HYT TR-800 Service Manual
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HYT TR-800 Service Manual

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  • Page 2: Table Of Contents

    Contents Revision History ........................1 General ..........................1 Repeater Overview ......................3 Software Specification......................5 Circuit Description ......................10 MPU Pins ........................... 16 Programming Guide ......................18 Part List 1(Logic Board Unit) ....................32 Parts List 1 (Power Management Board Unit) ..............39 Adjustment Description ......................

  • Page 3: Revision History

    TR-800 Service Manual Revision History Release Date Revision 2007-2-3 Initial Release 8130080000000 General Manual Scope This manual is intended for use by experienced technicians familiar with similar types of communication equipment. It contains all service information required for the equipment and is current as of the publication date.
  • Page 4 HYT endeavors to achieve the accuracy and completeness of this manual, but no warranty of accuracy or reliability is given. All the above specifications and design are subject to change without notice due to continuous development.

  • Page 5: Repeater Overview

    Blue LED ⑧ lights while the RPT/OPT is active, and goes out while inactive. 3. Repeater Setup/Knockdown ⑥ The Setup button is a momentary contact switch that enables or disables the main radio of TR-800. 4. LCD Display ⑦ Display current channel number, frequency, power level, receive status, etc.
  • Page 6 The N connector is for connecting with the main radio’s antenna, while the BNC connector is for the slave radio’s antenna. When using duplexer, choose the correct adaptor on the back of TR-800 according to your antenna connector type. 12. Fan The fan is temperature-controlled with continuously variable speed as temperature changes.

  • Page 7: Software Specification

    TR-800 Service Manual Software Specification Basic Operation Short press the Power Switch to turn on the repeater; rotate the Volume Control knob clockwise to adjust the volume for a comfortable listening level. Press the “Up” or “Down” button to select a desired channel, then the repeater operates as you set.
  • Page 8 TR-800 Service Manual Time-out Timer (TOT) The feature allows for efficient use of channels by limiting the maximum time of each transmission. It protects the radio from damage caused by long time transmission. Once a continuous transmission exceeds the preset time (15～1200s programmable), the transmission will be automatically terminated and alert tone will be heard.
  • Page 9 TR-800 Service Manual Modes Description Mode Description Press the SETUP button while the repeater is power on. The repeater Knockdown enters knockdown mode once the orange LED goes out. Press RPT and OPT buttons when the SETUP orange LED is on. The...
  • Page 10 TR-800 Service Manual LCD Display LCD Icon Description Indicator Description 1. Displays zone/channel number 2. Displays zone/channel name up to 12 alphanumeric characters (preprogrammed by your dealer) 3. Displays channel frequency 4. Displays preprogrammed function 1. Displays zone/channel number 2. Displays transmit power level (the 4 digit: H, M, L) 3.
  • Page 11 TR-800 Service Manual LED Indicator LEDs indicate real-time radio status shown as the following table: Description Indicates: Lights while the main radio is transmitting. Flashes while the main radio is receiving. Flashes while the main radio is monitoring channel activities.

  • Page 12: Circuit Description

    TR-800 Service Manual Circuit Description Repeater Communication Interface & Display Unit Theory of Operation Setup/Knockdown (U0107D, Q0101, Q0103, Q0106, Q0107 and Q0108): The Setup/Knockdown state at power-up can be configured via HR-800 programming software. The electronic switch, Q0106 and Q0108, causes the Setup/Knockdown action by applying or removing voltage at the ignition control, pin15, of “J0102-Main”.
  • Page 13 TR-800 Service Manual When the reverse key-up function is enabled, as in the bi-directional repeater configuration, S0101-8 must be on. Q0116 is a dc amplifier (buffer) for the Rx Carrier signal from pin6 of “J0102-Main”. An active low state at the input of the NAND gate U0107A, one quarter of a MC14011B, will be conversed to a high state to drive the buffer for the Rx Carrier signal.
  • Page 14 TR-800 Service Manual Figure Block Diagra Ⅰ － 12 －...
  • Page 15 The Over Voltage Detector consisting of U0206B and resistors R0274, R0275 and R0271 monitors the DC output of the TR-800 power supply. If the voltage exceeds 16.4Vdc, the output of U0206B-7 goes high and turns on relay driver Q0224. The station switches to battery power although there is no indication at the “BAT ON”...
  • Page 16 400mA, is used to maintain a “float” charging condition on the battery. After operating the TR-800 station on the battery for long periods of time, or if the battery reaches the low battery limit of the revert circuit, the battery must be recharged with an external high-current charger.
  • Page 17 TR-800 Service Manual Glossary Bi-directional Repeater: A repeater configuration in which the main and slave radios perform both receive and transmit functions. The audio and Rx Carrier signals from the receiver of the slave radio are routed to the transmitter of the main radio.

