contact contact control control C A, Motorola, Professional Radio, PRO Series and PRO Model numbers and HT Series and HT Model numbers are marks of Motorola, Inc. LTR is a registered trademark of E.F. Johnson Company. Transcrypt is a registered trademark of Transcrypt International, Inc. PassPort is a registered trademark of Trident Micro Systems, Inc. © 2000, 2001 Motorola, Inc. All rights reserved. Printed in U.S.A.
Safety-i SAFETY AND GENERAL INFORMATION IMPORTANT INFORMATION ON SAFE AND EFFICIENT OPERATION READ THIS INFORMATION BEFORE USING YOUR TWO-WAY RADIO The information provided in this document supersedes the general safety information contained in user guides published prior to July 2000. For information regarding radio use and hazardous atmosphere please refer to the Factory Mutual (FM) Approval Manual Supplement or Instruction Card, which is included with radio models that offer this capability.
Safety-ii Body-Worn Operation To maintain compliance with FCC RF exposure guidelines, if you wear a radio on your body when transmitting, always place the radio in a Motorola supplied or approved clip, holder, holster, case, or body harness. Use of non-Motorola-approved accessories may exceed FCC RF exposure guidelines. If you do not use a body-worn accessory, ensure the antenna is at least one inch (2.5 cm) from your body when transmitting.
Safety-iii SAFETY AND GENERAL • Use While Driving Check the laws and regulations on the use of radios in the area where you drive. Always obey them When using your radio while driving, please: • Give full attention to driving and to the road. • Use hands-free operation, if available. • Pull off the road and park before making or answering a call if driving conditions so require.
Safety-iv Intrinsically Safe Radio Information FMRC Approved Equipment Anyone intending to use a radio in a location where hazardous concentrations of flammable material exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500 (hazardous [classified] locations).
Safety-v Repair of FMRC Approved Products REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS ARE THE RESPONSIBILITY OF THE USER. You should not repair or relabel any Motorola manufactured communication equipment bearing the FMRC Approval label (FMRC Approved Product) unless you are familiar with the current FMRC Approval standard for repairs and service (Class Number 3605). You may want to consider using a repair facility that operates under 3605 repair service approval.
Safety-vi This page intentionally left blank.
vii Table of Contents Chapter 1 1.1 1.2 Scope of Manual ........................................................................................................... 1-1 Warranty and Service Support..................................................................................... 1-1 1.2.1 1.2.2 1.2.3 1.3 1.4 Warranty Period................................................................................................................... 1-1 Return Instructions .........................................
viii 2.9 VHF Transmitter .......................................................................................................... 2-12 Figure 2-10:VHF Transmitter Block Diagram.................................................................. 2-12 2.9.1 2.9.2 2.9.3 2.9.4 2.9.5 Power Amplifier.................................................................................................................. 2-12 Antenna Switch................................................................................
ix 2.18.3 Automatic Gain Control Circuit .......................................................................................... 2-28 2.18.4 Frequency Generation Circuit............................................................................................ 2-29 Figure 2-21:800 MHz Frequency Generation Unit Block Diagram.................................. 2-29 2.19 Synthesizer ..................................................................................................................
x 3.5 VHF Troubleshooting Charts ..................................................................................... 3-15 Troubleshooting Flow Chart for Controller ...................................................................................... 3-15 Troubleshooting Flow Chart for Receiver (Sheet 1 of 2) ................................................................ 3-16 Troubleshooting Flow Chart for Receiver (Sheet 2 of 2) ................................................................
xi Figure 4-9:VHF/UHF Complete Controller Schematic Diagram...................................... Figure 4-10:VHF/UHF Controller ASFIC/ON_OFF Schematic Diagram ......................... Figure 4-11: VHF/UHF Controller ASFIC/ON_OFF Schematic Diagram ........................ Figure 4-12:VHF/UHF Controller Micro Processor Schematic Diagram ......................... Figure 4-13:VHF/UHF Controller Micro Processor Schematic Diagram ......................... Figure 4-14:Controller Memory Schematic Diagram........
xii Figure 4-51:UHF (450-527MHz) Voltage Controlled Oscillator Schematic Diagram ...... 4-75 Figure 4-52:UHF (450-527MHz) Transmitter Schematic Diagram.................................. 4-76 Figure 4-53:UHF (450-527MHz) Voice Storage Schematic Diagram ............................. 4-77 Figure 4-54:VHF (136-174MHz) Main Board Top Side PCB 8486062B09..................... 4-83 Figure 4-55:VHF (136-174MHz) Main Board Bottom Side PCB 8486062B09................
xiii Figure 4-90:Low Band (29.7-42/35-50MHz) Frequency Generation Unit Synthesizer ............................................................................................................ Figure 4-91:Lowband (29.7-42/35-50MHz) Frequency Generation Unit VCO Diagram................................................................................................................ Figure 4-92:Lowband (29.7-42/35-50MHz) Transmitter Schematic Diagram ...............
xiv
1-1 Chapter 1 Introduction 1.1 Scope of Manual This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the equipment described and is current as of the printing date. Changes that occur after the printing date are incorporated by a complete manual revision or alternatively, as additions. NOTE Before operating or testing these units, please read the Safety Information Section in the front of this manual. 1.
1-2 1.3 Related Documents Related Documents The following documents are directly related to the use and maintainability of this product.
Radio Model Chart and Specifications Parts Order Entry 7:00 A. M. to 7:00 P. M. (Central Standard Time) Monday through Friday (Chicago, U. S. A.) To Order Parts in the United States of America: 1-800-422-4210, or 847-538-8023 1-800-826-1913, or 410-712-6200 (U. S. Federal Government) TELEX: 280127 FAX: 1-847-538-8198 FAX: 1-410-712-4991 (U. S. Federal Government) (U. S. A.
