Installation Manual LBI-38901T Orion™ Mobile Radio
CREDIT M/A-COM and EDACS are registered trademarks and Orion, ProGrammer, and ProVoice are trademarks of M/A-COM, Inc. TORX is a registered trademark of CAMCAR/TEXTRON. POZIDRIV is a registered trademark of Phillips International Company. IBM is a registered trademark of IBM. Windows is a registered trademark of Microsoft Corporation. Molex is a registered trademark of Molex Company. All other brand and product names are trademarks, registered trademarks or service marks of their respective holders.
TABLE OF CONTENTS Page INTRODUCTION ............................................................................. 4 UNPACKING AND CHECKING EQUIPMENT ............................ 5 INSTALLATION (Single Control Unit) ......................................... 11 STEP 1 – PLAN THE INSTALLATION ................................ 11 STEP 2 - LOCATE TOOLS REQUIRED................................ 12 Vehicles Powered By Liquefied (Lp) Gas ........................ 12 STEP 3 – INSTALL CABLES............................
INTRODUCTION This manual contains installation instructions for the Orion™ Mobile radio unit and associated accessories. These instructions cover the mounting and cabling of the radio. Interconnection and wiring diagrams are provided for reference.
UNPACKING AND CHECKING EQUIPMENT Carefully unpack the radio and identify each item in the shipping container as listed below. The available options for the Orion Mobile Radio are covered in Table 1. If damage has occurred to the equipment during shipment, file a claim with the carrier immediately.
Figure 3: Option Cables 6
At the time this manual was published, M/A-COM, Inc. was in the process of offering additional programming cables and replacing some of the accessory cables for the Orion mobile radio. This manual provides information on both the existing cable offerings and the replacement cables.
NOTE The programming cables shown in Figure 5 do not require the TQ3370 interface box.
Table 1: Orion Mobile Radio Options And Accessories OPTION DESCRIPTION Z OPTIONS D2ZN1A Accessory Kit–Front Mount with Standard Option Cable D2ZN1B Accessory Kit–Front Mount with Extended Option Cable D2ZN1C Accessory Kit–Front Mount Euro with Standard Option Cable D2ZN1D Accessory Kit–Front Mount Euro with Extended Option Cable D2ZN1F Accessory Kit–Remote Mount with Standard Option Cable, 50W TX and below D2ZN1G Accessory Kit–Remote Mount with Standard Option Cable, 60W TX and above D2ZN1H A
OPTION DESCRIPTION D2CE5V Radio Control Cable, Euro Remote Mount, 5.5M D2CE5W Radio Control Cable, Extended Option Euro Remote Mount, 5.5M D2CE5Z Dual Control Cable, Remote Mount, 9.0M D2CE7A Dual Radio Cable, Remote Mount, 2.0M D2CF7B Extended Option Accessory Cable, Motorcycle D2CF7C Radio Control Cable, Extended Option Remote Mount Motorcycle, 2.3M D2CF7D Radio Control Cable, Extended Option Euro Remote Mount Motorcycle, 2.3M D2CF7E Power Cable, Motorcycle, 1.0M D2CF9A Power Cable, 7.
INSTALLATION (SINGLE CONTROL UNIT) STEP 1 – PLAN THE INSTALLATION Figure 6 provides an example of a typical mobile radio (remote mount) installation. Before starting, plan the radio installation carefully so that it will be: • safe for the operator and passengers • away from airbag deployment area • convenient for the operator to use • protected from water damage • neat and easy to service • safe and out of the way for passengers and auto mechanics M/A-COM, Inc.
STEP 2 - LOCATE TOOLS REQUIRED The equipment required for installing the Orion Mobile Radio is listed below: • Crimping tool for fuse holder • Electric drill for drilling mounting holes • Drills and circle cutters as follows: No. 31 (1/8”) drill No. 27 (9/64”) drill 5/8” drill or circle cutter 3/4” circle cutter, hole saw or socket punch • Phillips and flat-blade screwdrivers • POZIDRIV® driver • No.
STEP 3 – INSTALL CABLES To ensure the feasibility of the planned cable routings, it is recommended that the cables be run before mounting the radio. The radio can be installed as a Front Mount, Remote Mount or Cassette Mount. The type of mount, the application, and the options to be installed should be considered when planning the cable runs.
