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Professional Digital Two-Way Radio System
MOTOTRBO™ Repeater
Basic Service Manual
DR 3000 Repeater
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Summary of Contents

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    Professional Digital Two-Way Radio System MOTOTRBO™ Repeater Basic Service Manual DR 3000 Repeater...

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    DR 3000 Title Page UHF Range 1 ™ MOTOTRBO Repeater Basic Service Manual 6866576D03-A...

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    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.

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    Document History The following major changes have been implemented in this manual since the previous edition: Edition Description Date 6866576D03-A Initial Release Feb. 2007 6866576D03-A February 21, 2007...

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    Notes February 21, 2007 6866576D03-A...

  • Page 6: Table Of Contents

    Table of Contents Table of Contents Foreword ...ii Product Safety and RF Exposure Compliance ...ii Computer Software Copyrights ...ii Document Copyrights ...ii Disclaimer...ii Trademarks ...ii Document History ... iii Chapter 1 Introduction ... 1-1 Notations Used in This Manual ... 1-1 Repeater Description ...

  • Page 7: Table Of Contents

    LED Indicator Descriptions ... 6-2 Appendix A EMEA Regional Warranty, Service and Support ...A-1 Warranty and Service Support ...A-1 European Radio Support Centre (ERSC) ...A-2 Piece Parts...A-2 Technical Support ...A-3 Further Assistance From Motorola...A-3 Glossary ... Glossary-1 February 21, 2007 Table of Contents 6866576D03-A...

  • Page 8: Table Of Contents

    viii List of Figures Figure 1-1. Repeater Model Numbering Scheme... 1-2 Figure 2-1. Mobile & Repeater Rear Programming Cable PMKN4010_ ... 2-2 Figure 2-2. Mobile & Repeater Rear Programming, Testing & Alignment Cable PMKN4016_... 2-3 Figure 4-1. Customer Programming Software Setup from Rear Accessory Connector ... 4-1 Figure 4-2.

  • Page 9: Table Of Contents

    List of Tables List of Tables Table 1-1. Frequency Ranges and Power Levels ... 1-1 Table 2-1. Recommended Test Equipment ... 2-1 Table 2-2. Service Aids ... 2-2 Table 3-1. Initial Equipment Control Settings ... 3-1 Table 3-2. Receiver Performance Checks ... 3-2 Table 4-1.

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    Related Publications February 21, 2007 6866576D03-A...

  • Page 11: Chapter 1 Introduction, Notations Used In This Manual, Repeater Description

    C a u t i o n Repeater Description The MOTOTRBO Repeater is Motorola’s newest two-way digital and analog repeater designed for your organization’s most demanding needs. The repeater is available in the following frequency ranges and power levels.

  • Page 12: Mototrbo Repeater Model Numbering Scheme, Figure 1-1. Repeater Model Numbering Scheme

    MOTOTRBO Repeater Model Numbering Scheme Model No.Example : Position AZ: Asia/Australia LA: Latin America AA: North America (except Mexico) MD: Europe/Middle East/Africa Repeater MOTOTRBO Repeater Model Series Band Q: 403-470MHz Power Level P: 25-40W Figure 1-1. Repeater Model Numbering Scheme February 21, 2007 Introduction: MOTOTRBO Repeater Model Numbering Scheme Physical Packages...

  • Page 13: Uhf1 High Power Mototrbo Repeater (403-470 Mhz) Model Chart

    Introduction: UHF1 High Power MOTOTRBO Repeater (403-470 MHz) Model Chart UHF1 High Power MOTOTRBO Repeater (403-470 MHz) Model Chart Model MDM27QPR9JA7AN Item PMLN4815_ PMLN4814_ PMUE2390_S 3002695D05 NNTN7373_R NNTN7374_R 6866537D37 X = Item Included _ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number. 6866576D03-A UHF1 403-470 MHz, 25-40W Description...

