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Motorola ASTRO Digital Saber Service Manual

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™ Digital SABER™
and
/R
Portable Radios
Detailed Service Manual

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  Summary of Contents for Motorola ASTRO Digital Saber

  • Page 1 ™ Digital SABER™ Portable Radios Detailed Service Manual...
  • Page 2: Table Of Contents

    ASTRO Digital SABER Detailed Model Chart ........
  • Page 3 6 - 800MHz Transceiver Board Detailed Theory of Operation ....6-1 Introduction ..............6-1 Frequency Synthesis .
  • Page 4 List of Figures Figure 1 . B+ Routing for VHF/UHF Transceiver Boards..............4-2 Figure 2. B+ Routing for 800MHz Transceiver Boards..............4-3 Figure 3. B+ Routing for Vocoder/Controller (VOCON) Boards ............ 4-5 Figure 4. VOCON Board - Controller Section................. 7-2 Figure 5.
  • Page 5 ASTRO Digital SABER (Model I) User’s Guide ........
  • Page 6: Foreword

    RF energy. Portable Radio Operation and EME Exposure Your Motorola radio is designed to comply with the following national and international standards and guidelines regarding exposure of human beings to radio frequency electromagnetic energy (EME): •...
  • Page 7 DO NOT hold the antenna when the radio is “IN USE”. Holding the antenna affects call quality and may cause the radio to operate at a higher power level than needed. Approved Accessories For a list of approved Motorola accessories look in the appendix or accessory section of your radio’s User Guide.
  • Page 8: Electromagnetic Interference/Compatibility

    Electromagnetic Interference/Compatibility NOTE: Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inadequately shielded, designed or otherwise configured for electromagnetic compatibility. Facilities To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio in any facility where posted notices instruct you to do so.
  • Page 9: Safety And General

    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. •...
  • Page 10: Operational Cautions

    OPERATIONAL CAUTIONS ANTENNAS Do not use any portable radio that has a damaged antenna. If a damaged antenna comes into contact with your skin, a minor burn can result. C a u t i o n BATTERIES All batteries can cause property damage and/or bodily injury such as burns if a conductive material such as jewelry, keys, or beaded chains touch exposed terminals.
  • Page 11 • Do not disassemble an 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”...
  • Page 12 REPAIRS FOR MOTOROLA PRODUCTS WITH FMRC APPROVAL 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”).
  • Page 13: Manual Revisions

    Accordingly, any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied or reproduced in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not...
  • Page 14: Replacement Parts Ordering

    TELEX: 280127 FAX: 1-847-538-8198 FAX: 1-410-712-4991 (Federal Government) Domestic (U. S. A.) after hours or weekends: 1-800-925-4357 International: 1-847-538-8023 Motorola Parts Accessories and Aftermarket Division (United States and Canada) Attention: Order Processing 1313 E. Algonquin Road Schaumburg, IL 60196 Accessories and Aftermarket Division Attention: International Order Processing 1313 E.
  • Page 15: Portable Radio Model Numbering System

    Portable Radio Model Numbering System Typical Model Number: Position: 12 13 Position 1 - Type of Unit Positions 13 - 16 “SP” Model Suffix H = Hand-Held Portable Position 12 - Unique Model Variations Positions 2 & 3 - Model Series C = Cenelec 04 = ASTRO N = Standard Package...
  • Page 16: Astro Digital Saber Detailed Model Chart

    ASTRO Digital SABER Detailed Model Chart Model Number Description H04KDC9PW5AN VHF 1-5 Watt ASTRO Digital SABER Model I H04KDF9PW7AN VHF 1-5 Watt ASTRO Digital SABER Model II H04KDH9PW7AN VHF 1-5 Watt ASTRO Digital SABER Model III H04RDC9PW5AN UHF 1-4 Watt ASTRO Digital SABER Model I...
  • Page 17: Glossary

    fixed logic configuration stored in a read-only memory; information can not be altered or reprogrammed. Frequency Generation Unit 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. Host Motorola HC11F1 microcontrol unit U204 (see MCU).
  • Page 18 Repeater Remote transmit/receive facility that re-transmits received signals in order to improve communications coverage. RESET Reset line; an input to the microcontroller that restarts execution. RF PA Radio Frequency Power Amplifier Radio Service Software RPT/TA RePeaTer/Talk-Around RX DATA Recovered digital data line. Signal Qualifier An operating mode whereby the radio is muted but still continues to analyze receive data Mode...
  • Page 19 Notes 1-14...
  • Page 20: Introduction

    This manual is to be used in conjunction with the ASTRO Digital SABER Portable Radios Basic Service Manual (Motorola part number 68P81076C05), which helps troubleshooting a problem to a particular board. Conduct the basic performance checks first. This will verify the actual need for analyzing the radio and help pinpoint the functional problem area.
  • Page 21: Notations Used In This Manual

    Notations Used in Throughout the text in this publication, you will notice the use of warnings, cautions, and notes. These notations are used to emphasize This Manual that safety hazards exist, and care must be taken and observed. NOTE: An operational procedure, practice, or condition, etc., which is essential to emphasize.
  • Page 22: General Overview Of An Astro Digital Saber Radio

    The ASTRO Digital SABER radio is available in three models, which are available in the following bands; VHF (136-174MHz), UHF (403- 470MHz or 450-512MHz), and 800MHz (806-870MHz).
  • Page 23: Analog Mode Of Operation

