00 360-02019-00 365-01673-00 362-01035-01 362-01106-00 362--01089-01 362-01091-01 362-01092-02 369-01039-00 304-07044-00 316-85027-00 356-01070-00 339-00010-53
Table D-3: Orca 5035 spares kit (TOPA-SP-402G) IPN 040-05500-08 219-50029-xx 220-01414-03 231-00010-45 232-00010-42 240-02156-01 252-00010-77 252-00010-56 303-10053-00 303-30072-00 308-01015-00 311-01049-00 311-01050-00 311-03108-00 311-03110-00 312-01087-00 303-23098-00 316-06763-00 316-06765-02 316-85133-00 345-00020-09 345-00020-11 352-00010-52 352-01053-00 353-00010-42 360-01060-00 360-02019-00 362-01035-01 362-01087-00 362-01106-00 362--01089-01 362-01091-01 362-01092-02 369-01039-00 316-85027-00 304-0
Table D-4: Orca 5015/2x/40 spares kit (TOPA-SP-403G) IPN 008-36671-80 040-05500-08 219-50029-00 220-01414-03 231-00010-45 232-00010-41 240-02156-01 252-00010-77 252-00010-56 303-10053-00 303-30072-00 308-01015-00 311-01049-00 311-01050-01 311-03108-01 311-03109-00 311-03113-00 312-01087-00 303-23098-00 316-06763-00 316-06765-02 316-85133-00 345-00020-09 345-00020-11 349-00030-00 352-00010-52 352-01053-00 353-00010-42 356-01070-00 360-01060-00 360-02019-00 362-01035-01 362-01087-00 362-01106-00 362--01089-01
Table D-5: Orca 5010/11/30 re-skinning kit (TOPA-SP-404) IPN 311-01049-01 311-01050-01 316-06765-00 345-00020-11 362-01106-00 362-01091-01 362-01092-02 OPP401 399-00010-69 399-00010-53 410-01064-01 316-06765-01 Description Channel Knob Volume Knob Rear Panel Screw M2x8mm SS Pan Torx Patch Rear Cover Seal Knob Seal Main Seal PHA Front Panel Assembly Plastic Bag 75x100mm Mini Grip Plastic Bag 150x250mm Packaging Header Card New Logo Rear Panel Quantity 1 1 1 2 1 1 1 1 1 1 1 1 Table D-6: Orca 5035 Re-skinni
Table D-8: Orca 5015/2x/35/40 User Interface PCB and Shield (TOPA-SP-407) IPN OPF200-B 311-04005-00 319-01026-00 399-00010-86 008-36671-80 304-07043-00 220-01501-00 369-01044-00 365-00011-38 Description UI PCB SMT Subassembly Ins Poly Dome for 5015/2x/40 Main Shield RF Static Shielding Bag 127x203mm LCD Display 12x2 Lines Flex LCD Frame Holder PCB Flexi User Interface Conductive Adhesive/Mylar Yellow Label Static Warning Quantity 1 1 1 1 1 1 1 Table D-9: Orca 5015/21 Re-skinning kit (TOPA-SP-408) IPN 311
PART E Battery packs and chargers This part provides information on the battery packs and chargers available for Tait Orca 5000 portable radios. The battery packs are not serviceable, and repair of chargers is limited to replacement of the spring contacts, the discharge tact switch and the DC jack. Contents Battery packs ..................................................................................................E-3 ....................................................................................
E-2 June 2003 IPN: M5000-00-105
Battery packs Six battery packs are available for Tait Orca 5000 portable radios. These battery packs are not serviceable, but their construction and expected life are described below. The battery packs available are: ■ TOPB100 NiCD battery pack; ■ TOPB600 NiCD battery pack (slim, no belt clip); to preserve the shift life of the battery: ■ Charge or change the battery as soon as the radio gives the ‘Low Battery’ warning. ■ Short condition the battery weekly.
Extending battery shift life Battery shift life can be extended by activating economy mode (conventional radios) or by using dynamic power control (trunked radios). During economy mode, the radio cycles between the normal receive state and a standby state, in which some of the radio’s circuitry is switched off or placed on standby mode. Dynamic power control optimises the radio’s power use by reducing the transmit power in high signal strength areas.