  • Page 18: Mpu Pins

    TR-800 Service Manual MPU Pins Repeater front panel (MPU Model: uPD780114, CRYSTAL: 9.8304MHz） Pin No. Pin Name Description AVref Connect VDD AVss To GND IC(V To GND (programming pin) short-circuit resistor added Clock Input Clock output RESET Knockdown Connect VDD...
  • Page 19 TR-800 Service Manual RPT/O RPT signal output Active: H KEYBL Keypad backlight control Active: H Rx Tone/I Slave radio signal input Active: L (external pull-up resistor connected) SETUP/I SETUP signal input On: H (rising edge trigger) OPT/I OPT key input...

  • Page 20: Programming Guide

    TR-800 Service Manual Programming Guide Overview This section describes the programming and setup of the TM-800 series radios and the front panel controller for use in both unidirectional and bi-directional repeater configurations. In the unidirectional repeater configuration, one radio operates as the receiver of the repeater and the other radio operates as the transmitter of the repeater.
  • Page 21 TR-800 Service Manual 7. Scan function is set to “Yes” and the same to Optional Signaling selection. They cannot be modified at the moment (the scan function will not be activated unless you push the Scan button on the front panel).
  • Page 22 TR-800 Service Manual 13. Check any other special programming requirements in the appropriate selection box. Your screen should appear similar to Figure 7-3. Figure 7-3 14. “Close” the Channel Edit screen and the Zone Information window. 15. Double click the “Optional Features” selection of “Main” from the opening HR800E “Tree View”...
  • Page 23 TR-800 Service Manual 19. Click the dropdown arrow button next to AUX3 to select “External PTT (Input)”. Your screen should appear similar to Figure 7-5. Figure 7-5 Slave Radio Programming 20. Close the “Optional Features” window of “Main”. 21. Select “Zone Information” of “Slave” from the opening HR800E “Tree View” window.
  • Page 24 TR-800 Service Manual 25. Click the “Channel Edit” tab on bottom right corner of the window. 26. You can check or re-edit the Rx/Tx frequency, CTCSS/CDCSS decode and encode, Power level as previously entered on the “Zone Information” window. 27. Click the “Squelch Mode” dropdown arrow button to select “CTCSS/CDCSS” if you have used CTCSS/CDCSS for your repeater.
  • Page 25 TR-800 Service Manual 33. You can enter a “Power On Text” that will be displayed, such as “TR-800 Rpt”. Your screen should appear similar to Figure 7-8. Figure 7-8 34. Click the “AUX Information” tab. 35. Click the dropdown arrow button next to AUX5 to select “Rx Tone (Output)”. Your screen should appear similar to Figure 7-9.
  • Page 26 TR-800 Service Manual 39. Click the dropdown arrow button to select a desired “Repeater Hang Time” in 1 second step. Your screen should appear similar to Figure 7-10. Figure 7-10 40. Enter any other special programming requirements in the appropriate window.
  • Page 27 TR-800 Service Manual Bi-directional Repeater Main Radio Programming 1. Read the Main radio and Slave radio (The red LED flashes and then follows the green LED). 2. After the radios are read, select “Zone Information” of “Main” from the opening HR800E “Tree View”...
  • Page 28 TR-800 Service Manual 11. Click the down-arrow button next to the “Time Out Timer(TOT)[s]” display. Each click will change the time by 15s. For repeater use, reduce the time to “off” to disable the TOT. Your screen should appear similar to Figure 7-12.
  • Page 29 TR-800 Service Manual 17. “Close” the Channel Edit screen and the Zone Information window. 18. Double click the “Optional Features” selection of “Main” from the opening HR800E “Tree View” window. 19. Click the “Option Function 1” tab. 20. Check the “Ignition Sense” box to enable the Setup/Knockdown function. Click the down-arrow button next to the “Timed Power off”...
  • Page 30 TR-800 Service Manual Slave Radio Programming 24. Close the “Optional Features” window of “Main”. 25. Select “Zone Information” of “Slave” from the opening HR800E “Tree View” window. 26. Enter the receive frequency for the slave radio of the bi-directional repeater in “Rx Frequency (MHz)”...
  • Page 31 38. Select the squelch level for your field application by clicking the up or down arrow button next to “SQL” display. 39. You can enter a “Power On Text” that will be displayed, such as “TR-800 Rpt”. Your screen should appear similar to Figure 7-18.
  • Page 32 TR-800 Service Manual 40. Click the “AUX Information” tab. 41. Click the dropdown arrow button next to AUX3 to select “External PTT (Input)”. 42. Click the dropdown arrow button next to AUX5 to select “Rx Tone (Output)”. Your screen should appear similar to Figure 7-19.
  • Page 33 TR-800 Service Manual 47. Enter any other special programming requirements in the appropriate window. 48. Program the repeater. Basic Unidirectional Repeater – S01 DIP Switch Settings Set the 10 positions of DIP switch S01 according to the following information: 49. The repeater is bi-directional: S01-1 “OFF” and S01-10 “ON”.

