Motorola ASTRO Digital Spectra Detailed Service Manual
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Motorola ASTRO Digital Spectra Detailed Service Manual

Motorola ASTRO Digital Spectra Detailed Service Manual

Clean cab railroad radio
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Summary of Contents for Motorola ASTRO Digital Spectra

  • Page 1 ® ASTRO ® Digital Spectra Clean Cab Railroad Radio Detailed Service Manual...
  • Page 3 Motorola, Inc. 8000 West Sunrise Boulevard Fort Lauderdale, Florida 33322-4104 9985809F01-A...
  • Page 5 No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola.

  • Page 7: Commercial Warranty

    Product Accessories One (1) Year Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty.
  • Page 8 Product item, transportation and insurance prepaid, to an authorized warranty service location. Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service.
  • Page 9 A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such claim; B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its settlement or compromise; and C.

  • Page 11: Table Of Contents

    CONTENTS FRONT MATTER Title Page Forward Product Safety and RF Exposure Compliance Manual Revisions Computer Software Copyrights Document Copyrights Disclaimer Trademarks Commercial Warranty Contents PART 1. INTRODUCTION SCOPE OF MANUAL RELATED PUBLICATIONS RADIO OVERVIEW RAILROAD RADIO MODEL CHART PERFORMANCE SPECIFICATIONS PART 2.
  • Page 12 PART 3. RADIO FUNCTIONAL OVERVIEW AND BLOCK DIAGRAMS GENERAL SIMPLIFIED DESCRIPTION FUNCTIONAL DESCRIPTIONS PART 4. THEORY OF OPERATION FRONT PANEL CIRCUITS 4.1.1 GENERAL 4.1.2 MICROCOMPUTER BOARD 4.1.3 DISPLAY BOARD REAR PANEL, TOP PANEL INTERCONNECT AND TRANSLATOR BOARDS 4.2.1 GENERAL 4.2.2 REAR PANEL INTERCONNECT BOARD 4.2.3 TOP PANEL BOARD...
  • Page 13 Typical Connections to Auxiliary Connector Figure 2-1-3 Radio Mounting in Clean Cab Tray Figure 2-1-4 Radio and Control Head Connectors Figure 2-1-4-1 Data Cable Wiring Diagram (Motorola PN 30-80390B48) Figure 2-1-5 Remote Control Head Thru-Hole Mounting Figure 2-1-6 Remote Control Head Surface Mounting...
  • Page 14 PART 3. RADIO FUNCTIONAL OVERVIEW AND BLOCK DIAGRAMS Figure 3-1 ASTRO Clean Cab Railroad Radio – Simplified Block Diagram Figure 3-2 ASTRO Clean Cab Railroad Radio Functional Block Diagram (4 sheets) PART 4. THEORY OF OPERATION Figure 4-1-1 Microcomputer I/O Lines Descriptions Figure 4-1-2 Serial Data Bus Logic Figure 4-1-3...
  • Page 15 PART 5. MAINTENANCE AND ALIGNMENT Figure 5-2-1 NOAA Receive Only Weather Channels Figure 5-2-2 AAR Channel Plan Figure 5-3-1 Recommended Test Equipment Figure 5-4-1 Fatal Power-Up Self Check Displays Figure 5-4-2 Non-Fatal Self Check Displays Figure 5-5-1 Service Mode Frequencies Figure 5-6-1 Translator Board / Rear Panel Interconnect Board Troubleshooting Figure 5-6-2...

  • Page 17: Part 1. Introduction

    RELATED PUBLICATIONS ASTRO Clean Cab Quick Reference Card 68P81097C37 ASTRO Digital Spectra Basic Service Manual 68P81076C20 This manual includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level and is typical of some local service centers, self-maintained customers, and distributors.
  • Page 18 All Spectra Clean Cab external cabling and connectors are compatible with ASTRO Clean Cab. The older Spectra Clean Cab control heads will also function with an ASTRO Clean Cab but they will not support analog/digital operation, the TONE button would access 3600 baud trunking if programmed and the display graphics may be incorrect.

  • Page 19: Railroad Radio Model Chart

    RAILROAD RADIO MODEL CHART Figure 1-1 ASTRO Clean Cab Railroad Radio Model Chart...

  • Page 20: Performance Specifications

    PERFORMANCE SPECIFICATIONS GENERAL RECEIVER TRANSMITTER FCC Designator: AZ492FT3772 Frequency Range: Frequency Range: Range 1: 146-174 MHz Range 1: 146-174 MHz Temperature Range: Operating: -30ºC to +60ºC Channel Spacing: 12.5kHz, 25 kHz Channel Spacing: 12.5 kHz, 25 kHz Storage: -40ºC to +85ºC Input Impedance: 50 Ohm Channel Increment Step: 2.5kHz Power Supply:...

  • Page 21: Part 2. Installation And Operation

    6. Measure the 12 dB SINAD signal level. 7. Check the antenna VSWR after installing the radio set. 2.1.3 ANTENNA INSTALLATION Installation instructions are supplied with all Motorola antenna kits. Refer to the instruction sheet for your particular installation. 2.1.4 CLEAN CAB MOUNTING TRAY INSTALLATION Motorola recommends using the clean cab mounting tray for installation of the ASTRO railroad radio.

  • Page 22: Radio Mounting

    Detail. Tighten all nuts and screws securely. Figure 2-1-1 Clean Cab Mounting Tray Detail Other mounting configurations may be implemented; however, these installations are the responsibility of the owner. Contact your Motorola Service Representative regarding your particular application. 2.1.5 RADIO MOUNTING...

  • Page 23: Radio Removal And Replacement

    6. Turn on primary power. Radio set is now operational. A metal clip (Motorola part no. 0702010A01) is located on the bottom panel assembly. The clip is secured directly to the bottom panel housing when the keylock cylinder is installed. When the radio is installed into a standard clean cab mounting plate, the clip provides pry protection to the keylock latch, giving added security to the installation.
  • Page 24 Figure 2-1-2 indicates the plug required to connect with the auxiliary connector, and the main signals provided by the connector. For example, the handset or microphone is placed in the on-hook state by shorting Hang-Up (pin K) to Hang-Up Return (pin J) through a hang-up switch. (The HUB SWITCH function must be enabled with the Radio Service Software to activate operation with the hang-up switch.) External speaker connections are made to pins M and N.

  • Page 25: Figure 2-1-3 Radio Mounting In Clean Cab Tray

    Figure 2-1-3 Radio Mounting in Clean Cab Tray...

  • Page 26: Remote Control Head Installation

    2.1.8 REMOTE CONTROL HEAD INSTALLATION The Remote (Secondary) Control Head Connector (J3007) is always available on the rear panel of the ASTRO Clean Cab. The Remote (Primary) Control Head Connector (J3011) is only available with the MBW654 option. See Figure 2-1-4 for locations of control head connectors. Figure 2-1-4 Radio and Control Head Connectors AAR 12-2 Control Stand Installation Figure 2-1-5 illustrates the control head installation into the standard 4"...
  • Page 27 1. Pick a suitable location for installation, observing cabling and connector requirements, and drill four holes in the mounting surface using a #4 drill bit (use the control head as a template, or refer to the dimensions given in Figure 2-1-5). 2.