Battery chargers Note: In order to charge TOPB700 NiMH batteries, the charger must have firmware version 2.07 or greater. TOPB500 NiMH batteries can be charged on chargers with firmware version 2.05 or greater. The trickle charger should not be used for NiMH battery packs as they can take up to 24 hours to charge fully and the overall lifetime of the battery may be reduced. NiMH battery packs should be charged using a fast charger.
Desktop fast charger The Tait Orca desktop fast charger (Figure E-1) is an intelligent charger that can charge, condition and analyse both NiCd and NiMH batteries of varying capacities. Fast charger operation A circuit diagram of the fast charger is shown in Figure E-2. The fast charger operates using constant current charging and multiple criteria for end-of-charge detection.
June 2003 IPN: M5000-00-105 Desktop fast charger E - 7 - + I/OPAD I/OPAD 1N4001 2 VIN C10 100N 1K0 R5 D2 4V7 C7 33P R9 XTAL 4M PA7 PA6 PA5 PA4 PA3 PA2 PA1 PA0 PA7 PA6 PA5 PA4 PA3 PA2 PA1 PA0 -RESET RESET -IRQ IRQ +V +V +5V 7 8 C11 100N RESET 6 GND 5 SO VOUT IC1 VZ L4949 VS C8 33P PB5/SDO PB5/SDO PB6/SDI PB6/SDI PB7/SCK PB7/SCK R6 47K OSC1 GND OSC1 GND 1M0 OSC2 OSC2 TCMP TCMP PD7/TCAP PD7/TCAP PD5 PD5 3 1 4 CT SI C2 2 100N PC7/VRH PC6/AN0 PC5/AN1 PC4/AN2 PC3/AN3 PC2 IC2 M
The discharge circuit is based around a constant current sink. This uses an N-channel MOSFET, Q6, controlled by an operational amplifier, IC3:B. R41 and R42 are the current sense resistors that allow the op amp to set the current. The nominal discharge current is 400 mA. The microprocessor needs to be able to monitor the battery voltage. A coarse voltage is provided by the voltage divider R48, R49 and R50.
Using the fast charger recharging (5°C to 40°C). Fast charger indicators are described in Table E-3. Approximate charge times are: Table E-3: Fast charger indicators ■ up to 1½ hours for TOPB100 and TOPB600; Indicator Meaning ■ up to 2 hours for TOPB200, TOPB400 and TOPB700; and steady red battery charging ■ up to 2½ hours for TOPB500.
To short condition the battery Turn off the radio and insert the battery/radio into the fast charger. When the charger LED glows red, press the conditioning button until the indicator flashes amber. Release the conditioning button. The LED will flash amber while the battery is being discharged. Once the battery is discharged, it will charge normally. The battery is ready to be used again when the charger LED glows green.
Replacing the spring contacts Remove the faulty contacts with a soldering iron and discard. If the replacement spring contacts have a larger diameter and will not fit through the PCB, the holes should be drilled out to 2.2mm. When placing the replacement contact, it must not be bent or otherwise damaged. Solder the replacement contact in place using a heavy-tip soldering iron (e.g. Weller 2PTCC8 tip).
Desktop trickle charger Figure E-5 shows the charger current profile. Figure E-6 shows the circuit diagram for the trickle charger. Trickle charger operation When the battery voltage is above approximately 8 V, the charge current is inversely proportional to the battery voltage. This characteristic is produced by Q100, Q101 and Q102. The charge current is determined by the current through R104, which is set by Q102, its emitter resistors and the reference voltage.
Figure E-6: Circuit diagram of the Tait Orca desktop trickle charger VIN = 12-18 VDC from T952-0X2 plug pack (12 VDC @ 1 A) Dropout voltage = 11.5 V Using the trickle charger The trickle charger is not recommended for NiMH battery packs, as they can take up to 24 hours to charge fully and the overall lifetime of your battery may be reduced. Use a fast charger instead. The battery can be recharged attached to the radio or as a separate unit.
Troubleshooting When inserting the battery/radio in the charger, there is no indication on the charger LED. ■ Check that the battery/radio is seated properly in the charger. ■ Check that the charger is properly plugged in and the correct plug pack is being used. ■ Check that the battery and charger contacts are clean and not obstructed. Clean the electrical contacts of the battery and charger using a fibre glass pencil, or the graphite tip of a type 4H (#4) or harder pencil.