3. Cut off 12-18″ from the red lead. Strip back the insulation approximately 3/8″ on each end of the wires. Insert the wire ends into the small openings at the end of each fuse holder section and crimp a fuse connector to each wire. Prepare the other end of the short wire in the same manner as in (2) and connect to the positive (+) terminal of the battery. NOTE • Do not install fuse into fuse holder until installation is completed and all connections have been checked.
NOTE CAUTION • The radio, as shipped from the factory, has the "ignition sense" feature disabled. As such, the radio is powered ON or OFF as determined by the front panel ON/OFF/ VOLUME control only (assuming A+ and A- are connected). To enable "ignition sense" feature, open top cover of radio and remove shield from logic PWB. Slide switch SW601 from position 3-2 to 1-2. Replace shield and top cover. Be sure to apply correct torque to screws holding top cover in place. See Maintenance Manual.
Accessory Cable (Front Mount) The basic accessory cable consists, at one end, the basic accessories connector (P3), the speaker connector (P2), and the ignition sense lead. At the other end, plug P1 connects to the Option/Remote Control connector (ORCC), which is mounted on the back of the radio. The EURO accessory cable contains the red and black leads of the power cable. The Extended Option accessory cable is the same as the basic accessory cable, but has an Extended Option plug (P4).
Figure 9: Front Mount Basic Accessory Interconnections (EURO Models Only) Figure 10: Front Mount Extended Option Accessory Interconnections using 19B802554P2 (USA Models Only) 17
*(P5) Provides access for Programming/ Keyloading/ Mobile Data Figure 11: Front Mount Extended Option Accessory Interconnections using CA101288V2 (USA Models Only) Figure 12: Front Mount Extended Option Accessory Interconnections (EURO Models Only) 18
(19B802554, Sh.1, Rev.
(19B802554, Sh.9, Rev.
(19B802554, Sh.2, Rev.
Figure 16: Front Mount Extended Option Accessory Cable CA101288V2 22
(19B802554, Sh.10, Rev.
Accessory and Control Cable (Remote Mount) The control cable connects the Control Unit (through the R1A) to the Radio Transceiver in remote applications. Plug P2, at one end, connects to the Remote Control Cable connector (RCCC) mounted on the back of the R1A. The Ignition Sense wire is also part of P2. The other end of the control cable (P1) connects to the ORCC mounted on the back of the radio. P1 of the EURO control cable contains the power cable leads.
Figure 18: Remote Mount Basic Accessory Interconnections (USA Models Only) Figure 19: Remote Mount Basic Accessory Interconnections (EURO Models Only) Figure 20: Remote Mount Extended Option Accessory Interconnections (USA Models Only) 25
*(P5) Provides access for Programming/Keyloading/Mobile Data Figure 21: Remote Mount Extended Option Accessory Interconnections using CA101288V4 (USA Models Only) Figure 22: Remote Mount Extended Option Accessory Interconnections (EURO Models Only) 26
(19B802554, Sh.5, Rev.
(19B802554, Sh.6, Rev.
(19B802554, Sh.3, Rev.
(19B802554, Sh.4, Rev.
Figure 27: Remote Extended Option Control Cable CA101288V4 31
(19B802554, Sh.11, Rev.
(19B802554, Sh.12, Rev.
STEP 4 – MOUNT CONTROL UNIT AND RADIO Control Unit Mounting (Remote Applications Only) 1. Use the bracket as a template and mark and drill the mounting holes. Be sure to leave enough room at the rear of the control unit for the cable connector. Refer to Figure 30 for control unit mounting bracket installation. 2. Secure the mounting bracket using the four No. 10 x 3/4 self-tapping screws supplied. (Use No. 10 x 1 ½ if needed.) 3.
NOTE When mounting two DB-15 connectors to the control unit, mount one pigtail bracket on each side of the existing mounting hardware of the control unit. 1. Attach DB15 connector to the rectangular end of bracket with 2 pan head machine screws and washers. See Figure 31. 2. Remove the ¼-20 x 5/8 hex head screw and washer from the side of the Control Unit bracket where the Pigtail installation is desired. Retain the hardware for Step 4. 3.
