Page 1 TP8100 Portables Service Manual MPC-00003-05 · Issue 5 · July 2014...
Page 2 CN200930009301.0, EU000915475-0001, without prior written permission from Tait Limited. EU000915475-0002, GB2413445, US12/870840, The word TAIT and the TAIT logo are trademarks of US13/082767, US13/185498, US13/465664, US13/ Tait Limited. 542062, US13/542147, US13/763531, US13/896969, US14/032876, US29/401234, US29/401235,...
Page 3 16 Installing a Serial Programming Cable ..... . . 287 Tait Software Licence Agreement ......289 TP8100 Service Manual ©...
Page 5 Preface Scope This manual describes repairs to a TP8100 portable radio and their accessories. Because board replacement is often the most cost-effective solution for this radio, no detailed circuit descriptions or faultfinding procedures to board component level are provided. If you have in-depth product knowledge and...
Page 6 To download the latest version of the applications: Downloading Software Log into the secured area of the Tait Technical Resources website. “Tait Support Website” on page From the product Programming Applications area, download the latest version as a zipped file called TP8100_PU_vxx_xx_xx.zip (where vxx_xx_xx is the version number).
Page 7 Documentation Tait Technical Resources website. See “Tait Support Website” on page The website also provides user documentation in other languages. You can request ‘PCB Information Documents’ from Tait Support. For PCB Information Documents more information see “Obtain a PCB Information Document” on page...
Page 8 Abbreviation Description CCDI Computer Controlled Data Interface (CCDI), a Tait-proprietary data protocol; on conventional radios only CCTM Computer-Controlled Test Mode CODEC Coder-Decoder CTCSS Continuous Tone-Controlled Subaudible Signalling Digital-to-Analog Converter Direct Current Digital Signal Processor DTMF Dual Tone Multiple Frequency, a tone-based system (‘touch tones’) used for the world’s...
Page 9 Part of the top UI switch assembly. computer The office PC or laptop on which you run the TP8100 software applications. Because a laptop can be used, the term ‘PC’ is generally avoided. firmware Software (programs or data) together with the hardware that it has been ‘written onto’.
Page 10 ‘accessory connector’. software The TP8100 applications that you run on a computer in order to back up, edit, and update the radio calibration and programming files; also the applications that you use to transfer new firmware to the radio. See “Programming and Calibration...
Page 11 Requirements Specific to the TP8100; added Midian TVS-2-TP8 encryption board (TIMS 70720); updated figure showing removal of SMA connector; added Spares Kits for Replacement Parts; added table of screws and torque for TP8100 radio; added instructions for positioning the FPC cable, top UI switch assembly; updated Initial Tasks and Final Tasks;...
Page 12 Pin 5 of the accessory connector now defined simply as “ground” (TIMS 106276) Updated product code of “T03-00119-XAAA Hirose Accessory Adapter”. Updated list of “Compatible Hirose accessories”. Updated product code of “T03-00119-XBAA 7.5mm Accessory Adapter”. Preface TP8100 Service Manual © Tait Limited July 2014...
Page 13 ■ If you wear your radio, you must always put it in a carrying accessory that ■ has been specifically approved by Tait for this radio. Using non-approved TP8100 Service Manual Safety and Compliance Information © Tait Limited July 2014...
Page 14 RF than recommended by the FCC’s occupational/controlled environment RF exposure limits. Ensure you only use Tait-approved antennas, batteries, and accessories. ■ For more information on what RF energy is and how to control your exposure to it, visit the FCC website at www.fcc.gov/oet/rfsafety/rf-faqs.html.
Page 15 Brief Declarations of Conformity appear on page 2 of this document. Declaration of To download the formal declaration of conformity, go to Conformity www.taitradio.com/eudoc. TP8100 Service Manual Safety and Compliance Information © Tait Limited July 2014...
Page 16 Obey all signs and instructions. Interference with blasting operations could cause serious injury or death. Safety and Compliance Information TP8100 Service Manual © Tait Limited July 2014...
Page 17 The following communication accessories can be used with an Intrinsically Safe TP8100 radio, but are suitable for IS / I / 1 / CD and NI / I / 2 / CD applications only: TPK-AA-101 heavy-duty speaker microphone (MIL-STD) with ■...