  • Page 34: Part List 1(Logic Board Unit)

    TR-800 Service Manual Part List 1(Logic Board Unit) Material No. Description Qty Ref. No. Address 3001060000000 Chip resistor 0603 0Ω J 1/10W(RoHS) R0158 3001060000000 Chip resistor 0603 0Ω J 1/10W(RoHS) R0164 3001060000000 Chip resistor 0603 0Ω J 1/10W(RoHS) R0170 3001060000000 Chip resistor 0603 0Ω J 1/10W(RoHS) R0176 3001060000000 Chip resistor 0603 0Ω...
  • Page 35 TR-800 Service Manual Material No. Description Qty Ref. No. Address 3001061030010 Chip resistor 0603 10KΩ J 1/10W(RoHS) R1120 3001061030010 Chip resistor 0603 10KΩ J 1/10W(RoHS) R1121 3001061040010 Chip resistor 0603 100KΩ J 1/10W(RoHS) R0118 3001061040010 Chip resistor 0603 100KΩ J 1/10W(RoHS) R0145 3001061040010 Chip resistor 0603 100KΩ...
  • Page 36 TR-800 Service Manual Material No. Description Qty Ref. No. Address 3001064730000 Chip resistor 0603 47KΩ J 1/10W(RoHS) R0154 3001064730000 Chip resistor 0603 47KΩ J 1/10W(RoHS) R0155 3001064730000 Chip resistor 0603 47KΩ J 1/10W(RoHS) R0156 3001064730000 Chip resistor 0603 47KΩ J 1/10W(RoHS) R0160 3001064730000 Chip resistor 0603 47KΩ...
  • Page 37 TR-800 Service Manual Material No. Description Qty Ref. No. Address 127 3101071020010 Chip capacitor 0805 1000PF K 50V(RoHS) C0169 128 3101071020010 Chip capacitor 0805 1000PF K 50V(RoHS) C0170 129 3101071020010 Chip capacitor 0805 1000PF K 50V(RoHS) C0175 130 3101071030010 Chip capacitor 0805 0.01UF K 25V(RoHS) C0124 131 3101071030010 Chip capacitor 0805 0.01UF K 25V(RoHS)
  • Page 38 TR-800 Service Manual Material No. Description Qty Ref. No. Address 170 3221506601000 Chip Ferrite Bead 0603 600Ω±25% (RoHS) L0105 171 3221506601000 Chip Ferrite Bead 0603 600Ω±25% (RoHS) L0106 172 3302030500020 Zener diode UDZSTE(1718B)18V SOD-323 (RoHS) VR0108 B4F 173 3302240000040 Zener diode BZX84C5V1LT1G-SOT-23-5.1V (RoHS) VR0101 B2F 174 3302240000040 Zener diode BZX84C5V1LT1G-SOT-23-5.1V (RoHS)
  • Page 39 Chip socket B11B-ZR-SM3-TF(LF) (RoHS) 227 5202011100010 J0107 Chip socket B11B-ZR-SM3-TF(LF) (RoHS) 228 410R800100040 TR-800 Logic board PCB FR4 1.6T/2L/2P 04(RoHS) 229 3002995020000 Ceramic alloy potentiometer 5KΩ K CT-94EW (RoHS) RV0102 B3E 230 3002995030020 Ceramic alloy potentiometer 50KΩ K CT-94EW (RoHS)
  • Page 40 TR-800 Service Manual Material No. Description Qty Ref. No. Address 256 5204008000000 RJ45 Plug MODS-A-8P8C-H-S (RoHS) J0109 257 7000037000000 Heat sink 15.3*17mm 00(RoHS) U0109 258 7103008001010 Machine screw M3.0*8.0mm Pan-head 01(RoHS 1 U0109 － 38 －...

