Service manual

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ASTRO

Digital Spectra

and Digital Spectra Plus

UHF

VHF

800 MHz

Mobile Radios

Basic Service Manual

Summary of content (176 pages)

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® ASTRO Digital Spectra and Digital Spectra Plus UHF VHF 800 MHz Mobile Radios Basic Service Manual ®
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Digital Spectra® and Digital Spectra Plus ® Title Page VHF/UHF/800 MHz Digital Mobile Radios Basic Service Manual Motorola, Inc.
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Foreword This manual covers all models of the ASTRO® Digital Spectra® and ASTRO Digital Spectra Plus mobile radios (models W3, W4, W5, W7, and W9), unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level and is typical of some local service centers, self-maintained customers, and distributors.
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Table of Contents iii Table of Contents Foreword .........................................................................................................ii Product Safety and RF Exposure Compliance ............................................................................................ii Manual Revisions ........................................................................................................................................ii Computer Software Copyrights ...............................
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iv Table of Contents Chapter 1 1.1 1.2 1.3 Notations Used in This Manual ...................................................................................................... 1-1 Radio Descriptions......................................................................................................................... 1-1 1.2.1 FLASHport®...................................................................................................................... 1-2 Control Head Descriptions ....................
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Table of Contents v 3.9.1 VHF Radios ...................................................................................................................... 3-6 3.9.2 UHF and 800 MHz Radios ................................................................................................ 3-6 3.10 Command Board............................................................................................................................ 3-6 3.11 VOCON (Vocoder/Controller) Board....................................
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vi Table of Contents 6.3.8 Transmitter Test Pattern ................................................................................................. 6-23 Chapter 7 Encryption ........................................................................... 7-1 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Universal Crypto Module Kits......................................................................................................... 7-1 7.1.1 ASTRO Digital Spectra ..................................................
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Table of Contents 8.3 8.4 8.2.8.1 Low-/Mid-Power Radio .......................................................................................... 8-13 8.2.8.2 High-Power Radio.................................................................................................. 8-13 8.2.9 VCO Board ..................................................................................................................... 8-14 8.2.9.1 Low-/Mid-Power Radio ..............................................................
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viii Table of Contents 11.11 Large Pushbutton Parts ............................................................................................................. 11-10 Appendix A Replacement Parts Ordering..............................................A-1 A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8 Basic Ordering Information ............................................................................................................A-1 Transceiver Board and VOCON Board Ordering Information............................
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List of Figures ix List of Figures Figure 1-1. Typical W3 Hand-Held Control Head .................................................................................... 1-3 Figure 1-2. Typical W4 Rotary Control Head........................................................................................... 1-4 Figure 1-3. Typical W5 Pushbutton Control Head ................................................................................... 1-4 Figure 1-4. Typical W7 Pushbutton Control Head ....................
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x List of Figures Figure 11-4. Figure 11-5. Figure 11-6. Figure 11-7. Figure 11-8. Figure 11-9. February 3, 2003 Model W9 Pushbutton Control Head Exploded View.......................................................... 11-5 Low-Power (15W) Radio Exploded View ............................................................................ 11-6 Mid-Power (20-40/25-50/35W) Radio Exploded View......................................................... 11-7 High-Power (50-110W) Radio Exploded View ................
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List of Tables xi List of Tables Table 1-1. ASTRO Digital Spectra/Spectra Plus Basic Features ........................................................... 1-2 Table 4-1. Recommended Motorola Test Equipment............................................................................. 4-1 Table 4-2. Wattmeter Plug-In Elements ................................................................................................. 4-2 Table 4-3. Recommended Non-Motorola Test Equipment .................................
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xii Related Publications Related Publications ASTRO Digital Spectra and Digital Spectra Plus Model W3 User’s Guide ..................................6881090C61 ASTRO Digital Spectra and Digital Spectra Plus Models W4, W5, W7, and W9 User’s Guide ..6881090C62 ASTRO Digital Spectra Hand-Held Control Head User’s Guide (Model W3)...............................6881073C25 ASTRO Digital Spectra (Model W4, W5, W7, and W9) User’s Guide..........................................
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Commercial Warranty xiii Commercial Warranty Limited Warranty MOTOROLA COMMUNICATION PRODUCTS I. What This Warranty Covers And For How Long MOTOROLA INC.
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xiv Commercial Warranty III. State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY. This warranty gives specific legal rights, and there may be other rights which may vary from state to state. IV.
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Commercial Warranty xv VI. Patent And Software Provisions MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the extent that it is based on a claim that the Product or parts infringe a United States patent, and MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in any such suit which are attributable to any such claim, but such defense and payments are conditioned on the following: A.
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xvi Model Numbering, Charts, and Specifications Model Numbering, Charts, and Specifications Mobile Radio Model Numbering Scheme Typical Model Number: T Position: 1 0 2 4 3 S 4 L 5 Position 1 - Type of Unit D = Dash-Mounted Mobile Radio M = Motorcycle Mobile Radio T = Trunk-Mounted Mobile Radio 9 7 P 8 W 9 7 10 A 11 N 12 S 13 P 14 0 15 1 16 Positions 13 - 16 SP Model Suffix Position 12 Unique Model Variations C = Cenelec N = Standard Package Positions 2 & 3 - Model Series 04 = ASTRO Posit
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Model Numbering, Charts, and Specifications xvii ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 1 and 2) Model Chart Model Number Description M04JGF9PW4AN M04JGF9PW5AN M04JGH9PW7AN M04KGF9PW4AN M04KGF9PW5AN M04KGH9PW7AN M04RGF9PW4AN M04RGF9PW5AN M04RGH9PW7AN M04UGF9PW4AN M04UGF9PW5AN M04UGH9PW7AN Model W4 (136-162 MHz), Range 1, 15 Watt, 128 Channels Model W5 (136-162 MHz), Range 1, 15 Watt, 128 Channels Model W7 (136-162 MHz), Range 1, 15 Watt, 128 Channels Model W4 (146-174 MHz), Range 2, 15 Watt,
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xviii Model Numbering, Charts, and Specifications ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 3 and 3.5) Model Chart Model Number M04RGF9PW4ANSP02 M04RGF9PW5ANSP02 M04RGF9PW4ANSP01 M04RGF9PW5ANSP01 M04RGH9PW7ANSP01 Item No.
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Model Numbering, Charts, and Specifications xix ASTRO Digital Spectra VHF 10–25 Watt Model Chart Model Number Description D04JHH9PW3AN D04JHF9PW4AN D04JHF9PW5AN D04JHH9PW7AN T04JHH9PW9AN D04KHH9PW3AN D04KHF9PW4AN D04KHF9PW5AN D04KHH9PW7AN T04KHH9PW9AN Model W3 (136-145.
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xx Model Numbering, Charts, and Specifications ASTRO Digital Spectra VHF 25–50 and 50–110 Watt Model Chart Model Number Description D04JKH9PW3AN D04JKF9PW4AN D04JKF9PW5AN D04JKH9PW7AN T04JKH9PW9AN D04KKF9PW3AN D04KKF9PW4AN D04KKF9PW5AN D04KKH9PW7AN T04KKH9PW9AN T04JLH9PW3AN T04JLF9PW4AN T04JLF9PW5AN T04JLH9PW7AN T04JLH9PW9AN T04KLH9PW3AN T04KLF9PW4AN T04KLF9PW5AN T04KLH9PW7AN T04KLH9PW9AN Model W3 (136-145.
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Model Numbering, Charts, and Specifications xxi ASTRO Digital Spectra VHF 10–25 and 50–110 Watt Model Chart (cont.) Model Number Description D04JKH9PW3AN D04JKF9PW4AN D04JKF9PW5AN D04JKH9PW7AN T04JKH9PW9AN D04KKF9PW3AN D04KKF9PW4AN D04KKF9PW5AN D04KKH9PW7AN T04KKH9PW9AN T04JLH9PW3AN T04JLF9PW4AN T04JLF9PW5AN T04JLH9PW7AN T04JLH9PW9AN T04KLH9PW3AN T04KLF9PW4AN T04KLF9PW5AN T04KLH9PW7AN T04KLH9PW9AN Model W3 (136-145.
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xxii Model Numbering, Charts, and Specifications ASTRO Digital Spectra UHF 10–25 Watt Model Chart Model Number D04RHH9PW3AN D04RHF9PW4AN D04RHF9PW5AN D04RHH9PW7AN T04RHH9PW9AN Item No.
