Motorola/Arris KVL 3000 PLUS Service Manual
  1. Manuals
  2. Brands
  3. Motorola/Arris Manuals
  4. Compact Loader
  5. SURFboard SB6183
  6. Service manual

Motorola/Arris KVL 3000 PLUS Service Manual

Key variable loader
Hide thumbs
Table of Contents

Advertisement

Quick Links

© 2004 M
, I
.
OTOROLA
NC
A
R
R
LL
IGHTS
ESERVED
P
U.S.A.
RINTED IN
KVL 3000 P
K
V
EY
ARIABLE
™
LUS
L
OADER
S
M
ERVICE
ANUAL
6880802E55-O
F
2004
EBRUARY

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the KVL 3000 PLUS and is the answer not in the manual?

Questions and answers

Summary of Contents for Motorola/Arris KVL 3000 PLUS

  • Page 1 KVL 3000 P ™ ARIABLE OADER ERVICE ANUAL © 2004 M OTOROLA 6880802E55-O IGHTS ESERVED 2004 EBRUARY U.S.A. RINTED IN...
  • Page 2 Trademark Information The following are registered trademarks of Motorola, Inc.: Motorola, the Motorola logo, ASTRO. The following are Motorola trademarks: KVL 3000 Plus. Any other brand or product names are trademarks or registered trademarks of their respective holders. Limitation of Liability...

  • Page 3: Table Of Contents

    ABLE ONTENTS ONTENTS ........BOUT ANUAL Scope .
  • Page 4 Parts List, CLN7493D KVL 3000 Plus Main Board ....... . .

  • Page 5: Bout This Manual

    RROR AND ONCERNS EPORTING Any errors or concerns about this manual or its contents should be addressed to KVL 3000 Plus Brand Manager and faxed to 1-847-435-9067. Include your name and phone number so we can follow up with you.

  • Page 6: How To Order Parts

    BOUT ANUAL OW TO RDER ARTS For complete information on ordering replacement modules, contact the appropriate Motorola Accessories and Aftermarket Division facility listed below. NITED TATES AND ANADA Mail Motorola, Inc. Accessories and Aftermarket Division 1309 East Algonquin Road Schaumburg, IL 60196 Phone (800) 422-4210 (847) 538-8023 (Outside the U.S.) (800) 622-6210...

  • Page 7: How To Return Parts For Repair

    KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL BOUT ANUAL OW TO ETURN ARTS FOR EPAIR For instructions on returning faulty modules for repair, contact the System Support Center at: Motorola System Support Center 1311 E. Algonquin Road Schaumburg, IL 60196 1-800-221-7144 1-847-576-7300 (outside the U.S.) 1-847-576-2172 (FAX)
  • Page 8 BOUT ANUAL HIS PAGE INTENTIONALLY LEFT BLANK 6 8 80 80 2E 5 5- O 20 0 4 E B R U A R Y...

  • Page 9: Chapter 1: Specifications

    ........The field replaceable units (FRUs) available for the KVL 3000 Plus Key Variable Loader are listed in Table 1-1.

  • Page 10: Accessories

    KVL 3000 Plus Bracket Stand ® 6881132E29 ASTRO 25 KVL 3000 Plus™ User’s Guide 6881131E52 Dimetra KVL 3000 Plus™ User’s Guide CCESSORIES ........
  • Page 11 C551AA MCS 2000™ TRN7414 Cable Adapter for SPECTRA, ASTRO SPECTRA, and XTL 5000 CKN6324 KVL 3000 Plus DB-9/Modem Cable C954AB Cables for SPECTRA and ASTRO SPECTRA (includes cable and adapter) ERFORMANCE PECIFICATIONS ........

  • Page 12: Performance Specifications

    1: S ERFORMANCE PECIFICATIONS HAPTER PECIFICATIONS 1-6 G ABLE ENERAL PECIFICATIONS CONTINUED Item Specification Operating Memory 512K x 8 RAM Tamper Protection Tone Generator Real Time Clock Power Regulation Continuous Power Regulation Switched Power Regulation Low Voltage Detection Low Battery Detection (<6.68V) Minimum Voltage to Upgrade KVL (7.24V) 5 V Detection Backup Power...