Radio Bracket Mounting For Radio Bracket mounting, the Pigtail Bracket is attached to either side of the Radio mounting bracket. Hardware Kit, KT101533V5, contains the Pigtail Bracket hardware to attach the Pigtail to the bracket. 1. Remove the plastic spacer/glide from the left or right side of the Orion transceiver mounting bracket. This will get reapplied to the other side of bracket where it is currently installed. 2. Slide the Orion into the transceiver bracket. 3.
Radio Front Mount And Final Hook-Up Typically, the bracket shown in Figure 34 is used for Front Mount applications. The bracket can be mounted so that it is either above or below the radio as convenient. The bracket shown in Figure 30 can also be used for Remote Mount applications but is not recommended for 110 watt VHF radios or 100 watt UHF radios. The following instructions are for a Front Mount installation using the bracket shown in Figure 34. 1.
Top Mount Bottom Mount Figure 34: Mounting Bracket Installation Radio Remote Mount and Final Hook-Up The bracket shown in Figure 35 is used for Remote Mounting (USA only). In some applications, the bracket shown in Figure 34 can also be used. The following instructions are for a Remote Mount installation using the bracket shown in Figure 35. 1. Using the bracket as a template, mark and drill the mounting holes using a No. 27 drill.
7. Connect other end of the remote control cable to the remote control cable connector (RCCC) on the remote control unit. 8. Connect remote mount accessory cable connector P1 to the option connector (OPT) on control unit. Then, connect the speaker to connector P2 and accessory connector P3 to any options (hookswitch, etc.). If connector P3 is not used, insulate and tie back to main cable. 9. Recheck all connections and cables before inserting fuse into transmit fuse assembly.
Cassette Mounting (EURO Only) The cassette mounting assembly is designed to mount in a standard DIN space in the instrument panel or console. This mounting permits rapid insertion and removal of the radio unit from the vehicle. All connections are made through a quick disconnect connector at the rear of the cassette mounting assembly to the radio unit. This connector is part of the cassette assembly. The cassette assembly is shown in Figure 36.
b. Using the machine screws and flat washers provided with the handle assembly, attach the handle to the bottom of the radio. The two holes on the handle should align with the two holes on the radio created by step (A). Once installed, the rubber handle should rotate freely from over top of the radio to just out in front of the control unit (approximately 90 degrees). Be sure to torque the two mounting screws within 6.5 to 8.25 in/lb limits. 5.
9. With the handle assembly in the UNLOCKED position (out in front of the control unit), insert the radio into the cassette assembly. Slide the radio into the cassette assembly until the back of the radio meets the back of the cassette assembly. NOTE Caution should be used while engaging the radio in the cassette the first few times until the cabling in the cassette mount assembly has settled into its permanent location.
(19C852366, Sh.2, Rev.
STEP 5 - INSTALL OPTIONS AND ACCESSORIES Speaker D2LS1F The speaker kit includes the speaker, mounting bracket and connecting cable. Mount the speaker so it is directed to the operator but does not present a hazard in the event of an accident. The speaker can be mounted on the lower edge of the instrument panel, the firewall or above the windshield in some trucks. 1. Use the mounting bracket as a template for locating the mounting holes and mount the speaker as shown in Figure 39. 2.
Siren and Light For instructions about installing the Federal Signal Corporation Siren and Light Kit, refer to the Federal Signal Corporation Installation Instructions (Federal Systems part number 255287B, rev. B or higher). Program the radio to work with the Federal Systems Siren and Light Kit, using the instructions outlined in the ProGrammer On-Line Help under “Siren and Light Options.
To resolve false activation, refer to TSM Vol. 25, #2 problem/solution below: Problem: Siren/Light functions change or turn off when switching between radios in Dual Radio installations with a SS2000 siren box. Solution: Keyboard maps and Siren/Light configuration must be identical in both radio personalities to prevent this. Additionally, in a Remote Mount Installation, there are three jumpers that must be reconfigured in the Orion Remote control Unit for Siren/Light operation.
