Motorola ASTRO XTL 2500 Installation Manual
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Motorola ASTRO XTL 2500 Installation Manual

Digital mobile radio m5 control head
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M5 Control Head
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  • Page 1 ASTRO 2500 ® ™ Digital Mobile Radio M5 Control Head Installation Manual...

  • Page 2: Foreword

    No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola.

  • Page 3: Installation Requirements For Compliance With Radio Frequency (Rf) Energy Exposure Safety Standards

    Product Safety and RF Exposure booklet enclosed with each radio (Motorola Publication part number 68P81095C99) to ensure compliance with Radio Frequency (RF) energy exposure limits. For a list of Motorola-approved antennas and other accessories, visit the following web site which lists approved accessories for your radio model: http://www.motorola.com/cgiss/index.shtml.
  • Page 4 This Page Intentionally Left Blank...

  • Page 5: Table Of Contents

    Radio Frequency (RF) Energy Exposure Safety Standards ......iii Mobile Radio Model Numbering Scheme.............x Commercial Warranty ..................xii Limited Warranty ............................xii MOTOROLA COMMUNICATION PRODUCTS ................xii I. What This Warranty Covers And For How Long ..............xii II. General Provisions ........................ xii III. State Law Rights ......................... xiii IV.
  • Page 6 Transceiver Rear Accessory Jack Connection ..............3-9 Chapter 4 Finishing the Installation: Cable Connection ....4-1 Appendix A Replacement Parts Ordering..........A-1 Basic Ordering Information ......................A-1 Motorola Online ..........................A-1 Mail Orders ............................ A-1 Fax Orders............................. A-2 Parts Identification ......................... A-2 Product Customer Service......................A-2 Glossary ..................Glossary-1...
  • Page 7 Related Publications ASTRO XTL 2500 Digital Mobile Radio Models M5 User’s Guide ..........HLN6942A ASTRO XTL 2500 Digital Mobile Radio User’s Guide CD (All Models) ........9964416H01 ASTRO XTL 2500 Digital Mobile Radio Basic Service Manual ...........6815853H01 CPS Programming Installation Guide ..................6881095C44 ASTRO Digital Spectra Mobile Radios Dual Control Head Radio System Service Manual..6881091C78...
  • Page 8 viii List of Figures List of Figures Figure 1-1. Front View of Dash Mount Transceiver Trunnion..............1-1 Figure 1-2. Side View of Dash Mount Transceiver Trunnion..............1-1 Figure 1-3. Dash Mount Configuration ....................1-2 Figure 1-4. Remote Mount Configuration....................1-2 Figure 1-5.
  • Page 9 List of Tables Table 2-1. Radio Functions Connections .................. 2-13 Table 2-2. Fuse Assembly for Yellow and Red Leads Parts List..........2-15 Table 3-1. VIP Output Connections .................... 3-1 Table 3-2. VIP Input Connections ....................3-2 Table 3-3. Rear Accessory Jack Pin Functions................3-11 Table 3-4.

  • Page 10: Mobile Radio Model Numbering Scheme

    Mobile Radio Model Numbering Scheme Mobile Radio Model Numbering Scheme Typical Model Number: M 2 0 U osition: 1 2 3 9 10 11 12 13 14 15 16 osition 1 -Type ofUnit ositions 13 - 16 M = Mobile S Model Suffix L = Table Top Station osition 12 -...
  • Page 11 Mobile Radio Model Numbering Scheme Notes October 12, 2005 HLN6947A...

  • Page 12: Commercial Warranty

    Product Accessories One (1) Year Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period.

  • Page 13: Iii. State Law Rights

    Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada.

  • Page 14: Vi. Patent And Software Provisions

    A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such claim; B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its settlement or compromise; and C.
  • Page 15 Commercial Warranty Notes October 12, 2005 HLN6947A...

  • Page 16: Chapter 1 Introduction

    Chapter 1 Introduction This manual covers the installation procedures for ASTRO XTL 2500 mobile radios with M5 control heads and accessories required to complete the radio system. The radio system consists of a control head, radio, antenna, microphone, speaker, cabling, and accessories.

  • Page 17: Dash Mount Configuration

    Introduction: Standard Configurations Standard Configurations 1.2.1 Dash Mount Configuration NOTE: The dash mount configuration is not applicable for 110W radios. In the dash mounting version of the XTL 2500, the control head is mounted on the front of the transceiver housing. Electrical connection between the two takes place within the radio via a flexible circuit board between the connectors on the front of the transceiver and at the back of the control head.