1-4 Radio Model Information . Table 1-2 Radio Model Number Example: AAH25KC9AA2 and LAH25KDC9AA3 Model Series H 25 H = Portable AA or LA = Motorola Internal Use AA or LA Type of Unit Freq. Band Power Level Physical Packages Channel Spacing Protocol Feature Level Model Revision Model Package A N K C C 9 AA 2 VHF (136174MHz) 2.
2-1 Chapter 2 Theory of Operation 2.1 Introduction This chapter provides a detailed theory of operation for the radio components. Schematic diagrams for the circuits described in the following paragraphs are located in Figures 4-1 through 4-120. 2.2 Radio Power Distribution A block diagram of the DC power distribution throughout the radio board is shown in Figure 2-1. A 7.5V battery supplies the basic radio power (UNSWB) directly to the electronic on/off control, audio power amplifier, 3.
2-2 Table 2-1 VDD Regulator Scheme by Band Vdd Regulator Scheme Band Low Band Dual VHF Dual UHF Dual 800 MHz Dual 900 MHz Dual Table 2-2 Radio Jumpers Dual Vdd Regulator Scheme Single Vdd Regulator Scheme R401 Y Y R402 N N R403 N Y R404 N N R405 Y N Jumpers R = Regulator Jumper 2.3 Keypad The keypad block diagram is shown in Figure 2-2. The comparator compares the voltage when any one of the keypad row or keypad column keys is pressed.
2-3 2.4 Controller Board The controller board is the central interface between the various radio functions. It is separated into MCU digital and audio/signalling functions as shown in Figure 2-3. To Synthesizer External Microphone Mod Out Internal Microphone 16.8 / 17.0 MHz Reference Clock from Synthesizer Audio/Signalling Recovered Audio Squelch External Speaker Audio Power Amplifier/Filter ASFIC Internal Speaker 3.
2-4 2.4.1 Real Time Clock Radios with displays support a real time clock (RTC) module for purposes of message time stamping and time keeping. The RTC module resides in the microcontroller. The clock uses a back-up lithiumIon battery for operating power when the primary battery is removed. 2.4.2 Circuit Description The RTC module circuit, shown in Figure 2-4, is powered by the MODB/VSTBY pin and PI6/PI7 from the crystal oscillator circuit. A clock frequency of 38.
2-5 2.4.1 Audio/Signaling The audio/signalling/filter/companding IC (ASFIC) and the audio power amplifier (Figure 2-3) form the main components of the audio/signalling section of the controller board. Inputs include a 16.8 MHz clock from the synthesizer, recovered audio and squelch, MCU control signals, and external or internal microphones. Outputs include a microprocessor clock (CLK), modulator output to the synthesizer, and amplified audio signals to an internal or external speaker. 2.
2-6 2.5.2 Antenna Switch The antenna switch circuit consists of two pin diodes (CR101 and CR102), a pi network (C107, L104 and C106), and two current limiting resistors (R101 and R170). In the transmit mode, B+ at PCIC (U102 pin 23) goes low turning on Q111, which applies a B+ bias to the antenna switch circuit to bias the diodes “on”. The shunt diode (CR102) shorts out the receiver port and the pi network.
2-7 Antenna RFJack Pin Diode Antenna Switch Varactor Tuned Filter RF Amp Varactor Tuned Filter Mixer Crystal Filter IF Amp AGC Control Voltage from ASFIC AGC Processing First LO from FGU Recovered Audio Squelch Demodulator RSSI IF IC Synthesizer 16.8 MHz Reference Clock SPI Bus Second LO VCO Figure 2-6: UHF Receiver Block Diagram 2.6.1 Receiver Front-End The RF signal received by the antenna is applied to a low-pass filter.
2-8 The IF signal coming out of the mixer is transferred to the crystal filter (FL301) through a resistor pad and a diplexer (C322 and L310). Matching to the input of the crystal filter is provided by C324 and L311. The crystal filter provides the necessary selectivity and intermodulation protection. 2.6.2 Receiver Back-End The output of crystal filter FL301 is coupled via R351 and C325 to the input of IF amplifier transistor Q302.
2-9 compared to normal operation at room temperature. Resistor R300 and Capacitor C397 form an R-C network used to dampen any transient instability while the AGC is turning on. 2.6.4 Frequency Generation Circuit The frequency generation circuit, shown in Figure 2-7, is composed of Fractional-N synthesizer U201 and VCO/Buffer IC U241. Designed in conjunction to maximize compatibility, the two ICs provide many of the functions that normally require additional circuitry.
2-10 To achieve fast locking for the synthesizer, an internal adapt charge pump provides higher current at U201 (pin 45) to put the synthesizer within lock range. The required frequency is then locked by normal mode charge pump at U201 (pin 47). Both the normal and adapt charge pumps get their supply from the capacitive voltage multiplier made up of C258, C259, C228, triple diode CR201, and level shifters U210 and U211. Two 3.
2-11 transmit mode, the audio signal to be frequency modulated onto the carrier is received through U201 (pin 41). When a high impedance is applied to U241 (pin 19), the VCO operates in BATTERY SAVER mode. In this mode, both the receive and transmit oscillators as well as the receive transmit and prescaler buffer are turned off.
2-12 2.9 VHF Transmitter The VHF transmitter consists of the following basic circuits as shown in Figure 2-10. • • • • Power amplifier Antenna switch/harmonic filter Antenna matching network Power control integrated circuit (PCIC) PCIC Vcontrol Vcontrol Antenna Matching Network Power Amplifier (PA) From VCO PA Driver PA Final Stage Antenna Switch/ Harmonic Filter Figure 2-10: VHF Transmitter Block Diagram 2.9.