INSTALLATION (DUAL CONTROL UNITS) The Dual Control feature can be configured for either front or remote mount radio units. Each configuration provides for a Main Control Unit and an Auxiliary Control Unit. In front mount configurations, the Main Control Unit is mounted to the radio unit and the Auxiliary Control Unit is located in a convenient location.
Figure 40: Step A Programming Diagram for Front Mount Dual Control Unit 48
Front Mount Procedure 2 Setup the Front Mount radio and the Auxiliary Control Unit with one of the three programming cables as shown in Figure 41.
Figure 41: Step B Programming Diagram Front Mount Dual Control 50
Remote Mount Procedure 1 Setup the remote mount radio and the main control unit with one of the three programming cables as shown in Figure 42.
Figure 42: Step A Programming Diagram Remote Mount Dual Control 52
Remote Mount Procedure 2 Setup the Remote Mount radio and the Auxiliary Control Unit with one of the three programming cables as shown in Figure 43.
Figure 43: Step B Programming Diagram Remote Mount Dual Control 54
STEP 2 – INSTALL DUAL CONTROL UNITS Front Mount The Dual Control Unit feature is configured such that only one Control Unit can be used for Extended Option accessories. Connect all Extended Option accessories through the Main Control Unit. 1. Referring to Figure 44 and Figure 45, run the Dual Control Cable (19B802554P9) between locations for the Radio Unit and Auxiliary Control Unit. Be sure to locate the P2/P3 connector assembly at the radio unit. 2.
7. Install a relay (19A149299P1) from the kits supplied at a location near the leads from each speaker. For mounting, use the #8 x 3/4” sheet metal screw and nut plate supplied with each kit. 8. At a convenient point, cut one of the wires in each of the 2-wire speaker cables, spread the leads, and strip the ends. Crimp a ¼” tab receptacle to each end. 9. Radio Unit Speaker: Connect the lead nearest the speaker to Pin 87A of the relay. Connect the lead nearest the connector to Pin 30 of the relay.
Figure 44: Dual Control Unit Front Mount Installation Configuration using 19B802554P1 or P2 57
Figure 45: Dual Control Unit Front Mount Installation Configuration using CA101288V2 Remote Mount 1. Referring to Figure 46 and Figure 47, run the Remote Control Cable (19B802554P3, 19B802554P4 or CA101288V4) between locations for the Radio unit and Main Control unit. 2. Run the Dual Control Cable (19B802554P9) between locations for the radio unit and Auxiliary Control unit. Be sure to locate the P2/P3 connector assembly at the radio unit. 3.
5. After installing the Auxiliary Control Unit in the normal fashion, connect the Dual Control Cable (P1) to the Auxiliary Control Unit and tighten the jackscrews. 6. Connect the accessory cable (19B802554P6) to the Auxiliary Control Unit. Connect either the accessory cable (19B802554P6) or the extended option accessory cable (19B802554P7) to the Main Control Unit as appropriate. 7. A yellow ignition sense lead is provided on each control cable.
13. For Each Relay: Connect a #18 AWG black wire between the relay, Pin 85 and accessory cable P3-1 (labeled “OUT2” on schematic diagrams in the service manual). Use a ¼” tab receptacle on the relay side and a mating Molex connector and pins on the accessory cable side. Connect the mating Molex connector to the accessory cable P3 when finished. (Refer to Figure 46 and Figure 47.) 14. For Each Relay: Connect one end of a #18 AWG red wire to the relay, Pin 86.
Figure 47: Dual Control Unit Remote Mount Installation Configuration using CA101288V4 61
(19B802554, Sh.7, Rev.
DUAL RADIO UNITS Configure the Dual Radio feature for two remote mount radio units, or one front mount unit and one remote mount unit. In remote mount configurations, the control unit is typically located in the vehicle cab, with the radio units located side-by-side in vehicle trunk. In front mount configurations, the front mount radio unit is located in the vehicle cab, with the remote mount radio unit located in a convenient location nearby.
Master Radio Programming Decide which radio unit shall be the Master Unit. For shop programming, setup the Master radio unit for programming as described in the Service Manual or in the ProGrammer On-Line Help. For field programming, setup the Master radio unit for programming as shown in Figure 49. THE SLAVE RADIO MUST BE DISCONNECTED. Program the Master radio and control unit with the control configurations shown in Table 1. Slave Radio Programming Decide which radio unit shall be the Slave radio unit.