  • Page 18: Base/Control Stations

    Introduction: Base/Control Stations GCAI 2. Not for Keypad Mic GCAI 1 Figure 1-5. Remote Mount Configuration, with 110W transceiver For details on these configurations, see Section 2.2.2 on page 2-8. Base/Control Stations NOTE: The base/control station option is not applicable for 110W radios. If mobile radio equipment is installed at a fixed location and operated as a control station or as a fixed unit, the antenna installation must comply with the following requirements in order to ensure optimal performance and compliance with the RF energy exposure limits in the standards and...

  • Page 19: Tools Required For Xtl 2500 Installations

    Introduction Tools Required for XTL 2500 Installations Tool Part Number 11/32 hex driver — RF cable tool HLN6695_ Regular slot screwdriver of — Phillips #2 Pin removal tool 6680163F01 1/4 hex driver — October 12, 2005 HLN6923A...

  • Page 20: Chapter 2 Standard Configurations

    Chapter 2 Standard Configurations Planning the Installation The XTL 2500 radio operates only in negative ground electrical systems. Before starting the radio installation, make sure that the ground polarity of the vehicle is correct. Accidentally reversing the polarity will not damage the radio, but will cause the cable fuses to blow. Planning is the key to fast, easy radio installation.

  • Page 21: Figure 2-1. Mounting Flexibility In Middle Console (Cannot Be Used For 110W Radios)

    Standard Configurations: Planning the Installation 2.1.1 Installation Examples Your mobile two-way radio offers various methods of installation, including dash or remote mount. Except for 110W radios, all versions of the XTL 2500 can be either dash or remote mounted (see Figure 2-1 through Figure...

  • Page 22: Figure 2-7. Radio Installation (Dash Mount) With Transceiver

    Standard Configurations: Planning the Installation 2.1.2 Wiring Diagrams Figure 2-7 through Figure 2-9 show the wiring diagrams for all the possible configurations. The title under each figure identifies the M5 control head configurations. Identify which of these figures shows the configuration that you are installing, and use the diagram when planning the installation. FUSE BATTERY RED LEAD...

  • Page 23: Figure 2-8. Radio Installation (Remote Midpower With Pinouts)

    Standard Configurations: Planning the Installation PORTS ON REAR OF REMOTE CONTROL HEAD FUSE BATTERY FUSE RED LEAD FUSE J400 YELLOW BLOCK LEAD VIP CONNECTOR PIN-OUT FUSE ANTENNA HORN J400 BLACK RELAY LEAD LIGHT RELAY VIP Cable Radio VIP Cable Radio (HKN6196_) Function (HKN6196_)

  • Page 24: Radio Mounting

    Standard Configurations: Radio Mounting Radio Mounting CAUTION: DO NOT mount the radio on a plastic dashboard without first reinforcing the dashboard; the weight of the radio may crack or break the dashboard. CAUTION: DO NOT mount the radio on a flat or concave surface C a u t i o n where the radio could be partially submersed in water.

  • Page 25: Figure 2-11. Trunnion Orientation For 110W Radios(Quick Release Trunnion)

    Standard Configurations: Radio Mounting Figure 2-11. Trunnion Orientation for 110W Radios (Quick Release Trunnion) Figure 2-12. Trunnion Orientation for 110W Radios (Screw-Mounted Trunnion) October 12, 2005 HLN6923A...

  • Page 26: Figure 2-13. Transmission Hump Trunnion Mounting

    Standard Configurations: Radio Mounting 2.2.1 Dash Mount with Trunnion NOTE: This configuration is not applicable for 110W radios. 1. Select the location to mount your radio on the transmission hump (see Figure 2-13) or under the dash (see Figure 2-14). When mounting the trunnion on the transmission hump take care the transmission housing is not affected.

  • Page 27: Remote Mount With Trunnion

    A typical mounting location recommended by Motorola is in the vehicle’s trunk. The trunnion provided may still be used to mount the transceiver, and the mounting process is the same as for the dash mount installation (Section 2.2.1 on page...

  • Page 28: Figure 2-15. 110W Radio Mounting Into Quick Release Trunnion

    Standard Configurations: Radio Mounting 2.2.2.1.1 110W Radios Only 1. After selecting the mounting location, use the trunnion mounting bracket as a template and mark the positions of the holes on the mounting surface. 2. Center-punch the spots you have marked and realign the trunnion in position. 3.