  • Page 28: Rs232 Data Port Connector

    A personal computer may be connected to the data port using a straight 9-pin female to 9-pin male EIA- 232 cable (Motorola part number 30-80390B48) available from the Accessories and Aftermarket Product Division (AAD). Alternatively, a cable may be constructed using the wiring diagram in Figure 2-1-4-1. Note that if a different type of device is connected to the data port, the wiring of the cable may vary.

  • Page 29: Figure 2-1-5 Remote Control Head Thru-Hole Mounting

    Figure 2-1-5 Remote Control Head Thru-Hole Mounting...

  • Page 30: Figure 2-1-6 Remote Control Head Surface Mounting

    Figure 2-1-6 Remote Control Head Surface Mounting...

  • Page 31: Figure 2-1-7 Remote Control Head Cable Schematic

    Figure 2-1-7 Remote Control Head Cable Schematic REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. 0582050H03 EYELET, tin (2 used) J1051 0902008A02 RECEPTACLE, 19-pin circular P3007 2802010A02 CONNECTOR, 19-pin circular 2900008S03 LUG, ring tongue #8 (2 used) 3002009A01 CABLE, 12-conductor EXANE 3002010A05...

  • Page 32: Figure 2-1-9 Remote Control Head Internal Wiring Schematic

    Figure 2-1-9 Remote Control Head Internal Wiring Schematic REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. 0102702A44 R/R Remote Handset Conn. Assembly 0900848764 RECEPTACLE 6-contact 0980133M01 CONNECTOR, receptacle (6 used) 1580075M03 HOUSING, connector 4210217A26 TIE WRAP, nylon natural, (2 used) L1050 7602001A01...

  • Page 33: Operation

    OPERATION 2.2.1 GENERAL The ASTRO Clean Cab is shipped factory programmed with the following channels: Channels 1-97 Standard AAR frequencies (25kHz) Channels 98-100 NOAA Weather Channels (RX Only) WX4(98) 162.425 MHz WX3(99) 162.475 MHz WX1(100) 162.550 MHz Channels 101-197 Standard AAR frequencies (12.5kHz) Channels 198-200 NOAA Weather Channels (RX Only) WX4(198)

  • Page 34: Power-Up Procedures

    Talk-Permit a quick multi-tone chirp that indicate a voice channel has been granted. Talk-Prohibit a continuous low pitched alert tone that indicates that a voice channel or system is unavailable. System Busy a low pitched repeating tone that indicates the system has no voice channels available.

  • Page 35: Figure 2-2-1 Standard Controls, Indicators And Displays

    D5 020 067 DISP CHAN DTMF RAD PA IC CALL VOLUME TRNK A / D HOME CALL CONTROLS AND INDICATIONS VOLUME ROCKER - Sets receiver volume. SWITCH CHANNEL BUTTON - Initiates Channel Select mode for selecting a transmit and receive frequency pair CHAN using the numbers on the 12 digit keypad.

  • Page 36: Normal Mode

    2.2.4 NORMAL MODE At all times, the ASTRO Clean Cab radio operates either in the "Normal" mode or one of four “Select” modes (CHAN, DTMF, TRNK and HOME). In Normal mode, the basic radio operations are performed. The speaker volume can be adjusted. The display indicates the selected dispatch tone(s), Home channel (if any), and transmit (TX) and receive (RX) channels on which dispatch and voice messages will be sent and received.

  • Page 37: Basic Operations

    Dispatch DTMF Select Mode The radio is capable of transmitting up to twelve DTMF tones (DO to D9, D# and D*). The DISP display indicates the currently selected DTMF tone (if any) as a "D" followed by a single digit. This represents the DTMF tone which is transmitted upon selection of a particular tone, and re-transmitted using the DISP key.
  • Page 38 To Adjust the Volume To adjust the volume to a comfortable level, execute the following: 1. Momentarily press the VOL rocker switch to the right to increase the volume level by one step, or to the left to decrease the volume level by one step. The VOLUME bar graph display indicates the relative speaker audio level (each LED segment corresponds to two steps in the twenty-step range).
  • Page 39 2. Before the 10-second time-out period, enter the new DTMF number using the numeric keypad. After 10 seconds, the radio reverts to Normal mode. NOTE The # key and/or the * key, or the entire DTMF keypad, may be disabled via the ASTRO Clean Cab CPS for one or both control heads.
  • Page 40 The DISP area of the control head display will indicate the tone sequence stored. For less than three DTMF tones, it will display the DTMF tone followed by one or two blanks. 3. To retransmit the displayed DTMF tone sequence, press the DISP button. The transmitter is enabled, the TX indicator lights, and the displayed DTMF tone sequence is transmitted for the programmed duration.

  • Page 41: Changing Channels

    2.2.7 CHANGING CHANNELS Common Select Mode Conditions In general, to enter a Select mode, the pertinent Select mode key is pressed. The corresponding display(s) change to dashes, with the data entry location being indicated by a flashing underscore. The numeric keypad is now configured to enter numbers. NOTE When the radio is in any Select mode, it continues to receive messages on the last selected RX channel.

  • Page 42: Selecting Analog And Digital Conventional Operation

    1. Momentarily press the TRNK button to initiate the Trunking Select state. The TX and RX displays become “TRUNK” followed by dashes, with a flashing underscore appearing in the leftmost (hundreds) position. The numeric keypad is now configured for number entry. 2.

  • Page 43: Pa / Intercom

    NOTE This feature only operates if the currently selected TX and RX channels are each programmed in CPS for ASTRO TX and Mixed-Mode RX. Any other combination will cause the A / D button to be disabled and a bad tone to sound if pressed. Changing channels will automatically switch to analog operation unless slaved to analog or digital.

  • Page 45: Part 3. Radio Functional Overview And Block Diagrams

    PART 3. RADIO FUNCTIONAL OVERVIEW AND BLOCK DIAGRAMS GENERAL This part presents a functional overview of the ASTRO Clean Cab Railroad Radio. The material is divided into two levels: Simplified Description and Functional Description. The Simplified Description provides a general overview of the modules and circuit boards in the radio. The Functional Description divides the circuits comprising the radio set into eleven functional groups and provides a brief description of each group.

  • Page 46: Figure 3-1 Astro Clean Cab Railroad Radio - Simplified Block Diagram

    · Command Board – microcomputer, memory, support ICs, voltage regulators and miscellaneous audio and control stages. · VOCON Board – DSP and audio processing. · VHF Receiver Front End Assembly · VHF RF Board - receiver IF, demodulator, and the synthesizer logic and filtering. ·...

