A Guide to ASTRO™ Digital Radios R03.00.00 – August 2007 Authored by r0f Note: This guide is NOT supported by Motorola Inc., nor does Motorola Inc. necessarily condone any information contained within, although it’s probably better than anything they could/would/should put out. The information is provided as-is for educational benefit only.
Table of Contents Preface ............................................................................................................................................................3 History .............................................................................................................................................................4 Model-specific Discussion: ASTRO™ Legacy Series ......................................................................................6 ASTRO Digital Saber™ ...
Preface The guide encompasses many modularized pieces of information which are scattered throughout Internet discussion boards, Motorola Inc. radio service manuals, service bulletins, technical briefs and personal technical notes assembled over the last six years. It is meant to serve as a technical outline and basis of understanding, to be used by radio-hobbyists, system planners and others who have an interest in learning about Motorola Inc.’s ASTRO™ and ASTRO25™ radio platforms.
History Development of Motorola Inc.’s ASTRO™ products began sometime around 1992. This is evidenced through reference to the 1992 time-line in all versions of product firmware at address C03Dh. Figure 1.1 Screen-shot of host firmware code referencing 1992 development. It is believed Motorola Inc.’s first ASTRO™ product, the ASTRO Digital Saber™, was released in 1995. When it was introduced, it was marketed to the U.S.
Figure 1.3 Voice coder vs. channel condition evaluation. The evaluation of four 7.2 kbps speech coders by the Telecommunications Industry Association (TIA) for the purpose of selecting a speech coder for the APCO Project 25 North American land mobile radio communication system produced the above results. During this evaluation, the IMBE™ Vocoder outperformed all codecs in every category. (Source: DVSI) Motorola Inc. engineers worked with DVSI to implement the IMBE™ codec into the ASTRO™ radio platform.
Model-specific Discussion: ASTRO Legacy Series ASTRO Digital Saber™ As stated earlier in the guide, Motorola Inc.’s flagship ASTRO™ radio was the ASTRO Digital Saber™ which was released in approximately 1995. Figure 2.1 Motorola Inc.’s ASTRO Digital Saber™ (Model III) The ASTRO Digital Saber™ comes in four different band-splits. The VHF “K” split (136-174 MHz), the UHF range 1 “R” split (403-470 MHz), the UHF range 2 “S” split (450-520 MHz) and the 800 MHz “U” split (806-870 MHz).
There are two versions of the ASTRO Digital Saber™: Versions manufactured prior to November 1996—which contain a 512K vocon board and models manufactured post-November 1996, which contain a 1-meg vocon board. What’s the difference? 512K vocons utilize three flash ROMs—two 256K flash ROMs (512K) for storage of the host firmware, and one 256K flash ROM for storage of the DSP firmware. 1-meg vocons utilize a 1MB flash ROM to store the host firmware and one 256K ROM to store the DSP firmware. Figure 2.
310AXA0399 The serial number can be broken down into sub-components which identify the year and week of the original production. You may ignore the 310A (first four digits) of the serial number. Digit five (X) of the example serial number identifies the year of manufacture. In year 2000, Motorola Inc. started their alphabet calendar from “A”. So a radio with an (X) representing the build year, indicates a manufacture year of 1998.
Another method of obtaining information about an ASTRO Digital Saber’s™ firmware version/revision,encryption module firmware, encryption algorithms, band-split, serial number, vocon size and FLASHport features is to put it in service mode. This is accomplished by powering on the radio, and pressing the “..” button on the side of the radio five times, within the first 10 seconds of completing the SELF TEST sequence. The radio will beep once and show SERVICE on the display.
XTS 3000™ Released in 1996, this was Motorola Inc.’s first Cosmo-series portable radio. It is compatible with nearly all Jedi-series audio accessories, including speaker-mics, hirose adapters, key-loading cables, 3.5mm threaded earphone adapters and other surveillance accessories. (Desirable at the time because of the MTS 2000™ popularity) Figure 3.1 Motorola Inc.’s XTS 3000™ (Model III) with speaker-mic. The XTS 3000™ comes in identical band-splits as the ASTRO Digital Saber™.