  • Page 14: Specifications

    Specifications Specification Channel Capacity Technical RF Output Frequency Dimensions (HxWxL) Weight Voltage Requirements Current Drain: Standby Transmit Operating Temperature Range Max Duty Cycle Specification Frequency Channel Spacing Frequency Stability (-30°C to +60°C) Analog Sensitivity Digital Sensitivity Intermodulation Adjacent Channel Selectivity: Spurious Rejection Audio Distortion @ Rated Audio Hum and Noise...

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    Introduction: Specifications Specification Frequency Channel Spacing Frequency Stability (-30°C to +60°C) Power Output Modulation Limiting FM Hum and Noise Conducted/Radiated Emission Adjacent Channel Power Audio Response Audio Distortion Digital Vocoder Type Digital Protocol Conforms to: ETSI TS 102 361 (Parts 1, 2 & 3) - ETSI DMR Standard 1999/5/EC (R&TTE - Radio and Telecommunications Terminal Equipment) 2002/95/EC (RohS - Banned Substances) 2002/96/EC (WEEE - Waste Electrical and Electronic Equipment)

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    Introduction: Specifications Notes February 21, 2007 6866576D03-A...

  • Page 17: Chapter 2 Test Equipment And Service Aids, Recommended Test Equipment, Table 2-1. Recommended Test Equipment

    Chapter 2 Test Equipment and Service Aids Recommended Test Equipment The list of equipment contained in Table 2-1 includes most of the standard test equipment required for servicing Motorola repeaters. Equipment Characteristic Service Monitor Can be used as a substitute for items...

  • Page 18: Service Aids, Programming Cables, Table 2-2. Service Aids

    Table 2-2 lists the service aids recommended for working on the repeater. While all of these items are available from Motorola, most are standard workshop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.

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    Test Equipment and Service Aids: Programming Cables DB 25 CONNECTOR 915 15 CABLE Figure 2-2. Mobile & Repeater Rear Programming, Testing & Alignment Cable PMKN4016_ 6866576D03-A USB CONNECTOR 1455 24 CABLE TO MOBILE RADIO ACCESSORY CONNECTOR VIEWED FROM FRONT (PIN END) OF CONNECTOR TABLE 2: WIRE DIAGRAM 26 PIN...

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    Test Equipment and Service Aids: Programming Cables Notes February 21, 2007 6866576D03-A...

  • Page 21: Chapter 3 Transceiver Performance Testing, General, Setup, Table 3-1. Initial Equipment Control Settings

    Chapter 3 Transceiver Performance Testing General The MOTOTRBO Repeater meets published specifications through their manufacturing process by utilizing high-accuracy laboratory-quality test equipment. The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 22: Table 3-2. Receiver Performance Checks

    Communications Test Name Rated Audio Mode: GEN Output level: 1.0 mV RF 4th channel test frequency* Mod: 1kHz tone at 3 kHz deviation Monitor: DVM: AC Volts Distortion As above, except to distortion Sensitivity As above, except SINAD, (SINAD) lower the RF level for 12 dB SINAD.

  • Page 23: Chapter 4 Repeater Tuning And Programming, Introduction, Customer Programming Software Setup

    Chapter 4 Repeater Tuning and Programming Introduction This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as well as the Tuner application, which are all designed for use on Windows 2000/XP operating system. These programs are available in one kit as listed in the Table 4-1. An Installation Guide is also included with the kit.

  • Page 24: Repeater Tuning Setup, Figure 4-2. Repeater Tuning Equipment Setup

    Repeater Tuning Setup A personal computer (PC), Windows 2000/XP and a tuner program (which is available as part of the MOTOTRBO CPS kit) are required to tune the repeater. To perform the tuning procedures, the repeater must be connected to the PC and test equipment setup as shown in Figure 4-2. 120 / 240 VAC Tx Port 30 dB Pad...

  • Page 25: Chapter 5 Disassembly/reassembly Procedures, Introduction, Preventive Maintenance, Inspection, Cleaning Procedures

    Chapter 5 Disassembly/Reassembly Procedures Introduction This chapter provides details about the following: • Preventive maintenance (inspection and cleaning). • Safe handling of CMOS and LDMOS devices. • Disassembly and reassembly of the repeater. • Disassembly and reassembly of the Transmit and Receive radios. •...