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Model Numbering, Charts, and Specifications xxiii ASTRO Digital Spectra UHF 20–40 Watt Model Chart Model Number Description D04QKH9PW3AN D04QKF9PW4AN D04QKF9PW5AN D04QKH9PW7AN T04QKH9PW9AN D04RKH9PW3ANSP01 D04RKF9PW4AN D04RKF9PW5AN D04RKH9PW7AN T04RKH9PW9AN D04SKH9PW3AN D04SKF9PW4AN D04SKF9PW5AN D04SKH9PW7AN T04SKH9PW9AN Model W3 (403-433 MHz), 20-40 Watt, 128 Channels Model W4 (403-433 MHz), 20-40 Watt, 128 Channels Model W5 (403-433 MHz), 20-40 Watt, 128 Channels Model W7 (403-433 MHz), 20-40 Watt, 2
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xxiv Model Numbering, Charts, and Specifications ASTRO Digital Spectra UHF 20–40 Watt Model Chart (cont.
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Model Numbering, Charts, and Specifications xxv ASTRO Digital Spectra UHF 50–110 Watt Model Chart Model Number Description T04QLF9PW4AN T04QLF9PW5AN T04QLH9PW7AN T04QLH9PW9AN T04RLF9PW4AN T04RLF9PW5AN T04RLH9PW7AN T04RLH9PW9AN T04SLF9PW4AN T04SLF9PW5AN T04SLHPW7AN T04SLHPW9AN Item No.
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xxvi Model Numbering, Charts, and Specifications ASTRO Digital Spectra UHF 50–110 Watt Model Chart (cont.) Model Number Description T04QLF9PW4AN T04QLF9PW5AN T04QLH9PW7AN T04QLH9PW9AN T04RLF9PW4AN T04RLF9PW5AN T04RLH9PW7AN T04RLH9PW9AN T04SLF9PW4AN T04SLF9PW5AN T04SLHPW7AN T04SLHPW9AN Item No.
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Model Numbering, Charts, and Specifications xxvii ASTRO Digital Spectra 800 MHz Model Chart Model Number D04UJF9PW3AN D04UJF9PW4AN D04UJF9PW5AN D04UJF9PW7AN T04UJF9PW9AN Item No.
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xxviii Model Numbering, Charts, and Specifications ASTRO Digital Spectra Plus VHF 25–50 and 50–110 Watt Model Chart Model Number Description D04JKH9SW7AN D04KKH9SW3AN D04KKF9SW4AN D04KKF9SW5AN D04KKH9SW7AN T04KKH9SW9AN T04KLH9SW3AN T04KLF9SW4AN T04KLF9SW5AN T04KLH9SW7AN T04KLH9SW9AN Model W7 (136-162 MHz), 25-50 Watt, 512 Channels Model W3 (146-174 MHz), 25-50 Watt, 512 Channels Model W4 (146-174 MHz), 25-50 Watt, 512 Channels Model W5 (146-174 MHz); 25-50 Watt, 512 Channels Model W7 (146-174 MHz), 25-
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Model Numbering, Charts, and Specifications xxix ASTRO Digital Spectra Plus VHF 25–50 and 50–110 Watt Model Chart (cont.
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xxx Model Numbering, Charts, and Specifications ASTRO Digital Spectra Plus UHF 20–40 Watt Model Chart Model Number Description D04QKH9SW3AN D04QKF9SW4AN D04QKF9SW5AN D04QKH9SW7AN T04QKH9SW9AN D04RKH9SW3AN D04RKF9SW4AN D04RKF9SW5AN D04RKH9SW7AN T04RKH9SW9AN Model W3 (403-433 MHz), 20-40 Watt, 512 Channels Model W4 (403-433 MHz), 20-40 Watt, 128 Channels Model W5 (403-433 MHz), 20-40 Watt, 128 Channels Model W7 (403-433 MHz), 20-40 Watt, 512 Channels Model W9 (403-433 MHz), 20-40 Watt, 512 Channels Model
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Model Numbering, Charts, and Specifications xxxi ASTRO Digital Spectra Plus UHF 20–40 Watt Model Chart (cont.
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xxxii Model Numbering, Charts, and Specifications ASTRO Digital Spectra Plus UHF 50–110 Watt Model Chart Model Number Description T04QLH9SW3AN T04QLF9SW4AN T04QLF9SW5AN T04QLH9SW7AN T04QLH9SW9AN T04RLH9SW3AN T04RLF9SW4AN T04RLF9SW5AN T04RLH9SW7AN T04RLH9SW9AN T04SLH9SW3AN T04SLF9SW4AN T04SLF9SW5AN T04SLH9SW7AN T04SLH9SW9AN Model W3 (403-433 MHz), 50-110 Watt, 512 Channels Model W4 (403-433 MHz), 50-110 Watt, 128 Channels Model W5 (403-433 MHz), 50-110 Watt, 128 Channels Model W7 (403-433 MHz), 50-110 W
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Model Numbering, Charts, and Specifications xxxiii ASTRO Digital Spectra Plus UHF 50–110 Watt Model Chart (cont.
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xxxiv Model Numbering, Charts, and Specifications ASTRO Digital Spectra Plus 800 MHz Model Chart Model Number Description M04UGF9SW4AN M04UGF9SW5AN M04UGH9SW7AN D04UJH9SW3AN D04UJF9SW4AN D04UJF9SW5AN D04UJH9SW7AN T04UJH9SW9AN Item No.
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Model Numbering, Charts, and Specifications xxxv ASTRO Digital Spectra Plus 800 MHz Model Chart (cont.) Model Number Description M04UGF9SW4AN M04UGF9SW5AN M04UGH9SW7AN D04UJH9SW3AN D04UJF9SW4AN D04UJF9SW5AN D04UJH9SW7AN T04UJH9SW9AN Item No.
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xxxvi Model Numbering, Charts, and Specifications VHF Radio Specifications GENERAL FCC Designations: RECEIVER AZ492FT3772 AZ492FT3773 Frequency Range: Range 1: Range 2: TRANSMITTER 136–162 MHz 146–174 MHz Frequency Range: Range 1: Range 2: 136–162 MHz 146–174 MHz Temperature Range: Operating: Storage: –30°C to +60°C –40°C to +85°C Power Supply: Channel Spacing: 12.
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Model Numbering, Charts, and Specifications xxxvii UHF Radio Specifications GENERAL FCC Designations: AZ492FT4786 AZ492FT4787 Temperature Range: Operating: Storage: Power Supply: RECEIVER –30°C to +60°C –40°C to +85°C Frequency Range: Range 1: Range 2: Range 3: Range 4: TRANSMITTER 403–433 MHz 438–470 MHz 450–482 MHz 482–512 MHz Channel Spacing: 12.
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xxxviii Model Numbering, Charts, and Specifications 800 MHz Radio Specifications GENERAL FCC Designations: RECEIVER AZ492FT5759 AZ492FT5751 Frequency Range: TRANSMITTER 851–869 MHz Frequency Range: Repeater Mode: Talkaround Mode: 806–824 MHz 851–869 MHz Channel Spacing: 12.5 kHz/20 kHz/25 kHz Input Impedance: 50 Ohm Rated Output Power: Mid-Power Radio: 15 Watt Frequency Separation: 18 MHz High-Power Radio: 35 Watt Sensitivity: (per EIA spec.
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Chapter 1 Introduction 1.1 Notations Used in This Manual Throughout the text in this publication, you will notice the use of note, caution, warning, and danger notations. These notations are used to emphasize that safety hazards exist, and due care must be taken and observed. NOTE: An operational procedure, practice, or condition that is essential to emphasize. ! CAUTION indicates a potentially hazardous situation which, if not avoided, might result in equipment damage. Caution ! WARNING ! DANGER 1.
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1-2 Introduction: Control Head Descriptions ASTRO Digital Spectra and Digital Spectra Plus radios are available in five models. Table 1-1 provides a description of basic features for the five models covered in this manual. Table 1-1.
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Introduction: Control Head Descriptions 1-3 1.3.1.1 Model W3 Control Head On/Off Button (T1) Orange Programmable Button (T2) Programmable Button (T3) LED Indicator Display Push-To-Talk (PTT) Button Switch Side Button 1 (S1) HOME Side Button 2 (S2) Side Button 3 (S3) Volume Control VOL MODE Mode Control 1Q Z 2 ABC 3 DEF 4 GH I 5 J KL 6 MNO 7 PRS 8 TUV 9 WXY Alphanumeric Keypad 0 Figure 1-1. Typical W3 Hand-Held Control Head 1.3.1.
