SHOULD IMMEDIATELY RETURN THE PRODUCT IN ITS ENTIRETY TO ITS PLACE OF PURCHASE FOR A REFUND. Motorola grants to You a non-exclusive license to use the SOFTWARE in the manner described in the docu- mentation associated with the product. Motorola retains ownership of the SOFTWARE including all patent, copyrights, and other intellectual property rights.
Table of Contents Product Safety and RF Exposure Compliance ......ix Chapter 1 Introduction Scope of Manual ....................1-1 Warranty and Service Support ................1-1 1.2.1 Warranty Period ....................1-1 1.2.2 Return Instructions ....................1-1 1.2.3 After Warranty Period..................1-1 Related Documents....................1-2 Technical Support ....................
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200 MHz Transmitter ....................3-5 3.5.1 Power Amplifier (PA)................... 3-5 3.5.2 Antenna Switch ....................3-6 3.5.3 Harmonic Filter....................3-6 3.5.4 Antenna Matching Network ................. 3-6 3.5.5 Power Control Integrated Circuit (PCIC) ............. 3-6 3.5.6 Temperature Cut Back Circuit................3-6 200 MHz Receiver ....................3-6 3.6.1 Receiver Front-End .....................
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Removing and Reinstalling the Circuit Board............4-6 Power Up Self-Test Error Codes................4-6 4.10 200 MHz Troubleshooting Charts ................4-8 4.11 700 MHz Troubleshooting Charts ................ 4-14 4.12 PassPort Trunking Troubleshooting Chart ............4-20 4.13 Keypad Troubleshooting Chart ................4-21 Chapter 5 Schematic Diagrams, Overlays, and Parts Lists Introduction ......................
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Figure 5-30. 700 MHz Audio Power Amplifier Schematic Diagram ......5-36 Figure 5-31. 700 MHz Controls and Indicators Schematic Diagram......5-37 Figure 5-32. 700 MHz Keypadd/PassPort Board Interface Schematic Diagram ..5-38 700 MHz Radio Parts List ....................5-39 Figure 5-33. PassPort Trunking Controller PCB Board Side 1 &...
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List of Figures Figure 3-1. DC Power Distribution Block Diagram............. 3-2 Figure 3-2. Keypad/PassPort Option Board Block Diagram ........3-2 Figure 3-3. Controller Block Diagram................. 3-3 Figure 3-4. RTC Circuit ....................3-4 Figure 3-5. 200 MHz Transmitter Block Diagram............3-5 Figure 3-6.
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List of Tables Table 1-1. Related Documents .................. 1-2 Table 1-2. Radio Model Number (Example: AAH25MDF4DP5AN) ......1-3 Table 3-1. Voltage Regulators ................... 3-1 Table 3-2. Radio Memory Requirements..............3-3 Table 3-3. MODB/VSTBY Supply Modes ..............3-4 Table 4-1. Recommended Test Tools ............... 4-4...
This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements. Before using this product, read the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 68P81095C98) to ensure compliance with RF energy exposure limits.
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Product Safety and RF Exposure Compliance...
In instances where the product is covered under a “return for replacement” or “return for repair” warranty, a check of the product should be performed prior to shipping the unit back to Motorola. This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty.
Motorola. If the part number is appended with an asterisk, the part is serviceable by a Motorola depot only. If a parts list is not included, this generally means that no user-serviceable parts are available for that kit or assembly.
Introduction Radio Model Chart and Specifications The radio model charts and specifications are located in the Basic Service Manual listed under the Related Documents paragraph of this chapter. Radio Model Information The model number and serial number are located on a label attached to the back of your radio. You can determine the RF output power, frequency band, protocols, and physical packages from these numbers.
WARNING: Do not disassemble the FMRC Approved Product unit in any way that exposes the internal electrical circuits of the unit. Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and FM Approval labeling. Radios will not be “upgraded” to this capability and labeled in the field.
2.2.3 Do Not Substitute Options or Accessories The Motorola communications equipment certified by Factory Mutual is tested as a system and consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or options, or both. This Approved portable and battery combination must be strictly observed. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit.
Chapter 3 Theory of Operation 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 5-1 through 5-34. Radio Power Distribution A block diagram of the DC power distribution throughout the radio board is shown in Figure 3-1. Four voltage regulators are used as follows: Table 3-1.