  • Page 41: Parts List 1 (Power Management Board Unit)

    TR-800 Service Manual Parts List 1 (Power Management Board Unit) Material No. Description Ref. No. Address 3001061000000 Chip resistor 0603 10Ω J 1/10W (RoHS) R2103 3001061020010 Chip resistor 0603 1KΩ J 1/10W (RoHS) R0285 3001061020010 Chip resistor 0603 1KΩ J 1/10W (RoHS) R2101 3001061030010 Chip resistor 0603 10KΩ...
  • Page 42 Zener diode BZX84C27 (RoHS) VR0215 72 3302040300010 Zener diode BZX84C27 (RoHS) VR0217 73 4011000000010 Self-recovery fuse SMD 200F-2 15V 2A (RoHS) F0202 TR-800 power management board PCB FR4 410R800200120 1.6T/2L/4P 02(RoHS) Zener diode BZX84C7V5LT1G-SOT-23-7.5V 75 3302240000030 (RoHS) VR0209 Zener diode BZX84C7V5LT1G-SOT-23-7.5V...
  • Page 43 TR-800 Service Manual Material No. Description Ref. No. Address Electrolytic Capacitor 6*12 100UF ±20% 25V 3103991070090 (RoHS) C0232 Electrolytic Capacitor 12.5*25 2200uF ±20% 3103992280020 25V (RoHS) C0241 3103994770030 Electrolytic Capacitor 2512 470UF 25V (RoHS) C0243 3216599224000 Bobbin inductor 0.35mm 220uH (RoHS)

  • Page 44: Adjustment Description

    20A/30V Power Supply 1set Ammeter 1set Digital Voltmeter 1set Test Jumper Cables (mating with test ports of TR-800 and the communication test set) Communication System Analyzer (such as HP8921 series) 1set Adjustment Radio Configuration Use HR-800E to program the TR-800. Table...
  • Page 45 Base Station Mode Make sure the TR-800 is in SETUP state and deactivate RPT & OPT functions. The TR-800 operates on base station mode with main radio to transmit and slave radio to receive (similar to a mobile radio). Correctly cable the test ports to communication system analyzer before adjustment.
  • Page 46 TR-800 Service Manual Duplex sensitivity: -117(+1/-3dBm) CTCSS sensitivity: Adjust the signal -117(+1/-3dBm) output amplitude of CDCSS sensitivity: Analyzer -117(+1/-3dBm) -47dBm, adjust Duplex frequency RV0101 to obtain a deviation: Uni-direct Channels system Main radio 2.9±0.2kHz (wide) ional with/ Communicatio deviation; check the RV0101 1.4±0.1kHz (narrow)
  • Page 47 Uni-directional Repeater Mode (reverse) Make sure the TR-800 is in SETUP state and activate OPT function. The TR-800 operates on uni-directional repeater mode with slave radio keys main radio to repeat transmission (backward direction). Correctly cable the test ports to communication system analyzer before adjustment.
  • Page 48 TR-800 Service Manual Tx S/N: ≥42dB (wide) ≥37dB (narrow) Max. Power output (without duplexer): 45±2W(UHF) 50±2W(VHF) d) Knockdown State Measure Adjustment Conditi Item Specification/Remark Instrument Point Point Method Short or long press of the Monitor and Scan button is disabled; unable...
  • Page 49 TR-800 Service Manual Circuit detect and temperature-control test Connect CN0201 (To Power Supply) and CN0204 (To Ext. Battery) with DC power output 13.8V respectively. Measure Adjustment Conditi Item Specification/Remark Instrument Point Point Method Gradually increase the voltage of Increase CN0201 to 16.4V, the protection...
  • Page 50 TR-800 Service Manual Floating charge test Connect CN0204 to 12V battery; CN0201 remains connected with 13.8V power supply. Measure Adjustment Item Condition Specification/Remark Instrument Point Point Method Check the charging current is about Floating Analog CN0204 Check 400mA, and will drop to 10-25mA...