  • Page 29: Figure 2-16. 110W Radio Mounting Into Screw-Mounted Trunnion

    2-10 Standard Configurations: Radio Mounting B. Screw-mounted trunnion (HLN6910_): See Figure 2-16. After mounting the trunnion to the vehicle using the screws provided, insert the rear of the radio into the rear catches of the trunnion and rotate the radio down into place. Secure the radio by firmly installing the four wing screws provided.

  • Page 30: 2.2.2.2 Control Head And Remote Mount Cabling

    Standard Configurations: Radio Mounting 2-11 2.2.2.2 Control Head and Remote Mount Cabling For radios equipped with optional remote mount control heads, see Figure 2-8 Figure 2-9. Choose a mounting location for the radio, considering accessibility, and control and antenna cable lengths.

  • Page 31: Figure 2-18. Control Head Installation Exploded View

    2-12 Standard Configurations: Radio Mounting IMPORTANT USE A METAL BACKING PLATE (NOT SUPPLIED) IF MOUNTING TRUNNION ON A PLASTIC DASHBOARD DRILL FOUR 5/32" HOLES IN DASHBOARD DASHBOARD TRUNNION USE FOUR MOUNTING SCREWS ON ALL INSTALLATIONS ADJUST THE CONTROL HEAD TO DESIRED ANGLE AND SECURE WITH WING SCREWS Figure 2-18.

  • Page 32: Table 2-1. Radio Functions Connections

    Standard Configurations: Radio Mounting 2-13 2.2.2.2.2 Remote Radio Control Cable Installation The radio control cable should go from the rear of the control head to the radio. Route the cables in the vehicle’s wiring troughs (where available) or route the cables where they are protected from pinching, sharp edges, or crushing.

  • Page 33: Figure 2-20. Fuseholder Assembly For Yellow And Red Control Cables

    2-14 Standard Configurations: Radio Mounting If either wire is to be connected in the vehicle’s battery compartment, pass the end of the wire through the same firewall hole that the red radio power cable uses. At this point, install a fuseholder assembly in both wires (see Figure 2-20);...

  • Page 34: Locking Kit (Optional)

    Standard Configurations: Radio Mounting 2-15 Table 2-2. Fuse Assembly for Yellow and Red Leads Parts List Motorola Part Number Description 1482882A01 Insulator, Fuseholder Body 1482883A01 Insulator, Fuseholder Cap 2900136968 2900824456 Lug, Ring Tongue 2900865065 Lug, Ring Tongue 4182885A01 Spring, Compression; Fuse...

  • Page 35: Power Cable

    2-16 Standard Configurations: Power Cable 2.2.3.2 110W Radios An integral lock is included in the quick release trunnion (HLN6909_). The use of this lock is required for proper operation (see Figure 2-22). Figure 2-22. Lock Supplied with 110W Quick Release Trunnion Power Cable Route the red radio power cable from the radio to the vehicle’s battery compartment, using accepted industry methods and standards.
  • Page 36 Standard Configurations: Power Cable 2-17 HLN6923A October 12, 2005...
  • Page 37 2-18 Standard Configurations October 12, 2005 HLN6923A...

  • Page 38: Ignition Sense Cable

    2-19 Ignition Sense Cable Motorola supplies an ignition sense cable and recommends that it be used with every mobile installation. The ignition sense cable allows the radio to be turned on and off with the vehicle ignition switch, and allows the radio to “remember” the state of the radio on/off switch, even if it is changed while the vehicle is off.

  • Page 39: Mini-Uhf Connection

    The mini-UHF connector tool (Motorola part number HLN6695_) is designed to securely tighten the antenna plug–radio jack connection without damaging either the plug or the jack.

  • Page 40: Figure 2-27. Mini-Uhf Connector Tool (As Shown On Mid-Power)

    Standard Configurations: Antenna Installation 2-21 1. Make sure that there is sufficient slack in the antenna cable. 2. Make sure that the collar of the antenna cable plug is loose and does not bind. 3. Make sure that the mini-UHF jack is tight in the radio housing. 4.

  • Page 41: Speaker

    2-22 Standard Configurations: Speaker Speaker CAUTION: DO NOT ground the radio's speaker leads. This system has a floating speaker output (dc voltage on both leads); damage to the audio circuit will result if either lead is grounded or if they are shorted together.