Multi-charger The multi-charger (TOPA-CH-300) is made up of six desktop fast chargers that operate independently of one another. Each multicharger PCB has an additional diode. Multi-charger operation The operation of the multi-charger is the same as that of the desktop fast charger.
■ Gently pull the wires through the multicharger top while aligning the charger with the three screw holes. ■ Close up the multi-charger, replacing the 10 screws using a Pozi 1 driver. ■ Fasten the charger to the multi-charger top using the three screws. ■ Reconnect the red and black wire to the fuse connector. Ensure that the polarity is correct. Fuse replacement Each charger is protected by a 3A fuse. To replace a fuse, open the multi-charger as described previously.
PART F Accessories This part describes how to interface accessories with Tait Orca 5000 portable radios, using the Tait Orca accessory connector and the 7.5 mm accessory adaptor. Detailed servicing information about the Tait Orca vehicle kit is also provided on page F-10. A list of audio accessories currently available for use with Tait Orca 5000 portable radios is found in Table A-1, on page A-7. Contents Tait Orca 5000 accessory connector ...............................................................
F-2 June 2003 IPN: M5000-00-105
Tait Orca 5000 accessory connector The Tait Orca 5000 portable radio has a versatile accessory interface on the rear of the radio for connecting external accessories, such as speaker microphones and headsets. P-Clip connector, and a Hex 2 driver for the DClip connector. Additionally a Torx T6 driver is required.
Accessory connector assembly Assemble the accessory connector as shown in Figure F-2. Figure F-2: Accessory connector assembly diagram 9 The order of assembly is as follows. 1 2 Thread the cable from your accessory through the accessory housing, making sure it goes through in the proper direction. Slide a grommet of appropriate size onto the cable and pull firmly so the cable and grommet fit in place. 3 Strip and tin the accessory signal wires.
Table F-1: Accessory connector signal specifications Signal Description Type Signal level Output impedance /current Input impedance RX-DET-AF-ACC Unmuted receive audio Analogue audio 1.15-1.6 VDC 53-225 mVrms 2.2 kΩ – MOD-AUDIO Modulator input Analogue audio 0-4.8 Vpp 2.4 VDC – 470 Ω +7V5-ACC* Accessory power DC supply 7.
Accessory connector signal descriptions EXT-MIC The EXT-MIC signal is an analogue input from the microphone of an accessory. RX-DET-AF-ACC The RX-DET-AF-ACC line carries unprocessed receive audio from the output of the detector IC. Connecting a microphone to EXT-MIC automatically turns off the radio’s internal microphone. MOD-AUDIO The MOD-AUDIO line is used during calibration to set up the modulation balance and by some accessories, such as modems.
Figure F-3: Tait Orca accessory connector circuit diagram June 2003 IPN: M5000-00-105 Tait Orca 5000 accessory connector F - 7
7.5 mm Accessory adaptor You can connect non-Tait accessories that require a 7.5 mm adaptor to the Tait Orca portable radio using the 7.5 mm accessory adaptor (TOPA-AA-005G). two separate lines for the Tait Orca portable radio. The adaptor also detects the presence of the accessory speaker and turns off the radio’s speaker. Such accessories use 3.5 mm and 2.5 mm phono plugs with 7.62 mm spacing between them. The speaker and microphone/PTT jacks for the 7.5 mm adaptor are shown in Figure F-4.
Figure F-5: Tait Orca 7.5 mm accessory adaptor circuit diagram June 2003 IPN: M5000-00-105 7.
Tait Orca vehicle kit Note that NiMH batteries are not charged by the vehicle kit, and that the desktop fast charger should still be used to short condition NiCd batteries each week. This section outlines the vehicle kit operation, specifications and servicing. A detailed circuit and interface description is also provided, to allow customised modification of the vehicle kit.