2-13 2.9.3 Harmonic Filter The harmonic filter consists of components C3532 to C3536, L3531, and L3532. This network forms a low-pass filter to attenuate harmonic energy of the transmitter to specifications level. The harmonic filter insertion loss is typically less than 1.2dB. 2.9.4 Antenna Matching Network A matching network, made up of L3538 and C3537, is used to match the antenna impedance to the harmonic filter. This optimizes the performance of the transmitter and receiver into an antenna. 2.9.
2-14 Antenna RFJack Pin Diode Antenna Switch Varactor Tuned Filter RF Amp Varactor Tuned Filter Crystal Filter Mixer AGC Control Voltage from ASFIC First LO from FGU Recovered Audio Squelch Demodulator RSSI IF IC Synthesizer 16.8 MHz Reference Clock SPI Bus Second LO VCO Figure 2-11: VHF Receiver Block Diagram 2.10.1 Receiver Front-End The RF signal is received by the antenna and applied to a low-pass filter consisting of L3531, L3532, C3532 to C3563.
2-15 The IF signal coming out of the mixer is transferred to the crystal filter (Y3200) through a resistor pad (R3321 - R3323) and a diplexer (C3320 and L3309). Matching to the input of the crystal filter is provided by C3200 and L3200. The crystal filter provides the necessary selectivity and intermodulation protection. 2.10.2 Receiver Back-End The output of crystal filter Y3200 is coupled to the input of IF amplifier transistor Q3200 by capacitor C3203.
2-16 pin is limited by resistors R3316, R3313, R3306, and R3324. Feedback capacitor C3326 provides some stability to this high gain stage. An additional gain control circuit is formed by Q3201 and associated components. Resistors R3206 and R3207 are voltage dividers designed to turn on Q3201 at a significantly higher RSSI level than the level required to turn on pin diode control transistor Q3301.
2-17 The loop filter, which consist of C3721, C3722, R3721, R3722, and R3723, provides the necessary dc steering voltage for the VCO and determines the amount of noise and spur passing through. In achieving fast locking for the synthesizer, an internal adapt charge pump provides higher current at U3701, pin 45 to put the synthesizer within lock range. The required frequency is then locked by normal mode charge pump at pin 43.
2-18 During the transmit condition, when PTT is pressed, 3.2 volts is applied to U3801, pin 19. This activates the transmit VCO by enabling the transmit oscillator and the transmit buffer of U3801. The RF signal at U3801, pin 10 is injected into the input of the PA module (U3501, pin16). This RF signal is the TX RF INJECTION. Also in transmit mode, the audio signal to be frequency modulated onto the carrier is received through U3701, pin 41.
2-19 2.13 Low Band Transmitter The low band transmitter consists of the following basic circuits as shown in Figure 2-15. • • • • Power amplifier (PA). Antenna switch/harmonic filter. Antenna matching network. Power control integrated circuit (PCIC). Antenna Switch Bias SPI Bus PCIC Gate Bias Vcontrol Antenna Matching Network Power Amplifier (PA) PA Driver From VCO PA Final Stage Antenna Switch/ Harmonic Filter Figure 2-15: Low Band Transmitter Block Diagram 2.13.
2-20 disconnecting the transmitter from the antenna while L103 and C147 form a series resonant circuit effectively connect the receiver to the antenna. 2.13.3 Harmonic Filter The harmonic filter consists of components C103, C106, C103, C107,C110, C111, C114, C115 and inductors L100, L101, and L102 which are a part of the SH100 assembly. The harmonic filter for lowband is pole zero design.
2-21 Antenna RFJack Lowpass Filter Antenna Switch Highpass Filter RF Amp Lowpass Filter Mixer IF Crystal Amp Filter AGC Processing First LO from FGU Recovered Audio Squelch Demodulator IF IC U303 RSSI Synthesizer 17.0 MHz Reference Clock SPI Bus Second LO VCO Figure 2-16: Low Band Receiver Block Diagram 2.14.1 Receiver Front-End The RF signal received by the antenna is routed through the transmitter lowpass filter and antenna switch.
2-22 2.14.2 Receiver Back-End The output of crystal filter FL301 is connected to the input of IF amplifier transistor U301. Components L303 and C348 and R301 form the termination for the crystal filter and the signal is coupled to one gate of U301 by C303. The IF amplifier is a dual gate MOSFET powered off of the 5 volt supply. The first gate receives the IF signal as indicated previously. The second gate receives a DC voltage from U302 which serves as an AGC control signal.
2-23 5V signal goes to pins 13 and 30 while the 3.3V signal goes to pins 5, 20, 34 and 36 of U201. The synthesizer in turn generates a superfiltered 4.3V which powers the VCOs and buffers. In addition to the VCO, the synthesizer also interfaces with the logic and ASFIC circuitry. Programming for the synthesizer is accomplished through the data, clock and chip select lines (pins 7, 8 and 9) from the microprocessor, U409. A 3.
2-24 7 DATA (U409 Pin 100) 8 CLOCK (U409 Pin 1) 9 CSX (U409 Pin 2) MOD IN (U404 Pin 40) +5V (U204 Pin 4) (U400 Pin 1) 10 CLK FREFOUT CEX GND MODIN IOUT 13,30 5,20,34,36 23 Reference Oscillator LOCK DATA 24 25 32 47 Voltage Multiplier VCC , DC5V VDD , 3.