Figure 3.2 A photo illustration of various PC boards found inside of the Motorola Inc. XTS 3000™. The NTN9121A encryption module is of the new UCM (version R03.xx firmware) generation. Note the lack of a “vocon” (combined vocoder-controller) board, which is only found in the ASTRO Digital Saber™ and ASTRO Digital Spectra™ products. Much confusion surrounds this issue on various Internet discussion forums.
Figure 3.3 A photo illustration of the two different flex connectors used on Motorola Inc. XTS 3000™ controller boards. This connector interfaces the user-electronics (knobs, buttons and switches) to the radio. Type “B” connectors are the most common. Type “A” connectors are rare and found only in early-production radios with older controller boards. Note the brittle design of the type “A” connector, which is susceptible to damage during the removal process. As Motorola Inc.
XTS 3500 The Motorola Inc. XTS 3500 was introduced as a bastard cousin to the XTS 3000. It was a supposed stepping-stone to the XTS 5000. The purpose was to increase the CPU speed and provide Type 1 encryption support—or at least that’s what the rumour was. Figure 4.1 A photo illustration of a Motorola Inc. XTS 3500 portable radio. It is identical in appearance to the XTS 3000, except it has a purple keypad and a different model number sticker above the speaker-grill.
ASTRO Digital Spectra™ The ASTRO Digital Spectra™ was released in approximately 1995. It shares the same vocon design as the ASTRO Digital Saber™, however the boards are not compatible with each other. ASTRO Digital Spectras™ manufactured prior to November 1996 included 512K of flash ROM memory for the host firmware. The same story of the ASTRO Digital Saber’s™ evolution to a 1M flash ROM and the vocon swap-outs after a depot visit also apply to the ASTRO Digital Spectra™.
Figure 5.2 A photo illustration of a model number tag on the rear of a Motorola Inc. ASTRO Digital Spectra™. There are several useful pieces of information displayed in the tag, including the model number, serial number, manufacture code (FLASHport™), host firmware flash ROM size (1M) and indication of a 2.5 KHz narrow-band RF board. The ASTRO Digital Spectra™ has been through many different revisions of command boards. The command board is what interfaces the vocon to the control head, PA and RF boards.
Figure 5.4 A photo illustration which identifies various components which must be replaced or discarded. (Modifications have already been performed in this example.) Point 1 is C562. Remove and discard. Point 2 is VR403. The original part number is 4813830A22—a 9.1V Zener. You must replace it with 4813830A26—a 13V Zener diode. Point 3 is R520 (10K). The original part number is 0611077A98. You must replace it with 0611077A74—a 1K chip resistor. Point 4 is C334 on the RF board.
Note not all command boards must be modified. Newer production boards have had modifications/changes made at the factory. If your serial number indicates a pre-2000 radio, you must perform all modifications. Radios made in 2000 and 2001 (A and B in 5th place of serial number) must have C562 from the command board and C334 from the RF board removed. No further modifications are required. Do a physical inspection of the command board if in doubt.
The W4 control-head can also be modified to disable the ignition-sense. JU1 and JU2 must be installed. Figure 5.8 blown-up schematic illustration of 0-ohm chip resistors JU1 and JU2 which must be installed on the Motorola ASTRO Digital Spectra™ W4 control-head if the ignition-sense circuit is to be disabled. The ASTRO Digital Spectra™ is available in low-power (15W) motorcycle versions, mid-power 4050W versions and 110W remote/trunk-mount high-power versions.
Model-specific Discussion: ASTRO25 Series XTS 5000™ This is the first ASTRO25™-series portable released to the market back in approximately late 2003. It may look similar to the Motorola Inc. XTS 3000™ portable, but under the case is a far superior radio. The Patriot IC is the powerhouse of the radio. It’s a dual-core processor which contains both a 32-bit micro-controller unit (MCU) and a 16-bit digital signal processor (DSP) in one IC package.
With this said, the Motorola Inc. ASTRO25™ line has been compromised. There exists a very covert market which offers XTS 5000™ portables with nearly all FLASHport™ features enabled, latest host and DSP firmware and legitimate serial numbers. While there is no definite source for these radios, they do appear for sale on eBay and certain radio-related Internet discussion boards from time-to-time. The value of a featureless XTS 5000™ with old host and DSP firmware (anything below R07.xx.xx) is about $1000 US.