  • Page 47: Functional Descriptions

    FUNCTIONAL DESCRIPTIONS The following is a functional description of the ASTRO CleanCab radio. To support discussion, refer to Figure 3-2, Radio Block Diagram, which appears at the end of this section. This discussion is not intended to be a comprehensive theory of operation for the circuits, but a brief description of the functional groupings within the radio.
  • Page 48 A brief description of each functional group is given in the following paragraphs. ASTRO Front-End Receiver The receiver front-end consists of a preselector, a mixer circuit, and an injection filter. The receiver injection (1st local oscillator) comes from the VCO assembly through a coax cable. The injection filter is either fixed-tuned or tuned at the factory depending upon the bandsplit.
  • Page 49 All transmit circuitry operates from keyed 9.4 V to reduce current drain while the radio is receiving. A transistor/resistor network drives the PIN diodes in the VCO tank. These driver networks provide forward bias current to turn diodes on and reverse the bias voltage to turn the diodes off. AUX 1 and AUX 2 lines control the PIN diode driver networks.
  • Page 50 The support-logic IC 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 VOCON board controls a crystal-pull circuit to adjust the crystal oscillator frequency on the microcontrol unit, so that the E-clock harmonics do not cause interference with the receive channel.
  • Page 51 board and on the front panel microcomputer board, control the communications between the microcomputers. SW A + is applied to two regulators on the microcomputer board which supply this board and the display board with + 5 V dc and + 9.6 V dc. Also, the microcomputer board contains a handset audio amplifier which provides the optional handset earpiece with a fixed-gain volume level.
  • Page 53 J1000 P1000 FRONT PANEL HOUSING 5V SOURCE SW A+ UNSW A+ CARTRIDGE Q1005 U1011 U1010 5V REG PRE-AMP HIGH PASS LOW PASS U1006 FILTER FILTER AUTO W1000 / W1001 LEVEL (FLEX CONN) CONTROL U1004 FRONT PANEL 9.6V REG DISPLAY BOARD U1007 SW A+ SW A+...
  • Page 55 TO AUXILLARY PLUG CABLING HANDSET CONNECTOR REMOTE CONTROL HEAD CONNECTOR TO C3800 ON PA/COMMAND J3004 INTERCONNECT J3003 P3007 P3004 BOARD REAR PANEL TOP PANEL J3000 P3000 INTERCONNECT BOARD INTERCONNECT BOARD TO P1000 J3001 P3001 P6001 CLEAN CAB SW B+ FRONT PANEL SW 5V MICRO...
  • Page 57 J3008 P3008 5V REG 0 (DNP) RAD_5V EEPROM AT25160N A0-A15 SCI BUS A0-A15 ADDRESS BUS A0-A15 FLASH ROM D0-D7 SRAM D0-D7 DATA BUS D0-D7 AT29C010 CYC199202I SCI_TXD SCI_RXD MOD_CNTL2 Y101 7.9488 MHz m P_RESET PTTH CHIP SELECT AUX_PTT CHIP SELECT MICROPROCESSOR MC68HC11F1 CHIP SELECT...
  • Page 59 Q3850 Q3875 CONNECTOR BOARD AMPLIFIER Q3801 * - Refer to ASTRO Digital Spectra Detailed Service Manual for information on these modules. TO W6002 ON TOP PANEL NTERCONNECT BOARD Figure 3-2 ASTRO Clean Cab Railroad Radio Functional Block Diagram: ASTRO Transceiver/RF PA...

  • Page 61: Part 4. Theory Of Operation

    PART 4. THEORY OF OPERATION FRONT PANEL CIRCUITS 4.1.1 GENERAL This section describes the electrical details for the circuits contained within the Clean Cab Front Panel Assembly of the ASTRO Clean Cab Railroad Radio. The front panel circuits provide the control interface between the operator and the ASTRO transceiver module.

  • Page 62: Figure 4-1-1 Microcomputer I/O Lines Descriptions

    PIN(s) LABEL DESCRIPTION RESET This line is pulled LOW to reset the microcomputer. Interrupt request pin normally pulled HIGH through R1034. This pin must be connected directly to Vdd on the EEPROM version microcomputer - MC68HC705C8. Microcomputer output to control status of BUSY line. 6, 7 PA5-PA6 Momentarily inputs after reset cycles to read status of group selection Jumpers.

  • Page 63: Figure 4-1-2 Serial Data Bus Logic

    Serial Input/Output IC The Serial Input/Output IC (SIOIC-U1001) performs the following functions: 1. Buffer/inverter for the DISPLAY STROBE signal (U1001, pins 21 and 23). Refer to the display board theory for a description of this signal. 2. Inverter for the AUXILIARY DETECT signal (U1001, pins 35 and 36). A LOW from U1000-26 is inverted by the SIOIC, which biases Q1006 and enables the microcomputer to read jumpers JU1005 and JU1006 for the presence of certain options.
  • Page 64 BUS+ and BUS- form a differential pair (there is always a difference of 5V between the two lines, that is, when one is HIGH the other is LOW). Their idle states are: BUS+ = HIGH (+5V); BUS- = LOW (0V). Figure 4-1-2 summarizes the serial data bus logic states.
  • Page 65 Therefore the speaker outputs must never be grounded. Use an audio isolation transformer (e.g. Motorola Part No. SLN6435A) to isolate test equipment from the Audio PA/speaker. The differential output is routed to the internal front panel speaker via P1002 pins 1 and 2. Alternately, the audio is routed through P1000 pins 1 to 4 to the rear panel interconnect board;...

  • Page 66: Display Board

    Resistors R1072 through R1077 ensure that the input lines are held high until a key press. When a particular key is pressed, the key pad contacts close, allowing the low-going pulse to return to U1000 via the corresponding sense line. U1000 then sends a serial bus message to the translator board processor, identifying which key has been pressed.
  • Page 67 Two cascaded driver ICs are required to control the VFD. Each device consists of a 12-bit series in/parallel-out shift register with high-voltage output stages. The VFD driver ICs share the microcomputer- controlled CLOCK, serial DATA, DISPLAY LE, and STROBE lines with the three shift registers. Serial data to enable the various characters is clocked and latched in the same manner as that described for the indicator and bar graph LEDs.

  • Page 69: Figure 4-1-3 Clean Cab Front Panel Microcomputer Board Overlay

    Figure 4-1-3 Clean Cab Front Panel Microcomputer Board Overlay VLN5284E...