  • Page 13: User Interface

    KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL ERFORMANCE PECIFICATIONS NTERFACE • Bitmapped LCD Display • LCD Annunciator Line • 4x4 Numeric Keypad (0 - 9 and A - F keys) • Two General purpose softkeys • Scroll Left/Increment Key •...

  • Page 14: Environmental Testing

    1: S ERFORMANCE PECIFICATIONS HAPTER PECIFICATIONS NVIRONMENTAL ESTING 1-8 E ABLE NVIRONMENTAL ESTING TANDARDS AND OMPLIANCE Standard Method Procedure Test Performance MIL-STD 810E 516.4 Thermal Shock Meets or exceeds published specs following shock testing. MIL-STD 810E 516.4 Vibration Meets or exceeds published specs following vibration testing.

  • Page 15: Diagram Theory

    ........This chapter describes the KVL 3000 Plus circuitry at a block diagram level. See Figure 2-1 for the block diagram.
  • Page 16 2: B OWER LOCK HAPTER LOCK IAGRAM HEORY SW_5V RS232 7.5 VDC CONT_5V COMM CONT_3.3V 3.0 VDC SW_5V SW_3.3V PWR_SWITCH* POWER SW_2.8V BATT_3V SW_5V BATT_3V ARMOR_TAMPER* ARMOR_ERASE* PROG_VOLT_LOW* LOW_BATTER Y * uP_Control* 5V_DETECT* CONT_3.3V SW_3.3V SW_5V ARMOR SCI ENCRYPTION ENCRYPTION IC CONTROL (ARMOR) ARMOR_TAMPER* CLKOUT...
  • Page 17 OLTAGE EGULATORS There are five regulators on the KVL 3000 Plus. Two regulators (5V Continuous and 3.3V Continuous) provide continuous regulated outputs as long as there is a valid voltage source attached. The others (5V Switched, 3.3V Switched, and 2.8V Switched) can be switched on and off. The continuous regulators are used to power circuitry which should not be shut off, and the switched regulators are used for the remaining circuitry.

  • Page 18: Processor Block

    ROCESSOR The processor (U300, a Motorola 68332 processor) controls the majority of the circuitry in the KVL 3000 Plus. Circuitry not under control of the processor consists primarily of power circuitry or tamper/low-voltage circuitry. The processor consists of five basic sections: •...

  • Page 19: Khz Oscillator (Y300)

    The memory block (Figure 5-3) consists of three memory devices. The first is FLASH memory U202 which is used to hold the operational software of the KVL 3000 Plus. The second is EEPROM U201which is used to store encrypted key data. The third is the RAM (U204), which is used by the processor during operation.

  • Page 20: User Interface Block

    2: B NTERFACE LOCK HAPTER LOCK IAGRAM HEORY NTERFACE LOCK ........The user interface block (Figure 5-5) is made up of the following: a 16 key hex keypad circuit, an 8 key control keypad circuit, display control circuitry, and a tone generator circuit.

  • Page 21: Display Control Circuitry

    KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL ISPLAY ONTROL IRCUITRY ISPLAY ONTROL IRCUITRY ........The display control circuitry consists of a few gates which are controlled by the processor.

  • Page 22: Real Time Clock Block

    EEPROM. The KVL 3000 Plus also contains circuitry designed to hold a sufficient charge without the main battery in place. This allows the user a minimum of 30 seconds to replace the battery without destroying the KPK.

  • Page 23: Chapter 3: Major Signal Descriptions

    ........This chapter describes each of the major signals, buses, and control lines in the KVL 3000 Plus circuitry.
  • Page 24 3: M HAPTER AJOR IGNAL ESCRIPTIONS This is the address strobe line used to indicate the validity of an address on the address bus. This signal is used to indicate when data is valid on the data bus or when a device should place its data on the data bus.

  • Page 25: Serial Peripheral Interface (Spi)

    NTERFACE The SPI interface is a master/slave type. In the KVL 3000 Plus, the processor is always the master. The operation of the interface is that of a circular shift register with 8 bits residing in the master and the other 8 residing in the slave.