  • Page 42: Microphone Hang-Up Clip

    Standard Configurations: Microphone Hang-Up Clip 2-23 Microphone Hang-Up Clip 2.7.1 Standard Hang-Up Clip The hang-up clip must be within reach of the operator(s). Measure this distance before actually mounting the bracket. Since the bracket has a positive-detent action, the microphone can be mounted in any position.
  • Page 43 2-24 Standard Configurations: Completing the Installation This Page Intentionally Left Blank October 12, 2005 HLN6923A...

  • Page 44: Chapter 3 Options And Accessories Installation

    Chapter 3 Options and Accessories Installation VIP Overview The vehicle interface port (VIP) allows the control head to operate outside circuits and to receive inputs from outside the control head. There are three VIP outputs which are used for relay control. There are also three VIP inputs which accept inputs from switches.

  • Page 45: Vip Input Connections

    Options and Accessories Installation: VIP Overview When installing relays to the VIP OUT lines, a diode is necessary to prevent damage to the transistor or MOSFET, due to “back EMF” when the field collapses on the relay coil. Some vendor relays already come with this diode built-in, and other relays require the customer to install it.

  • Page 46: Emergency Pushbutton, Footswitch, Horn Relay, And Light Relay Installation

    Options and Accessories Installation: Emergency Pushbutton, Footswitch, Horn Relay, and Light Relay Installation 3-3 NOTE: Remote Mount requires the VIP cable cable to be attached to J400. CAUTION: XTL 2500 radios equipped with the following features are capable of transmitting automatically, even if the radio is turned off: •...

  • Page 47: Dash-Mount Accessory Installation

    For dash-mounted configurations, the accessories must be installed through the accessory connector assembly that is located on the rear of the radio, adjacent to the power connector. Motorola-approved accessories are supplied with male terminals crimped to a 20-gauge wire specifically designed to fit the plug of the accessory connector assembly.

  • Page 48: Horn And Lights (External Alarms) Relays

    Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 110W) 3.3.2 Horn and Lights (External Alarms) Relays For installations that use the horn/lights option, select a suitable location for mounting (normally under the dash) and, referring to Figure 3-4, perform the following procedure: NOTE: The handheld control head can have a horn or light option, but not both.

  • Page 49: Installation Into The Vehicle

    Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 110W) 3.4.1 Installation into the Vehicle CAUTION Before installing any electrical equipment, check the vehicle manufacturer’s user manual. The installation of this device should be completed by an authorized servicer or installer.

  • Page 50: Disassembly And Assembly

    Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 110W) 3.4.3 Disassembly and Assembly 3.4.3.1 Disassembly 1. Disconnect the negative terminal from the vehicle’s battery. Make sure that the battery cable is secured such that it will not power the vehicle’s electrical system. See Figure 3-5.

  • Page 51: Adapter Cable

    Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 110W) 5. Squeeze the covers together bending the wires in the strain-relief features. You may need a pair of pliers to seat the assembly covers. 6. Once the covers are fully seated, fasten them with the cover screws. Tighten the screws firmly but do not over-tighten them.

  • Page 52: Transceiver Rear Accessory Jack Connection

    Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 110W) It is highly recommended that you attach the correct adapter. Installing the wrong adapter may cause damage to the data communication circuitry inside your radio. If you are unsure of the pinout of your former wiring harness, please consult your ASTRO radio installation technician.

  • Page 53: Figure 3-9. Control Head Rear Accessory Jack Pin Configuration (J100)

    3-10 Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 110W) NO CONNECT USB+ CHAN ACTIVITY NO CONNECT (APCO=[A(p)] USB- OUT 2 USB PWR NO CONNECT NO CONNECT OUT 1 SWB+ NO CONNECT NO CONNECT WIRE AUX MIC NO CONNECT (APCO=[A(tx)] AUX PTT...

  • Page 54: Table 3-3. Rear Accessory Jack Pin Functions

    300 mVrms for future APCO accessories. The DC impedance is 660 ohms and the AC impedance is 560 ohms. Table 2-1 in Chapter 2 for wiring options. Note: Please see the XTL 2500 Basic Service manual (Motorola publication part number 6815853H01) for more detailed descriptions of these pins. HLN6923A October 12, 2005...

  • Page 55: Table 3-4. Rear Connector And Front Connector Naming Schemes

    3-12 Options and Accessories Installation: Accessory Connector Assembly Details (P2) (All Models Except 110W) Table 3-4. Rear Connector and Front Connector Naming Schemes EIA Compatible Name at J2 Pin Number J2 Pin Name Pin Alternate Name Rear Connector J2 J2-4 UARTA_TX No change TX_DCE...