There’s also a Q53 FPP FLASHport™ option which requires an external hardware key for operation. This is similar to the aged JT 1000™ Jedi-series portable operation. Q53 is an option for nongovernment users, however many have reported having no troubles ordering Q52, even if they’re not qualified as government customers. It’s also said Q53 is required for the Radio Cloning feature. The XTS 5000™ supports Type 1 encryption algorithms, which are used to convey secret and topsecret communications exchanges.
Figure 6.4 A Motorola Inc. NNTN5032 UCM (hardware encryption module) for the XTS 5000™. The NNTN5032 modules can be ordered with any Type 3 encryption algorithm. Care must be exercised when purchasing these modules on eBay or from other Internet sources as they could be blank, have AES-256 only, or contain other unwanted algorithms contrary to what the seller is advertising. Avoid “I think it is” auctions. There are many eBay auctions which offer NNTN5032 encryption modules for sale.
Figure 6.5 A photo illustration of an XTS 5000™ with the location-data feature enabled, with a HMN4080A GPS-capable speaker-microphone attached. Note the awkward and dysfunctional display format of the data, which is not supported by many third-party mapping applications. When configured as such, the user may opt to disable the data feature (OFF) so the radio does not send GPS data over the air.
Figure 6.7 A photo illustration of a Motorola Inc. XTS 5000™ engaged in the TMS menu. Recipients and message templates may be predefined in CPS. Note THE_ALEX is the recipient of the corresponding message. Hobbyist “akardam” has prepared a most useful and comprehensive guide about using and configuring the TMS feature. It may be downloaded at the following URL: http://www.akardam.net/moto/docs/xts5k-tms.
XTS 2500™ The Motorola Inc. XTS 2500™ is a compact version of the XTS 5000™. It utilizes waris-series batteries, but has a jedi accessory connector. Figure 7.1 A photo illustration of a Motorola Inc. XTS 2500 portable radio, in a model III configuration. According to Motorola Inc., the XTS 2500™ supports 512 modes, whereas the XTS 5000™ supports 850. Another difference is the lack of Type 1 encryption algorithm support. Motorola Inc.
XTS 4000™ Supposedly, this is an SP product developed for a federal agency. The design mimics an iDEN™ phone, and offers very discrete operation when compared to a bulky ASTRO™ or ASTRO25™ portable. Figure 8.1 An illustration of the XTS 4000™, taken from an FCC document. At the time of its release, the XTS 4000™ was only available in VHF. It supports encryption (unknown if Type 1 is supported) and all trunking features. It programs with the ASTRO25™ portable programming software.
XTS 1500™, SSE 5000™, XTL 2500™, XTL 1500™, XTL 2500™, XTL 5000™, MT 1500™, PR 1500™and Digital Spectra Plus™ Not enough information about these radios is known, however they function identical to other Motorola Inc. ASTRO™ and ASTRO25™ products, with the exception being they do not support the Q52/Q53 FPP options—or at least there is no documentation advertising as such. These radios program with the ASTRO25™ series mobile and portable CPS. The XTL 5000™ supports Type 1 encryption algorithm operation.
Radio Operating System (ROS) and DSP Firmware Discussion ASTRO™ Firmware Motorola Inc. ASTRO™ and ASTRO25™ radios function much like computer. They require an operating system to function. The Digital Signal Processor (DSP) also has its own code which consists of instructions on how to process calls. These could be a mixture of analog, IMBE™ or VSELP communications. Firmware updates are applied to Motorola Inc. ASTRO™ and ASTRO25™ products via a FLASHport™ upgrade.
or EEPROM which stores the CSD. At the time this guide was written, this statement applies only to Motorola Inc. ASTRO™ series radios. ASTRO25™ radios are not manipulated using the same process. More is discussed later in the guide. The first version of host firmware ever released is unknown. The earliest version I’ve come across is cp_D01.04.00. Another confirmed VSELP revision is ap_R03.20.01. are internally dated as ©1996 by Motorola Inc. I’m inclined to believe there’s much earlier firmware than this.