    The display module is a two-line, liquid crystal display with associated circuitry. The display module is an integral part of the front cover keypad. This module utilizes chip-on-board technology and is not considered field repairable. The available encryption module connects directly to the VOCON board and interfaces directly to the vocoder digital circuitry.
  • Page 24: Transceiver Board Overview

    Transceiver Board The receiver front end consists of a preselector, an RF amplifier, a second preselector, and a mixer. Both preselectors in the VHF and UHF Overview radios are varactor-tuned, two-pole filters controlled by the microcontrol unit through the digital/analog (D/A) IC. On the 800MHz receiver front end, these filters are fixed-tuned.
  • Page 25 The SLIC acts as an extension of the microcontrol unit by providing logic functions such as lower address latch, reset, memory address decoding, and additional control lines for the radio. The microcontrol unit controls the crystal-pull circuit to adjust the crystal oscillator’s frequency on the microcontrol unit, so that the E-clock’...
  • Page 26: Radio Power

    Radio Power Introduction This section of the manual provides a detailed circuit description of the power distribution for an ASTRO Digital SABER radio. General In the ASTRO radio, power is distributed to three boards: • transceiver • VOCON • display In the case of a secure model radio, the encryption module is supplied also.
  • Page 27: B+ Routing For Vhf/Uhf Transceiver Boards

    B+ Routing for Refer to Figure 1 and your specific schematic diagram. VHF/UHF Raw B+ (7.5V) from the battery (Batt B+) enters the radio on the Transceiver Boards transceiver board through a 3-contact spring pin arrangement (J3) as B+, where it is routed through two ferrite beads on the VHF (E1, E101) and three ferrite beads on the UHF (E1, E101, E106) to the RF power amplifier module (U105) and ALC IC (U101, pin 13).
  • Page 28: B+ Routing For 800Mhz Transceiver Boards

    The SC3 signal at U102 pin 14 controls the Rx 5V switch U106, and the receive 5 volts (R5). A voltage on the synthesizer SOUT line at U204 pin 19 supplies power (Vcc) to the VCO buffer at U201 pin 3. During the receive mode, regulator U106 supplies regulated 5V (R5) to the receiver front end.
  • Page 29: B+ Routing For Vocon Boards And Display Modules

    receive 5 volts (R5). During the receive mode, switch Q503 supplies regulated 5volts (R5) to the receiver front end. B+ Routing for Refer to Figure 3 and your specific schematic diagram. VOCON Boards and Power for the radio is derived from a 7.5 volt battery, which is applied Display Modules to the transceiver board through J3.
  • Page 30: Figure 3. B+ Routing For Vocoder/Controller (Vocon) Boards

    Display Module 8Kx24 DSP56001 SRAM U405 ADSIC U402 U406 256Kx8 8Kx24 Audio FLASH SRAM SW_B+ Switch U404 U403 Q207 U401 8Kx24 SRAM SRAM U202 5V Regulator U414 5V Analog U410 B+_Sense Controls 256Kx8 EEPROM Flex FLASH 5V Digital U201 5V Regulator U205 U409 256Kx8...
  • Page 31 Notes...
  • Page 32: Vhf/Uhf Transceiver Board Detailed Theory Of Operation

    Introduction This section of the manual provides a detailed circuit description of an ASTRO Digital SABER VHF and UHF Transceiver Board. When reading the theory of operation, refer to your appropriate schematic and component location diagrams located in the back section of this manual.
  • Page 33 is divided into one of three pre-determined frequencies. A time-based algorithm is used to generate the fractional-N ratio. If the two frequencies in the synthesizer’s comparator differ, a control (error) voltage is produced. The phase detector error voltage (V control) at pin 31 and 33 of U204, is applied to the loop filter consisting of resistors R211, R212, and R213, and capacitors C244, C246, C247 and C275.
  • Page 34: Antenna Switch

    Antenna Switch Two antenna switches are part of the radio circuitry. One of the switches which is located in the radio casting is mechanical. It switches between the radio antenna and a remote antenna. Switching is accomplished by a plunger located on the accessory connector. With a remote antenna installed, continuity between the radio antenna and the RF input line is broken;...
  • Page 35: Receiver Back End

    the first IF frequency. The first IF frequency of VHF and UHF bands are 45.15MHz and 73.35MHz respectively. The 1st LO signal for VHF is 45.15MHz higher than the carrier frequency while that for the UHF is 73.35MHz lower than the carrier frequency. The 1st IF signal output, at U2 pins 4 and 6, is routed through transformer T2 and impedance matching components, and applied to a 2-pole crystal filter (FL1), which is the final stage of the receiver front end.
  • Page 36: Transmitter

    Transmitter The transmitter consists of three major sections: • Harmonic Filter • RF Power Amplifier Module • ALC Circuits Harmonic Filter RF from the power amplifier (PA) module (U105) is routed through the coupler (U104), passed through the transmit antenna switch (CR108), and applied to a harmonic filtering network in UHF.
  • Page 37 Notes...
  • Page 38: 800Mhz Transceiver Board Detailed Theory Of Operation

    Introduction This section of the manual provides a detailed circuit description of an ASTRO Digital SABER 800MHz Transceiver Board. When reading the theory of operation, refer to your appropriate schematic and component location diagrams located in the back section of this manual.
  • Page 39: Antenna Switch