2-25 rejecting the receive LO injection signals at 139 - 160 MHz. This filter is comprised of L204, L211, L212, C230 and C231. The other filter is a highpass filter which passes 139 - 160 MHz signals for the receive LO into the mixer while rejecting the transmit injection signals at 29.7 -50 MHz. This filter is comprised of C228, C229, C235 and L215. 2.16.5 Prescalar Feedback The prescalar input signal for receive and transmit is tapped off of the outputs of each filter by resistors R234 and R238.
2-26 This RF driver IC is capable of supplying an output power of 0.3W (pin 13 and 14) with an input signal of 2.5mW (4dBm) (pin16). The current drain would typically be 200mA while operating in the frequency range of 806-870MHz. The 85Y73 LDMOS PA is capable of supplying an output power of 4.5W with an input signal of 0.3W. The current drain would typically be 1100mA while operating in the frequency range of 806-870MHz.
2-27 2.18 800 MHz Receiver The receiver functions are shown in Figure 2-20 and are described in the paragraphs that follow. Antenna Pin Diode Antenna Switch RFJack 3-Pole Ceramic Block Filter RF Amp 3-Pole Ceramic Block Filter Mixer Crystal Filter IF Amp AGC Processing First LO from FGU Recovered Audio Squelch Demodulator U351 RSSI IF IC Synthesizer 16.8 MHz Reference Clock SPI Bus Second LO VCO Figure 2-20: 800MHz Receiver Block Diagram 2.18.
2-28 2.18.2 Receiver Back-End The output of crystal filter FL350 is matched to the input of the dual gate MOSFET IF amplifier transistor U352 by components L355, R359 and C376. Voltage supply to the IF amplifier is taken from the receive 5 volts (R5). AGC voltage is applied to the second gate of U352. The IF amplifier provides a gain of about 11dB. The amplified IF signal is then coupled into U351(pin 3) via L352, R356 and C365 which provides the matching for the IF amplifier and U351.
2-29 • the slope of the voltage at the output of U302 vs. the strength of the incoming RF at the antenna. As the RF into the antenna increases the following occurs: • • • The output voltage of the receiver backend inverter U350 decreases. The voltage at the output of the front end inverter U302 increases. The result is the forward biasing of pin diode CR301.
2-30 Transmit modulation from the ASFIC is supplied to pin10 of U201. Internally the audio is digitized by the Fractional-N and applied to the loop divider to provide the low-port modulation. The audio runs through an internal attenuator for modulation balancing purposes before going out to the VCO. 2.19 Synthesizer The Fractional-N Synthesizer uses a 16.8MHz crystal (FL201) to provide a reference for the system. The LVFractN IC (U201) further divides this to 2.1MHz, 2.225MHz, and 2.
2-31 2.19.1 Voltage Control Oscillator (VCO) The voltage controlled oscillator block diagram is shown in Figure 2-23.
2-32 The operation logic is shown in Table 2-7. Table 2-7 Desired Mode Level Shifter Logic AUX 4 AUX 3 TRB Tx Low High (@3.2V) High (@4.8V) Rx High Low Low Battery Saver Low Low Hi-Z/Float (@2.5V) In the receive mode, U250 pin 19 is low or grounded. This activates the receive VCO by enabling the receive oscillator and the receive buffer of U250. The RF signal at U250 pin 8 is run through an injection amplifier, Q304.
2-33 for customization for special requirements, and provision made to further standardized features to be added to the protocol in the future. The standard defines only the over-air signalling and imposes only minimum constraints on system design. 2.20.4 PassPort™ Trunked Systems PassPort is an enhanced trunking protocol developed by Trident Microsystems that supports wide area dispatch networking. A network is formed by linking several trunked sites together to form a single system.
2-34 2.20.4.5 BackLight Driver and LED's The logic level signal from the radio microcontroller is translated via Q611 and applied to Q610 which uses Switched Battery Voltage (SWB+) to operate the keypad backlight LED’s. 2.20.4.6 Voice Storage The Voice Storage (VS) can be used to store audio signals coming from the receiver or from the microphone. Any stored audio signal can be played back over the radio’s speaker or sent out via the radio’s transmitter. The PTCB hosts the Voice Storage circuitry.
2-35 The 900 MHz transmitter contains the following basic circuits: • • • • 2.21.1 power amplifier antenna switch harmonic filter power control integrated circuit (PCIC). Power Amplifier The power amplifier consists of two devices: • • 5185130C65 driver IC (U101) and 4813828A09 LDMOS PA (Q101). The 30C65 driver IC contains a 2 stage amplification with a supply voltage of 7.5V. This RF driver IC is capable of supplying an output power of 0.3W (pin 6 and 7) with an input signal of 2.5mW (4dBm) (pin16).
2-36 2.22 900 MHz Receiver Antenna Pin Diode Antenna Switch RFJack 3-Pole Ceramic Block Filter RF Amp 3-Pole Ceramic Block Filter Mixer Crystal Filter IF Amp AGC Processing First LO from FGU Recovered Audio Squelch Demodulator U351 RSSI IF IC Synthesizer 16.8 MHz Reference Clock SPI Bus Second LO VCO Figure 2-25: 900 MHz Receiver Block Diagram 2.22.1 Receiver Front-End The RF signal is received by the antenna and applied to a low-pass filter.
2-37 2.22.2 Receiver Back-End The output of crystal filter FL350 is matched to the input of the dual gate MOSFET IF amplifier transistor U352 by components L355, R359, and C376. Voltage supply to the IF amplifier is taken from the receive 5 volts (R5). AGC voltage is applied to the second gate of U352. The IF amplifier provides a gain of about 11dB. The amplified IF signal is then coupled into U351(pin 3) via L352, R356 and C365 which provides the matching for the IF amplifier and U351.