  • Page 26: Encryption Interface Signals

    RMOR AMPER The KVL 3000 Plus accepts encryption keys and keeps them secure by storing the keys in encrypted form. The only piece of “RED” (unencrypted) information is the key with which all of the other keys are encrypted. To keep this key secure, the KVL 3000 Plus has a tamper detection device which, when activated, will destroy the RED key.
  • Page 27 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL ARMOR_RST_DIRECT (A RMOR ESET IRECT This signal is combined with the RESET line to reset the Armor. This signal originates from TPU channel 4 of the processor and ends at the Armor's RESET. Therefore there are three ways to reset the Armor Encryption IC: Hardware reset, software reset, and set TPU channel 4 output to high.
  • Page 28 P_CONTROL* (M ICROPROCESSOR ONTROL The processor uses this signal to power down the KVL’s circuitry. When the KVL 3000 Plus is off, pressing the key directly activates a latch which turns on the SW_5V regulator (and turns on the KVL circuitry). When the user presses the key to turn the KVL off, the processor is notified via an interrupt.
  • Page 29 ........This section provides disassembly instructions for replacing the main circuit board in the KVL 3000 Plus.

  • Page 30: Chapter 4: Disassembly Instructions

    4: D HAPTER ISASSEMBLY NSTRUCTIONS 4-1 D KVL ( ROCEDURE ISASSEMBLING EASSEMBLING THE CONTINUED With the chassis free of the front housing, lift the wide end of the chassis, pulling the flex cable through the center slot until the chassis is free of the flex cable.
  • Page 31 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL MODEL T6717A KITS TOP HOUSING ASSY CLN7493D MAIN PCB 1583789X02 CLN7722A LCD DISPLAY HOUSING CNN6002A KVL BATTERY 1583312X01 NTN7395BR HIGH CAP BATT. CLN6985A HARDWARE KEYPAD CLN7724A TOP HOUSING FLEX CABLES 3883318X02 CLN7064A CHASSIS MAIN–3083681X01 CLN7135A NAMEPLATE...
  • Page 32 4: D HAPTER ISASSEMBLY NSTRUCTIONS HIS PAGE INTENTIONALLY LEFT BLANK 6 8 80 80 2E 5 5- O 20 0 4 E B R U A R Y...

  • Page 33: Chapter 5: Troubleshooting

    (RTC), and other components that bring information to or take information from the processor section. Use this conceptual partitioning to isolate the source of a problem within the KVL 3000 Plus. For example, if the non-working operation is an interface operation, first determine if the connections are complete.
  • Page 34 5: T ROUBLESHOOTING ROCEDURES HAPTER ROUBLESHOOTING 5-1 T ABLE ROUBLESHOOTING ROCEDURE Component Symptom Solution Power No display when PWR key is pressed • Ensure the main battery is charged. • Ensure the tamper switch/back cover is closed. If problem persists, check the following: •...
  • Page 35 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL ROUBLESHOOTING ROCEDURES TOP VIEW BOTTOM VIEW 5-1 M IGURE OARD 68 8 08 02 E5 5 -O 2 00 4 E B R U A R Y...
  • Page 36 5: T ROUBLESHOOTING ROCEDURES HAPTER ROUBLESHOOTING HIS PAGE INTENTIONALLY LEFT BLANK 6 8 80 80 2E 5 5- O 20 0 4 E B R U A R Y...