    6 and 7 must both be high. For talkaround TX frequencies 851- 870MHz, pin 6 must be low while pin 7 must be high. The synthesizer IC (U303) consists of a prescaler, a programmable loop divider, a divider control logic, a phase detector, a charge pump, an A/D converter for low-frequency digital modulation, a balance attenuator to balance the high frequency analog modulation to the low frequency digital modulation, a 13V positive-voltage multiplier, a...
  • Page 40: Receiver Front End

    CR102, biasing them to a low-impedance state. Bias current returns to ground through U504 pin 20. In receive, U504 pin 21 is pulled down to ground and pin 20 is pulled up to B+, reverse biasing diodes CR104 and CR102 to a high impedance. Receiver Front End For the purposes of this discussion, the receiver front end is defined to be the circuitry from the antenna switch to the output of the IF crystal...
  • Page 41: Receiver Back End

    of U205 via bypass C213. The mixer’s LO port is matched to the radio’s PLL by a capacitive tap, C207 and C206. A balun transformer (T202) is used to couple the RF signal into the mixer. The primary of T202 is matched to the preceding stage by capacitor C223, with C227 providing a dc block to ground.
  • Page 42: Transmitter

    Transmitter The 800MHz RF power amplifier (PA) is a 5-stage amplifier (U502). The RF power amplifier has a nominal input and output impedance of 50 ohms. An RF input drive level of approximately +3dBm, supplied from the VCO buffer IC (U303), is applied to pin 1 of U502. The dc bias for the internal stages of U502 is applied to pins 2, 5, and 6 of the module.
  • Page 43 Notes...
  • Page 44: Vocon Board Detailed Theory Of Operation

    The controller section is the central interface between the various subsystems of the radio. It is very similar to the digital logic portion of the controllers on many existing Motorola radios. Its main task is to interpret user input, provide user feedback, and schedule events in the radio operation, which includes programming ICs, steering the activities of the DSP and driving the display.
  • Page 45: Controller Section

    Controller Section Refer to Figure 4 and your specific schematic diagram. The controller section of the VOCON board consists entirely of digital logic comprised of a microcontrol unit (MCU-U204), a custom support logic IC (SLIC-U206), and memory consisting of: SRAM (U202), EEPROM (U201), and FLASH memory (U205, U210).
  • Page 46: Vocoder Section

    The controller performs the programming of all peripheral ICs. This is done through a serial peripheral interface (SPI) bus. ICs programmed through this bus include the synthesizer, DAIC, reference oscillator, display, and ADSIC. On secure-equipped model, the encryption board is also controlled through the SPI bus. In addition to the SPI bus, the controller also maintains two asynchronous serial busses;...
  • Page 47: Figure 5. Vocon Board - Vocoder Section

    In the transmit mode, the ADSIC (U406) provides a serial digital-to- analog (D/A) converter. The data generated by the DSP is filtered and reconstructed as an analog signal to present to the VCO as a modulation signal. Both the transmit and receive data paths between the DSP and ADSIC are through the DSP SSI port.
  • Page 48: Switched Regulator

    Switched Regulator All of the digital circuitry on the VOCON is supplied 5 volt regulated dc by a switched mode regulator (refer to Figure 3 on page 5 of Chapter 4). The fundamental parts of the regulator are U409, L402, C470, CR403, C463, and U407.
  • Page 49: Rx Signal Path

    RX Signal Path The vocoder processes all received signals digitally. This requires a unique back end from a standard analog radio. This unique functionality is provided by the ABACUS IC with the ADSIC (U406) acting as the interface to the DSP. The ABACUS IC located on the transceiver board provides a digital back end for the receiver section.
  • Page 50 DIN and DIN* are the data lines in which the I and Q data words are transferred from the ABACUS. These signals make up a deferentially encoded current loop. Instead of sending TTL type voltage signals, the data is transferred by flowing current one way or the other through the loop.
  • Page 51: Tx Signal Path

    The ADSIC contains four general purpose I/O labeled GCB0 -GCB3. These are connected to the AUDIO PA and are used for enabling the speaker and microphone amplifiers in the IC and for steering the speaker and microphone audio paths from internal to external. These I/O are controlled by the DSP through the ADSIC parallel configuration bus.
  • Page 52 samples, the DSP reads the microphone samples from registers mapped into it's memory space starting at Y:FFF0. The ADSIC provides an 8kHz interrupt to the DSP on IRQB for processing these microphone data samples. As with the received trunking low speed data, low speed data is processed by the MCU and returned to the DSP at the DSP SCLK port connected to the MCU port PA0.
  • Page 53: Controller Bootstrap And Asynchronous Buses

    Controller The SB9600 bus is an asynchronous serial communications bus utilizing a Motorola proprietary protocol. Its purpose is a means for Bootstrap and the MCU to communicate with other hardware devices. In the ASTRO Asynchronous Buses Digital SABER radio, it communicates with hardware accessories connected to the universal connector.
  • Page 54: Vocoder Bootstrap

    RS232_DATA_OUT. This multiplex occurs in the SLIC IV U206, which must also be properly configured. The ASTRO Digital SABER radio has an additional asynchronous serial bus which utilizes RS232 bus protocol. This bus utilizes the UART in the SLIC IC (U206). It is comprised of RS232_DATA_OUT (15), RS232_DATA_IN (J201-8), CTSOUT* (J201-14), and RTSIN* (J201-10).
  • Page 55: Spi Bus Interface