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1-4 Introduction: Control Head Descriptions 1.3.1.3 Models W4, W5, W7, and W9 Controls Head PAGE or SECURE or EMERGENCY Page Emer SCAN PHONE HOME HORN/ LIGHTS Home Phon SELECT MONITOR CALL Scan DIRECT Call Dir Sel Mode H/L Mon Volume XMIT Dim BUSY Mic Pwr PRIORITY/ NON-PRIORITY INDICATORS DIRECT INDICATOR MODE POWER ON/OFF/ KNOB VOLUME KNOB Figure 1-2.
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Introduction: Control Head Descriptions 1-5 FUNCTION BUTTON PRIORITY DIMMER INDICATOR STATUS* CONTROL XMIT BUSY DIM FUNCTION ON/OFF INDICATORS Emer Dir MODE ROCKER Vol 2 3 4 Phon 5 H/L 6 7 Sts 8 9 Msg Call Scan Pri Non Pri Mode 1 Sel Home VOLUME SELECT HOME ROCKER 0 Sql Rcl MESSAGE* Del RECALL DELETE SQUELCH NON-PRIORITY INDICATOR KEYPAD * Optional buttons (included but not installed or programmed) Figure 1-5. Typical W9 Pushbutton Control Head 1.3.1.
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1-6 Introduction: Control Head Descriptions • Option Buttons — The option buttons are used for turning options on and off, such as Phone, Scan, Emergency Call, and Secure. • Display — The vacuum fluorescent (VF) display’s primary function is to display mode numbers, mode names, volume level, and the status of options. It also functions as an on-off indicator for the entire system and plays an integral role in the operator’s reconfiguration of options.
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Chapter 2 Basic Maintenance 2.1 Introduction This section of the manual describes preventive maintenance, handling precautions, and some basic repair procedures and techniques. Each of these topics provides information vital to the successful operation and maintenance of your radio. 2.2 Preventive Maintenance Radios are shipped from the factory with a worst-case frequency error of ±200 Hz for VHF, ±300 Hz for UHF, and ±500 Hz for 800 MHz.
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2-2 Basic Maintenance: Handling Precautions ! Caution 2.2.4 The effects of certain chemicals and their vapors can have harmful results on certain plastics. Aerosol sprays, tuner cleaners, and other chemicals should be avoided. Cleaning External Plastic Surfaces The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio.
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Basic Maintenance: Handling Precautions 2-3 • If a static-sensitive device is to be temporarily set down, use a conductive surface for placement of the device. • Make skin contact with a conductive work surface first and maintain this contact when the device is set down or picked up. • Always wear a conductive wrist strap when servicing this equipment. The Motorola part number for a replacement wrist strap that connects to the table mat is 42-80385A59.
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2-4 Basic Maintenance: Handling Precautions Notes February 3, 2003 6881076C20-E
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Chapter 3 Basic Theory of Operation 3.1 Introduction The following theory will help isolate the problem to a particular board. Using circuit board replacement as the basic service approach maximizes the working time of the radio. 3.2 General Overview The ASTRO Digital Spectra and Digital Spectra Plus radios are wideband, synthesized, fixed-tuned radios. The ASTRO Digital Spectra is available with VHF, UHF, and 800 MHz bands. The ASTRO Digital Spectra Plus is available with VHF and 800 MHz bands only.
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3-2 Basic Theory of Operation: Analog Mode of Operation 3.3 Analog Mode of Operation 3.3.1 Receive Operation When the radio is receiving, the signal comes from the antenna/antenna-switch on the power amplifier board to the front-end receiver assembly. The signal is then filtered, amplified, and mixed with the first local-oscillator signal generated by the voltage-controlled oscillator (VCO).
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Basic Theory of Operation: Control Head Assembly 3.5.2 3-3 Display (W9 Model) The control head assembly for a W9 model has an 11-character, alphanumeric, vacuum fluorescent display. It needs three separate voltages to operate: the cathode needs 35V to accelerate electrons to the anode; the grid needs 40V to totally shut off current flow; the filament needs 3.8 Vrms at 80 mA. These voltages are obtained from the transformer on the display controller board. 3.5.
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3-4 3.5.8 Basic Theory of Operation: Power Amplifier Vehicle Interface Port (VIP) 3.5.8.1 Remote-Mount The VIPs allow the control head to operate outside circuits and to receive inputs from outside the control head. There are three VIP outputs that are used for relay control. There are also three VIP inputs that accept inputs from switches. See the cable kit section for typical connections of VIP input switches and VIP output relays.
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Basic Theory of Operation: Front-End Receiver Assembly 3.6.2 3-5 Power Control A directional coupler and detector network controls power. It senses the forward power from the last gain stage and feeds the detected voltage back to the command board control circuitry, where it is compared to a reference voltage set during power-set procedures. The dc feed voltage is corrected and supplied to the “controlled” stage of the power amplifier.
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3-6 Basic Theory of Operation: Voltage-Controlled Oscillator (VCO) Synthesizing for the first and second VCO is performed by the prescaler and synthesizer ICs. These ICs are programmed through a serial data bus from signals generated on the VOCON board. A dc voltage, generated on the command board, sets the synthesizer’s reference oscillator frequency of 16.8MHz. This voltage is controlled by the digital-to-analog converter (D/A), and is the only element of the RF board requiring alignment.
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Basic Theory of Operation: VOCON (Vocoder/Controller) Board 3-7 The regulator and power control circuits include an unswitched +5V discrete circuit and the regulator/ power control IC, which produces both switched +5V and 9.6V. The unswitched +5V source is used as a reference for its switched +5V source. Filtered unswitched +5V is used for the microcontrol circuits. Switched +5V and 9.6V are controlled by a digital transistor from the serial input/output IC.
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3-8 Basic Theory of Operation: VOCON (Vocoder/Controller) Board The VOCON board controls receive/transmit frequencies, the display, and various radio functions, using either direct logic control or serial communication to external devices. The connector J801 provides an interface between the encryption module and the VOCON board for encrypting voice messages. The VOCON board executes a stored program located in the FLASH ROM. Data is transferred to and from memory by the microcontroller unit data bus.
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Chapter 4 Test Equipment, Service Aids, and Tools 4.1 Recommended Test Equipment The list of equipment contained in Table 4-1 includes most of the standard test equipment required for servicing Motorola mobile radios, as well as several unique items designed specifically for servicing this family of radios.
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4-2 Test Equipment, Service Aids, and Tools: Service Aids and Recommended Tools Table 4-2 contains a listing of the plug-in elements that are available for the BIRD wattmeters listed in the Table 4-1. Table 4-2.
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Test Equipment, Service Aids, and Tools: Service Aids and Recommended Tools 4-3 Table 4-4.
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4-4 Test Equipment, Service Aids, and Tools: Service Aids and Recommended Tools Table 4-5 lists additional service aids that can be used in troubleshooting ASTRO Digital Spectra radios. Table 4-5. Service Aids for ASTRO Digital Spectra Board-Level Troubleshooting Motorola Part Number Description Application RLN-4008_ Radio Interface Box (RIB) Enables communications between the radio and the RSS RLN-1015_ Smart RIB (SRIB) Enables communications between the radio and the RSS.
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Test Equipment, Service Aids, and Tools: Field Programming Equipment 4-5 Table 4-6. Service Aids for ASTRO Digital Spectra Plus Board-Level Troubleshooting Motorola Part Number Description Application 30-85001D01 Programming Flash Cable Used with Tuner Software, CPS, and FLASHport RVN-4185 Customer Programming Software and Tuner Software Programming and radio alignment software on CD Table 4-7.
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4-6 Test Equipment, Service Aids, and Tools: Field Programming Equipment The following items, available through the Customer Care and Services Division (except the computer), are required when programming ASTRO Digital Spectra Model radios. Table 4-8. ASTRO Digital Spectra Field Programming Items Type or Part Number Description 01-80300B10 Programming Cable Used to connect high-power radios (50W-110W) directly to the RIB or SRIB. 30-80369B71 Computer Interface Cable RLN-4008 RIB-to-computer cable.
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Test Equipment, Service Aids, and Tools: Field Programming Equipment 4-7 In mid-power radios, when this cable is used, programming must be done through the rear accessory connector. 4.3.2 ASTRO Digital Spectra Plus The ASTRO Digital Spectra Plus radios use a flash memory device to store information on frequencies, squelch codes, signaling codes, time-out timer durations, and other parameters.