Theory of Operation Controller The controller is the central interface between the various radio functions. It is separated into MCU digital and audio/signalling functions as shown in Figure 3-3. External Mod Out Microphone To Synthesizer Internal Microphone 16.8 / 17.0 MHz Reference Clock Audio/Signalling External...
Theory of Operation 3.4.2 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 lithium- Ion battery for operating power when the primary battery is removed. 3.4.3 Circuit Description The RTC module circuit, shown in Figure 3-4, is powered by the MODB/VSTBY pin and PI6/PI7 from...
Theory of Operation 3.4.5 Audio/Signaling The audio/signalling/filter/companding IC (ASFIC) and the audio power amplifier (Figure 3-3) 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.
Theory of Operation 3.5.2 Antenna Switch The antenna switch circuit consists of two pin diodes (D3521 and D3551), a pi network (C3531, L3551, C3550), and two current limiting resistors (R3572-3). In the transmit mode, pin 32 of PCIC U3502 goes high which applies a B+ source to the antenna switch circuit to bias the diodes "on". The shunt diode (D3551) shorts out the receiver port and the pi network.
Theory of Operation Antenna RF Amp Crystal Filter Filter 1st Mixer Filter RX from Antenna Switch Inj Filter First LO from Synthesizer Cer Fltr Cer Fltr Ceramic Resonator Recovered Audio Demodulator RSSI Figure 3-6. 200 MHz Receiver Block Diagram 3.6.1 Receiver Front-End The received signal from the antenna is routed through the harmonic filter and antenna switch and applied to the antenna filter, consisting of L3320-22 and C3340-47.
Theory of Operation The IFIC is a low-voltage monolithic FM IF system incorporating a mixer/oscillator, two limiting IF amplifiers, quadrature detector, logarithmic received signal strength indicator (RSSI), voltage regulator and audio and RSSI op amps. The second LO frequency is determined by Y3200. Additional IF selectivity is provided by two ceramic filters, FL3204 (between the second mixer and IF amp) and FL3206 (between the IF amp and the limiter input).
Theory of Operation 3.7.2 Fractional-N Synthesizer The Fractional-N synthesizer, shown in Figure 3-8, uses a 16.8 MHz reference oscillator (Y3762) to provide a high stability reference for the system. Stability is better than 2.5 ppm over temperatures of -30 to 60 °C. Electronic frequency adjustment is achieved by an internal DAC which provides a frequency adjustment voltage from U3701 pin 25 to the reference oscillator module.
3-10 Theory of Operation vary between 3.5V and 9.5V. An additional loop filter pole (R3828, C3831 and C3843, further attenuate noise and spurs on the steering line voltage. In the receive mode, the TRB line (U3801 pin 19) is low. This activates the receive VCO and the receive buffer of U3801, which operate within the range of 261.85 to 266.85 MHz.
Theory of Operation 3-11 700 MHz Transmitter The 700 MHz transmitter consists of the following basic circuits as shown in Figure 3-10. • Power amplifier • Antenna switch/harmonic filter • Antenna matching network • Power control integrated circuit (PCIC) PCIC Antenna Matching Vcontrol...
3-12 Theory of Operation 3.8.3 Harmonic Filter The harmonic filter is a modified Zolotarev design optimized for efficiency of the PA. It consists of a combination of lumped components (C102-7, L101-2) and microstrip elements. This type of filter has the advantage that it can give a greater attenuation in the stop-band for a given ripple level. The design was optimized to meet critical attenuation requirements for the second harmonic in the 1559- 1610 MHz GNSS band.
Theory of Operation 3-13 Antenna RF Amp Crystal Crystal Filter Filter 1st Mixer Filter Filter RX from Antenna Switch Inj Filter First LO from Synthesizer Cer Fltr Cer Fltr Ceramic Resonator Recovered Audio Demodulator RSSI Figure 3-11. 700 MHz Receiver Block Diagram 3.9.1 Receiver Front-End The received signal from the antenna is routed through the harmonic filter and antenna switch and...
3-14 Theory of Operation 3.10 700 MHz Frequency Generation System 3.10.1 Overview The frequency generation system, shown in Figure 3-12, is composed of two circuit blocks, the Fractional-N synthesizer IC U201, the VCO/Buffer IC U600, and associated circuitry. Figure 2-13 shows the peripheral interconnect and support circuitry used in the synthesizer block, and Figure 2-14 details the internal circuitry of the VCOBIC and its interconnections to the surrounding components.