    SPI Bus Interface This bus is a synchronous serial bus made up of a data, a clock, and an individual IC unique select line. It's primary purpose is to configure the operating state of each IC. ICs programmed by this include; display module, ADSIC, Fractional N Synthesizer, Pendulum Reference Oscillator, DAIC, and if equipped, the secure module.
  • Page 56: Keypad And Display Module

    Most of the signals are extensions of circuits described in other areas of this manual. However there are two option select pins used to configure special modes; Option Select 1 and Option Select 2. These pins are controlled by accessories connected to the universal connector.
  • Page 57: Controls And Control Top Flex

    Controls and The control top controls include an on/off switch, volume, 16 position mode select switch with two position toggle, and ergo code/clear mode Control Top Flex switch with additional emergency switch. The side controls include three momentary push button switches (monitor, RAT1, RAT2) and PTT.
  • Page 58: Controller Memory Map

    S902 is a binary coded switch. The output pins from this switch are connected to I/O ports on the controller. It provides a 4 bit binary word to the MCU indicating which of the 16 positions the rotary is set to.
  • Page 59: Figure 12. Controller Memory Mapping

    external SRAM through the gate U211. XTSCB3 is used as general purpose I/O for interrupting the secure module. In bootstrap mode the memory map is slightly different. Internal EEPROM is mapped at $FE00-$FFFF and F1 internal SRAM starts at $0000-$03FF. In addition a special bootstrap ROM appears in the ROM space from $B600-$BFFF.
  • Page 60: Vocoder Memory Map

    The SLIC is controlled through sixteen registers mapped into the MCU memory at $1400 - $14FF. This mapping is achieved by the following signals from the MCU: R/W*, CSIO1*, HA0-HA4,HA8, HA9. Upon power-up, the MCU configures the SLIC including the memory map by writing to these registers.
  • Page 61: Figure 13. Vocoder Memory Mapping

    $FFFF ADSIC Registers ADS Vectors $E000 $DFFF External ROM External ROM 16KB Physical 16KB Physical Banks Banks $20000-3FFFF $00000-1FFFF $A000 $9FFF $8000 $7FFF External External External U402 U403 U414 $2000 $1FFF $1000 $0FFF ADS P Ram $0200 ADS Dx Ram ADS Dy Ram $01FF Internal X Rom...
  • Page 62: Mcu System Clock

    program code contains the interrupt vectors and the reset vector and is basically an expanded bootstrap code. When the MCU messages the DSP that the ADSIC has been configured, the DSP overlays more code from the ROM into external SRAM and begins to execute it. Overlays occur at different times when the DSP moves code from the ROM into external SRAM depending on immediate mode of operation, such as changing from transmit to receive.
  • Page 63 things, the DSP memory map. While this is happening, the DSP is fetching code from the ROM U404 into internal RAM and beginning to execute it. It then waits for a message from the MCU that the ADSIC has been configured, before going on. During this process, the MCU does power diagnostics.
  • Page 64: Secure Modules

    Secure Modules Introduction The secure modules are designed to digitally encrypt and decrypt voice and ASTRO data in ASTRO SABER™ radios. This section covers the following secure modules: • NTN7770 • NTN1152 • NTN7771 • NTN1153 • NTN7772 • NTN1158 •...
  • Page 65: Circuit Description

    “E E E E R R R R R R R R O O O O R R R R 0 0 0 0 9 9 9 9 / / / / 1 1 1 1 0 0 0 0 ” message on the radio display. Troubleshooting Refer to the Basic Service Manual, Motorola publication number 68P81076C05 for disassembly and reassembly information. A key Secure Operations variable loader (KVL) and oscilloscope are needed to troubleshoot the secure module.
  • Page 66: Troubleshooting Procedures

    Introduction The purpose of this section is to aid in troubleshooting a malfunctioning ASTRO Digital SABER radio. It is intended to be detailed enough to localize the malfunctioning circuit and isolate the defective component. Most of the ICs are static sensitive devices.
  • Page 67: Voltage Measurement And Signal Tracing

    RF millivoltmeter, and oscilloscope (preferably with 100MHz bandwidth or more). The “Recommended Test Equipment, Service Aids, and Tools” section in the ASTRO Digital SABER Portable Radios Basic Service Manual outlines the recommended tools and service aids which would be useful. Of special note is the REX-4200A Housing Eliminator, which allows the technician to open the radio to probe points while in operation.
  • Page 68: Power-Up Self-Check Errors

    Power-Up Each time the radio is turned on the MCU and DSP perform some internal diagnostics. These diagnostics consist of checking the Self-Check programmable devices such as the FLASH ROMs, internal and external Errors EEPROMs, SRAM devices, and ADSIC configuration bus checksum. At the end of the power-up self-check routines, if an error exists, the appropriate error code is displayed on the display.
  • Page 69 Start EMC: Set the EMC wake-up line low (emc irq line). Wait 5ms. Set the EMC wake-up line high. Wait 10ms. Set the EMC wake-up line low (emc irq line). Wait 5ms. Set the EMC wake-up line high. Begin power-up self-tests. Begin RAM tests: External RAM ($1800-3FFF).
  • Page 70 - Fail 02/81 if DSP RAM fails. Wait for the ADSIC checksum. - Fail 02/90 if 100ms. - Fail 02/90 if failure. Wait for the first part of the DSP version number. - Fail 02/90 if 100ms. Wait for the second part of the DSP version number. - Fail 02/90 if 100ms.
  • Page 71: Standard Bias Table