Ensure the vehicle kit release button is down and insert the radio into the radio cavity. Push the radio firmly into place against the locating pegs and radio interface. You should hear the radio snap into place and the release button will pop up. Locking a radio in the vehicle kit You can use the supplied key to lock the radio into the vehicle kit when you leave the vehicle unattended. To lock the radio in the vehicle kit, insert the supplied key in the lock and turn it clockwise.
mobile microphone must be used; and ■ the radio’s speaker will be inoperative when an external speaker has been installed. Volume can be adjusted from the radio’s volume control. The standard installation results in the charger and external speaker being turned off when the ignition is off. If the vehicle kit determines that the vehicle’s battery is too low (less than 11 V), the vehicle kit will turn off. Vehicle kit specifications The following table outlines the vehicle kit specifications.
Servicing the vehicle kit The vehicle kit contains four PCBs, and the following servicing instructions outline the disassembly of the vehicle kit to allow replacement of these PCBs. Warning: Screw head types There are four different types of Torx screws used in the vehicle kit: KC22x6, KC25x6, KC30x8 and KC30x10. All these screws require a Torx head screwdriver. When tightening any screws, be careful not to strip the threads in the plastic mouldings by exerting too much force.
Reassembling the vehicle kit To assemble the vehicle kit, reverse the disassembly process. Note that when doing up the KC30x10 screws the threads in the plastic PA moulding must not be stripped. It is important that the audio PA is held firmly against the backplate, as the backplate serves as a heatsink. Trigger reassembly When reassembling the trigger assembly, insert the peg moulding into the front panel. Insert the quarter turn moulding and rotate it until the peg moulding prevents it from turning.
Table F-7: Vehicle kit spares kit (TOPA-SP-301) IPN Description Quantity supplied Legend OPA-VK-010 TOP vehicle kit charger PCB 1 F-12 OPA-VK-020 TOP vehicle kit options PCB 1 F-13 OPA-VK-030 TOP vehicle kit accessory probe PCB 5 F-10 OPA-VK-040 TOP vehicle kit charger probe PCB 10 F-11 219-02665-00 Cable - RF (MCX to BNC connectors) 5 F-9 219-02666-00 Cable - charger to charger probe PCBs 5 F-9 219-02667-00 Cable - options to accessory PCBs 5 F-9 240-04021-74 Mobile microph
Table F-8: Vehicle kit reskinning kit (TOPA-SP-302) IPN Description Quantity supplied Legend 305-00003-00 Lens 4 305-00004-00 Front moulding 4 — — 305-00005-00 Rear moulding 4 — 305-00006-00 Probe moulding 4 — 305-00012-00 Auxiliary seal 4 — 305-00013-00 Probe seal moulding 4 — 305-00015-00 Back plate 4 — 305-00023-00 Lock 4 F-6 (7) 353-05006-00 Washer 7/16 beryllium 1 — 365-01610-00 Front warning label 5 — 365-01611-00 Front operation label 5 — 365-01612-00 R
Custom modifications nal 12 kΩ resistor wired correctly. The following information is provided to enable modifications to be made to the standard vehicle kit installation: Figure F-8: Vehicle kit - rear view showing external connectors ■ signal descriptions and specifications for the vehicle kit external connectors; 3 ■ block diagrams of the vehicle kit PCBs; and ■ circuit descriptions for each vehicle kit PCB.
Table F-9: Vehicle kit power connector (SK1 on the charger PCB) Pin Signal 1 N/C 2 3 4 Pin Signal Description – 1 GND Signal ground GND Main ground connection 2 RX-IN RS-232 Receive data to radio IGN Switched accessory power connect to permanent power to disable ignition sense 3 TX-OUT 4 N/C – Main connection to +13.8 V (vehicle battery). Use 3 A fuses.
Figure F-9: Vehicle kit interconnection diagram Vehicle kit circuit descriptions This section provides an outline of the design and describes the modular assembly of the vehicle kit. The vehicle kit contains four PCBs: ■ the accessory probe and charger probe PCBs, interfacing to the radio and battery; and ■ the charger and options PCBs, containing the electronic circuitry. Vehicle kit accessory probe PCB (IPN 220-01506-xx) This PCB provides the interface to the radio’s accessory connector.
Figure F-11: Vehicle kit charger probe PCB block diagram Vehicle kit charger probe PCB (IPN 220-01564-xx) This PCB provides the interface to the radio battery for charging and is connected to the charger PCB via an 8-way MicroMatch ribbon cable. A block diagram of this PCB is shown in Figure F-11. Vehicle kit charger PCB (IPN 220-01504-xx) This PCB contains the fast charger circuit module, the majority of the power supply module and about half of the power save module.