3-16 Theory of Operation In the transmit mode, Q603 is off and U600-19 is pulled high to 5V by R655, enabling the transmit VCO and buffer. The 746-794 MHz RF signal from U600 pin 10 is applied as TX_INJ to the input of the transmitter driver IC (U101 pin 16).
Theory of Operation 3-17 3.11 Trunked Radio Systems Trunked systems allow a large number of users to share a relatively small number of frequencies or repeaters without interfering with each other. The airtime of all the repeaters in a trunked system is pooled, which maximizes the amount of airtime available to any one radio and minimizes channel congestion.
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3-18 Theory of Operation 3.11.2.3 Low Speed Data Filter This analog circuitry is a 4 pole, 150 Hz cutoff low pass filter comprised of U603-1, U603-2 and associated passive components. In receive mode, it removes noise and voice band signals leaving only the low speed data waveform which is applied to the ADC input of the MCU.
Chapter 4 Maintenance Introduction This chapter of the manual describes: • 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. Inspection Check that the external surfaces of the radio are clean, and that all external controls and switches are functional.
When damaged parts are replaced, identical parts should be used. If the identical replacement component is not locally available, check the parts list for the proper Motorola part number and order the component from the nearest Motorola Communications parts center listed in the “Piece Parts”...
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• 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 mini- thermojet hand piece. On either unit, adjust the temperature control to 700 degrees F. (370 degrees C), and adjust the airflow to a minimum setting.
• Remove the circuit board and inspect the repair. No cleaning should be necessary. Recommended Test Tools Table 4-1. lists the recommended tools used for maintaining this family of radios. These tools are also available from Motorola. Table 4-1. Recommended Test Tools Motorola Part Number...
Maintenance 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 4-1.The radio must be disassembled to replace the fuses as described inthe Basic Service Manual (see Chapter 1 - Related Documents), then the circuit board separated from the radio chassis as described in the paragraphs that follow.
2. Lift the circuit board out of the radio chassis, then remove and discard the thermal pad located between the circuit board and chassis. 3. After repairs, replace the thermal pad (Motorola P/N 7580556Z01) then reinstall the circuit board into the radio chassis.
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Maintenance If the error code Then, there is To correct the problem ... displayed is ... a ... No Display improperly connected check connection between main board and display display module or module or replace with new display module. damaged display module.
Maintenance 4.10 200 MHz Troubleshooting Charts MCU Check Press PTT. Red LED does not Before replacing light up Power Up Not able to pro- MCU, check SPI Alert Tone gram RF Board Audio at AUDIO clock, SPI data, Audio PA J403 Audio and RF IC select (U420) input...
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Maintenance START Bad SINAD Bad 20dB Quieting No Recovered Audio Audio at pin 8 Check Controller of U3101? Induce or inject 1st IF into XTAL Filter IF Freq: 44.85 MHz Audio heard? Check 2nd Voltage at U3101 Pin 4 Level approx.
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4-10 Maintenance Inject RF into J3501 Trace IF signal Q3200 collec- from C3200 to IF Signal at tor OK? Q3200. Check for C3281? IF signal bad XTAL filter. present? Before replac- ing U3101, 1st LO check U3101 O/P OK? (+5 voltages;...
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Maintenance 4-11 START No Power Check U3502 Pin 32 Is There B+ voltage, R3572-3, Bias for Ant etc. switch TX Cur- Is Control Volt- Check PCIC rent nor- age High or Low mal? High Check Drive to Module 1. Check Pin Diodes 2.
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4-12 Maintenance Check U3201, 3.3V at U3701 Start L3731 pins 5, 20, 34 & 36 Visual Check D3701, Correct check of the D3702, U3701, Problem Board OK? C3701 - C3707 U3701 Pin 47 Is 16.8MHz 16.8MHz Replace at pin 6 of approx.
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Maintenance 4-13 START Change U3801 L3831, RX LO Change L3832, signal L3831, L3832 L3833 O/ present? Pin 10 (U3801 Tx Carrier? Pin 19) 3.2V in >1V? TX Mode? VCO OK Check R3811, L3811 for dry joint AUX 3 or faulty Check High in TX R3829...
4-14 Maintenance 4.11 700 MHz Troubleshooting Charts MCU Check Press PTT. Red LED does not Before replacing light up Not able to pro- Power Up MCU, check SPI gram RF Board Alert Tone AUDIO clock, SPI data, Audio at J403 Audio AudioPA (U420) and RF IC select at Pin 2 &...