  • Page 71: Figure 4-1-4 Clean Cab Front Panel Microcomputer Board Schematic (4 Sheets)

    Jumper Purpose JU1002 NORMALLY IN; OUT TO DISABLE AUDO LEVEL CONTROL JU1003 NORMALLY OUT; IN TO DISABLE AUTO LEVEL CONTROL JU1008 ALWAYS IN JU1010 NORMALLY OUT; IN FOR MIC AUDIO FILTER BYPASS Figure 4-1-4 Clean Cab Front Panel Microcomputer Board Schematic VLN5284E (Sheet 1 of 4)
  • Page 73 Jumper Purpose JU1001 NORMALLY OUT; SHORTED TO DISABLE WATCHDOG JU1004 NORMALLY OUT; SHORTED MOMENTARILY TO BEGIN DIAGNOSTIC MODE JU1005 NORMALLY IN; GROUP ADDRESS JUMPER JU1006 NORMALLY OUT; GROUP ADDRESS JUMPER JU1007 NORMALLY OUT; GROUP ADDRESS JUMPER Figure 4-1-4 Clean Cab Front Panel Microcomputer Board Schematic VLN5284E...
  • Page 75 Figure 4-1-4 Clean Cab Front Panel Microcomputer Board Schematic (Sheet 3 of 4)
  • Page 77 Figure 4-1-4 Clean Cab Front Panel Microcomputer Board Schematic (Sheet 4 of 4)

  • Page 79: Figure 4-1-5 Clean Cab Front Panel Microcomputer Board Parts List (2 Sheets)

    REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. SYMBOL PART NO. 0102702A08 F/P Heatsink Assembly C1062 2113741Y32 C1155 2113741F49 .01uF consists of: C1063 2113741Z49 100000pF C1156-C1157 2113741Z49 100000pF 0310943J04 SCR, tpg TT2.5 x 0.45 x 8 starpan...
  • Page 81 REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. SYMBOL PART NO. Resistor, chip, 5%, 1/8W Resistor, chip, 5%, 1/8W Transformer (unless otherwise stated) (unless otherwise stated) T1000 2580277J03 voltage converter R1-R2 0662057A73 R1054...

  • Page 83: Figure 4-1-6 Clean Cab Front Panel Display Board Overlay

    Figure 4-1-6 Clean Cab Front Panel Display Board Overlay VLN5247D...

  • Page 85: Figure 4-1-7 Astro Clean Cab Front Panel Display Board Schematic

    Figure 4-1-7 ASTRO Clean Cab Front Panel Display Board Schematic VLN5247D...

  • Page 87: Figure 4-1-8 Clean Cab Front Panel Display Board Parts List

    REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. Capacitor, chip, uF, 5%, X7R, 50V Transistor C2000-C2004 2113741B69 Q2001-Q2004, 4813824A10 NPN, chip, SOT-23 C2005-C2006 2113741B45 0.01 Q2010-Q2022 4813824A10 NPN, chip, SOT-23 Q2005-Q2008, 4813824A10 NPN, chip, SOT-23 (only placed with...

  • Page 89: Rear Panel, Top Panel Interconnect And Translator Boards

    REAR PANEL, TOP PANEL INTERCONNECT AND TRANSLATOR BOARDS 4.2.1 GENERAL This section describes the electrical details for the Clean Cab Rear Panel Interconnect Board, Translator Board and the Universal Top Panel Interconnect Board. The functional relationship of these boards to the other radio circuits is shown in Figure 3-2, Radio Functional Block Diagram.
  • Page 90 the handset or auxiliary microphone PTT is pressed the mechanical switch can generate voltage spikes in excess of the MIC_HI bootstrap voltage threshold (approx 13Vdc). These spikes could cause the ASTRO mobile transceiver to briefly enter and exit bootstrap mode causing a system reset. Identical circuitry is present for rear panel board handset connector microphone audio (HNDST_MIC_AUD).
  • Page 91 The Dual Remote Control Head Connector (J3004) kit is not interchangeable with the Spectra Clean Cab radio. Using the wrong kit may cause radio damage. Reset The system reset bus ties the ASTRO transceiver module, translator board microprocessor, and control head microprocessor(s) reset lines together.
  • Page 92 A+ to J3001-27 (MIC_HI-PROG_MOD_CNTL). This signal causes the ASTRO transceiver processor to bootstrap. Similarly, when FLASHing the translator board the RPTB _MOD_CNTL signal (PROG_MOD_CNTL is not connected) becomes active grounding the drains of Q10 and Q12. These signals (J3008-16 and J3008- 22) go to the translator board’s microprocessor and chip enable logic causing it to bootstrap.

  • Page 93: Top Panel Board

    Auxiliary / Primary Remote Control Head Connector Connector P3004 is used for the mutually exclusive auxiliary connector and dual remote control head connector kits. The AAR auxiliary connector (J3010) consists of a wire / connector assembly, which provides the operator with access to power, handset and speaker lines from the rear panel interconnect board. In this way, the auxiliary connector can be used to connect an external speaker to the radio, as an alternative handset connector, or for other operator-specified applications (refer to Figure 2-1-2).

  • Page 94: Translator Board

    CleanCab radio. Microprocessor The microprocessor, U1 (Motorola 68HC11F1), operating at an approximate 2MHz clock speed, is the heart of the translator board. All serial bus messages are passed through the microprocessor to and from the ASTRO transceiver and control head(s) via the DUART.
  • Page 95 Each serial bus consists of three lines. The RAD_BUS+, RAD_BUS- and RAD_BUSY are used to support the ASTRO transceiver bus, and the CH_BUS+, CH_BUS-, and CH_BUSY signals are used to support the control head bus. All bus- / bus+ signals are balanced lines to form a complementary signal (bus- is inverted from the state of bus+) for noise rejection.
  • Page 96 Refer to section 5.5 for determining the version number of the installed board. Go to the Motorola Online service web site https://businessonline.motorola.com to determine the latest version. If the firmware needs to be updated, follow the online instructions for downloading and FLASHing the latest version.

  • Page 97: Figure 4-2-1 Clean Cab Rear Panel Interconnect Board Overlay (2 Sheets)

    Figure 4-2-1 Clean Cab Rear Panel Interconnect Board Overlay (Front) VLN5738A...
  • Page 99 Figure 4-2-1 Clean Cab Rear Panel Interconnect Board Overlay (Back) VLN5738A...

  • Page 101: Figure 4-2-2 Clean Cab Rear Panel Interconnect Board Schematic (2 Sheets)

    Figure 4-2-2 Clean Cab Rear Panel Interconnect Board Schematic (Sheet 1 of 2) VLN5738A...
  • Page 103 Figure 4-2-2 Clean Cab Rear Panel Interconnect Board Schematic (Sheet 2 of 2) VLN5738A...

  • Page 105: Figure 4-2-3 Clean Cab Rear Panel Interconnect Parts List (2 Sheets)

    REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. SYMBOL PART NO. Capacitor, chip, 5%, X7R, 50V Capacitor, chip, 5%, X7R, 50V Resistor, chip, 5%, 1/16W (unless otherwise stated) (unless otherwise stated) (unless otherwise stated)
  • Page 107 REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. SYMBOL PART NO. Resistor, chip, 5%, 1/16W Integrated Circuits Non-referenced items (unless otherwise stated) 5105109Z13 LT1129CQ 0102702A09 FR-Rear PNL Int Cab Assy Univ R107 0611077A01...

  • Page 109: Figure 4-2-4 Aar Auxiliary Connector Schematic And Parts List

    REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. 0310943J10 SCR, tpg TT3 x 0.5 x 8 intstarpan (4 used) 0702009A03 PLATE, mounting aux connector J3004 0984279D03 CONNECTOR, crimp (10 used) J3010 0984465M01 CONNECTOR, AAR standard 12 cont 1110019C21 GLUE, hot melt 1484277D15...