    Standard Bias Table 3, below, outlines some standard supply voltages and system clocks which should be present under normal operation. These should be checked as Table a first step to any troubleshooting procedure. Table 2 . Standard Operating Bias Signal Name Nominal Value Tolerance Source...
  • Page 72: Troubleshooting Waveforms

    Troubleshooting Waveforms Introduction This section contains images of waveforms which may be useful in verifying operation of certain parts of the circuitry. These waveforms are for reference only; the actual data depicted will vary depending upon operating conditions. Waveforms Tek stopped: 103 Acquisitions 2.00V M 200us Ch1...
  • Page 73: Figure 15. Waveform W2

    2893 Acquisitions Tek stopped: Ch1 Freq 19.991kHz Low signal amplitude 5.00V M 20.0us Ch1 2.2 V 5.00V 5.00V MAEPF-24377-A W2: DSP SSI Port RX mode. Receiving 1KHz tone @ 3KHz deviation, -60dBm. Trace 1 - RFS Trace 2 - RXD Trace 3 - SCKR (2.4/0.600MHz) Note 1: Typically SCKR is a 2.4 MHz clock.
  • Page 74: Figure 17. Waveform W4

    13 Acquisitions Tek stopped: Ch1 Freq 74.610kHz 2.00V M 10.0us Ch1 2.2 V MAEPF-24379-O W4: ABACUS programming captured during mode change. Trace 1 - (ADSIC) SBI Figure 17 . Waveform W4 Tek stopped: 34513 Acquisitions Ch1 Freq 2.251920 MHz Low resolution 2.00V 500mV M 5.00us Ch1...
  • Page 75: Figure 19. Waveform W6

    18 Acquisitions Tek stopped: Tek stopped: Ch1 Freq = Hz No period found 5.00V 5.00V M 50ns Ch1 2.2 V 5.00V MAEPF-24381-A W6: SPI Bus Programming ADSIC. Trace 1 - ADSIC_SEL* Trace 2 - SPI_SCK Trace 3 - MOSI Note: These waveforms are typical to any device on the SPI bus.
  • Page 76: Figure 21. Waveform W8

    Tek stopped: 507 Acquisitions Ch1 Freq 7.9872kHz Low signal amplitude 5.00V 500mV M 200us Ch1 1.5 V 20.0mV 500mV MAEPF-24383-A W8: Transmit Audio. 1KHz Tone which provides 3KHz deviation. Trace 1 - IRQB @ DSP (8KHz) Trace 2 - MODIN Trace 3 - EXT MIC @ node C484/R408 Trace 4 - MAI @ node R492/U401 MICAMPOUT...
  • Page 77: Figure 23. Waveform W10

    Tek stopped: 493 Acquisitions Ch1 Freq 2.4038MHz 2.00V M 200ns 1.64 V W10 ADSIC 2.4 MHz Reference Trace 1 - IDC @ U406 MAEPF-24385-O Figure 23 . Waveform W10 11-6...
  • Page 78: Troubleshooting Diagrams

    Troubleshooting Diagrams Introduction to This Section This section contains troubleshooting diagrams necessary to isolate a problem to the component level. Use these diagrams in conjunction with the theory of operation, troubleshooting procedures, charts, and waveforms. Table 3 . J201 VOCON Board to Universal Connector J201 Description To/From...
  • Page 79: Table 4. J601Vocon Board To Display Board

    Table 4 . J601 Table 6 . J1/J401 VOCON Board to Display Board Transceiver Board to VOCON Board J601 Pin # Description From J401 Transceievr VOCON Description Board Board MOSI U204-J6 J801-8 J401-9 DOUT* U401-4 U406-H3 SPI SCK U204-G5 DOUT U401-5 U406-K3 J801-9...
  • Page 80: Table 7. J801 Vocon Board To Encryption Board

    Table 7 . J801 Table 8 . J901 VOCON Board to Encryption Board VOCON Board to Control Top Flex J801 Pin # Description To/From J901 Pin # Description To/From SW B+ J401-17 UNSW B+ J401-19 SW B+ J401-17 TG1/PROG SWITCH U204-D3 EMC RXO U405-B7...
  • Page 81 Notes 12-4...
  • Page 82 *6881076C10* Motorola 8000 West Sunrise Boulevard Fort Lauderdale, Florida 33322 68P81076C10-A...
  • Page 83 Troubleshooting Charts This section contains detailed troubleshooting flowcharts. These charts should be used as a guide in determining the problem areas. They are not a substitute for knowledge of circuit operation and astute troubleshooting techniques. It is advisable to refer to the related detailed circuit descriptions in the theory section prior to troubleshooting a radio.
  • Page 84 START START Good Power- Error Display Good Up Self Message? Model? Error Display Power-Up/ Test? Message? Model? Self Test? See Table T1; Use RSS to Go to Transmitter Is There Power-up Self See Table T1; Use RSS to display TX Power? Go to Transmitter Is There Chart C.37...
  • Page 85 Radio Power-Up Synopsis Failure. This failure assumes the radio fails to power up correctly and Verify Host Port: does not send any Power up Use ohmmeter to Verify standard failure messages via the electrically verify bias per table display or serial bus. Some following signal connections Table 3 pertaining basic failure modes:...
  • Page 86 Host µC Synopsis The host µC bootstrap mode is Bootstrap Failure. used during reprogramming of the host µC and DSP FLASH ROMs. Refer to appropriate Verify standard Theory of operation section for bias per table description of bootstrap Table 3. operation.
  • Page 87: Chart 6. 01/81 Host Rom Checksum Failure