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Maintenance 4-15 START Bad SINAD Bad 20dB Quieting No Recovered Audio Audio at pin 8 Check Controller of U350? Induce or inject 1st IF into XTAL Filter IF Freq: 73.35 MHz Audio heard? Check 2nd Voltage at U350 Pin 4 Level Approx.
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4-16 Maintenance Inject RF into J101 Trace IF signal Q350 collec- from L304 to IF Signal tor OK? Q350. Check for at L304? IF signal bad XTAL filter present? Before replac- ing U350, check U350 voltages; 1st LO O/P trace IF signal OK? (+8 dBm RF Signal at Check FGU...
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Maintenance 4-17 START No Power Is There B+ Check U102 Pin Bias for Ant 32 voltage, R101, switch R102, etc. Is TX Is Control Volt- Current Check PCIC age High or Low normal? High Check Drive to Module 1. Check Pin Diodes 2.
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4-18 Maintenance Check U203, 3.3V at U201 Start L202, etc. pins 5, 13, 20, 34 & 36 Visual Check CR201-2, Correct check of the C223-5 and associ- Problem Board OK? ated circuitry. Is U201 Pin Is 16.8MHz 16.8MHz at R203 & Replace 47 approx.
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Maintenance 4-19 Troubleshoot Q601 and START associated circuitry RF signal Change at U600 U600 Pin 10? Is RX LO signal Change L253 O/C? present? L253 Is TRB Is U600 (U600 Pin 19) Tx Carrier? Pin 10 5V in TX >1V? Mode? VCO OK Check R605 &...
4-20 Maintenance 4.12 PassPort Trunking Troubleshooting Chart Start Check Radio Operation on a Non PassPort Zone with a Conventional Personality without the Option Board Enabled Check Radio PassPort Programming using CPS Check Switched Battery and Vdd from Radio on PTCB Check Radio PassPort Programming using CPS Rx Demod...
1. Unless otherwise stated, resistances are in Ohms (k = 1000), and capacitances are in picofarads (pF) or microfarads (µF). 2. DC voltages are measured from point indicated to chassis ground using a Motorola DC multime- ter or equivalent. Transmitter measurements should be made with a 1.2 µH choke in series with the voltage probe to prevent circuit loading.
Schematic Diagrams, Overlays, and Parts Lists 5.2.3 Universal Flex Connector J403 J416 J415 J414 J413 J412 J411 J410 J409 J408 J407 J406 J405 J404 Back Metal Front Metal View From Top Side View From Top Side Figure 5-3. Universal Flex Connector...
Schematic Diagrams, Overlays, and Parts Lists 5-19 UNSWB+ BATTERY F501 CONTACTS S502 PB505 IT C H SWTCH SWITCH MECH_SWB+ 1880619Z02 4080523Z01 IT C H B501 BATT_CODE EMER C502 TAB2 DATA C3336 C504 C536 C503 C535 L505 0.47uF 10uF 100pF 1000pF 390n 390nH 0.47uF...
Schematic Diagrams, Overlays, and Parts Lists 5-21 200 MHz Radio Parts List (PCB 8486236Z06) Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Part No. Part No. Part No. Circuit Motorola C459 2113743N50 100 pF C3206 2113743M24 0.1 uF +80/-20%; 16 V...
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5-22 Schematic Diagrams, Overlays, and Parts Lists Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. 0.1 uF ±10%; 16 V C3705 2113743E20 C3827 not used H3501 2680499Z01 Heatsink...
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Schematic Diagrams, Overlays, and Parts Lists 5-23 Circuit Motorola Circuit Motorola Circuit Motorola Circuit Motorola Description Description Description Description Part No. Part No. Part No. Part No. R424 0662057N12 36 K R606 0662057N23 100 K R3563 0662057N33 270 K R3835...
5-30 Schematic Diagrams, Overlays, and Parts Lists 4.6 V Super Filter Supply from U201 C625 RX VCO 51pF R607 1.9 V when selected C617 R605 Freq Range R600 819.35 to 837.35 MHz C612 C616 C615 C614 C613 C611 C610 0.1uF C626 2.2uF 0.1uF...
5-44 Schematic Diagrams, Overlays, and Parts Lists Figure 5-34. Keypad/PassPort Option Board Schematic Diagram...
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Motorola, Intelligence Everywhere, Professional Radio are trademarks of Motorola, Inc. LTR is a registered trademark of E.F . Johnson Company. PassPort is a registered trademark of Trident Datacomm Technologies, Inc. All other product or service names are the property of their respective owners.