  • Page 26: Safe Handling Of Cmos And Ldmos Devices

    “snow” trays used for storage and transportation of other semiconductor devices. CMOS device. We recommend using the Motorola Static Protection Assembly (part number 0180386A82), which includes a wrist strap, two ground cords, a table mat, and a floor mat.

  • Page 27: Table 5-1. Lead Free Solder Wire Part Number List

    When damaged parts are replaced, identical parts should be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola part number and order the part from the nearest Motorola Radio Products and Solutions Organization listed in Appendix A of this manual.

  • Page 28: Disassembly Of Cover, Figure 5-1. Removing Top Cover Of Repeater Enclosure

    • 19 mm Deep Well Socket Driver If a unit requires more complete testing or service than is customarily performed at the basic level, please send repeater to a Motorola Service Center listed in Appendix A. The following disassembly procedures should be performed only if necessary.

  • Page 29: Disassembly Of Repeater Indicator Board, Figure 5-2. Disconnecting Ethernet Cable And Flex Cable

    Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 5.6.2 Disassembly of Repeater Indicator Board (Refer to Figure 5-2 and Figure 5-3) 1. Disconnect the blue ethernet cable from the ethernet connector on the Repeater Indicator Board. 2. Disconnect flex cable from 30-position connector on Repeater Indicator Board, noting orientation of cable which is identified with a solid black line.

  • Page 30: Disassembly Of Fan, Figure 5-3. Repeater Indicator Board Disassembly, Figure 5-4. Fan Orientation

    7. Store Repeater Indicator Board in an anti-static bag when it is not being serviced. Front Panel Repeater Indicator Board M3 Screws (4) Figure 5-3. Repeater Indicator Board Disassembly 5.6.3 Disassembly of Fan 1. Unplug the fan cable from the mating connector on the connector board assembly. 2.

  • Page 31: Removing Transmit Radio, Figure 5-5. Tx Radio Disassembly

    Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 5.6.4 Removing Transmit Radio (Refer to Figure 5-5) 1. Disconnect flex cable from 30-position connector on Transmit radio, noting orientation of cable which is identified with a solid blue line. This is important for reassembly. 2.

  • Page 32: Removing Thermal Pad And Heatsink, Removing Receive Radio, Power Supply And Connector Board Assembly

    5.6.4.1 Removing Thermal Pad and Heatsink (Refer to Figure 5-5) 1. Remove all of the seven screws which secure the heatsink to the Transmit radio using a T10 TORX™ driver. 2. Remove the heatsink from the Transmit radio. 3. Peel off and discard the thermal pad. 4.

  • Page 33: Figure 5-6. Receive Radio Removal

    Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 9. Take precaution not to damage the power supply or the connector board assembly and place assembly on a flat surface. Receive Bracket Connector Board Receive Radio Assembly M5 Screws M3 Screws (5) Power Supply Washer Figure 5-6.

  • Page 34: Disassembly Of Receive Radio, Disassembly Of Connector Board Assembly, Disassembly Of Power Supply

    5-10 5.6.5.1 Disassembly of Receive Radio (after Receive radio assembly is removed from repeater) 1. With assembly on a flat surface, loosen and remove the two M5 screws and washers that secure the Receive radio to the bracket using a T25 TORX™ driver. 2.

  • Page 35: Transceiver Board And Receiver Board Removal, Figure 5-7. Die Cast Cover Removal

    Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly — Detailed Transmit and Receive Radio Disassembly — Detailed To remove Transmit and Receive radios from the repeater, refer to Sections 5.6.4 and 5.6.5 accordingly. 5.7.1 Transceiver Board and Receiver Board Removal 1. Remove the seven screws from the die cast cover using the T20 TORX™ driver as shown in Figure 5-7.