2-38 Table 2-8 Hear Clear Logic and IC Status LO Clamp Disable U851-C2 GND 0 0 HCI Disable U851-B6 SWB+ 1 1 LO Clamp Disable U851-D1 GND 0 0 *RX1:receive voice with carrier squelch, PL or DPL (Flutter Fighter can be on or off). **RX2:refers to receive mode with all other data HST/MDC/DTMF (Flutter Fighter must be off). 2.22.3.1 Receive Path for Radios with Hear Clear The audio signal enters Hear Clear controller from DEMOD_OUT signal on DISC.
2-39 The output of inverter U350 is also used to control the receiver front end AGC. The receiver front end automatic gain control circuit provides and additional 20 dB of gain reduction. The output of the receiver back end inverter U350 is fed into the receiver front end AGC inverter U302. The components R317, R314, and C318 determine: • • the RF level at which the front end AGC is activated, and the slope of the voltage at the output of U302 vs. the strength of the incoming RF at the antenna.
2-40 the microprocessor. A 3.3V dc signal from synthesizer lock detect line indicates to the microprocessor that the synthesizer is locked. Transmit modulation from the ASFIC is supplied to pin10 of U201. Internally the audio is digitized by the Fractional-N and applied to the loop divider to provide the low-port modulation. The audio runs through an internal attenuator for modulation balancing purposes before going out to the VCO. 2.24 900 MHz Synthesizer The Fractional-N Synthesizer uses a 16.
2-41 2.
2-42 The operation logic is shown in Table 2-9. Table 2-9 Level Shifter Logic Desired Mode AUX 4 AUX 3 TRB Tx Low High (@3.2V) High (@4.8V) Rx High Low Low Battery Saver Low Low Hi-Z/Float (@2.5V) In the receive mode, U250 pin 19 is low or grounded. This activates the receive VCO by enabling the receive oscillator and the receive buffer of U250. The RF signal at U250 pin 8 is run through an injection amplifier, Q304.
3-1 Chapter 3 Maintenance 3.1 Introduction This chapter of the manual describes: • • • 3.2 Preventive maintenance Safe handling of CMOS devices Repair procedures and techniques Preventive Maintenance The radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. 3.3 Inspection Check that the external surfaces of the radio are clean, and that all external controls and switches are functional.
3-2 Safe Handling of CMOS and LDMOS isopropyl alcohol to the frame, front cover, or back cover. NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage). 3.4 Safe Handling of CMOS and LDMOS Complementary metal-oxide semiconductor (CMOS) and lateral diffusion metal oxide semiconductor (LDMOS) devices are used in this family of radios. Their characteristics make them susceptible to damage by electrostatic or high voltage charges.
General Repair Procedures and Techniques • • 3-3 Chip Components Use either the RLN-4062 Hot-Air Repair Station or the Motorola 0180381B45 Repair Station for chip component replacement. When using the 0180381B45 Repair Station, select the TJ-65 minithermojet hand piece. On either unit, adjust the temperature control to 700 degrees F. (370 degrees C), and adjust the airflow to a minimum setting. Airflow can vary due to component density.
3-4 Recommended Test Tools • Next, rub the soldering iron tip along the edge of the shield to smooth out any excess solder. Use solder wick and a soldering iron to remove excess solder from the solder pads on the circuit board. • Place the circuit board back in the R1070’s circuit board holder. • Place the shield on the circuit board using a pair of tweezers. • Position the heat-focus head over the shield and lower it to approximately 1/8” (0.3 cm) above the shield.
Replacing the Circuit Board Fuse 3.7 3-5 Replacing the Circuit Board Fuse In cases where the radio fails to turn on when power is applied, the circuit board fuse should always be checked as a probable cause of the failure. The locations of the fuse for both the UHF and VHF boards are shown in Figure 3-1.
Replacing the Circuit Board Fuse 3-6 J102 C359 C338 L330 R311 R312 C503 C128 C130 C123 CR501 L505 SH242 CR241 SH202 C522 C219 R202 R201 C234 C232 C243 C245 C250 C246 R241 R242 C224 U201 C263 L261 C264 C223 37 1 R349 L281 VR441 24 25 4 3 C372 R331 Q310 U3701 VR442 C254 C523 C208 R281 C265 3 4 U211 R204 C204 25 13 C371 R330 C373 Y3762 R3703 2 C252 VR442 D3761 C3751 C3705 R3702 C3703 D3701 C3701 R3704 C3702 13 12 C3708 R3705 1 C3734 48 R3726 C3815 R3829
Removing and Reinstalling the Circuit Board 3.2 3-7 Removing and Reinstalling the Circuit Board Both the UHF and VHF circuit boards are removed from the radio chassis in the following manner: 1. Refer to the Basic Service Manual (see Chapter 1 - Related Documents) for radio disassembly, then use a Torx driver and a T-6 bit to remove the four Torx screws shown in Figure 3-2. 2.
3-8 Power Up Self-Test Error Codes If the error code displayed is ... No Display Then, there is a ... improperly connected display module or damaged display module. To correct the problem ... check connection between main board and display module or replace with new display module. For LTR Models: Then, there is a ... If the error code displayed is ... To correct the problem ... ESN BAD defective PTCB return to factory for PTCB replacement.
UHF Troubleshooting Charts 3.4 3-9 UHF Troubleshooting Charts MCU Check PTT Press PTT. Red LED does not light up INT AUDIO J403 Audio NO at Pin 2 & Pin 3 Audio at AudioPA (U420) input YES YES NO Audio from Pin 41 ASFIC, U404? Check Spk. Flex Connec- NO PTT U409 Pin 53 low? Check Audio PA (U420) YES Power Up Alert Tone OK? Check PB504 Press PTT Q502-2 High? NO NO Speaker OK? NO Audio at Pin 2 U404? Check ASFIC U404 YES U409 EXTAL= 7.