DSP firmware capabilities also depend on the revision letter which prefixes the major release number. They are: DSP Firmware Revision A F I M N Notes Analog only. Paired with N/F. Analog/digital. Field testing? Paired with A/N Analog/digital operation. Paired with M. Anaog only. Paired with I. Analog/digital. Paired with A/F. F revision DSP firmware is extremely rare. It has been paired with host version D08.97.26 in a Motorola Inc. ASTRO Digital Spectra™, configured as a dedicated RF modem.
R07.01.00 R07.01.00 continued… XTS 3000™ / ASTRO Digital Saber™ trunked priority talkgroup scan problem. (missed calls) SRN1330. XTS 3000™ displays "REMOTE" on screen when removed from XTVA. Upgrade to R07.01.00 or later. SRN1320 R07.01.01 – R07.07.00 ASTRO Digital Saber™, XTS 3000™ Equipped with DVP-XL may experience missed words. SRN1368 R07.01.01 and newer Transmit Audio Gain Control (AGC) is introduced.
R09.50.00-R11.06.02 cont… mode, with 12.5 KHz and 25 KHz channels mixed in scan list, and receiving weak signals. SRN1354 R09.60.04 Highest firmware version that installs on 512K ASTRO Digital Spectra™ vocons. R11.01.01 Transmit Audio Gain Control (AGC) is introduced. This is the most significant enhancement to digital audio on ASTRO digital systems ever implemented. SRN1370 (April 2002) R11.01.01 – R11.07.00 ASTRO Digital Spectra™ trunked priority talkgroup scan problem. (missed calls) SRN1330.
07.xx.xx continued… AGC enabled in codeplug. Reproduced audio during packet-loss is quiet and at times muted. 08.xx.xx A major improvement in audio tone for both analog and digital (IMBE™) audio recovery. When used with subscriber AGC, all levels are balanced. All ASTRO™ product users are encouraged to upgrade to DSP release 8. Current version is 08.03.03. ASTRO25 Radio Firmware Notes Enhancement/Change Host R04.00.00 & DSP R04.00.00 (11/10/2003) Trunked integrated voice and data is introduced.
Host R04.00.00 & DSP R04.00.00 continued… Subscriber is slow to unmute (35 sec.) upon channel change to an active talkgroup. Issue update. Subscriber unit occasionally switches sites after cycling power of mode change. Issue update. Subscriber unit stays on SmartZone™ site when user selects a SmartNet™ talkgroup. Issue update. ASTRO Digital Spectra Plus™ dual control-head initial volume is not set properly after turning ignition on. Issue update.
Host R04.00.00 & DSP R04.00.00 continued… CPS now supports the Advanced System Key (ASK). Enhancement. CPS now supports feature-level security. Enhancement. CPS now allows the 12.5 KHz offset frequencies. Issue update. CPS now allows the re-use of deleted sector ID's within the fireground accountability feature. Issue update. CPS now supports USB adaptor for FLASHkeys. Issue update. CPS incompatibility with other software. Known problem.
Host R04.50.00 & DSP R04.50.00 continued… Rekey request in conventional data-scan has been enhanced to send the request on the designated data-channel. Enhancement. Problem with multi-key subscribers scanning a scan-list with mixed analog and digital members. Issue update. Problems with various smart-PTT settings and telephone interconnect in conventional mode. Issue update. Audio-level changes several times when an XTS 5000™ is inserted into an XTVA during a call. Issue update.
Host R04.50.00 & DSP R04.50.00 continued… Portable radios with the commander microphone can experience large volume changes if radio volume control moved. Issue update. CPS now supports alternate table view. Enhancement. CPS now supports Frequency pick-lists for dialogs. Enhancement. CPS now supports channelannouncement feature. Enhancement. CPS now supports remote programming. Enhancement. CPS incompatibility with other software. Known problem.
Host R04.80.00 & DSP R04.80.00 continued… Host R04.80.01 & DSP R04.80.00 (9/30/2004) An inhibited XTL 5000™ intermittently becomes partially re-enabled if powered on while the automobile is started. Issue update. XTL 5000™ PTT does not work unless the rear control-head is selected as primary. Issue update. When in poor-coverage, radio sometimes emits a continuous talk-prohibit tone until power is cycled. Issue update. View OTAR IDs button added in CPS. Enhancement.