    Fail 01/81 Synopsis DC Supply Failure This failure implies a problem Host ROM Checksum with the DC power distribution. Synopsis Failure It may relate to a battery This failure indicates the Host supply or one of the regulated Connect supply or supplies.
  • Page 88: Chart 7. 01/82 Or 002, External Eeprom Checksum Failure

    Fail 01/82 or 002 External EEPROM Synopsis Checksum Failure This failure indicates the Fail 01/84 External EEPROM data Synopsis SLIC Init Failure containing mostly customer This failure indicates a failure Use ohmmeter to electrically specific channel/mode in verification of the data in the verify following signal information is incorrect.
  • Page 89: Chart 10. 01/92, Internal Eeprom

    Fail 01/88 Host µC External RAM Synopsis Failure. This failure indicates a failure in the µC external SRAM at power up test. Some basic Verify standard failure modes: bias per table 1) Missing supply or ground to Table 3 pertaining SLIC.
  • Page 90: Chart 11. 02/A0, Adsic Checksum Faiure

    Fail 02/81 DSP ROM Checksum Synopsis Failure Fail 02/A0 This failure indicates the DSP Synopsis ADSIC Checksum ROM program code is incorrect. The ADSIC calculates a checksum of the Failure It is implied that the DSP found configuration bus data programmed through the Host µC SPI interface.
  • Page 91: Chart 13. 02/88, Dsp External Sram Failure U414

    Fail 02/84 Synopsis DSP SRAM U403 On power-up the DSP writes Failure data to the device and then verifies the data. This failure indicates the DSP SRAM failed this pattern/checksum test. Use ohmmeter to Besides utiling decoding logic electrically verify from the DSP (U405), U403 Fail 02/88 following signal connections...
  • Page 92: Chart 15. 02/82, Dsp External Sram Failure U402

    Fail 02/82 Synopsis DSP SRAM U402 Fail 02/90 On power up the DSP writes DSP Hardware Failure Synopsis Failure On power-up the host µC sends data to the device and then several handshake commands verifies the data. This failure through the host interface to the DSP system to coordinate indicates the DSP SRAM failed Verify standard...
  • Page 93: Chart 17. 09/10, Secure Hardware Failure