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4-8 Test Equipment, Service Aids, and Tools: Field Programming Equipment Notes February 3, 2003 6881076C20-E
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Chapter 5 Performance Checks 5.1 Introduction This section covers performance checks used to verify that the radio meets published specifications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule. 5.
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5-2 5.2.2 Performance Checks: Test Mode ASTRO Digital Spectra Plus COMMUNICATIONS ANALYZER RF PORT RF ATTENUATOR RADIO WATTMETER AGILENT 8901B MODULATION ANALYZER RX MATCHING TRANSFORMER TEST SPEAKER SINAD METER AC VOLTMETER OR COMMUNICATIONS ANALYZER Vert/SINAD Dist/ DVM Counter MAEPF-27501-O Figure 5-2. ASTRO Digital Spectra Plus Performance Checks Test Setup 5.
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Performance Checks: Test Mode 5-3 Table 5-1.
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5-4 Performance Checks: Test Mode 2. In RF test mode, press the Volume rocker to adjust the volume. The volume display for the ASTRO Digital Spectra will be in 256 increments, not the usual 16, while in the test mode. This allows for precise setting of rated audio, etc. For the ASTRO Digital Spectra Plus, the volume is still displayed as a value between 0 to 15. 3.
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Performance Checks: Test Mode 5-5 Table 5-3. Signaling Types Display Modulation Demodulation Type CSQ None None Carrier Squelch TPL 192Hz 192Hz Private-Line AST 1200Hz N/A ASTRO (digital) USQ None None Open Squelch When in the transmit test mode, DTMF modulation produces a sidetone in the speaker. All signaling types will continually modulate the transmitted signal for detection/measurement by external instruments. 5.3.
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5/9/94 5-6 Performance Checks: Receiver Performance Checks KEY 81 KEY 100 KEY 49 KEY 102 KEY 101 KEY 99 KEY 80 KEY 50 KEY 103 PWR Phon Mode KEY 82 KEY 83 Scan Call Sel Vol 1 2 3 4Sts 5 6Msg 7H/L 8Mon 9Dir O #Del XMIT DIM BUSY HOME Mic KEY 51 KEY 53 KEY 54 KEY 56 KEY 57 KEY 48 KEY 59 Rcl KEY 97 KEY 96 KEY 52 KEY 58 KEY 55 VIP IN 1: KEY 16 VIP IN 2: KEY 17 VIP IN 3: KEY 18 MIC PTT: KEY 01 MIC HUB*: KEY 06 IGN SENSE: KEY 07 * TAKE MIC OFF HOOK MAEPF-24120-A Figure 5-4.
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Performance Checks: Transmitter Performance Checks 5-7 Table 5-4. Receiver Performance Checks (Continued) Test Name System Analyzer Radio Test Condition Comments Sensitivity (SINAD) As above, except SINAD, lower the RF level for 12 dB SINAD TEST MODE, 1 CSQ Release PTT switch. RF input to be < 0.35µV Noise Squelch Threshold (only radios with conventional system need to be tested) RF level set to 1 mV RF TEST MODE, 1 CSQ Release PTT switch. Set volume control to 3.
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5-8 Performance Checks: Transmitter Performance Checks Table 5-5. Transmitter Performance Checks (Continued) Test Name System Analyzer Radio Test Condition Comments PL Modulation (radios with conventional, clear mode, coded squelch operation only) Change frequency to 1st channel test frequency**; B/W to narrow TEST MODE, 1 TPL Remove modulation input from dummy microphone. Press and hold PTT switch.
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Chapter 6 Radio Alignment Procedure 6.1 Introduction This section describes both receiver and transmitter radio alignment procedures using either of the following radio alignment software: • ASTRO Digital Spectra Radio Service Software (DOS-based) • ASTRO Digital Spectra and Digital Spectra Plus Tuner software (Windows-based) 6.2 RSS 6.2.1 ASTRO Digital Spectra An IBM or IBM PC-compatible computer and radio service software (RSS) are required to align the ASTRO Digital Spectra radio.
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6-2 Radio Alignment Procedure: RSS SERVICE F2 - TRANSMITTER ALIGNMENT MENU F1 - HELP F2 - REFERENCE OSCILLATOR ALIGNMENT F3 - TRANSMIT POWER ALIGNMENT F4 - TRANSMIT CURRENT LIMIT F5 - TRANSMIT DEVIATION BALANCE (COMPENSATION) ALIGNMENT F6 - TRANSMIT DEVIATION LIMIT ALIGNMENT F10 - EXIT, RETURN TO SERVICE MENU Figure 6-2. RSS Service Menu Layout All SERVICE screens read and program the radio codeplug directly; you do NOT have to use the RSS GET/SAVE functions to use the SERVICE menus. 6.2.
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Radio Alignment Procedure: RSS 6.2.3 6-3 Reference Oscillator Alignment Radios are shipped from the factory with a worst-case frequency error of ±200 Hz for VHF, ±300 Hz for UHF, and ±500 Hz for 800 MHz. These specifications are tighter than the more stringent FCC requirement of 1.5 ppm for all bands. For radios that have been in storage for over six months from the factory ship date, the reference oscillator should be checked when the radio is initially deployed to the field.
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6-4 Radio Alignment Procedure: RSS MOTOROLA Radio Service Software ASTRO Model: T04SLF9PW7AN Use UP/DOWN Arrows To Adjust Softpot. MAIN:SERVICE:TX ALIGN:REF OSC REFERENCE OSCILLATOR -------------------Frequency --------869.9875 Current Value ------------72 New Softpot Value......72 Transmitter..On 0 255 MIN |----+----+----+----X----+----+----+----+----+----+----+----| MAX F1 HELP F2 F3 F4 F5 F6 TOGGLE PTT F7 F8 PROGRAM VALUE F9 F10 EXIT Figure 6-4. Reference Oscillator Alignment Screen 6.
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Radio Alignment Procedure: RSS 6-5 NOTE: The power amplifier must be firmly mounted to the transceiver for accurate power adjustment. 1. From the SERVICE MENU, press F2 to select the TRANSMITTER ALIGNMENT MENU. 2. Press F3 to select the TRANSMIT POWER alignment screen. The screen will indicate the transmit frequencies to be used (Figure 6-5). MOTOROLA Radio Service Software ASTRO Model: T04SLF9PW7AN Use UP/DOWN Arrows To Adjust Softpot.
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6-6 Radio Alignment Procedure: RSS Table 6-2. Transmit Power Settings (Continued) 800 MHz Rated Output Power Min. Level Max. Level 15W 15W 20W 35W (Repeater Mode) 37W 42W 30W (Talkaround Mode) 32W 42W 6. Press F6 to dekey the radio. 7. Press F8 to program the value. 8. Repeat steps 3-7 for the remaining frequencies. 9. Press F10 once to return to the TRANSMITTER ALIGNMENT MENU, or press F10 twice to return to the SERVICE MENU. 6.2.5 Transmit Current Limit Alignment 1.
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Radio Alignment Procedure: RSS 6-7 8. Press F10 once to return to the TRANSMITTER ALIGNMENT MENU, or press F10 twice to return to the SERVICE MENU. 6.2.6 Transmit Deviation Balance (Compensation) Alignment NOTE: Compensation alignment is only required after replacing (or servicing) the command board, VOCON (vocoder/controller) board, RF board, or the VCO board. Compensation alignment balances the modulation sensitivity of the VCO and reference modulation (synthesizer low-frequency port) lines.
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6-8 Radio Alignment Procedure: RSS MOTOROLA Radio Service Software ASTRO Model: T04SLF9PW7AN Use UP/DOWN Arrows To Adjust Softpot. MAIN:SERVICE:TX ALIGN:BAL ATTN TRANSMIT DEVIATION BALANCE (COMPENSATION) ----------------------------------------Current Frequency Value New Softpot Value ------------------------------806.0125 30 30 821.0125 30 30 851.0125 30 30 866.0125 45 45 869.9875 45 45 Transmitter..
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Radio Alignment Procedure: RSS 6-9 - In the “RF Control” section of the R-2670, enter the frequency displayed on the RSS screen (choose a test frequency from the list of frequencies displayed under TRANSMIT DEVIATION LIMIT screen in RSS). Move the cursor to the “B/W” setting and select “WIDE +/- 100 kHz” via the soft key menu. - Place the R-2670 cursor in the “Display” zone. Move the cursor to the “Meter” setting and select “AC VOLTS” via the soft key menu.