  • Page 110: Figure 4-2-5 Top Panel Interconnect Board Overlay

    Figure 4-2-5 Top Panel Interconnect Board Overlay VLN5736A Figure 4-2-6 Top Panel Interconnect Board Schematic VLN5736A...

  • Page 111: Figure 4-2-7 Top Panel Interconnect Board Parts List

    REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. 0102702A10 Top Panel Interconnect Board Cable Assembly: consists of P6001 0982061P07 RECEPTACLE, IDC female 25 pos. polar 3000029M06 CABLE, ribbon 28 AWG 26 pos. 12 in. W6000 0102702A12 Wire and U-Lug Assembly: consists of...

  • Page 112: Figure 4-2-8 Dual Remote Control Head Auxiliary Connector Schematic

    Figure 4-2-8 Dual Remote Control Head Connector Schematic VLN5747A REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. 0310943J10 SCR, tpg 3 x 0.5 x 8 intstarpan (4 used) 0702009A03 PLATE, mounting aux. connector. J3011 0902001A03 RECEPTACLE, 19-pin J3004 0984279D03 CONNECTOR, crimp (19 used)

  • Page 113: Figure 4-2-10 Translator Board Overlay

    Figure 4-2-10 Translator Board Overlay VLN5739A...

  • Page 115: Figure 4-2-11 Translator Board Schematic

    Figure 4-2-11 Translator Board Schematic VLN5739A...

  • Page 117: Figure 4-2-12 Translator Board Parts List

    REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. SYMBOL PART NO. Capacitor, chip, 5%, X7R, 50V Connector Integrated Circuits (unless otherwise stated) P3008 2805801V01 CONN_P 5113802A27 MC68HC11F1CFN3 C1-C5 2113740F67 470pF 5185143E29 DUART SC28L92 2109822S04 10.0uF, 35V...

  • Page 119: Figure 4-2-13 Flash Cable Diagram

    DB-15M DB25-F To Service Conn To SRIB PROG_RESET MOD_CTL BUS+ SCI_RX SRIB_TX PROG_VPP BIAS RADIO FLASH SRIB_RX PROG_MOD DB-15M To Service Conn RESET_CTL BUS- SRIB_TX SRIB_RX FLASH TB_MOD Figure 4-2-13 FLASH Cable Diagram (3085864F01)

  • Page 121: Power Converter And Filter Modules

    POWER CONVERTER AND FILTER MODULES 4.3.1 GENERAL This section describes the electrical details for the Universal 72/12V Power Converter Board (VLN5745A) (hereafter referred to as the "power converter"), the (optional) 36/12V Power Converter Board (VLN5746A) and the (optional) Universal 12V Filter Board (VFN4004B). The power converter (or filter board) is housed within a section of the bottom panel assembly, beneath a metal cover.

  • Page 122: Figure 4-3-1 72/12 V Power Converter Board Block Diagram

    is controlled by U4001 on a pulse-by-pulse basis to achieve the desired output level. As a forward converter, this circuit uses the transformer in the forward mode, meaning that power is delivered to the load every time the voltage chopper is on and current is allowed to flow in the primary. When Q4001 and Q4002 are on, a voltage is developed across the secondary winding.
  • Page 123 through feedback loops, the output can be regulated for varying load conditions. The regulation process is described in the following paragraphs dealing with sensing and fault detector circuitry, and under-voltage lockout circuitry. The voltage chopper circuitry includes a snubber circuit composed of CR4005, R4017, and C4019 which controls voltage spikes which are due to the leakage inductance of T4001.

  • Page 124: Figure 4-3-2 Universal 12V Filter Board Schematic

    over-voltage comparator, U4004, turning on Q4005. This pulls U4001-1 low which disables the internal error amplifier, thereby turning off the power converter. The 72 V input voltage is applied to voltage divider R4021 and R4023, with the divided voltage being applied to comparator U4004-3.

  • Page 125: Figure 4-3-3 Universal 12V Filter Board Parts List

    REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. C4066, C4007 2313748E31 CAPACITOR, electrolytic, uF 2200uF, 20%, 50V CR404 4802012A01 DIODE, rectifier, 20A, 100V Schottky F4002 6500004637 FUSE, 20A, 32V L4003 2584696M01 COIL, 100uH, 16A J4001 0980255E01 RECEPTACLE, power, 2 connector P4000 2884468M01...

  • Page 126: Figure 4-3-4 Universal 12V Filter Board Overlay

    Figure 4-3-4 Universal 12V Filter Board Overlay...

  • Page 127: Figure 4-3-5 Universal 72/12 V Power Converter Board Overlay

    Figure 4-3-5 Universal 72/12 V Power Converter Board Overlay...

  • Page 129: Figure 4-3-6 Universal 72/12 V Power Converter Board Schematic

    Figure 4-3-6 Universal 72/12 V Power Converter Board Schematic...

  • Page 131: Figure 4-3-7 Universal 72/12 V Power Converter Board Parts List

    REFERENCE MOTOROLA REFERENCE MOTOROLA REFERENCE MOTOROLA DESCRIPTION DESCRIPTION DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. SYMBOL PART NO. Capacitor Zener Diode Fuse C1-C2 4.7n, 4kVAC 1N4736A 6.8V 1W 5% FUSE 6.25A 250V 3453QS1, ELEC 1200uF 20% 200V 1N4746A 18V 250mA...

  • Page 133: Figure 4-3-8 Universal 36/12 V Power Converter Board Overlay

    Figure 4-3-8 Universal 36/12 V Power Converter Board Overlay...

  • Page 135: Figure 4-3-9 Universal 36/12 V Power Converter Board Schematic

    Figure 4-3-9 Universal 36/12 V Power Converter Board Schematic...

  • Page 137: Figure 4-3-10 Universal 36/12 V Power Converter Board Parts List

    REFERENCE MOTOROLA REFERENCE MOTOROLA REFERENCE MOTOROLA SYMBOL PART NO. DESCRIPTION SYMBOL PART NO. DESCRIPTION SYMBOL PART NO. DESCRIPTION Capacitor Zener Diode Fuse C1-C2 4.7n 4kVAC 1N4736A 6.8V 1W 5% FUSE 15A 250V 3453QS1 ELEC 680u 100V 20% 1N4746A 18V 250mA C4-C5 POLY FKS2 2.2nF 10% 250V...

  • Page 139: Astro Transceiver Module And Rf Power Amplifer

    ASTRO TRANSCEIVER MODULE AND RF POWER AMPLIFER 4.4.1 ASTRO TRANSCEIVER MODULE The ASTRO transceiver module, located in a casting within the top panel assembly, contains most of the receiver, transmitter injection, synthesizer, and associated control circuits for the ASTRO railroad radio. For further detail, refer to the ASTRO Service Manual referenced in Part 1.2 RELATED DOCUMENTS.