Host R04.80.01 & DSP R04.80.00 continued… XTS 5000™ will not pass audio on a system-wide call. Evacuation-tone not always sounded at full volume. Issue update. Host R04.80.02 & DSP R04.80.00 (10/13/2004) ASTRO Spectra Plus™ consolette non-priority indication is not selectable when in scan-list programming. Issue update. Host R05.00.00 & DSP R05.00.00 (12/6/2004) Introduction of the XTS 2500™ model 1.5. New model. Introduction of the XTL 5000™ VHF high-power mobile.
Host R05.00.00 & DSP R05.00.00 continued… 6.x user may hear static or crackling noises during silent periods while receiving a digital call at full volume. Issue update. 6.x subscriber will emit six tones while sending a call-alert. Issue update. CPS now supports clone express. New feature. CPS now supports incremental installs. New feature. CPS now supports channel picklist. New feature. CPS now supports remoteprogramming via Internet. New feature. CPS Advanced System Key enhanced.
Host R05.00.00 & DSP R05.00.00 continued… CPS problems when other serial communication software is open. Known problem. CPS problem with French version of Windows. Known problem. CPS problem closing dialog box. Known problem. Host R05.00.01 & DSP R05.00.00 (1/13/2005) XTS 5000™ with commander mic has no volume-control after power-up until the radio has unmuted once. Issue update. Host R05.01.00 & DSP R05.01.00 (3/15/2005) UHF high power XTL 5000™ introduced. New model.
Host R05.01.00 & DSP R05.01.00 continued… Host R05.01.01 & DSP R05.01.00 (4/14/2005) Conventional voting-scan does not vote the strongest channel. Issue update. 16th talkgroup in a personality doesn’t work. Hard key-zeroize in silentemergency causes tone to sound. Known problem. Subscriber transmits DTMF digits at 8 KHz deviation. Issue update. 16th talkgroup in a personality doesn’t work. Known problem. Hard key-zeroize in silentemergency causes tone to sound. Known problem.
It cannot be stressed enough how important it is to keep your host and DSP firmware up-todate. There have been tremendous improvements in the audio quality of ASTRO™ digital (IMBE™) transmissions since the first IMBE™ DSP codec was released in 1996. Some major law-enforcement agencies are still using host and DSP firmware combinations dated from 1995-1997. The tone of reproduced audio using DSP firmware version 6 and no subscriber AGC is terrible. Motorola Inc.
. Figure 9.2 Recommended settings for optimized subscriber AGC operation in ASTRO™ CPS. Figure 9.3 Recommended settings for optimized subscriber AGC operation in ASTRO25™ CPS.
It’s hard to believe, but those simple configuration options and current firmware make a world of difference. The bottom line is if you’re a systems administrator and are just learning about this information now through the guide, Motorola Inc. has not educated you well in their product and its optimal performance. You must keep up with Service Release Notices (SRNs) and other technical documentation which is routinely released by Motorola Inc. to address these and other technical issues.
FLASHport™ Technology FLASHport™ is simply a fancy name which means “upgrade”. By upgrading, you may add features (FLASHport™ options) and/or update the host and DSP firmware in a radio. This is accomplished by putting the radio into bootstrap mode and communicating with the flash ROMs and EEPROM. In older ASTRO™-series radios, a Smart Radio Interface Box (SRIB), a flash/programming cable and an i-button were required hardware for this procedure.
FLASHport™ Feature Chart – ASTRO™/ASTRO25™ Options POSITION 12 11 10 9 8 7 6 5 4 3 2 1 WEIGHT 1 2 (N/A) 4 8 1 2 4 8 1 2 (N/A) 4 8 1 2 4 (N/A) 8 (N/A) 1 2 4 8 1 2 4 8 1 2 (N/A) 4 8 1 2 4 8 1 2 4 8 (N/A) 1 2 4 8 1 2 4 8 1 2 4 8 OPTIONS G806/Q806 ASTRO Digital Operation G114/H14 Enhanced Digital ID Display H14/H44 ASTRO Data G101/H101 Repeater Access Q52 Federal Government FPP (ASTRO25 only) H869/W969 Hardware Multikey Encryption G298/Q498 Hardware Multikey Encryption with OTAR G170/H43 Trunked Ra
To calculate an entire flashcode by hand can be time-consuming. Several hobbyists have written online flashcode decoders which convert a flashcode into human-readable options displayed in text format. Other hobbyists have written small executable programs which does the same task offline. Unfortunately the stand-alone offline decoder is no longer available for download. Here are useful links: http://www.radioreference.com/modules.php?name=Flash http://www.akardam.net/moto/tools/decode3.