3-10 UHF Troubleshooting Charts START Bad SINAD Bad 20dB Quieting No Recovered Audio Audio at pin 27 of U301? Yes Check Controller No Induce or inject 1st IF into XTAL Filter IF Freq: 45.1MHz A Check Q320 bias circuitry for faults Yes Audio heard? B Rotate Freq. Knob No Check 2nd LO Control Voltage at C363 No Activity on U301 sel pin? Yes B VCO locked? Check controller Yes No No Check FGU 16.8 MHz check at pin 22 U301? Before replacing U301, check 2nd VCO Q320.
UHF Troubleshooting Charts 3-11 B Inject RF into J101 Trace IF signal from L311 to Q302. Check for bad XTAL filter Yes IF Signal at L311? Q302 collector OK? IF signal present? No Yes RF Signal at T301? No Yes Yes RF Signal at C310? No 1st LO O/P OK? Locked? No Check FGU Yes Before replacing U301, check U301 voltages; trace IF signal path Check T301, T302, CR306, R308, R309, R310 Check filter between C310 & T301 Check for 2.
3-12 UHF Troubleshooting Charts START No Power Is There B+ Bias for Ant switch Yes Check Q111 Low No Yes No Is Control Voltage High or Low Is Current OK? Check PCIC High Check Drive to Module 1. Check Pin Diodes 2. Check Harmonic Filter No Is Drive OK? Inspect/Repair Tx.
UHF Troubleshooting Charts 3-13 3.3V at U201 pins 5, 20, 34 & 36 Start Check CR201, U210, U211, C258, C259 & C228 Check U248, L201 & L202 YES Visual check of the Board OK? NO Correct Problem NO YES YES 5V NO at pin 6 of CR201 Is U201 Pin 47 NO NO YES Check L202 Check Q260, Q261 & R260 YES YES Are signals at Pin’s 14 & 15 of U201? Is 16.8MHz signal at U201 pin 23? NO YES Replace U201 NO Check 5V Regulator NO Is U241 Pin 19 <0.7 VDC in RX & >4.
3-14 UHF Troubleshooting Charts START Change U241 No L253 O/C? Yes Yes No LO? Change L253 A No Yes No Yes Pin 10 >1V? No TRB = 5V? Tx Carrier? Yes No VCO OK Check R245 for dry joint or faulty AUX 3 High? Check R260 No Check U201 Pin 2 for 3.
VHF Troubleshooting Charts 3.5 3-15 VHF Troubleshooting Charts MCU Check PTT Press PTT. Red LED does not light up INT AUDIO NO J403 Audio at Pin 2 & Pin 3 Audio at AudioPA (U420) input YES NO PTT U409 Pin 53 low? Check Audio PA (U420) YES YES NO Check PB504 Audio from Pin 41 ASFIC, U404? Check Spk. Flex Connec- Power Up Alert Tone OK? Press PTT Q502-2 High? NO NO Speaker OK? NO Audio at Pin 2 U404? Check ASFIC U404 YES U409 EXTAL= 7.
3-16 VHF Troubleshooting Charts START Bad SINAD Bad 20dB Quieting No Recovered Audio Yes Audio at pin 27 of U3220? Check Controller No Induce or inject 1st IF into XTAL Filter IF Freq: 45.1MHz A Check Q3270 bias circuitry for faults. Yes Audio heard? B Rotate Freq. Knob No Check 2nd LO Control Voltage at C3279 No Activity on U3220 sel pin? Yes B VCO locked? Check controller. Yes No No Check FGU 16.8 MHz check at pin 21 U3220? Before replacing U3220, check 2nd VCO Q3270.
VHF Troubleshooting Charts 3-17 B Inject RF into J3501 Trace IF signal from C3200 to Q3200. Check for bad XTAL filter. Yes IF Signal at C3200? Q3200 collector OK? IF signal present? No Yes RF Signal at T3301? 1st LO O/P OK? Locked? No Yes Yes RF Signal at R3313? No No Check FGU Yes Before replacing U3220, check U3220 voltages; trace IF signal path Check T3301, T3302, CR3301, R3321, R3322, R3323 Check filter between C3313 & T3301 Check for 2.
3-18 VHF Troubleshooting Charts START No Power Is There B+ Bias for Ant switch Yes Yes No Check Q3561 Low No Is Control Voltage High or Low Is Current OK? Check PCIC High Check Drive to Module 1. Check Pin Diodes 2. Check Harmonic Filter Is Drive OK? Inspect/Repair Tx.
VHF Troubleshooting Charts 3-19 3.3V at U3701 pins 5, 20, 34 & 36 Start Check D3701, D3702, U3701, C3701 - C3707 NO Correct Problem NO Check U3201, L3731 YES Visual check of the Board OK? YES YES 5V NO at pin 6 of D3701 Is U3701 Pin 47 AT = 13 VDC NO NO YES Check L3701, R3701 Check Q260, Q261 & R260 YES YES Are signals at Pin’s 14 & 15 of U3701? Is 16.8MHz signal at U3701 pin 23? NO YES Replace U3701 NO Check 5V Regulator NO Is U3701 Pin 19 <0.7 VDC in RX & >4.
3-20 VHF Troubleshooting Charts START Change U3801 No L3831, L3832, Yes L3833 O/ C? Yes Change L3831, L3832 No LO? A No Yes No Yes Pin 10 >1V? No TRB = 3.2V? Tx Carrier? Yes No VCO OK Check R3811, L3811 for dry joint or faulty Yes AUX 3 High? Check R3829 No Change L3821, L3822, L3823,L243 Check U3701 Pin 2 for 3.