  • Page 56: Chapter 4 Finishing The Installation: Cable Connection

    Chapter 4 Finishing the Installation: Cable Connection Perform the following if it has not been previously done: 1. Remove the control head from its mounting trunnion. Plug the radio's CAN cable into the proper location on the back of the control head (see Figure 2-18 Figure 2-19 in Chapter...
  • Page 57 Finishing the Installation: Cable Connection Notes October 12, 2005 HLN6923A...

  • Page 58: Appendix A Replacement Parts Ordering

    Crystal orders should specify the crystal type number, crystal and carrier frequency, and the model number in which the part is used. The ASTRO XTL 2500 Digital Mobile Radio Basic Service Manual (Motorola publication part number 6815853H01) includes complete parts lists and parts numbers.

  • Page 59: Fax Orders

    Replacement Parts Ordering: Telephone Orders Telephone Orders Radio Products 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) Fax Orders Radio Products and Services Division*...

  • Page 60: Glossary

    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 See analog-to-digital conversion. Abacus IC A custom integrated circuit providing a digital receiver intermediate frequency (IF) backend.
  • Page 61 Glossary-2 Term Definition See baseband interface port. baseband interface Synchronous serial interface to the transceiver board used to transfer port transmit and receive audio data. See ball grid array. ball grid array A type of IC package characterized by solder balls arranged in a grid that are located on the underside of the package.
  • Page 62 FLASHcodes are only applicable for radios which are upgradeable through the FLASHport process. FLASHport A Motorola term that describes the ability of a radio to change memory. Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to, again and again.
  • Page 63 Glossary-4 Term Definition frequency Number of times a complete electromagnetic-wave cycle occurs in a fixed unit of time (usually one second). frequency This unit generates ultra-stable, low-phase noise master clock and other generation unit derived synchronization clocks that are distributed throughout the communication network.
  • Page 64 Data transmitted on the control channel from the central controller to the word subscriber unit. over-molded pad- A Motorola custom IC package, distinguished by the presence of solder array carrier balls on the bottom pads. over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the radio.
  • Page 65 Glossary-6 Term Definition paging One-way communication that alerts the receiver to retrieve a message. Patriot IC A dual-core processor that contains an MCU and a DSP in one IC package. PC Board Printed Circuit Board. Also referred to as a PCB. phase-locked loop A circuit in which an oscillator is kept in phase with a reference, usually after passing through a frequency divider.
  • Page 66 Glossary-7 Term Definition real-time clock A module that keeps track of elapsed time even when a computer is turned off. receiver Electronic device that amplifies RF signals. A receiver separates the audio signal from the RF carrier, amplifies it, and converts it back to the original sound waves.
  • Page 67 Glossary-8 Term Definition Serial Peripheral How the microcontroller communicates to modules and ICs through the Interface CLOCK and DATA lines. signal An electrically transmitted electromagnetic wave. Signal Qualifier An operating mode in which the radio is muted, but still continues to mode analyze receive data to determine RX signal type.
  • Page 68 Glossary-9 Term Definition transmitter Electronic equipment that generates and amplifies an RF carrier signal, modulates the signal, and then radiates it into space. TSOP See thin small-outline package. Transmit. UART See also Universal Asynchronous Receiver Transmitter. Ultra-High Frequency. Universal A microchip with programming that controls a computer's interface to its Asynchronous attached serial devices.
  • Page 69 Glossary-10 Notes October 12, 2005 HLN6923A...

  • Page 70: Index

    Index Index tools ............... 1-4 transmit/receive control, installing ....... 2-13 configurations 100W radios ............1-3 dash mount ............1-2 Numerics remote mount ............1-2 control head ............3-1, 3-2 100W radios cabling ..............2-11 antenna connection ..........2-20 dash mount ............1-2 configurations ............1-3 diagrams ..............
  • Page 71 Index-2 pin configuration ..........2-3, 3-9 light ..............3-3, 3-5 remote mount accessory installations .......... 3-3 cabling ..............2-11 configuration ............1-2 leads control cable installation ........2-13 black ..............2-16 control head installation ........2-11 green ........2-13, 2-14, 2-15, 2-19 installation ............. 2-4 orange ........2-13, 2-14, 2-15, 2-19 installation examples ..........

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