  • Page 140: Antenna Fault Detector

    Figure 4-4-1 Command Board /RF PA Ribbon Cable Assembly 4.4.4 ANTENNA FAULT DETECTOR The ASTRO Clean Cab radio equipped with the VLD4122B VHF RF Power Amplifier is capable of detecting faults in the antenna system external to the radio. This is accomplished by sensing the reverse power which is produced by impedance mismatches in a faulty antenna system.
  • Page 141 Theory of Operation Board detail, schematic and parts list for the RF PA board with Antenna Fault Detector are provided in figures 4-4-8, 4-4-9 and 4-4-10 at the end of this section. For servicing information on the RF amplifier stages on this board, refer to the VHF PA section in the ASTRO Service Manual. The VLD4122B PA board contains a dual directional coupler consisting of microstrip transmission lines 5, 6 and 8.

  • Page 142: Figure 4-4-2 Astro Adaptor Board Detail

    COMPONENT SIDE – BLUE (top) SOLDER SIDE – RED (bottom) Figure 4-4-2 ASTRO Adaptor Board Detail VLN5737A...

  • Page 143: Figure 4-4-3 Astro Adaptor Board Schematic

    Figure 4-4-3 ASTRO Adaptor Board Schematic VLN5737A REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. Connector P5001 2802003A01 HEADER, male 26-pin, pos. polar, w/ eject P502 2880102M08 HEADER, male 37-pin Non-referenced items 8485151C01 PCB, ASTRO Adaptor Figure 4-4-4 ASTRO Adaptor Board Parts List VLN5737A...

  • Page 144: Figure 4-4-5 Vhf Pa/Command Interconnect Board Detail

    Figure 4-4-5 VHF PA/Command Interconnect Board Detail...

  • Page 145: Figure 4-4-6 Vhf Pa/Command Interconnect Board Schematic

    Figure 4-4-6 VHF PA/Command Interconnect Board Schematic REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. CAPACITOR, chip, pF, 5%, NPO, 50V (unless otherwise stated) C3890 - 3900 2113740B65 C3800 2182812H03 1000, –0/+100, 500V, feed through cer P850 2802007A01 PLUG, vertical 12 pos.

  • Page 147: Figure 4-4-8 Vhf Rf Power Amplifier Board Detail

    Figure 4-4-8 VHF RF Power Amplifier Board Detail VLN4122B...

  • Page 149: Figure 4-4-9 Vhf Rf Power Amplifier Schematic (2 Sheets)

    Figure 4-4-9 VHF RF Power Amplifier Schematic (Sheet 1 of 2) VLN4122B...
  • Page 151 Figure 4-4-9 VHF RF Power Amplifier Schematic (Sheet 2 of 2) VLN4122B...

  • Page 153: Figure 4-4-10 Vhf Rf Power Amplifier Parts List

    REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. SYMBOL PART NO. Capacitor, chip, pF, 5%, Diode Resistor, chip, 5%, 1/8W NPO,50V CR3920-CR3921 4880236E24 (unless otherwise stated) (unless otherwise stated) CR3922 4880142L01 PIN, SOT-23...

  • Page 155: Part 5. Maintenance And Alignment

    (Motorola part number 01-80386A82). This kit includes a wrist strap, two ground cords, a static- control table mat and a static-control floor mat. 6. Always wear a conductive wrist strap when servicing this equipment. The Motorola part number for a replacement wrist strap that connects to the table mat is 42-80385A59.
  • Page 156 Refer to publication 68P81113E77, Removal and Replacement of Chip Components on Circuit Boards for more detailed information on this subject. This free publication can be ordered using the “Available Background Reference Publications” order form (Motorola part number, 68P80200W02) located at the back of this manual.

  • Page 157: Channel Frequencies

    CHANNEL FREQUENCIES The ASTRO CleanCab is factory-programmed with 188 transmitter/receiver channels in accordance with the frequencies established by the North American Frequency Allocation Plan (FAP) from the AAR (refer to figure 5-2-2). In addition, nine receive-only channels have been programmed with the NOAA weather service frequencies (refer to figure 5-2-1).

  • Page 158: Figure 5-2-2 Aar Channel Plan

    Channel Frequency Channel Frequency Channel Frequency Channel Frequency Number (MHz) Number (MHz) Number (MHz) Number (MHz) 159.8100 160.8600 159.8100 160.8600 159.8100 160.8750 159.8100 160.8750 159.9300 160.8900 159.9300 160.8900 160.0500 160.9050 160.0500 160.9050 160.1850 160.9200 160.1850 160.9200 160.2000 160.9350 160.2000 160.9350 160.2150 160.9500 160.2150...

  • Page 159: Recommended Test Equipment

    RECOMMENDED TEST EQUIPMENT Refer to the ASTRO Service Manual for a detailed list of test equipment and cables. Motorola Model Number Description Characteristics Application R-1013_* or SINAD Meter w/o RMS audio voltmeter Receiver sensitivity measurements R-1370_* SINAD Meter with RMS...

  • Page 161: Power-Up Self-Check

    POWER-UP SELF-CHECK Each time the radio is turned on the microprocessors in the ASTRO transceiver module, translator board and front panel control board(s) perform internal diagnostics. These diagnostics consist of checking the programmable devices such as the FLASH ROMs, DSP, internal and external EEPROMs, SRAM devices, and ADSIC configuration bus checksum.

  • Page 162: Figure 5-4-2 Non-Fatal Self Check Displays

    Display Possible Cause Remedy (Non-Fatal) ERROR 05/02 Last User States Codeplug failure Cleancab automatically uses default Last User State & resets ERROR 25/50 Button Stuck a. Control head button actuated during powerup. b. Replace Front Panel Display Board. ERROR A5/50 Button Stuck a.

  • Page 163: Front Panel Service Mode

    FRONT PANEL SERVICE MODE To aid in testing the radio may be placed in service mode from the control head. The service mode has various menus for selecting specific test modes. Controls The following control head buttons are used to initiate and the control the front panel service mode. HOME Used to toggle between frequency select and mode select (CSQ, TPL, etc…)
  • Page 164 Pressing the HOME button will toggle the flashing character between the number and the first letter of the mode name ( i.e. “1 CSQ”). The menu can be changed to the following using the # and * buttons. Carrier Squelch Tone PL (Code: 7A - 192.8 Hz) ASTRO Deviation (Transmits a 1200 Hz analog tone for testing deviation level, receive is disabled)

  • Page 165: Troubleshooting And Repair

    TROUBLESHOOTING AND REPAIR Failure messages, “FAIL xx/xx”, or error messages, “ERROR xx/xx”, are related to either the ASTRO transceiver, Front Panel Microcomputer Board(s) or the Translator Board. Refer to Figure 5-4-1 to determine the source of the failure or error. NOTE When probing internal connectors and components it may be necessary to us a Top/Bottom Housing...

  • Page 166: Figure 5-6-1 Translator Board / Rear Panel Interconnect Board Troubleshooting

    Symptom Possible Cause Correction or Test (Measurements Taken at 20°C) Missing or no alert 1. Setup and programming Check CH volume. Verify Alert Tones are enabled and minimum alert tone volume is tones properly set in ASTRO Spectra CPS. Some tones are not heard at Auxiliary SPKR (trunking tones) outputs, other tones may not match those heard at the CH speaker and handsets.