Page 18 The radio is designed to satisfy the applicable compliance regulations. Do not make modifications or changes to the radio that are not expressly approved by Tait Limited. Failure to do so could invalidate compliance requirements and void the user’s authority to operate the radio.
Page 19 Notice Tait Limited recommends that you do not affix additional labels to the surfaces between the radio chassis and the battery. The fit between these surfaces is intentionally firm and any added thickness will damage the points of attachment between radio and battery.
Page 23 Introduction The TP8100 series is a range of high-performance microprocessor- controlled analog portable radios for voice and data communication. The radios are small and rugged with a dust and immersion rating of IP67 and IP65. All models demonstrate superior battery shift life and cycle times, and support a range of standard and custom features and protocols.
Page 24 G2, H5, and H6 frequency bands ■ whip (half-wave) antennas for K6 and L3 frequency bands ■ For a full list of compatible antennas please refer to the TP8100 Specifications Manual (MPC-00025-xx). Introduction TP8100 Service Manual...
Page 25 Tuning an antenna If an antenna is tuneable, use the cutting chart that is supplied with the antenna. Tuneable antennas for the TP8100 include TPA-AN-001 (136-225MHz) and TPA-AN-101 (174-225MHz). Measure the antenna from the top of the end cap to the bottom of the SMA connector.
Page 26 TPK-AA-002B or with the accessory connector kit TPB-AA-005. Warning Use only IS-approved accessories with an Intrinsi- cally Safe (IS) radio. The Tait website has the current list of FM-approved accessories. See also “Servicing Intrinsically Safe (IS) Equipment” on page For more information about connecting accessories, see the Accessories section at the end of this manual.
Page 27 The bottom of the label carries regional compliance markings and legal ■ notices. See “Type Codes (Compliance Codes)” on page 214. For full compliance information see the TP8100 Safety and Compliance Information document (MPC-00004-xx). TP8100 Service Manual Introduction © Tait Limited July 2014...
Page 28 (S/N) on the label. A S/N greater than 5 000 000 but less than 25 000 000 confirms that the label describes the PCB. The PCB label is also a different shape. See Figure 1.3 Figure 1.4. Introduction TP8100 Service Manual © Tait Limited July 2014...
Page 29 (DOM) in the format YYWW (year-week) ■ barcode in a machine-readable format ■ A hole in the label is aligned with the vent hole in the battery. “Attaching a Label” on page 183. TP8100 Service Manual Introduction © Tait Limited July 2014...
Page 30 If the battery label shows IS information and the Factory Mutual (FM) diamond logo, the battery is certified Intrinsically Safe. See “Servicing Intrinsically Safe (IS) Equipment” on page APPROVED Introduction TP8100 Service Manual © Tait Limited July 2014...
Page 31 On the outside of the battery is an attachment for a belt clip. If a belt clip adapter (TPA-CA-208) is used with a belt clip, the radio stays vertical while attached to a belt. For battery dimensions see Table 1.2 on page TP8100 Service Manual Description © Tait Limited July 2014...
Page 32 Circled numbers in this section refer to items in Figure 2.1. The same figure is repeated, with part numbers, in Chapter 7, Spare Parts. For radio dimensions see Table 1.1 on page Figure 2.1 Radio components Description TP8100 Service Manual © Tait Limited July 2014...
Page 33 Notice Install the two battery catch springs precisely, and verify their operation before you replace the rear panel. Follow the instructions pro- vided. If the springs are misaligned, it is extremely difficult to re-open the radio without causing damage. Contact your regional Tait office for assistance. 2&...
Page 34 See “List of Spares Kits” on page 200. Any attempt to repair or replace these parts may compromise the IP rating of the radio. See “Vacuum and Pressure Testing” on page Description TP8100 Service Manual © Tait Limited July 2014...
Page 35 New knobs fit firmly and may be hard to pull off: each time they are removed and replaced, the fit naturally becomes less firm. TP8100 Service Manual Description © Tait Limited July 2014...
Page 36 The PTT clips secure the PTT keypad to the front panel. The clips fit ■ tightly over notches on the two black plastic posts that project from the PTT frame into the front panel. Description TP8100 Service Manual © Tait Limited July 2014...