  • Page 51: Duplexer Instructions

    The following procedure assumes that the duplexer is applied and the radios should be connected to the proper ports of the duplexer with the RF coaxial cables provided in the TR-800 kit. The duplexer should not be mounted on the bracket and the tuning screws of the duplexer (on the other side of the cavities, opposite to the RF connectors) should be accessible.
  • Page 52 TR-800 Service Manual RF source with a 1kHz tone at 60% system deviation to facilitate “hearing” the signal during the tune-up procedure. Tuning the Main Radio Section Tuning the main radio section of the duplexer begins with the tuning screw closest to the antenna port of the duplexer.
  • Page 53 TR-800 Service Manual 13a. Slightly loosen the locking nuts of the tuning screws to allow the tuning screws to turn more freely (but not “sloppy”) and 13b. Increase the level of the communication test set or generator to maintain an audible 1kHz tone.

  • Page 54: Battery Revert

    Battery Revert Overview The battery revert is an integral part of the power management system in the TR-800 repeater housing. This accessory allows you to cable your unit to a back-up battery which will engage in case of a power outage.
  • Page 55 TR-800 Service Manual percentages of time the repeater is expected to transmit and receive/standby must be factored in. Personal experience or that of others may give you a close approximation. If all else fails, assume a standard eight (8) hour shift operating solely on the battery with an extra hour before and another on after the shift.
  • Page 56 TR-800 Service Manual Therefore: ⎡ ⎤ ⎛ ⎞ ⎛ ⎞ ⎜ ⎟ ⎜ ⎟ × × × ⎢ ⎥ ⎜ ⎟ ⎜ ⎟ ⎢ ⎥ ⎝ ⎠ ⎝ ⎠ ⎣ ⎦ Now, how big is it? Let’s consider the rated battery capacity, C, as a function of the C calculated above.
  • Page 57 TR-800 Service Manual A 60 A-h (0.1C) battery would provide the required energy at room temperature environment. 20 hours ⎡ ⎤ ⎛ ⎞ ≈ × ⎢ ⎜ ⎟ ⎥ ⎝ ⎠ ⎢ ⎥ ⎣ ⎦ ≈ A 65 A-h (0.05C) battery would provide the required energy at room temperature environment.

  • Page 58: Troubleshooting Flow Chart

    TR-800 Service Manual Troubleshooting Flow Chart Table I Troubleshooting for Repeaters (General) Symptom Probable Cause(s) Possible Solution(s) 1a. Turn on power supply and plug 1a. Power supply not turned ON or power supply cord into ac mains ac line cord not plugged into ac outlet.
  • Page 59 TR-800 Service Manual 4a.Leaky coaxial cable(s). 4a.Check coaxial cables and replace if 4. Loss of receiver necessary. sensitivity when 4b.Loose antenna connector(s). main radio is keys 4b.Check antenna connector(s) and 4c.Faulty antenna connector(s). (repeater toggles replace, if necessary. from transmit 4d.Duplexer not tuned correctly (if...
  • Page 60 TR-800 Service Manual 2a. Repeater function not enabled (if Enable repeater function applicable). pushbutton RPT/OPT. 2b. Repeater not in setup state (if 2b. Place repeater in setup state through applicable). front panel SETUP contact switch. 2c. Loose or bad repeater cable(s).