  • Page 37: Parts List, Cln7493D Kvl 3000 Plus Main Board

    , CLN7493D KVL 3000 P ARTS OARD Part Part Reference Number Description Reference Number Description capacitor, fixed: integrated circuit (see note 1): C201 – 204 2113743E20 CAP CHIP .10 UF 10% C300 – 305 2113743E20 CAP CHIP .10 UF 10% U201 5191080A01 IC EEPROM 128KX8 28C010...
  • Page 38 R507 0662057P10 RES CHIP 10.0K 1% 30X60 R508, 509 0662057B47 CHIP RES 0 OHMS +-.050 OHMS 8482867Y03 PCB KVL 3000 PLUS R510 0611079F01 RES CHIP 1.00K 1/10W 1% 0805 5482006W02 RIBBON THERMAL XFER R511 0611079F48 RES CHIP 3.09K 1/10W 1% 0805...
  • Page 39 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL ROUBLESHOOTING 5-2 F IGURE UNCTIONAL LOCK IAGRAM 68 8 08 02 E5 5 -O E B R U A R Y 2 00 4...
  • Page 40 5: T HAPTER ROUBLESHOOTING 5-3 S IGURE CHEMATIC IAGRAM EMORY LOCK 6 8 80 80 2E 5 5-O E B R U A R Y 20 04...
  • Page 41 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL 5-4 S IGURE CHEMATIC IAGRAM ROCESSOR IRCUITRY 68 8 08 02 E5 5 -O E B R U A R Y 2 00 4...
  • Page 42 5: T HAPTER ROUBLESHOOTING 5-5 S IGURE CHEMATIC IAGRAM NTERFACE IRCUITRY 5-10 6 8 80 80 2E 5 5-O E B R U A R Y 20 04...
  • Page 43 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL REAL TIME CLOCK CIRCUITRY SW_5V SW_5V R808 R800 C812 EN VCC 0.1 uF 5V_DETECT* FORCEOFF FORCEON C1POS C1NEG 0.1 uF U801 C2POS C808 ROM 68332 PROCESSOR 0.1 uF C2NEG C806 R IN INVAL IO SCI_TXD T IN...
  • Page 44 5: T HAPTER ROUBLESHOOTING 5-7 S , PCMCIA C IGURE CHEMATIC IAGRAM IRCUITRY 5-12 6 8 80 80 2E 5 5-O E B R U A R Y 20 04...
  • Page 45 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL 5-8 S IGURE CHEMATIC IAGRAM NCRYPTION RMOR IRCUITRY 5-13 68 8 08 02 E5 5 -O E B R U A R Y 2 00 4...
  • Page 46 5: T HAPTER ROUBLESHOOTING 5-9 S , CPLD C IGURE CHEMATIC IAGRAM IRCUITRY 5-14 6 8 80 80 2E 5 5-O E B R U A R Y 20 04...
  • Page 47 For all error messages other than those shown in this table, check the KVL 3000 Plus cable connection and try the operation again. If it still fails, the KVL 3000 Plus must be returned to the service center for troubleshooting and repair.

  • Page 48: Appendix A: Error Essages

    A: E PPENDIX RROR ESSAGES A-1 E ABLE RROR ESSAGES CONTINUED Error Message Display Method Probable Cause Remedy Press/hold Del/Shift key, Faulty Keyload Ensure proper keyload cable connections at each end; BAD INDEX then press E key. Cable or connection try known good keyload cable.
  • Page 49 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL A-1 E ABLE RROR ESSAGES CONTINUED Error Message Display Method Probable Cause Remedy Displayed during KVL 3000 Return KVL to service center for troubleshooting and Defective encryption Plus operation. repair of encryption IC. IC in target device CRC OF A Return KVL to service center for troubleshooting and...
  • Page 50 A: E PPENDIX RROR ESSAGES A-1 E ABLE RROR ESSAGES CONTINUED Error Message Display Method Probable Cause Remedy Press/hold Del/Shift key, Faulty Keyload Ensure proper keyload cable connections at each end; NO SECURITY then press E key. Cable or connection try known good keyload cable.
  • Page 51 KVL 3000 P ™ K ARIABLE OADER ERVICE ANUAL A-1 E ABLE RROR ESSAGES CONTINUED Error Message Display Method Probable Cause Remedy Press/hold Del/Shift key, Faulty Keyload Ensure proper keyload cable connections at each end; SBOX FAIL then press E key. Cable or connection try known good keyload cable.
  • Page 52 A: E PPENDIX RROR ESSAGES HIS PAGE INTENTIONALLY LEFT BLANK 6 8 80 80 2E 5 5- O 20 0 4 E B R U A R Y...

Table of Contents