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6-10 6.2.8 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Bit Error Rate (BER) Performance Check This check tests the Bit Error Rate (BER) of the radio’s receiver at a desired frequency. Required equipment and software: R-2670 system analyzer, with P25 option; IBM PC-compatible computer, RSS In Generate mode, the R-2670 system analyzer modulates the RF carrier with a 1011Hz tone test pattern to test the Unit Under Test (UUT) receiver.
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Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-11 COMMUNICATIONS ANALYZER RF PORT RF ATTENUATOR WATTMETER RADIO AGILENT 8901B MODULATION ANALYZER RX MATCHING TRANSFORMER TEST SPEAKER SINAD METER AC VOLTMETER OR CONTROL HEAD *30-85001D01 RX TX GND COMMUNICATIONS ANALYZER Vert/SINAD Dist/ DVM Counter COMPUTER dash mount applications, ASTRO Spectra Plus program/flash cable * For (30-85001D01) will be connected to the microphone port on the control head.
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6-12 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Figure 6-10. Tuner Menu Layout The alignment screens introduce the concept of the “softpot,” an analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls. ! Caution Do NOT switch radios in the middle of any alignment procedure. Always left-click the Close button on the screen to return to the MAIN menu screen before disconnecting the radio.
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Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-13 Figure 6-11. Typical Softpot Adjustment Screen Adjusting the softpot value sends information to the radio to increase (or decrease) a voltage in the corresponding circuit. For example, left-clicking the UP spin button (▲) on the Reference Oscillator screen instructs the radio’s microcomputer to increase the voltage across a varactor in the reference oscillator, which increases the frequency.
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6-14 6.3.1 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Radio Information Figure 6-12 shows a typical Radio Information screen. All of the data appearing here is informational and cannot be changed.. Figure 6-12. Radio Information Screen 6.3.2 Reference Oscillator Alignment Reference oscillator alignment is required after replacing (or servicing) the transceiver board.
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Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-15 - Attenuation: 20dB - Mon RF in: RF I/O - Meter: RF Display - Mode: STD - Input Level: uV or W - Display: Bar Graphs - Squelch: Mid-range or adjust as necessary • Initial set up using the 8901_ Series Modulation Analyzer: - Press the green Automatic Operation button on the analyzer. - Press the FREQ key. - Type 7.1 followed by SPCL button to set the 8901_ modulation analyzer for maximum accuracy. 1.
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6-16 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Table 6-3. Reference Oscillator Alignment Band 800 MHz Target ±100 Hz 6. Left-click the Program (Digital Spectra) or Program All (Digital Spectra Plus) button on the screen to dekey the radio and save the tuned values. 7. Left-click the Close button on the screen to return to the Transmitter Alignments menu. 6.3.
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Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-17 2. Left-click the desired frequency field (starting with the highest frequency shown). 3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting. 4. Measure the transmit power of the radio with a service monitor. 5. Adjust the softpot value until the required power, as shown in Table 6-4, is indicated on the service monitor. Table 6-4.
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6-18 6.3.4 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Transmit Current Limit Alignment This procedure is required for mobile radios only. Transmit Current Limit adjustment is required after replacing (or servicing) the RF Board. This alignment procedure limits the transmitter current drain of the radio. 1. Click on the PTT Toggle button to make the radio transmit. 2. While transmitting, measure the current drain at each of the test frequencies. 3.
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Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-19 This procedure needs to be performed at multiple frequencies to allow for proper alignment across the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in each zone. Proper alignment requires a modulation analyzer or meter with a frequency response to less than 10Hz modulating frequency.
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6-20 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Figure 6-16. Transmit Deviation Balance (Compensation) Alignment Screen 6. Left-click the PTT Tone: Low button. 7. Left-click the PTT Toggle button on the screen to enable transmission. The screen indicates whether the radio is transmitting. Wait approximately 5 seconds until the voltage shown on R2670, or the deviation shown on the 8901_ analyzer, stabilizes. 8.
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Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-21 This test can be done with either the R-2670 Communication Analyzer or the 8901_ Series Modulation Analyzer. The method of choice is the R-2670 analyzer. 1. Initial set up using the R-2670 Communication Analyzer: - Connect a BNC cable between the “DEMOD OUT” port and the “VERT/SINAD DIST/DMM COUNTER IN” port on the R-2670. - Press the SPF key on the R-2670 to display the “SPECIAL FUNCTIONS MENU.
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6-22 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 5. Left-click the PTT Toggle button on the screen to make the radio transmit. Wait approximately 5 seconds until the deviation/voltage displayed on the analyzer stabilizes. The screen indicates whether the radio is transmitting. 6. Adjust the deviation limit to within 0.158 to 0.163 Vac on the R-2670 (2.785 to 2.885 kHz). The optimum setting is 0.160 Vac (2.83 kHz). 7.
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Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-23 Figure 6-18. Bit Error Rate Test Screen 6.3.8 Transmitter Test Pattern This screen is used to transmit specific test patterns at a desired frequency so that the user can perform tests on the radio’s transmitter and contains the following fields: • Tx Frequency: This field selects the Transmit Frequency directly in MHz. • Channel Spacing: This field allows the user to select the desired transmit deviation.
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6-24 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Notes February 3, 2003 6881076C20-E
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Chapter 7 Encryption 7.1 Universal Crypto Module Kits This information applies to both conventional and trunked systems. The following tables contain the Universal Crypto Module (UCM) kits for the ASTRO Digital Spectra and Digital Spectra Plus radios. 7.1.1 ASTRO Digital Spectra Table 7-1. ASTRO Digital Spectra UCM Listing Kit Number 7.1.
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7-2 Encryption: Load an Encryption Key • The secure status annunciator not lit (OFF) indicates that the transmitted signal is nonencrypted. Whether the current personality is strapped for secure or clear, the secure status annunciator correctly displays the transmit operation as being either secure (encrypted) or clear (non-encrypted). NOTE: You cannot change from secure to clear while the PTT button is pressed. The radio will generate an illegal tone and the transmission will be terminated.
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Encryption: Erase a Key 7.2.2 7-3 Models W4, W5, W7, and W9 To load an encryption key into a Model W4, W5, W7, or W9 radio: 1. Turn on the radio and set the volume level. The position of the D button is not important. 2. Connect the cable from the key-variable loader (KVL) to the microphone connector on the radio. 3. Load an encryption key into the radio’s memory from a KVL using the correct loader for the radio’s encryption type. Refer to your KVL user’s manual for more information on keyloading. 7.
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7-4 7.3.2 Encryption: Erase a Key Models W4, W5, W7, and W9 The Select Key to Erase feature allows you to manually select any one, or all, of the encryption keys to erase. 1. To enter the Advanced Secure menu, press and hold the button until a tone sounds.
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Encryption: Erase a Single Key (Model W3) 7.4 7-5 Erase a Single Key (Model W3) To erase a single key: 1. Press the button below SNGL to request erasure of the selected key. ERASE SNGL KEY, YES and NO are displayed. 2. Press the button below YES. The internal selected key is set to zero. ERASED is alternately displayed with the key name confirming the erasure. 3. To exit the menu without erasing a key, press the m button below ABRT, or the PTT button, or the mode button, or O.
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7-6 7.5.2 Encryption: Over-the-Air Rekeying Models W4, W5, W7, and W9 1. To enter the Advanced Secure menu, press and hold the button until a tone sounds.
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Encryption: Over-the-Air Rekeying 7.6.1 7-7 ASTRO Digital Spectra Model W3 1. Press until REKY appears. 2. Press below REKY. REQUEST REKY is displayed. 3. Press the PTT button to send the rekey request. PLEASE WAIT is displayed. 4. One of the following occurs: The radio sounds five tones when the dispatcher has received the request. NOTE: Any subsequent pressing of the PTT button will exit the feature and allow you to transmit in the normal manner.
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7-8 Encryption: Over-the-Air Rekeying If the display shows NO ACK and a bad-key tone sounds, then the dispatcher has not acknowledged your request after the radio has tried five times to send it. The radio then returns to the display message in step 2, allowing you to retry the request. If the request is accepted and the radio is successfully rekeyed, the display momentarily shows REKEYED.
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Encryption: Over-the-Air Rekeying 7.6.2 7-9 ASTRO Digital Spectra Models W4, W5, W7, and W9 1. To enter the Advanced Secure menu, press and hold the button until a tone sounds.
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7-10 Encryption: Advanced Secure Operation 5. One of the following occurs: If the radio receives an acknowledgment from the dispatcher, five tones sound. If the radio does not receive an acknowledgment from the dispatcher, the display shows NO ACK. After the radio is rekeyed, it displays REKEYED and returns to dispatch mode. If the dispatcher does not allow it to be rekeyed, the radio displays DENIED and returns to dispatch mode after three seconds. 6. Press to exit and return to normal operation. 7.