Low Band Troubleshooting Charts 3.6 3-21 Low Band Troubleshooting Charts MCU Check PTT Press PTT. Red LED does not light up INT AUDIO NO J403 Audio at Pin 2 & Pin 3 Audio at AudioPA (U420) input YES NO PTT U409 Pin 53 low? Check Audio PA (U420) YES YES NO Check PB504 Audio from Pin 41 ASFIC, U404? Check Spk. Flex Connec- Power Up Alert Tone OK? NO Press PTT CR502-2 High? Audio at Pin 2 U404? Check CR502-2 voltage NO Speaker OK? NO Check ASFIC U404 YES U409 EXTAL= 7.
3-22 Low Band Troubleshooting Charts START Bad SINAD Bad 20dB Quieting No Recovered Audio Audio at pin 27 of U303? Yes Check Controller No Spray of inject 1st IF into XTAL Filter IF Freq: 109.65 MHz A Check Q301 bias circuitry for faults. Yes Audio heard? B Rotate Freq. Knob No Check 2nd LO Control Voltage at C308 No Activity on U303 sel pin? Yes B VCO locked? Check controller. Yes No No Check FGU 17.0 MHz check at pin 22 U303? Before replacing U303, check 2nd VCO Q301.
Low Band Troubleshooting Charts 3-23 B Inject RF into J101 Trace IF signal from L301 to U301.
3-24 Low Band Troubleshooting Charts START No Power Yes Is Current ~ 2 A? No No Is control voltage at U101 Pin 1 > 5 Check PCIC Yes Check input to U101, Pin 16 1. Check Pin Diodes 2. Check Harmonic Filter 3. Check PA Bias Is voltage > 1 Vpp? Inspect/Repair Tx.
Low Band Troubleshooting Charts 3-25 3.3V at U205 pins 5, 20, 34 & 36 Start NO Correct Problem NO Check U200 and L225 YES Visual check of the Board OK? YES Check C247, C249, C283, C284, C285, C286, D210, D211, R285, and R286 NO Is U205 Pin 47 > 12V NO YES +5V at U205 Pin’s 13 & 30? YES Is 17.0 MHz Signal at U205 Pin 19? YES Signals at Pin 14 and 15 of U205? NO NO YES Is U205, pin 18 at 4.
3-26 Low Band Troubleshooting Charts No TX LO or No signal at U205 Pin 32 in TX No RX LO or No signal at U205 Pin 32 in RX Check signal at collector of Q201 Check signal at collector of Q201 Yes Level > +2 dBm Check L204, L211, L212, L215, C221, C228, C229, C230,C231, C235,C297, R204, R234, R238 Yes Level > +10 dBm? No No Check signal at drain of Q202 and Q204 Check signal at drain of Q203 Yes Level > -3 dBm? Yes Replace Q201 No No Check DC voltage across R203 Check C215, C216, L207, L2
800 MHz Troubleshooting Charts 3.7 3-27 800 MHz Troubleshooting Charts MCU Check PTT Press PTT. Red LED does not light up INT AUDIO Audio at Audio PA (U420) input (U447) NO J403 Audio at Pin 2 & Pin 3 YES Power Up Alert Tone OK? YES PTT U409 Pin 53 low? Check Audio PA (U420) NO YES NO NO Check PB504 Speaker OK? NO Replace Speaker Audio from Pin 41 ASFIC, U404? Check Spk.
3-28 800 MHz Troubleshooting Charts START Bad SINAD Bad 20dB Quieting No Recovered Audio Audio at pin 27 of U351? Yes Check Controller No Spray or inject 1st IF into XTAL Filter IF Freq: 109.65 MHz A Check Q350 bias circuitry for faults Yes Audio heard? B Rotate Freq. Knob No Check 2nd LO Control Voltage at R365 No Activity on U351 pin 19? Yes B VCO locked? Check controller Yes No No Check FGU 16.
800 MHz Troubleshooting Charts 3-29 B Inject RF into J101 Trace IF signal from L353 to U352. Check for bad XTAL filter. Yes IF Signal at L353? Is the level of the IF signal of the output of U352 as indicated? No No Yes RF Signal at pin 8 of U301? Yes Before replacing U351, check U351 voltages; trace IF signal path.
3-30 800 MHz Troubleshooting Charts START Low Power No Power No Power out or Low Power No No Replace F501 Is the fuse F501 OK? Is overall radio current between 0.8 and 1.3 A when transmitting? No Check L101, L102, C101, CR101 for open circuit Yes Is there a short circuit after C113? Yes Yes Is the voltage at pin 4 of U102 between 2V and 5.6V? No Yes Replace Q101 No Is the voltage at R105 and C116 between 1.8V and 2.
800 MHz Troubleshooting Charts 3-31 3.3V at U201 pins 5, 20, 34 & 36 Start Check D201, D202, C244, C245, C246 & C247. Check U248 & L202 YES Visual check of the Board OK? NO Correct Problem NO YES YES 5V at pin 6 of D201 NO Is U201 Pin 47 AT = 13 VDC NO NO YES +5V at U201 Pin’s 13 & 30? YES Is 16.8MHz Signal at U201 Pin 19? Is 16.8MHz signal at U201 pin 23? NO YES Replace U201 NO YES Check L200 Check FL201, C235, C237, C236, CR203 & R211.
3-32 800 MHz Troubleshooting Charts START Yes VCO is OK. Yes Is Tx signal present at the PA driver IC, U101? Is LO signal present at the mixer IC U301? No Is resonator IC U206 soldered OK? No Resolder or replace U205. No No Is resonator IC U205 soldered OK? Resolder or replace U206. Yes Is the 4.6V VSF voltage present at pins 3, 18, & 14 of U250? Yes No Check the 4.6V biasing circuitry and pin 28 of U201. Troubleshoot the Synthesizer. Is the 4.