  • Page 36: Figure 5-8. Accessory Connector Removal, Figure 5-9. Rf/dc Retention Clips Removal

    5-12 Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly — Detailed 3. Remove the accessory connector from the radio assembly by inserting a flat-blade screwdriver into the slot on the side of the connector as shown in Figure 5-8. The accessory connector should never be removed when the cover is still assembled to the radio.

  • Page 37: Figure 5-10. Transceiver Board Removal

    Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly — Detailed 5. Remove the transceiver board by sliding a finger into the opening provided at the front of the radio and gently press up on the 30-pin connector, lifting up the front of the board, as shown in Figure 5-10.

  • Page 38: Figure 5-11. Thermal Pads And Shield Gasketing On Chassis And Die Cast Cover

    5-14 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed Transmit and Receive Radio Reassembly — Detailed The following reassembly procedures are applicable to both the Transmit and Receive radios. 1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks, cuts, etc.) or debris.

  • Page 39: Transceiver Board And Receiver Board Reassembly, Figure 5-13. Replacing Gps Plug

    Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 3. Assembly of the GPS Plug Push the GPS plug into the chassis opening until it is fully seated. Refer to Figure 5-13. GPS Plug 5.8.1 Transceiver Board and Receiver Board Reassembly 1.

  • Page 40: Figure 5-15. Inserting Rf/dc Retention Clips, Figure 5-16. Inserting Accessory Connector

    5-16 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 2. Insert the RF/DC retention clips and fully seat them. The DC clip should be inserted first to properly locate the transceiver board. Refer to Figure 5-15. RF/DC Retention Clips Figure 5-15.

  • Page 41: Figure 5-17. Assembling Of Pa Pad And O-ring

    Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5-17 4. Place the PA pad on to the die cast cover by aligning the two holes in the PA pad with the alignment pins on the die cast cover. 5. Fit the O-ring onto the die cast cover securely. Refer to Figure 5-17. O-ring PA Pad Die Cast Cover...

  • Page 42: Figure 5-18. Assembling Die Cast Cover Onto Chassis

    5-18 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 6. Place the die cast cover onto the chassis orienting the die cast cover so that screw holes 6 and 7 align with the bosses on the chassis as shown in Figure 5-18. Screws (7) Die Cast Cover Radio Chassis...

  • Page 43: Thermal Pad Replacement Procedure, Figure 5-19. Screw Sequence To Tighten Die Cast Cover

    Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 7. Using a T20 TORX™ driver, tighten the seven screws between 2.94 N-m (26 lbs-in) in the order shown in Figure 5-19. 8. Repeat tightening the seven screws in the order shown otherwise the first three screws will likely be loose.

  • Page 44: Figure 5-21. Aligning Driver Pad On Chassis

    5-20 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed Driver Thermal pad Replacement 1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad. 2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary. Care should be taken to minimize any cleaning-agent contact with the surrounding shield gasket.

  • Page 45: Reassembly Of Receive Radio, Power Supply And Connector Board Assembly, Reassembly Of Power Supply

    Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5.8.3 Reassembly of Receive Radio, Power Supply and Connector Board Assembly (Refer to Figure 5-6) Visually inspect repeater enclosure to ensure that no metal shavings or debris are found. 5.8.3.1 Reassembly of Power Supply 1.

  • Page 46: Reassembly Of Transmit Radio, Replacing The Thermal Pad And Heatsink

    5-22 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 12. Insert the solder terminal end of the SSI cable into the 11-position connector at the front face of Receive radio. A dashed black line is visible from the top view. 5.8.4 Reassembly of Transmit Radio (Refer to Figure 5-5)

  • Page 47: Reassembly Of Fan, Reassembly Of Repeater Indicator Board, Reassembly Of Cover, Figure 5-23. Fan Orientation

    Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5.8.5 Reassembly of Fan 1. Position the fan in the enclosure with arrow pointing outward and the wires on the fan at the bottom right corner of the fan. 2. Position the fan grill outside of the enclosure aligning with the screw holes. 3.