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Chapter 8 Disassembly/Reassembly Procedures 8.1 Introduction This section details the procedures necessary to remove and replace the printed circuit boards in the ASTRO Digital Spectra and Digital Spectra Plus radios. After troubleshooting and determining which board needs to be replaced, disconnect the test equipment, the antenna cable, and unhook the dc power. ! WARNING Disconnect all dc power to the radio before removing any boards from the radio.
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8-2 8.2.1 Disassembly/Reassembly Procedures: Replacement Procedures Required Tools and Supplies Table 8-2. Required Tools and Supplies Tools and Supplies Small, flat-blade screwdriver 2.5 mm hex-key driver Torx® T8, T10, and T15 drivers 3.0 mm Allen wrench Thermal compound (Motorola part number 11-83166A01, or equivalent) Electromagnetic Interference (EMI) metallic shielding tape (Motorola part number 11-85984D01, or equivalent) 8.2.2 Control Head Boards 8.2.2.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-3 11. Remove the circuit board assembly from the housing. 12. Remove the keypad [6] from the housing assembly [7]. 8.2.2.2 Models W4, W5, and W7 NOTE: For the following procedure, refer to Chapter 11: Exploded Views and Parts Lists, beginning on page 11-3, for the exploded view and associated parts list applicable to the model being disassembled. 1. Unplug the microphone. 2. Remove the two front panel screws using a 2.5mm hex-key driver. 3.
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8-4 Disassembly/Reassembly Procedures: Replacement Procedures 7. Carefully separate the printed circuit board, internal spacer, and elastomer keypad assembly from the front panel. On rotary control head models, care must be taken not to damage the flex circuit when separating the printed circuit board from the front housing. Do not disturb the buttons in the front panel. On rotary control head models, the flex circuit must also be unplugged. 8.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-5 3. Using a Torx T10 driver, remove the five 8mm tapping screws [17] from the Display Board Kit [37], the two 10mm captive screws [12] with the leaf assembly spring [11], and the two 16mm tapping screws [38] from the control PC board. 4. Remove the Command Board Kit [36] from the back housing and the Display Board Kit [37] from the front housing. 5.
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8-6 8.2.4 Disassembly/Reassembly Procedures: Replacement Procedures Remote Interconnect Board 8.2.4.1 Low-/Mid-Power Radios 1. Remove the two front panel screws using a 2.5mm hex key driver. 2. Grasp the front panel firmly, and carefully unplug it from the radio. 3. Remove the three screws that hold the remote interconnect board to the front panel using a Torx T10 driver. 4. Install the new remote interconnect board onto the front panel, and replace the screws. Torque the screws to 6-8 in.-lbs.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-7 13. Fold the ribbon cable down flat. Replace the top cover and torque the two screws to 6-8 in.lbs. These screws are self-tapping and caution should be used so that the screws enter the previously cut threads. 8.2.5 Power Amplifier Board 8.2.5.1 Low-/Mid-Power Radios 1. Use a Torx T15 driver to remove the four screws from the PA cover, and then remove the cover and the PA shield. 2. Use a metric 3.
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8-8 Disassembly/Reassembly Procedures: Replacement Procedures NOTE: Before disconnecting, note which RF cable goes to the VCO (TX injection) and which goes to the RX front end. This will facilitate assembly. 12. Apply a thin white coat of thermal compound (for example, Motorola part no. 11-83166A01) in the power transistor mounting locations of the chassis where the thermal compound was removed. 13.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-9 6. Use a Torx T15 driver to remove the larger screws. (Five screws are used on 15-watt, six on the 20- and 35-watt.) 7. Carefully lift the PC board from the heatsink. NOTE: Before unsoldering the RF cables, note which cable is attached to each connector on the board. This will facilitate assembly since the cables differ in length. 8. Unsolder the antenna coax cable attached to the bottom of the board. 9.
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8-10 Disassembly/Reassembly Procedures: Replacement Procedures APPLY TERMINAL COMPOUND HERE 6 5 PASS DEVICE INSULATION HERE 2 3 4 1 Figure 8-4. PA Board Screw Fastening Sequence (800 MHz 20- and 35-Watt PA) 7. Place the power module shield over the power module. 8. Install the power module and shield with two compression washers and screws (torque 6-8 in.-lbs.). 9. 20- and 35-watt radios only (Figure 8-5): Solder the final device leads and five caps.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-11 7. Tighten the mounting screws (torque 8-10 in.-lbs.). 8. 20- and 35-watt radios only: Press the PA compartment shield, and install the PA cover. 8.2.6 VOCON (Vocoder/Controller) Board NOTE: If you want to keep the information currently stored in the radio code plug, save its contents with the appropriate application software before you remove the original VOCON board.
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8-12 Disassembly/Reassembly Procedures: Replacement Procedures 7. Carefully lift the command board from the housing, making sure that the floating header is with the RF board. 8. To reassemble the command board, apply a thin coat of thermal compound (for example, Motorola part no. 11-83166A01) to the audio amplifier mounting surface. NOTE: Do not use a thick coating of compound as it could degrade the thermal efficiency of the heatsink.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-13 17. Replace the section VOCON board shield and the top cover, and then torque the screws to 68 in.-lbs. 8.2.8 Receiver Front-End Board 8.2.8.1 Low-/Mid-Power Radio 1. Remove the radio top cover. 2. Remove the two mounting screws and unplug the control head. 3. Remove the EMI metallic shielding tape (Motorola Part No.11-85984D01). Be careful to prevent any tape particles from falling inside the chassis. 4.
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8-14 Disassembly/Reassembly Procedures: Replacement Procedures 9. Carefully remove the front-end receiver board from the radio chassis cavity and disconnect the coaxial cable beneath it. NOTE: Be careful to insert the Rx injection coaxial cable straight into the receptacle on the VCO board, and be sure it is fully inserted. Also, be careful to not bend the tip of the coaxial cable, which provides the contact for the connection.
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Disassembly/Reassembly Procedures: Replacement Procedures 8-15 8.2.9.2 High-Power Radio 1. Turn the radio topside down and remove the four bottom-cover screws, and remove the bottom cover. 2. Remove the power amplifier and RF board shields. 3. Remove the six VCO board shield screws and remove the VCO board shield. 4. Gently pry up on the VCO board, where it extends over the RF board, until the VCO board is disconnected from the RF board. 5.
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8-16 Disassembly/Reassembly Procedures: Final Reassembly 8.2.10.2 High-Power Radio 1. Turn the radio topside down, remove the four bottom-cover screws, and then remove the bottom cover. 2. Remove the six VCO board shield screws. 3. Remove the VCO board and the RF board shields from the radio chassis. 4. Gently pry up on the VCO board, where it extends over the RF board, until the VCO board is disconnected from the RF board. 5. Remove the six RF board screws, and then move the VCO board out of the way.
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Disassembly/Reassembly Procedures: Final Reassembly 8.3.2 8-17 Command Board NOTE: This assumes the PA is attached, the control head is detached, and the control head interconnect board is disconnected. 1. Before reassembly, apply a thin coat of thermal compound (for example, Motorola Part No. 11-83166A01) to the bottom of the audio PA. 2. Insert the command board into the PA accessory connector (J503) before inserting it into the RF board connector (P500).
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8-18 Disassembly/Reassembly Procedures: Fastener Torque Chart B. Pivot the circuit board’s display down under the retention features in the housing and rotate the board downward, ensuring that the board is positioned between the snap features. Ensure that the microphone assembly’s [8] wire passes through the opening in the circuit board. C. Press downward firmly on the board until the seven snap features lock the board into place. 5.
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Disassembly/Reassembly Procedures: Fastener Torque Chart 8-19 Table 8-3. Fastener Torque Chart (Continued) Part Number Description Repair Torque (in.-lbs.) Where Used 03-10943J15 Screw, tapping M3.
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8-20 Disassembly/Reassembly Procedures: Fastener Torque Chart Notes February 3, 2003 6881076C20-E
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Chapter 9 Basic Troubleshooting 9.1 Introduction This section of the manual contains troubleshooting charts, error codes, a functional block diagram, interconnect diagrams, and flexible circuit information. This section can help you isolate a problem to the board level. Board-level troubleshooting does not attempt to isolate problems to the component level. Component-level service information can be found in the ASTRO Digital Spectra and Digital Spectra Plus Mobile Radios Detailed Service Manual.