  • Page 167: Figure 5-6-2 Transmitter Troubleshooting Preferred Test Setup

    UHF-TO-N N CONNECTOR ADAPTOR POWER RADIO 20 dB PAD METER Figure 5-6-2 Transmitter Troubleshooting Preferred Test Setup Figure 5-6-3 lists a number of transmitter-related symptoms which may occur that interrupt normal radio operation. Refer to this figure to assist in troubleshooting and repairing transmitter problems to the board level.
  • Page 168 Therefore the speaker outputs must never be grounded. Use an audio isolation transformer (e.g. Motorola Part No. SLN6435A or equivalent) to isolate test equipment from the Audio PA/speaker.

  • Page 169: Figure 5-6-4 Receiver Troubleshooting

    Symptom Possible Cause Correction or Test (Measurements Taken at 20°C) Radio dead; 1. Blown fuse Check fuses (F4001 and F4002) on power converter board display does not 2. Power Converter / Verify A+ (13.8Vdc) is present at P3002-1; if not, check power converter circuitry. light up RPIB Verify A+ is present at J3001-1,18,19,36,37 and J3008-2;...
  • Page 170 Symptom Possible Cause Correction or Test (Measurements Taken at 20°C) Audio distorted or 1. Synthesizer not on Refer to the ASTRO Service Manual for troubleshooting. not loud enough frequency/working 2. RF Board Refer to the ASTRO Service Manual for troubleshooting. 3.

  • Page 171: Radio Set Disassembly / Assembly

    RADIO SET DISASSEMBLY / ASSEMBLY The procedures described in this section detail the disassembly and reassembly of the ASTRO Clean Cab. When executing the following procedures, refer to the exploded view diagrams located at the end of this part. Disconnect all DC power to the radio before removing any boards from the radio.
  • Page 172 Disassembly of Radio Housing 1. With the radio turned on the side opposite the handle, remove the four screws located on the corners of the bottom panel. 2. Place the radio upright and locate the slot at the rear of the radio. Placing a suitable blade screwdriver in the slot, carefully pry the top and bottom panels apart slightly.
  • Page 173 3. Remove nine screws securing power converter cover and remove cover (these screws also secure power converter/filter board). 4. Disconnect power cable (P/J4001) from power converter board. 5. Remove three screws securing mounting bracket to the bottom panel housing, remove RPIB and bracket from housing.
  • Page 174 7. Start all nine mounting screws before applying any torque (the three long screws go through the power converter heat sink). Tighten power converter screws. 8. Position rear panel board assembly into its slot in the bottom panel housing and ensure that P/J3008 mates with P/J3008 on Translator Board.
  • Page 175 PA board and re-solder to the new PA board. To reinstall the power amplifier board, perform the following: 1. Apply a thin coat of thermal compound (e.g. Motorola part number 11-83166A01) to the pre-driver, driver and final device heat sink mounting surfaces.
  • Page 176 NOTE After replacing or repairing the power amplifier board, you must ensure its proper operation by performing the specified RF alignments found in the ASTRO Service Manual. Top Panel Interconnect Board Replacement Refer to figure 5-7-4 for the following: 1. Before attempting to remove the top panel board, the ASTRO transceiver must be removed as described previously.

  • Page 177: Figure 5-7-2 Astro Railroad Radio Front And Bottom Panel Exploded View

    Figure 5-7-2 ASTRO Railroad Radio Front and Bottom Panel Exploded View...

  • Page 179: Figure 5-7-3 Front And Bottom Panel Hardware Parts List

    REFERENCE MOTOROLA DESCRIPTION REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. SYMBOL PART NO. 0102702A29 Lens Assembly - Clean Cab VLN5284E Clean Cab Microcomputer Board consists of: 0310907A33 SCR, tpg TT3.5 x 0.6 x 30 1110019A88 ADHESIVE, RTV intstarpan (5 used) 3282172J01...

  • Page 181: Figure 5-7-4 Astro Railroad Radio Top Panel Exploded View And Parts List

    REFERENCE MOTOROLA DESCRIPTION SYMBOL PART NO. 1502004A02 HOUSING, top panel VLN5736A Top Panel Interconnect Board 0300040M10 SCR, M2 x 0.4 x 8 mm instar (2 used) 0482318N01 WASHER, flat 0310943J10 SCR, tpg TT3 x 0.5 x 8 intstarpan (15 used)

  • Page 183: Part 6. Options And Accessories

    6.1.4 MBW81 Ear Bracket for Padlock This option provides an ear bracket (Motorola part no. 0702006A02) and the necessary screws (Motorola part no. 0300040M11) to fasten the bracket to the bottom panel housing of the radio, directly below the power connector. When the radio is installed into a standard clean cab mounting plate, the ear bracket lines up with a similar ear on the plate.

  • Page 184: Mbw654 Dual Control Panels With Two Remote Control Heads

    The remote-mount control head can be installed into the standard 4" X 10" AAR 12-2 control stand opening, or surface-mounted in another suitable location. The auxiliary connector remains unchanged (i.e. is compatible with the standard AAR auxiliary connector). No Radio Service Software (RSS) programming is necessary.

  • Page 185: Accessories

    The following accessories are available for the ASTRO Clean Cab Railroad Radio. All items marked with an asterisk (*) are available from Motorola RPSD. The remaining accessories can be obtained from the factory at the time the order is placed (all accessories must be ordered separately). For radio service programming accessories, refer to 6.3 PROGRAMMABLE FEATURES.

  • Page 186: Tmn6082 Handset With Aar Connector

    6.2.4 *TMN6082 Handset with AAR Connector The TMN6082 is a telephone type dynamic handset designed for use in railroad installations. The handset is equipped with a conventional neoprene coiled cord which is terminated in an AAR-specified connector. The connector mates with the handset connector (J3003) at the rear of the ASTRO railroad radio.

  • Page 187: Antennas: (Specify Frequency)

    and parts list are provided in Figure 6-4. Board detail, schematic, and parts list are provided in Figures 6- 5 to 6-7. 6.2.10 *Antennas: (specify frequency) TAD6010 Rigid "Firecracker" Flange Mount TAD6020 Conduit Mounting Whip TDD6110 4" Train Antenna Sinclair 221...

  • Page 188: Figure 6-2 Railroad Handset Exploded View And Parts List

    REFERENCE SYMBOL MOTOROLA PART NO. DESCRIPTION 1583982F01 CAP, receiver 1480368B67 INSULATOR, handset 4680368B66 WEIGHT, handset 5984058A01 CARTRIDGE, receiver 1584605F01 HOUSING, handset w/ transmitter cap 0300124432 SCR, mch 4-40 x ¼ phl stl (2 used) 4083985F01 SWITCH, PTT 1584053A01 COVER, switch...

  • Page 189: Figure 6-3 Railroad Handset Schematic

    Figure 6-3 Railroad Handset Schematic...