  • Page 61: Disassembly And Installation

    TR-800 Service Manual Disassembly and Installation Removing and Installing the Top Cover 1. Use a screwdriver to remove the seven screws (M3.0X6.0) that locking the top cover o f repeater, ① shown as Figure 14-1. 2. Remove the top cover , shown as Figure 14-1.
  • Page 62 TR-800 Service Manual Removing and Installing the Control Panel 1. Remove the Volume Control knob ① shown as Figure 14-3. 2. Remove the nut using a special spanner , shown as Figure 14-3. ② 3. Use a screwdriver to remove the six screws (ST3.0X8.0) that secure the control panel, shown as ③...
  • Page 63 TR-800 Service Manual Figure 14-5 Removing and Installing the Radio 1. Remove the screw (M4.0X6.0) that secure the thermistor sensor using a screwdriver, shown as ① Figure 6. 2. Use a screwdriver to remove the eight screws (M3.0X6.0) that secure the bracket of radio, shown ②...
  • Page 64 TR-800 Service Manual Removing and Installing the Housing 1. Remove the six screws (M3.0X6.0) that secure the housing using a screwdriver, to remove the housing , shown as Figure 14-8. ① 2. Install the housing as the reverse steps. Figure 14-8 Removing and Installing Switch Power 1.
  • Page 65 TR-800 Service Manual Removing and Installing the Power Management PCB 1. Remove the four screws (M3.0X6.0) that secure the power management PCB using a screwdriver, to remove the power management PCB , shown as Figure 14-10. ① 2. Install the power management PCB as the reverse steps.

  • Page 66: Exploded View

    TR-800 Service Manual Exploded View 17 18 14 15 12 13 10 11 － 64 －...

  • Page 67: Parts List 2

    Socket (RoHS) 4302030000040 Channel selector (RoHS) 3307990000080 LED LT5CB4-81-XA400714 ultra bright blue (RoHS) 4210080000700 Connecting cable of speaker (with 2 Pin plug) 2-core (RoHS) 6100135000000 TR-800 Silica rubber key 00(RoHS) 6201197000000 SM07 Hook 00(RoHS) 6201166000010 Top cover 01(RoHS) － 65 －...
  • Page 68 TR-800 Service Manual 4200200000000 Jumper cable (RoHS) Optional Duplexer 4220300000200 TR-800 RF cable (RoHS) 6201171000000 TR-800 Duplexer bracket 00(RoHS) 4200400000200 Power cord (RoHS) 4200250000200 Power cord (RoHS) 6201170001000 Mobile radio bracket 00(RoHS) 1201800U10030 Main unit (without control head) (RoHS) 4408100002000...

  • Page 69: Wiring Diagram

    TR-800 Service Manual Wiring Diagram － 67 －...

  • Page 70: Packing

    TR-800 Service Manual Packing － 68 －...
  • Page 71 Logic Board Top View...

  • Page 72: Logic Board Top View

    Logic Board Bottom View...

  • Page 73: Power Management Board Top View

    Power Management Board Top View...

  • Page 74: Power Management Board Bottom View

    Power Management Board Bottom View...

  • Page 75: Logic Board Schematic

    DB15/F 2ROWS RESET R0168 RESET R0167 SI/RXD R1100 SO/TXD HYT Science & Technology Co., Ltd SO/TXD 0/NU 1. Pin assignments for J2, J3 and J4 are identical. 3. S2 and all sections of S1 are shown "OFF". Q0115 Q0117 DT14...

  • Page 76: Power Management Board Schematic

    C0241 R0295 4.7K CR0222 2200uF Rth0201 1N5821 R0297 100K NTC R0294 C0240 R2103 HYT Science & Technology Co. Ltd. 2.2K 0.1u PAGE MODEL TR-800 THERMAL CONTROLLED VARIABLE SPEED FAN Part Name DATE Battery Revert & Power Management Board April, 2006 FILE NO.

  • Page 77: Specifications

    TR-800 Service Manual Specifications General VHF:136MHz~174MHz;U5:350MHz~400MHz Frequency Range U1: 400MHz~470MHz; U2: 450MHz~512MHz Channel Capacity Channel Spacing 25KHz/12.5KHz Power Supply Requirement 13.8 V DC±20%/88-264V AC 50/60Hz Duty Cycle 100% Continuous (5/10/25W) / 50% Intermittent (45/50W) <1.8A Standby Power Consumption <2.5A Receive <13A @ 50/45W Transmit (13.8V dc)

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