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9-2 9.3.1 Basic Troubleshooting: Power-Up Error Codes ASTRO Digital Spectra Table 9-1. ASTRO Digital Spectra Power-Up Error Codes Error Code Description Corrective Action 01/02 External EEPROM checksum non-fatal error Reprogram the codeplug. 01/81 ROM checksum failure Reprogram the FLASH memory. 01/82 External EEPROM checksum failure Reprogram the codeplug. 01/84 EEPROM is blank Program the EEPROM. 01/88 RAM failure - Note: not a checksum failure Turn the radio off, then on.
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Basic Troubleshooting: Power-Up Error Codes 9.3.2 9-3 ASTRO Digital Spectra Plus Table 9-2. ASTRO Digital Spectra Plus Power-Up Error Codes Error Code 6881076C20-E Description Error Type Corrective Action ERROR 01/02 FLASH ROM Codeplug Checksum NONFATAL Reprogram the codeplug. ERROR 01/12 Security Partition Checksum NONFATAL Reprogram the security partition. ERROR 01/22 Tuning Codeplug Checksum NONFATAL Reprogram the tuning partition.
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9-4 Basic Troubleshooting: Operational Error Codes Table 9-2. ASTRO Digital Spectra Plus Power-Up Error Codes (Continued) Error Code 9.4 Description Error Type Corrective Action FAIL 08/81 Siren ROM Checksum Error FATAL Replace the siren. ERROR 09/10 Secure Hardware Error NONFATAL Replace the secure module. FAIL 09/90 Secure Hardware Fatal Error FATAL Replace the secure module. ERROR 12/10 VRS Hardware Error NONFATAL Turn the radio off, then on.
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Basic Troubleshooting: Transmitter Troubleshooting 9.4.2 9-5 ASTRO Digital Spectra Plus Table 9-4. ASTRO Digital Spectra Plus Operational Error Codes Error Code 9.5 Description Error Type Corrective Action FAIL 001 Synthesizer Out-of-Lock NONFATAL 1. Reprogram codeplug 2. Replace RF board. FAIL 002 Personality checksum or system block error NONFATAL Reprogram codeplug.
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9-6 Basic Troubleshooting: Transmitter Troubleshooting Table 9-5. Transmitter Troubleshooting Chart (Continued) Symptom No Modulation Possible Cause VCO Board Correction or Test (Measurements Taken at Room Temperature) 1. All modulation testing should be done with the radio keyed and 1Vrms on the microphone high line of the microphone. 2. Is radio properly tuned? (See Chapter 6. Radio Alignment Procedure.) 3. Is there > 400 mVrms at J500 pin 11? If so, replace the VCO board.
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Basic Troubleshooting: Transmitter Troubleshooting 9-7 Table 9-5. Transmitter Troubleshooting Chart (Continued) Symptom Bad Microphone Sensitivity No/Low signaling (PL, DPL, Trunking, MDC) 6881076C20-E Possible Cause Correction or Test (Measurements Taken at Room Temperature) Check Deviation and Compensation Retune, if necessary. Microphone Speak loudly into the microphone while monitoring the microphone line (pin 6 of P502). If it is not >80 mVrms, then replace the microphone.
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9-8 Basic Troubleshooting: Transmitter Troubleshooting Table 9-5. Transmitter Troubleshooting Chart (Continued) Symptom Can’t Set Compensation Possible Cause Correction or Test (Measurements Taken at Room Temperature) VOCON Board Vary deviation and compensation controls from maximum to minimum. With the low frequency source active (using the appropriate radio programming software–see Chapter 6: Radio Alignment Procedure) voltage or pin 48 of P501 should vary from <100 mVrms to >3 mVrms.
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Basic Troubleshooting: Receiver Troubleshooting 9.6 9-9 Receiver Troubleshooting The following table can help you troubleshoot problems that might occur in the receiver section of your radio. Table 9-6. Receiver Troubleshooting Chart Symptom Radio Dead, Display Does Not Light Up Radio Dead, Display Lights Up Possible Cause Correction or Test (Measurements Taken at Room Temperature) Blown Fuse Check fuse in red lead of power cable (or green lead if used.
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9-10 Basic Troubleshooting: Receiver Troubleshooting Table 9-6. Receiver Troubleshooting Chart (Continued) Symptom No Receiver Audio or Receive Does Not Unsquelch Audio Distorted or Not Loud Enough February 3, 2003 Possible Cause Audio PA Circuit Correction or Test (Measurements Taken at Room Temperature) 1. Check codeplug to ensure correct frequency and signaling (PL, DPL) is enabled (use the appropriate radio programming software). 2. Check continuity of F500 on command board.
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Basic Troubleshooting: Receiver Troubleshooting 9-11 Table 9-6. Receiver Troubleshooting Chart (Continued) Symptom RF Sensitivity Poor Possible Cause Correction or Test (Measurements Taken at Room Temperature) Synthesizer Not On Frequency/Working Check local oscillator frequency. If off by more than 250 Hz, then go to the Synthesizer Troubleshooting Chart (page 9-12). Antenna Switch (Amplifier Board) Check insertion loss from antenna connector to Rx front end coax from the PA.
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9-12 Basic Troubleshooting: Synthesizer Troubleshooting NOTE: The P501 pins can be probed on the extender cable (see the P501 Extender Cable diagram on page 10-6). 9.7 Synthesizer Troubleshooting The following table can help you troubleshoot problems that might occur in the synthesizer section of your radio. Table 9-7.
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Basic Troubleshooting: Synthesizer Troubleshooting 9-13 Table 9-7. Synthesizer Troubleshooting Chart (Continued) Correction or Test (Measurements Taken at Room Temperature) Symptom Possible Cause Synthesizer Malfunctioning Synthesizer Not Locked Check the synthesizer lock line (pin 14 of J500). If > 1 V, then the synthesizer is not locked. Go to Does Not Lock on Some Channels above. Reference Oscillator Not On Frequency/ Working 1. Check the reference oscillator frequency. It should be 16.
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9-14 Basic Troubleshooting: Synthesizer Troubleshooting Notes February 3, 2003 6881076C20-E
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Chapter 10 Functional Block Diagrams and Connectors This chapter contains the ASTRO Digital Spectra and Digital Spectra Plus functional block diagrams and connector locations.
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10-2 Functional Block Diagrams and Connectors: Digital Spectra Functional Block Diagram (Models W3, W4, W5, W7, and W9) 10.
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Functional Block Diagrams and Connectors: Digital Spectra Plus Functional Block Diagram (Models W3, W4, W5, W7, and W9) 10-3 10.
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10-4 Functional Block Diagrams and Connectors: Radio Connectors 10.
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Functional Block Diagrams and Connectors: Radio Connector Locations 10-5 10.4 Radio Connector Locations 10.5 Radio Connector Locations (cont.) COMMAND BOARD (VIEWED FROM SIDE 1) DASH-MOUNT RADIO ANTENNA J2 PWR P503 14 2 1 P502 F500 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 PWR Mod e 0 Vol Phon U450 Scan Call DIM 26 25 13 Sel 1 HOME XMIT BUSY 4 Sts 7H/L Rcl P104 2 5 8 Mon 3 6 Msg 24 13 19 J500 1 12 6 9 Dir Del 2 1 30 50 0 25 P501 49 MAEPF-24496-O Figure 10-8.
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10-6 Functional Block Diagrams and Connectors: Extender Cable (P501) 10.6 Extender Cable (P501) 10.
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Chapter 11 Exploded Views and Parts Lists This chapter contains the exploded views and associated parts lists for each of the ASTRO Digital Spectra and Digital Spectra Plus control heads. Tables containing pushbutton parts lists are also included.
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11-2 Exploded Views and Parts Lists: Model W3 Hand-Held Control Head Exploded View 11.1 Model W3 Hand-Held Control Head Exploded View Table 11-1. Model W3 Hand-Held Control Head Exploded View Parts List Item No. 1 2 3 4 4 Motorola Part No.
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Exploded Views and Parts Lists: Model W4 Rotary Control Head Exploded View 11-3 11.2 Model W4 Rotary Control Head Exploded View Table 11-2. Model W4 Rotary Control Head Parts List Item No. Figure 11-2. Model W4 Rotary Control Head Exploded View 6881076C20-E Motorola Part No.
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11-4 Exploded Views and Parts Lists: Models W5 and W7 Pushbutton Control Head Exploded View 11.3 Models W5 and W7 Pushbutton Control Head Exploded View Table 11-3. Models W5 and W7 Pushbutton Control Head Parts List Item No. Figure 11-3. Models W5 and W7 Pushbutton Control Head Exploded View Motorola Part No.