Figure 49: MASTER Radio Field Programming Configuration (Dual Radio) 65
Figure 50: SLAVE Radio Field Programming Configuration (Dual Radio) 66
STEP 2 – INSTALL CABLES/EQUIPMENT Front Mount 1. Plan the mounting locations of the two radio units. Note that the maximum cable length allowed between the two radios is two meters. Referring to Figure 53 and Figure 54, run Dual Radio cable (19B802554P10 or CA101288V10) between locations for Master and Slave radio units. Be sure to locate the P2/P3 connector assembly at the Master radio unit.
P1 O R C C RADIO #2 (SLAVE) DUAL RADIO ADAPTER CABLE 19B802554P10 O R C C RADIO #1 (MASTER) CU P3 1 SPKR P2 P1 P2 2 OPTIONS P3 ACCESSORY CABLE 19B802554P1 or 19B802554P2 EXTENDED OPTIONS P4 (OPTIONAL) Figure 51: Orion Dual Radio Front Mount Installation Configuration *Provides access for Programming/ Keyloading/ Mobile Data **(A + B) Optional Extension Cable for Remote Dual Radio (CA101288V30) provides access flexibility for Programming and Keyloading to the second radio of a dual config
Remote Mount 1. Plan the mounting locations of the two radio units. Note that the maximum cable length allowed between the two radios is two meters. Referring to Figure 53 and Figure 54, run Dual Radio cable (19B802554P10 or CA101288V10) between locations for Master and Slave radio units. Be sure to locate the P2/P3 connector assembly at the Master radio unit.
REMOTE CONTROL CABLE 19B802554P3 or 19B802554P4 CU #B IGN A+ R C C C RIA RADIO #1 (MASTER) P3 P2 P2 OPT 1 SPKR P2 2 OPTIONS EXTENDED OPTIONS (OPTIONAL P3 P1 O R C C DUAL RADIO ADAPTER CABLE 19B802554P10 P1 P1 ACCESSORY CABLE 19B802554P6 OR 19B802554P7 RADIO #2 (SLAVE) O R C C P4 Figure 53: Orion Dual Radio Remote Mount Installation Configuration *Provides access for Programming/ Keyloading/ Mobile Data **(A + B) Optional Extension Cable for Remote Dual Radio (CA101288V30) provides ac
(19B802554, Sh.8, Rev.
Figure 56: Dual Radio Control Cable CA101288V10 72
Figure 57: Programming Interface Cable CA101287V1 73
Keyloading the Radio 1. Attach the Keyloading Interface Cables’, Male DB-15, connector to connector P5 of CA101288V2, V4 or V10 and the Male RJ-45 to the Keyloader. 2. Turn on power of radio to be keyloaded from the control unit. 3. Access the KEYLOAD function via the radio’s menu. This enables the radio to accept the loading of encryption keys. The parameter settings are up to 8 banks of 7 keys.
Keyloading a Dual Radio 1. Attach the Keyloading Interface Cables’ DB-15 to the radio to be keyloaded through connector P5, and the RJ-45 connector to the Keyloader. 2. Select the radio to be keyloaded from the control unit by accessing the RADIO function via the radio’s menu. Toggle to the radio to be keyloaded. 3. Access the KEYLOAD function via the radio’s menu. This enables the radio to accept the loading of encryption keys.
Figure 60: Shop Programming Cable CA101288V15 76
Figure 61: Extension Cable for Dual Remote Radio CA101288V30 77
TECHNICAL ASSISTANCE M/A-COM’s Technical Assistance Center (TAC) resources are available to help you with the overall system’s operation, maintenance, and product support. TAC is your point of contact when you need technical questions answered. For more information about technical assistance services, contact your sales representative, or call the Technical Assistance Center directly at: 78 North America: 1-800-528-7711 International: 434-385-2400 FAX: 1-434-455-6712 E-mail: tac@tycoelectronics.
NOTES 79
M/A-COM Wireless Systems 221 Jefferson Ridge Parkway Lynchburg, Virginia 24501 (Outside USA, 434-385-2400) Toll Free 800-528-7711 www.macom-wireless.com Printed in U.S.A.