  • Page 48: Repeater Exploded Mechanical Views And Parts Lists, Figure 5-24. Repeater Assembly Exploded View

    5-24 Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists Repeater Exploded Mechanical Views and Parts Lists Transmit Bracket & Radio Assembly See following pages for breakdown. Figure 5-24. Repeater Assembly Exploded View February 21, 2007 Receive Bracket & Radio assembly See following pages for breakdown.

  • Page 49: Figure 5-25. Receive Bracket And Radio Assembly Exploded View

    Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists 5-25 20 31 Figure 5-25. Receive Bracket and Radio Assembly Exploded View Figure 5-26. Transmit Bracket and Radio Assembly Exploded View 6866576D03-A February 21, 2007...

  • Page 50: Figure 5-27. Front Panel Complete Assembly Exploded View, Table 5-3. Repeater Exploded View Parts List

    5-26 Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists Figure 5-27. Front Panel Complete Assembly Exploded View Table 5-3. Repeater Exploded View Parts List Item No. Screw, TT6x1.0x10, Starpan, EM6219 (black) Repeater Indicator Board Cable, Flex SSI Cable, Flex 30-Position Fan Assembly Enclosure Assembly Top Cover...

  • Page 51: Torque Chart, Table 5-4. Torque Specifications For Nuts And Screws

    Disassembly/Reassembly Procedures: Torque Chart Table 5-3. Repeater Exploded View Parts List Item No. Lock Nut M4 Power Supply Screw, M5x0.8x8.0, Starpan STLZNC Receive Radio Brick Assembly Connector Board Assembly Screw, M3x0.5x5, Starpan STLZNC RX Bracket Assembly Transmit Radio Brick Assembly Thermal Pad Heatsink Screw, M3x0.5x10, Starpan STLZNC...

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    5-28 Disassembly/Reassembly Procedures: Torque Chart Notes February 21, 2007 6866576D03-A...

  • Page 53: Chapter 6 Basic Troubleshooting, Introduction, High Power Rf Precaution, Replacement Service Kit Procedures

    Introduction This chapter contains error codes and board replacement procedures. If the repeater does not pass all the performance checks in Chapter 3, then please send the repeater to a Motorola Service Center listed in Appendix A. NOTE: To access the various connector pins, use the housing eliminator/test fixture along with the diagrams found in this section of the manual.

  • Page 54: Led Indicator Descriptions, Table 6-1. Led Indicator Descriptions

    LED Indicator Descriptions Status Power Solid GREEN Solid RED Repeater Solid RED Disable Blinking RED Digital Solid BLUE Analog Solid YELLOW TX-A Solid GREEN Solid GREEN RX-A Solid YELLOW Solid YELLOW TX-B Solid GREEN RX-B Solid YELLOW February 21, 2007 Basic Troubleshooting: LED Indicator Descriptions Table 6-1.

  • Page 55

    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.

  • Page 56

    Some replacement parts, spare parts, and/or product information can be ordered directly. If a complete Motorola part number is assigned to the part, it is available from Motorola Radio Products and Solutions Organization (RPSO). If no part number is assigned, the part is not normally available from Motorola.

  • Page 57

    EMEA Regional Warranty, Service and Technical Support: Technical Support Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions which may be encountered. North Europe - Stephen Woodrow Telephone: +44 (0) 1256 488 082 Fax: +44 01256 488 080 Email: CSW066@motorola.com...

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    EMEA Regional Warranty, Service and Technical Support: February 21, 2007 6866576D03-A...

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    Light Emitting Diode: An electronic device that lights up when electricity is passed through it. Motorola Digital Communications. Megahertz: One million cycles per second. Used especially as a radio- frequency unit.

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    Glossary-2 Term PC Board Printed Circuit Board. Also referred to as a PCB. Private-Line Tone Squelch: A continuous sub-audible tone that is transmitted along with the carrier. Programming Cable A cable that allows the CPS to communicate directly with the radio using RS232.

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    MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners. © 2007 Motorola, Inc. All rights reserved. March 2007 . www.motorola.com/mototrbo @6866576D03@...

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