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Exploded Views and Parts Lists: Model W9 Pushbutton Control Head Exploded View 11-5 11.4 Model W9 Pushbutton Control Head Exploded View Table 11-4. Model W9 Pushbutton Control Head Parts List (Continued) Item No. Figure 11-4. Model W9 Pushbutton Control Head Exploded View Table 11-4. Model W9 Pushbutton Control Head Parts List Item No. 6881076C20-E Motorola Part No.
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11-6 Exploded Views and Parts Lists: Low-Power (15W) Radio Exploded View 11.5 Low-Power (15W) Radio Exploded View Table 11-5. Low-Power (15W) Radio Parts List (Continued) Item No. Figure 11-5. Low-Power (15W) Radio Exploded View Table 11-5. Low-Power (15W) Radio Parts List Item No. February 3, 2003 Motorola Part No. Description Motorola Part No.
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Exploded Views and Parts Lists: Mid-Power (20-40/25-50/35W) Radio Exploded View 11.6 Mid-Power (20-40/25-50/35W) Radio Exploded View 11-7 Table 11-6. Mid-Power (20-40/25-50/35W) Radio Parts List Item Motorola Description No. Part No. Table 11-6. Mid-Power (20-40/25-50/35W) Radio Parts List Item Motorola Description No. Part No. 1 0312016A27 SCREW, Tapping 3.5 x 0.
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11-8 Exploded Views and Parts Lists: High-Power (50-110W) Radio Exploded View 11.7 High-Power (50-110W) Radio Exploded View Table 11-7. High-Power (50-110W) Radio Parts List Item No. 7 Figure 11-7. High-Power 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 (50-110W) Radio Exploded View 46 Table 11-7. High-Power (50-110W) Radio Parts List 47 48 Item Motorola Description 49 No. Part No. 1 0312016A27 SCREW, Tapping 3.5 x 0.
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Exploded Views and Parts Lists: Motorcycle Interconnect Board and Assembly 11-9 11.8 Motorcycle Interconnect Board and Assembly 11.9 Low- and Mid-Power Interconnect Board and Assembly 7 7 6 6 8 5 10 4 8 5 9 9 10 4 3 3 2 2 1 1 11 MAEPF-27269-O MAEPF-27270-O Figure 11-8. Motorcycle Interconnect Board and Assembly (HLN6365) Exploded View Figure 11-9. Low- and Mid-Power Interconnect Board and Assembly (HLN6344) Exploded View Table 11-8.
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11-10 Exploded Views and Parts Lists: Small Pushbutton Parts 11.10 Small Pushbutton Parts 11.11 Large Pushbutton Parts Table 11-10. Small Pushbutton Parts List Graphic Legend Part Number Part Number Graphic Legend 3805671X02 1 3805671X21 9wxy 3805671X03 2 3805671X22 * Rcl 3805671X04 3 3805671X23 #Del 3805671X05 4 3805671X24 1Ste Table 11-11. Large Pushbutton Parts List (Continued) Table 11-11.
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Appendix A A.1 Replacement Parts Ordering Basic Ordering Information When ordering replacement parts or equipment information, the complete identification number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufficient description of the desired component to identify it.
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A-2 A.5 Replacement Parts Ordering Telephone Orders Telephone Orders Customer Care and Services Division* (United States and Canada) 7:00 AM to 7:00 PM (Central Standard Time) Monday through Friday (Chicago, U.S.A.) 1-800-422-4210 1-847-538-8023 (International Orders) U.S. Federal Government Markets Division (USFGMD) 1-800-826-1913 Federal Government Parts - Credit Cards Only 8:30 AM to 5:00 PM (Eastern Standard Time) A.
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Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to ASTRO portable and mobile subscriber radio products. Term Definition A/D See analog-to-digital conversion. Abacus IC A custom integrated circuit providing a digital receiver intermediate frequency (IF) backend. ADC See analog-to-digital converter. ADDAG See Analog-to-Digital, Digital-to-Analog and Glue. ALC See automatic level control.
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Glossary-2 Term Definition CPS See Customer Programming Software. Customer Programming Software Software with a graphical user interface containing the feature set of an ASTRO radio. See also RSS. D/A See digital-to-analog conversion. DAC See digital-to-analog converter. default A pre-defined set of parameters.
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Glossary-3 Term Definition Electrically Erasable Programmable Read-Only Memory A special type of PROM that can be erased by exposing it to an electrical charge. An EEPROM retains its contents even when the power is turned off. FCC Federal Communications Commission. firmware Code executed by an embedded processor such as the Host or DSP in a subscriber radio. This type of code is typically resident in non-volatile memory and as such is more difficult to change than code executed from RAM.
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Glossary-4 Term Definition inbound signaling word Data transmitted on the control channel from a subscriber unit to the central control unit. integrated circuit An assembly of interconnected components on a small semiconductor chip, usually made of silicon. One chip can contain millions of microscopic components and perform many functions. ISW See inbound signaling word. key-variable loader A device used to load encryption keys into a radio. kHz See kilohertz.
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Glossary-5 Term Definition MOSI See Master Out Slave In. multiplexer An electronic device that combines several signals for transmission on some shared medium (e.g., a telephone wire). MUX See multiplexer. NiCd Nickel-cadmium. NiMH Nickel-metal-hydride. OMPAC See over-molded pad-array carrier. open architecture A controller configuration that utilizes a microprocessor with extended ROM, RAM, and EEPROM.
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Glossary-6 Term Definition PTT See Push-to-Talk. Push-to-Talk The switch or button usually located on the left side of the radio which, when pressed, causes the radio to transmit. When the PTT is released, the unit returns to receive operation. radio frequency The portion of the electromagnetic spectrum between audio sound and infrared light (approximately 10 kHz to 10 GHz). radio frequency power amplifier Amplifier having one or more active devices to amplify radio signals.
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Glossary-7 Term Definition RPCIC Regulator/power control IC. RPT/TA See repeater/talkaround. RSS See Radio Service Software. RTC See real-time clock. RX Receive. RX DATA Recovered digital data line. SAP See Serial Audio CODEC Port. SCI IN Serial Communications Interface Input line. Serial Audio CODEC Port SSI to and from the GCAP II IC CODEC used to transfer transmit and receive audio data.
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Glossary-8 Term Definition Standby mode An operating mode in which the radio is muted but still continues to monitor data. static RAM A type of memory used for volatile, program/data memory that does not need to be refreshed. Synchronous Serial Interface DSP interface to peripherals that consists of a clock signal line, a frame synchronization signal line, and a data line.
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Glossary-9 Term Definition vocoder An electronic device for synthesizing speech by implementing a compression algorithm particular to voice. See also voice encoder. vocoder/controller A PC board that contains an ASTRO radio’s microcontroller, DSP, memory, audio and power functions, and interface support circuitry. voice encoder The DSP-based system for digitally processing analog signals, and includes the capabilities of performing voice compression algorithms or voice encoding. See also vocoder.
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Glossary-10 Notes February 3, 2003 6881076C20-E
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Index Index Numerics 800 MHz radio specifications ............................... xxxviii A advanced secure operation .....................................7-10 alignment procedures RSS BER (bit error rate) performance check ...........6-10 introduction .........................................................6-1 reference oscillator .............................................6-3 transmit current limit ...........................................6-6 transmit deviation balance ............................
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Index-ii ASTRO Digital Spectra Plus .................................. 4-7 equipment ............................................................. 4-5 FLASHport technology .............................................. 1-2 frequencies, test ....................................................... 5-4 front-end receiver theory of operation ....................... 3-5 front-panel access test-mode displays ...................... 5-2 H handling precautions .................................................
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Index-iii small .................................................................. 11-10 R radio descriptions ........................................................... 1-1 features ................................................................. 1-2 information screen ............................................... 6-14 upgrading with FLASHport .................................... 1-2 reassembly command board .................................................. 8-17 dash control-head board ...............
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Index-iv current limit alignment RSS ................................................................... 6-6 tuner ................................................................ 6-18 current limit alignment screen RSS ................................................................... 6-6 tuner ................................................................ 6-18 deviation balance (compensation) alignment RSS ................................................................... 6-7 tuner ..................
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Motorola, Inc. 8000 West Sunrise Boulevard Ft. Lauderdale, FL 33322 MOTOROLA, the Stylized M Logo, ASTRO, and Spectra are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners. © Motorola, Inc. 2002, 2003. All rights reserved. Printed in U.S.A.