PassPort Trunking Troubleshooting Chart 3.
3-34 3.
900 MHz Troubleshooting Charts 3-35 3.10 900 MHz Troubleshooting Charts PTT Press PTT. Red LED does not light up. INT AUDIO Audio at Audio PA (U420) input (C447). NO J403 Audio at Pin 2 & Pin 3. YES YES PTT U409 Pin 53 low? Check Audio PA (U420). NO YES NO Check PB504. Audio from Pin 41 ASFIC, U404? Check Spk. Flex Connection. Press PTT Q502-2 High? NO YES No YES Audio at Pin 2 U404? Check Q502-2 voltage. YES YES Audio from Pin F4, HC, U851? NO Check ASFIC U404.
3-36 900 MHz Troubleshooting Charts MCU Check. Power Up Alert Tone OK? Before replacing MCU, check SPI clock, SPI data, and RF IC select. Not able to program RF Board ICs. YES NO Speaker OK? NO Replace Speaker. YES YES U409 EXTAL= 7.3728 MHz? Read Radio OK? YES NO U201 Pin 19 16.8 MHz. NO NO Check Setup. Reprogram the correct data. See FGU Troubleshooting. YES 5V at U202? 3.3V at U203? NO NO Check Q400. YES YES U409 Reset Pin 94 High? 7.5V at Pin 3/5 U202? 4/3.3V at Pin 1 U203.
900 MHz Troubleshooting Charts 3-37 START Bad SINAD. Bad 20dB Quieting. No Recovered Audio. Audio at pin 27 of U351? Yes Check Controller. No Spray or inject 1st IF into XTAL Filter. IF Freq: 109.65 MHz A Check Q350 bias circuitry for faults Yes Audio heard? B Rotate Freq. Knob No Check 2nd LO Control Voltage at R365 No Activity on U351 pin 19? Yes B VCO locked? Check controller Yes No No Check FGU 16.
3-38 900 MHz Troubleshooting Charts B Inject RF into J101. Trace IF signal from L353 to U352. Check for bad XTAL filter Yes IF Signal at L353? Is the level of the IF signal of the output of U352 as indicated? No No Yes RF Signal at pin 8 of U301? Yes Before replacing U351, check U351 voltages; trace IF signal path No 1st LO O/P OK? Locked? Check FGU Check U301, R320, R321, R322.
900 MHz Troubleshooting Charts 3-39 START Low Power Check C163, C127, and C142 for open circuit. No No Power No Power out or Low Power. Yes Replace parts. Replace F501. No No Is the fuse F501 OK? Is overall radio current between 0.8 and 1.3 A when transmitting? No Check L104, L105, C120, CR101 for open circuit. Yes Is there a short circuit after C113? Yes Yes Is the voltage at pin 4 of U102 between 2V and 5.6V? No Yes Replace Q101 No Is the voltage at R105 and C116 between 1.8V and 2.
3-40 900 MHz Troubleshooting Charts START 3.3V at U201 pins 5, 20, 34 & 36. Start Yes VCO is OK. Check D201, D202, C244, C245, C246 & C247. Yes Is Tx signal present at the PA driver IC, U101? No Resolder or replace U205. YES NO Is U201 Pin 47 AT = 13 VDC No Is resonator FL202 soldered OK? Resolder or replace U206. NO NO YES +5V at U201 Pin’s 13 & 30? YES Is resonator FL201 soldered OK? No Check the 4.6V biasing circuitry and pin 28 of U201. Troubleshoot the Synthesizer.
4-1 Chapter 4 Schematic Diagrams, Overlays, and Parts Lists 4.1 Introduction This chapter provides schematic diagrams, overlays, and parts lists for the radio circuit boards and interface connections. 4.1.1 Notes For All Schematics and Circuit Boards * Component is frequency sensitive. Refer to the Electrical Parts List for value and usage. 1. Unless otherwise stated, resistances are in Ohms (k = 1000), and capacitances are in picofarads (pF) or microfarads (µF). 2.
4-2 SIDE 1 LAYER 1 (L1) LAYER 2 (L2) LAYER 3 (L3) LAYER 4 (L4) LAYER 5 (L5) LAYER 6 (L6) INNER LAYERS 6-LAYER CIRCUIT BOARD DETAIL VIEWING COPPER STEPS IN PROPER LAYER SEQUENCE SIDE 2 Flex Layout 40 <- TO KP Front Metal View from Top side 8480475Z02 REV A C 98 TO CTRL -> 40 4.
4-3 4.2.
4-4 4.2.
4-5 4.2.
Figure 4-5: Keypad Top and Bottom Board Overlays R619 Q602 Q601 2 R632 C612 R622 C611 R613 R605 R618 R621 R647 C616 R615 R614 R610 18 R611 J601 R612 Q603 R649 C609 R617 R620 R616 C613 J602 R626 39 40 R627 R629 R601 R604 R603 U602 R602 C615 R646 C614 R628 R609 R608 R607 R630 R625 R633 R631 R639 R641 R643 R645 R606 R648 R637 Bottom View C610 R644 R642 R640 R638 FL0830720O R634 VIEWED FROM SIDE 2 M619 M616 M613 M610 M607 M604 D603 D604 D601 M620 M617 M614 M6
MANUAL REVISION ® Professional Radio™ 6881088C46-D PRO Series Detailed Service Manual This revision outlines changes that have occurred since the printing of your manual. Use this information to supplement your manual. REVISION CHANGE: On page 4-6, the bottom view of Figure 4-5 (in Section 4.2.