  • Page 191: Part 7. Astro Spectra Cleancab Radio Programming

    Home channel configurations, dispatch tone durations, and controlhead configurations. The radio can be reprogrammed by any authorized Motorola Service Shop. Alternately, the radio can be field programmed by connecting a Windows computer, using the appropriate interface hardware, to connector J3006 on the CleanCab and following the prompts and help screens contained within the CPS.

  • Page 192: Setup

    7.1.3 Setup The same setup is used for programming with both the ASTRO Spectra CPS and the CleanCab CPS. Connect the RIB to a serial port (COM1 or COM2) on your computer. Connect the programming cable from the RIB to the 15 pin service connector J3006 on the back of the ASTRO CleanCab radio. The RIB can receive its power from the radio, however it is recommended that the RIB be powered from an AC adapter, when AC line power is available.

  • Page 193: Programmming Guidelines

    PROGRAMMMING GUIDELINES There are a wide selection of features which are programmable in the ASTRO transceiver contained in the ASTRO CleanCab radio. Some of these features are not compatible with the ASTRO CleanCab radio controlhead and ergonomics, and others are not appropriate for typical railroad use. This section will provide guidelines for programming the radio for railroad use.
  • Page 194 MDC tab These options are not supported in the CleanCab radio, and should be unchecked. ASTRO tab Use this tab to set the Network ID and other options related to ASTRO digital voice transmissions. ASTRO Call tab These options are not supported in the CleanCab radio, and should be unchecked. ASTRO Talkgroup tab These options are not supported in the CleanCab radio, and should be unchecked.
  • Page 195 Phone tab In this tab, <Phone Interconnect> should be set to Unlimited. WAC_AMSS tab If WAC-AMSS is enabled, set the frequencies on this tab. WAC-AMSS may be enabled on the failsoft tab. Failsoft tab Select the failsoft type and failsoft frequency on this tab. Emergency Revert tab This option is not supported in the CleanCab radio.

  • Page 196: Other Programmable Parameters

    7.2.2 Other Programmable Parameters Radio Wide Parameters In the tree view, expand Radio Configuration, then double click the Radio Wide line. A "tabbed" view of the Radio Wide parameters will appear. General tab This tab contains miscellaneous parameters. The <Out Of Range> indicator selection is ignored by the CleanCab radio. Emergency tab The CleanCab radio does not provide an Emergency switch, thus the settings of this tab are ignored.
  • Page 197 VRS tab These options are not supported in the CleanCab radio, and should be unchecked. Home Mode tab This option is not supported in the CleanCab radio, and should be unchecked. Audio Gain Options tab This tab can be used to adjust the audio levels from the mic to the transmitter. NOTE The CleanCab controlhead mic has a hardware AGC circuit.
  • Page 198 The remaining parameters in this tab are ignored by the CleanCab controlhead. DTMF timing is set with the CleanCab RSS (see section 7.3.2 F6 – Tones dialog). DTMF Codes These parameters are ignored by the CleanCab controlhead. Phone List These parameters are ignored by the CleanCab controlhead. Secure Parameters This option is not supported in the CleanCab radio, and all these parameters should be left disabled.
  • Page 199 Mode Steering tab This option is not supported in the CleanCab radio, and should be disabled. Advanced tab System pre-time for MDC IDs may be set on this tab. It is recommended that the remaining parameters be left at the factory defaults. ASTRO Configuration Parameters This selection contains three tabs, which contain parameters relevant to the APCO packet data option.
  • Page 200 Phone These parameters are ignored by the CleanCab radio, and it is recommended they be left at the factory defaults. Trunking System Parameters In the tree view, expand Trunking, then Trunking System, then double click the system to be edited. A "tabbed"...

  • Page 201: Astro Spectra Cleancab Cps

    ASTRO SPECTRA CLEANCAB CPS This section covers the programming of the parameters which are unique to the CleanCab radio, using the CleanCab CPS. CleanCab CPS is a Windows program used to select the unique CleanCab features in the ASTRO Spectra CleanCab radio. To install the CPS, simply change to the CPS directory on the CD-ROM, and run the setup.exe program.

  • Page 202: Editing Cleancab Parameters

    Help Extensive help text is included in the CPS. Select "Help" from the Help menu, click on the Help button in any editing screen, or press F1 to access the help screens. 7.3.2 Editing CleanCab parameters The CleanCab parameters are presented in several editing dialogs, which are displayed in a tree view. Initially the tree view is collapsed;...
  • Page 203 Dispatch Sequences When enabled, allows the user to enter a 1- to 3- digit dispatcher call sequence, which will be transmitted when the DISP button is pressed. When disabled, only a single digit may be entered. Fixed Home Mode Dispatch Tones If Fixed Home Mode Dispatch Tones is enabled, a dispatch tone is assigned to each Home Mode by the CPS programming.
  • Page 204 Advanced Options dialog It is recommended that the default values in this section not be changed. Keypad Entry Timer This timer sets the length of time in milliseconds the radio will wait for a user to complete entering a value in a select state (e.g.

  • Page 205: Utility Programs

    NOTE The CPS does not verify that these channel numbers are actually present in the radio's programming. Home Mode Dispatch Tone Enter the DTMF digit to be sent when the DISP button is pressed in this Home Mode. This selection is not available if Dispatch Sequences has been enabled on the General Options screen.

  • Page 206: Figure 7-2 Pc-Srib-Radio Connection Diagram (Flash Upgrading Translator Board)

    FLASHport process; refer to the ASTRO Service Manual for instructions. Installation To install the ASTRO CleanCab Translator Board Updater (SPLASH) on your PC simply extract the following files from splash.zip to your computer’s hard drive: splash.cfg splash.exe cc.bat cc_boot.s mastodon.s (latest firmware release [R02.00] as of the release of this manual) NOTE All of the above files must reside in the same directory, or the updater will not work properly.
  • Page 207 12. Check display for the correct firmware version: CNTLHDxx. (xx will be the abbreviated firmware version number, e.g. xx = 20 for firmware version R2.0) 13. Reset the CleanCab. NOTE In the event of any future updates to the translator board firmware, a new splash.zip package will be distributed Motorola Online service site https://businessonline.motorola.com...

  • Page 209: Appendix A Replacement Parts Ordering

    Model Chart in the front of this manual, read the Transceiver Board or VOCON Board note, and include the proper information with your order. Motorola Online Motorola Online users can access our online catalog at https://www.motorola.com/businessonline To register for online access, please call 800-814-0601.
  • Page 210 Telephone Orders Radio Products Services Division (United States and Canada) 7:00 AM to 7:00 PM (Central Standard Time) Monday through Friday (Chicago, U.S.A.) 800-422-4210 847-538-8023 (International Orders) U.S. Federal Government Markets Division (USFGMD) 800-826-1913 Federal Government Parts - Credit Cards Only 8:30 AM to 5:00 PM (Eastern Standard Time) Fax Orders Radio Products Services Division...
  • Page 212 Motorola, Inc. 8000 West Sunrise Boulevard Ft. Lauderdale, FL 33322 MOTOROLA, the Stylized M Logo, ASTRO, and Spectra are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners.

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