Page 37 FPC cable from the (optional) internal options board to the control board. See Figure 4.5 on page For more information about the control board see “Hardware and Software Architecture” on page TP8100 Service Manual Description © Tait Limited July 2014...
Page 38 RF board . A 26-way FPC cable connects the options board to the control board For more information about the RF board see “Hardware and Software Architecture” on page Description TP8100 Service Manual © Tait Limited July 2014...
Page 39 ■ two selection keys (the enter/menu key and the clear key) ■ The enter/menu key is sometimes called the ‘confirm/select’ key. The clear key is sometimes called the ‘cancel/clear’ key. TP8100 Service Manual Description © Tait Limited July 2014...
Page 40 The screw is generally tightened only by hand. For a comprehensive list of accessories that are compatible with the radio, please refer to the TP8100 Specifications Manual (MPC-00025-xx). Description TP8100 Service Manual © Tait Limited July 2014...
Page 41 Dynamic microphones are not supported. ACC RXD Asynchronous serial port. Digital, 3V3 CMOS Data direction is from computer to radio. See also “Accessory Connector Contacts and Signals” on page 266. TP8100 Service Manual Description © Tait Limited July 2014...
Page 42 Power supply circuitry ■ Figure 2.4 on page 43 shows a block diagram of the overall hardware Block Diagrams architecture. Chapter 3, Circuit Diagrams provides a detailed block diagram for each individual circuit. Description TP8100 Service Manual © Tait Limited July 2014...
Page 44 The boot code, the radio application code, and the DSP code include hardware and interface drivers. Figure 2.5 Software architecture Microprocessor Flash Boot Code Radio Application Code DSP Code DSP Code Databases Description TP8100 Service Manual © Tait Limited July 2014...
Page 45 To transfer programming and calibration databases to or from the radio see Programming and Calibration Files “Programming and Calibration Applications” on page To upgrade the firmware that is installed on the radio see “Upgrading the Radio Firmware Radio Firmware” on page 172. TP8100 Service Manual Description © Tait Limited July 2014...
Page 46 The second IF passes through the WB filter and, if the radio is set to narrow band, through the NB filter as well. A signal from the software switches the NB filter in for narrow band and out for wide band. Description TP8100 Service Manual © Tait Limited July 2014...
Page 47 RF signal strength at the antenna. The following items in the receiver path are factory-calibrated: Calibration front-end tuning ■ ■ noise squelch ■ RSSI ■ For more information see the Help of the calibration application. TP8100 Service Manual Description © Tait Limited July 2014...
Page 49 The power delivered to a speaker is limited by the impedance of that speaker. The impedance is 8Ω for the internal speaker, but can be higher for an external speaker. TP8100 Service Manual Description © Tait Limited July 2014...
Page 50 (to remove high frequency components). The audio samples are then scaled, ready for dual point modulation. The signalling encoders inject their signals into various points in the audio Signalling Encoders processing chain. The injection point depends on whether pre-emphasis is required. Description TP8100 Service Manual © Tait Limited July 2014...
Page 51 A B1 or C0 VHF radio amplifies the RF signal in three stages to produce Amplification a total gain of approximately 30dB: An exciter buffers and amplifies output from the VCO to about 32 mW. An LDMOS driver amplifies the signal to about 1W. TP8100 Service Manual Description © Tait Limited July 2014...
Page 52 The gate voltage to the driver is adjusted to reduce the error between the two voltages, and this results in a change to the output power. Description TP8100 Service Manual © Tait Limited July 2014...
Page 53 Correct ramp-up and ramp-down timing ensures that the radio meets Transient Adjacent Channel Power specifications. Figure 2.7 shows how power is ramped over time. Figure 2.7 Typical ramping waveforms High power power Time TP8100 Service Manual Description © Tait Limited July 2014...
Page 55 Power supply circuitry is on the RF board and on the control board. See Figure 3.8. These figures are block diagrams. For schematics, please see the relevant PCB Information document. This service manual provides no detailed circuit descriptions or board-level faultfinding instructions. TP8100 Service Manual Circuit Diagrams © Tait Limited July 2014...
Page 59 Figure 3.4 Frequency synthesizer circuitry SYN DIG LOCK DET DIG SYN LATCH DIG SYN SPI CLK DIG SYN SPI DATA DIG SYN EN DIG SYN TCXO MOD TP8100 Service Manual Circuit Diagrams © Tait Limited July 2014...