    Fail 09/10 Synopsis Secure Hardware This failure relates only to Failure secure equipped radios and Fail 09/90 Synopsis indicates a power up self-test Secure Hardware This failure relates only to failure for the secure module. Failure secure equipped radios and More specifically this failure Verify connections indicates a power up self-test...
  • Page 94 2) Use of wrong KVL or KVL 2) Bad connection. Side Button so NTN7330 T3014DX & T3010DX DVP-XL & DVP cable for ASTRO Digital Saber 3) Defective switches or pads. NTN7370 T3014DX & T3012DX DVP-XL & DVI-XL radio. display reads CH.
  • Page 95 Volume Set Error Synopsis This chart relates to a failure in volume set knob. Basic Failure modes are as follows: Verify operation of 1) Failure in control top/ptt Keypad volume knob per flex circuit. "Button Check" flow Error. 2) Bad connection. Synopsis chart C.20.
  • Page 96 Top/Side Button Error Synopsis This chart relates to a failure Zone/Channel Select in reading the buttons: Top, Top Error. Synopsis Side, Side Button 1, or Side Verify operation of Button 2. Basic Failure modes This chart relates to a failure buttons per "Button are as follows: in reading the zone/channel...
  • Page 97 No Display. Synopsis This chart relates to a failure in the display. The display is considered not field repairable Verify display model and must be replaced as a uint. with RSS. Basic Failure modes are as follows: 1) Non-display model radio. 2) Bad connection.
  • Page 98 No TX Modulation (Vocoder Failure) Synopsis Verify signals at U401 are: Fig. W8- This failure indicates a lack of Signal Logic Trace 4 transmit modulation with the EXT/INT_SPKR present? fault lying with the vocoder. It MICEN Verify standard bias assumes no power up fail codes per Table 3.
  • Page 99 No TX Deviation VHF/UHF Transceiver No TX Deviation 800MHz Transceiver Set radio to test mode CSQ. Connect radio to R4005B test box or equivalent and inject a 1KHz mic signal with amplitude Set radio to test mode CSQ. sufficient to provide 3KHz deviation (about 11mV RMS).
  • Page 100 No Receive Audio (Vocoder Failure) Synopsis This failure indicates a lack of received audio with the fault lying with the vocoder. It Set radio to test mode assumes a functional CSQ. Inject a 1KHz transceiver board and no power modulated signal at the up fail codes were displayed.
  • Page 101 FGU No Lo Injection/TX Unlock Bad SINAD Bad 20Db Quieting No Recovered Audio NOTE: INJECT MODULATED ON CARRIER FREQUENCY VDC at Replace SIGNAL AS REQUIRED VCTRL (TP5), U204 <0.7V? Spray or Inject 1st IF into XTAL Filter IF FREQS: FL1. 45.15 VHF 73.35 UHF/800MHz 5V at...
  • Page 102 FGU No Lo Injection/TX Unlock VDC at Replace V Con Pin 1 U302 U307 <0.7V 5V at VDC at U302 Pin 11, U305 Pin 1, 20, 23, 2 & 8 OK 25, 42? Check Continuity Between Check Continuity VDC at U302-2 &...
  • Page 103 VCO TX/RX UNLOCK Check VDC at C246 (VCTRL) NOTE: If C240 is found NOTE: If C240 is found Replace 13V/0.7V/ ONLY ONLY defective, change to 2.7PF (VHF)/ defective, change to 2.7PF (VHF)/ U201 Drifting 2.4PF (UHF1)/2.4PF (UHF2) 2.4PF (UHF1)/2.4PF (UHF2) For VHF 4.6V at Replace components &...
  • Page 104 VCO TX/RX Unlock 800MHz DC Switch. U307-9 U302-19 U302-20 U302-17 Voltage at Q503-4? Check Continuity Refer to Check C310 if Between Chart DC OK Change U302-19 & Switch C.37 U302 U307-9 Check 0V at Q503 Voltage at continuity Pin 5 - RX U305-1? between U305 Pin 3 - TX?
  • Page 105 No R5 U106 Pin 2 Voltage at U106 Pin 8? Less Replace than 4.8V at U106 U106 Pin 3? Check L131, Voltage L121 and CR109 and L122 For at Q107, Pin 2? Open Connections 5V at Replace U102 U102 Pin 1? Check DC Power Voltage Supply Failure...
  • Page 106 Replace No/Low Power Ant Switch Check Check GOOD GOOD Check RF @ Continuity Input Drive Continuity at Current RF Connector across Ant. Switch U502-1 >500 mA U501 >1dBm GOOD Check L102, Go to VCO Replace U501 L105, C114, Chart C.34 C101, C108 Go to DC Switch Chart C.35...
  • Page 107 No/Low Power Go to DC Switch TX Current Is T5 On Routine Chart C.36 > 500 mA? at C153? B+ at Check B+, E1 & E101 RF at RF U105, Pin 5 (VHF), E1, E2, E3 & Check antenna (VHF) E101, E104 (UHF) and Connector,J2 switch...
  • Page 108 UHF1 UHF2 VCTRL (TP5) C240(RX) >3.0V? C223(TX) A complete part description and Motorola part number for ordering Program Radio to is located in the service manual. High Band Edge 178 MHz (VHF) 470 MHz (UHF1) 520 MHz (UHF2) Replace C240 or C223...
  • Page 109: Block Diagrams, Schematics, Electrical Parts Lists, And Circuit Board Details

    Block Diagrams, Schematics, Electrical Parts Lists, and Circuit Board Details 13-1...
  • Page 110: Radio Interconnect Diagram

    Transceiver Board Integrated Circuit Modules U101 ANTENNA UNIVERSAL CONNECTOR SWITCH EXTERNAL ANTENNA CATH 1 V CON TX 1 INT CAP OUT 62U72 X ANODE 2 XXYY X REF V RT BIAS RX 1 MIXER THERM TX 2 TX 5V CATH 2 DIGITAL 2-POLE 2-POLE...
  • Page 111: Nld8892R Vhf Transceiver Board Schematic Diagram

    63B81094C71-O NLD8892R VHF Transceiver Board Schematic Diagram 13-3...
  • Page 112: Nld8892R Vhf Transceiver Circuit Board Details And Parts List

    C209 2113932K15 0.1 uF +80/-20% 16V Electrical Parts List C210 2113932E07 .022 uF 10% 16V C211 2113931F13 VIEWED FROM SIDE 1 MOTOROLA ITEM DESCRIPTION PART NUMBER C212 ----------------- Not Placed. C214 2113930F21 5.6 pF 50V ±0.25 pF 50V CAPACITOR, Fixed: pF ±5%; 50V...
  • Page 113 For optimum performance, order replacement diodes, transistors, and circuit C429 2113932K15 0.1 uF +80/-20% 16V L205 2462587V38 220 nH R213 0662057A41 modules by Motorola part number only. When ordering crystals, specify carrier frequency, crystal frequency, crystal C430 2311049J23 10 uF L208, L209 2462587T30 1 uH R214 0662057A87 type number, and Motorola part number.
  • Page 114: Nle4560K Uhf Range 1 Transceiver Board Schematic Diagram

    REFER TO BOM FOR A SPECIFIC KIT FOR CORRECT PART LIST. 63B81094C73-O NLE4560K UHF Range 1 Transceiver Board Schematic Diagram 13-6...
  • Page 115: Nle4560K Uhf Range 1 Transceiver Circuit Board Details And Parts List