D4 and R46 create a virtual ground (VGND) and protect the MAX1627 from over voltages. Conducted noise is filtered by C42, C43 and L5. The blocking diode, D6, stops the radio battery from powering the vehicle kit when the current source is off. measurements is IC3 pin 17. Battery temperature is measured via IC3 pin 18. This pin is pulled to ground via a 10 kΩ (nominal) thermistor inside the battery case. The battery capacity input used to tell the charger whether the battery is NiCd or NiMH is IC3 pin 19.
tions. If the vehicle battery gets below 11 V, the Schmitt trigger built around IC2:A will go high, turning on Q1 and pulling the RESET line low. This will turn off the fast charger to conserve the vehicle battery. The output of IC2:A is also fed to the options PCB and the base of Q6. This puts the audio power amplifier (IC4) into standby to conserve the vehicle battery.
Note that the recommended method for changing the gain of the audio power amplifier is to adjust the ratio of the voltage divider formed by R69 and R68. The second path for the single ended audio signal present at pin 7 of IC2:B is via R78 and C52, to become the AUDIO-D25 signal. This signal has its output at pin 6 on the D25 connector on the charger PCB. The minimum input impedance of a circuit that connects to AUDIO-D25 is 6k Ω. The recommended input impedance would be 47k Ω.
MIC-D25 line. Thus whenever the radio is in the vehicle kit the internal microphone is disabled. RS-232 Conversion An RS-232 level 3 wire serial port is provided at the DB25 connector (TX-OUT, RX-IN, GND), for use by devices such as data terminals. The radio provides CMOS level serial communications via the RXD and TXD signals. These signals are converted to full RS-232 voltage levels (i.e. +10 V for a logic 0, and -10 V for a logic 1) by IC3.
PART G Additional information This part provides a glossary of terms. Contents Glossary ........................................................................................................ G-3 Accessory connector compatibility ...............................................................
G-2 June 2003 IPN: M5000-00-105
Glossary Note: Terms that appear in italics are also defined in this glossary. sending commands down a serial link to the radio. active The ‘on’ (asserted) state of a signal or indicator. channel A receive/transmit frequency pair. ADC Analog to digital converter. An electronic device that outputs binary data dependant upon the magnitude of voltage input. ANR Automatic Noise Reduction brownout A dip in the supply voltage sufficient to put the control section into hardware reset.
new D-Clip has a green dot on the outside at the bottom left corner. The D-Clip must be checked for compatibility with the chassis before use (see “Accessory connector compatibility” on page G-8). DAC Digital to analog converter. An electronic device that outputs a voltage dependent upon the value of binary data input. database The set of programmable data points that allows the product to be customised for a particular application or mode of operation. DC Direct current. DCS Digitally coded squelch.
G-STAR General Electric status and reporting system. Signaling is used to identify individual radio users by assigning a unique number to each radio. This is sent out each time the radio transmits, and is decoded by the dispatcher, giving a visual identification of the radio in use. idle The state of the radio in trunked mode when it is not engaged in a call or call setup, or in conventional mode when the radio is not transmitting.
programming mode The mode of operation of the radio in which computer equipment can read from and write to the radio database. PSTN Public switched telephone network. quarter turn This is the part of the accessory connector that rotates 90 degrees to lock the connector to the radio. The quarter turn tip is the end with the lugs. RAM Random access memory.
TCXO Temperature compensated crystal oscillator (voltage controlled). The frequency reference for the RF part of the radio. er (PLL) and the modulation signals TCXOMOD and VCO-MOD. VOX Voice operated transmit. test mode The operating mode of the radio whereby computer (computer equipment can control various radio functions by sending controlled) commands down a serial link to the radio. traffic channel The channel used by the radio for the duration of a call.
Accessory connector compatibility Attempting to use an incompatible accessory connector with a particular chassis will result in damage to both the radio and connector. See “New chassis” on page 5. the old and new accessory connectors with the various chassis. How to identify a P-Clip, Green P-Clip or DClip accessory connector is explained in the Glossary.
Notes June 2003 IPN: M5000-00-105 G-9