Hardware Hacking There are two product-families of digital-capable radios: The ASTRO™ and ASTRO25™ series. The hardware hacking section of this guide applies only to ASTRO™-series radios. These are the Motorola Inc. ASTRO Digital Saber™, the ASTRO Digital Spectra™ and the XTS 3000™. The ASTRO Digital Saber™ and the XTS 3000™ share the same host (ROS) and DSP firmware builds. The ASTRO Digital Spectra™ has its own host firmware build, but shares the same DSP firmware as the portable radios.
Many hobbyists may not be aware the same host ROS and DSP firmware code is shared among the ASTRO™ portable radio-family. Host ROS and DSP firmware may be cloned from an XTS 3000™ and written to a ASTRO Digital Saber™, or vise-versa. The ASTRO Digital Spectra™ host ROS firmware is not cross-platform-compatible with the ASTRO Digital Saber™ or XTS 3000™. Figure 11.2 A Motorola Inc. ASTRO Digital Spectra™ vocon is shown with the host and DSP flash ROMs removed.
The ASTRO™ platform uses a 32K x8 EEPROM to store the radio-codeplug in. The same chip—an Atmel 28C256E, is used in the ASTRO Digital Saber™, ASTRO Digital Spectra™ and the XTS 3000™. It is fitted in a TSOP-28 package. Normally hobbyists use leaked copies of Motorola Inc. Lab-tool or Depot software to manipulate codeplug options such as band-split, serial number or FLASHport™ options.
There are some other interesting points to note about the ASTRO™ host ROS firmware. Over the years there’s been discussion about the ASTRO™ product-family supporting the Multiple Private Line (MPL) feature. There’s no reference in RSS or CPS to this sought-after feature, but there’s reference to it in the host ROS firmware as a soft-menu item. This applies to both the mobile and portable host ROS firmware builds. Figure 11.
the host ROS firmware as the “VOX ON” and “VOX OFF” soft menus. “WHISPER ON” and “WHISPER OFF” soft-menus also exist—however they are not referenced in the RSS or CPS software releases. These are possibly SP features for certain customers. Figure 11.8 An illustration which highlights the VOX and high-sensitivity WHISPER soft-menu features, which aren’t seen anywhere in RSS or CPS programming screens.
Guidelines For Buying & Selling ASTRO™/ASTRO25™ Kit Over the last five years, eBay has become the primary source to find new and used ASTRO™/ASTRO25™ kit at reasonable prices. Some sellers do an excellent job when listing their products for sale, stating all critical information in their auctions.
Radio Programming: Software and Hardware Part Numbers ASTRO™ Portables (ASTRO Digital Saber™, XTS 3000™): RVN4100 (RSS MS-DOS software. No longer sold.) RVN4182 (CPS; runs in Windows environment.) RKN4046A ASTRO Digital Saber™ programming cable RKN4035D XTS 3000™ programming cable RLN4008B RIB Programming interface (required) ASTRO™ Mobile (ASTRO Digital Spectra™): RVN4100 (RSS MS-DOS software. No longer sold.) RVN4183 (CPS; runs in Windows environment.
ASTRO™/ASTRO25™ Encryption Hardware Detailed encryption capabilities of the ASTRO™ and ASTRO25™ family radios are not outlined in the Guide to ASTRO™ Radios, however an excellent encryption primer has already been written by batdude and is most helpful in building a foundation of knowledge in this area. It is available for download here (link working as of 8/12/2007): http://members.aol.com/batlabsdotcom/encryption.
Change Log The Guide to ASTRO™ Digital Radios has undergone several changes since the time of a short “FAQ” post on the BatBoard Internet Discussion Forum in October 2003. A more detailed, but highly disorganized website was erected in 2005, but I’ve since taken it offline. This was referred to as release 2.0. This guide will now be presented in PDF format, and a change log will list what’s new or updated in each forthcoming release. Unlike Motorola Inc.