    NLE4560K UHF Range 1 Transceiver Board C153 2113930F47 Electrical Parts List C201 2113930F03 1 pF 50V ±0.1 pF 50V C202 ----------------- Not Placed. VIEWED FROM SIDE 1 MOTOROLA C203 2113930F07 1.5 pF 50V ±0.1 pF 50V ITEM DESCRIPTION PART NUMBER C204 2113930F51 S207 S201 S203 CAPACITOR, Fixed: pF ±5%;...
  • Page 116 For optimum performance, order replacement diodes, transistors, and circuit C438 2113932K15 0.1 uF +80/-20% 16V L201 2462587T38 22 nH R212, R213 0662057A46 modules by Motorola part number only. C442 ----------------- Not Placed. L202 2462587Q20 2.2 uH 20% R214 0662057A89 When ordering crystals, specify carrier frequency, crystal frequency, crystal type number, and Motorola part number.
  • Page 117: Nle4244P Uhf Range 2 Transceiver Board Schematic Diagram

    REFER TO BOM FOR A SPECIFIC KIT FOR CORRECT PART LIST. 63B81094C73-O NLE4244P UHF Range 2 Transceiver Board Schematic Diagram 13-9...
  • Page 118: Nle4244P Uhf Range 2 Transceiver Circuit Board Details And Parts List

    NLE4244P UHF Range 2 Transceiver Board C149 2113930F27 Electrical Parts List C150 2113930F23 6.8 pF 50V ±0.25 pF 50V C151 2113930F17 3.9 pF 50V ±0.25 pF 50V MOTOROLA VIEWED FROM SIDE 1 C152 2113932K15 0.1 uF +80/-20% 16V ITEM DESCRIPTION PART NUMBER C153 2113930F47...
  • Page 119 C513 ----------------- Not Placed. L210 2405619V03 15.1 nH R215 0662057A88 For optimum performance, order replacement diodes, transistors, and circuit modules by Motorola part number only. C514, C515 2113932K15 0.1 uF +80/-20% 16V L211 2405619V07 9 nH R217 0662057A77 When ordering crystals, specify carrier frequency, crystal frequency, crystal...
  • Page 120: Nuf6411K 800 Mhz Transceiver Board Schematic Diagram

    63B81094C75-O NUF6411K 800 MHz Transceiver Board Schematic Diagram 13-12...
  • Page 121: Nuf6411K 800 Mhz Transceiver Circuit Board Details And Parts List

    NUF6411K 800 MHz Transceiver Board C328 2113930F51 100 Electrical Parts List C329, C330 2109720D14 0.1 uF VIEWED FROM SIDE 1 C339 2113930F29 12 MOTOROLA C340 2113932K15 0.1 uF +80/-20% 16V ITEM PART DESCRIPTION C341 2113932E07 .022 uF 10% 16V NUMBER C342 2113930F19 4.7 pF 50V ±0.25 pF 50V...
  • Page 122 For optimum performance, order replacement diodes, transistors, and circuit C606 2113930F24 7.5 pF 50V ±0.25 pF 50V R405 0662057A13 33 modules by Motorola part number only. C609 2113930F15 3.3 pF 50V ±0.25 pF 50V R406 0662057A69 6.8k When ordering crystals, specify carrier frequency, crystal frequency, crystal C610 2113930F24 7.5 pF 50V ±0.25 pF 50V...
  • Page 123 U206 (SLIC) VOCON U406 (ADSIC) VOCON Board Data Bus (D) Pinouts U204 (MCU) VOCON Board Signals U206 Pin # Description To/From U406 Pin # Description To/From U402 U403 U404 U405 U406 U414 U204 Pin # Description To/From Due to the nature of the schematic-generating program, PH0 RTA0 J901-11 D8/3...
  • Page 124: Ntn7749G Vocon (Vocoder/Controller) Board Schematic Diagram, Sheet 1 Of 2

    MAEPF-27100 SHEET 1 NTN7749G VOCON (Vocoder/Controller) Board Schematic Diagram, Sheet 1 of 2 13-16...
  • Page 125: Ntn7749G Vocon (Vocoder/Controller) Board Schematic Diagram, Sheet 2 Of 2

    MAEPF-27100-O SHEET 2 NTN7749G VOCON (Vocoder/Controller) Board Schematic Diagram, Sheet 2 of 2 13-17...
  • Page 126: Ntn7749G Vocon (Vocoder/Controller) Circuit Board Details & Parts List

    0.1 uF +80/-20% 16V Electrical Parts List C463 2311049C08 33 uF 20V 10% C464, C465 2311049J12 4.7 uF VIEWED FROM SIDE 1 MOTOROLA C466 2113932K15 0.1 uF +80/-20% 16V ITEM PART DESCRIPTION C467 2113930F21 5.6 pF 50V ±0.25 pF 50V...
  • Page 127 Not Placed. Notes: R233 0662057A85 R438, R439 0662057A73 For optimum performance, order replacement diodes, transistors, and circuit modules by Motorola part number only. R234, R235 0662057A73 R440 ----------------- Not Placed. When ordering crystals, specify carrier frequency, crystal frequency, crystal R236...
  • Page 128 VOCON Board U204: MCU U206: SLIC U406:ADSIC Integrated Circuit Modules U201: EEPROM Fiducial Fiducial VSS1 SCLK DECIN RXDIN VSSAb V20b OVERRIDE VAGB SC380017ZP VAG0b IRQB VDDAb SC415012ZP GDRN HC11RST ADSIC SLIC IV P3 EPSb IRQB SCNEN IRQA 62U52 X XIRQ 32Kx8 EE VSS1 VDD3...

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