Page 60 DIG UI SPKR SW DIG OPT RX POST VOL DIG UI SPKR SW +5V5 DIG UI AUDIO PA SW DIG OPT MICSW DIG ACC SPKR [+/-] DIG INT MIC EN Circuit Diagrams TP8100 Service Manual © Tait Limited July 2014...
Page 61 DIG OPT GPIO[9..6] DIG SYS RESET DSP CODEC PDN DSP CODEC RST TX DIG TEMP ACC DIG EXTPTT RX DIG RSSI UI DIG VOLWIPER DIG TXBIAS RXSQLSET DIG TXPWR RXFE TP8100 Service Manual Circuit Diagrams © Tait Limited July 2014...
Page 62 ACC TXD DIG ACC UART0TX ACC RXD DIG ACC UART0RX +7V5 ACC PTT Signal Types ACC PWR +3V3 analog digital digital clock synchronous serial data stream asynchronous serial data stream Circuit Diagrams TP8100 Service Manual © Tait Limited July 2014...
Page 63 +3V3 +1V26 DIG RX 3V0RX EN +3V3 +7V5 SW +3V0_AN Shift Register DIG 5V0 3V0 AN EN Digital DIG TX 5V5TX EN Transmitter +7V5 BATT +5V5 +7V5 BATT +5V5 +5V5 TP8100 Service Manual Circuit Diagrams © Tait Limited July 2014...
Page 65 Tait Support Website ........
Page 67 General Servicing Information This chapter describes techniques and processes, and provides other information that will enable you to service a TP8100 radio correctly. It includes the following sections: Repair Recommendations ■ Tait Support Website ■ Servicing Precautions ■ Tools, Equipment, and Consumables ■...
Page 68 The Global Repair Center delivers advanced support and expertise to the regional Tait offices. An experienced and fully equipped service team handles repairs submitted by the regional Tait offices. TP8100 servicing includes tasks of varying degrees of difficulty, from simple TP8100 Tasks to more complex. Simple tasks include, for example: upgrading the firmware on the radio ■...
Page 69 4.1.2 Required Training, Tools, and Equipment Notice Do not attempt a TP8100 repair that is beyond your current capabilities or you could cause permanent damage to the radio. To repair a TP8100, you require: Relevant and current product training. ■...
Page 70 The recommended maximum repair time for any one repair to a TP8100 is TP8100 MTTR a total of one hour, comprising: 20 minutes to diagnose the fault ■ 20 minutes to do the repair ■ 20 minutes to recalibrate and test the radio ■...
Page 71 4.3.1 Avoid Unauthorized Changes This radio is designed to satisfy stringent compliance regulations. Make a change to the radio only if the change is expressly approved by Tait. See also “Repair Recommendations” on page 67 “Servicing Intrinsically Safe (IS) Equipment” on page Notice Unauthorized changes could violate compliance requirements and/or void the customer’s authority to operate the radio.
Page 72 For the torque drivers needed to service this radio see “Assembly Toolkit” on page For the screws used in this radio and the torque to apply to each screw see “Screws” on page 138. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 73 Protect the mechanical parts of the radio from scratches by working on a cleared area of a non-scratch bench top. The bench top must also meet the anti-static requirements outlined below. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 74 (ESD). Handle every device carefully and in strict accordance with the procedures defined in the data book pro- vided by the manufacturer. Tait Communications recommends that you buy an anti-static bench kit Anti-Static Bench from a reputable manufacturer. The bench must have: a dissipative rubber bench top ■...
Page 75 While servicing, do not program or operate the transmitter on a reserved frequency band. 156.8MHz ±375kHz, 243MHz ±5kHz, and 406.0 to 406.1MHz are reserved worldwide for use by distress beacons. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 76 IS-approved exposes the customer to a risk of explosion which could cause serious injury or death. If a TP8100 radio or battery has a ‘2’ in the product code in the position Identifying an IS Radio or Battery T03-2nnnn-XXXX the radio or battery is certified Intrinsically Safe.
Page 77 Tools, Equipment, and Consumables Use the kits and tools described here when servicing a TP8100 radio. See also “Tait Support Website” on page 4.4.1 Service Kits There are two service kits for the TP8100: TP8100 Service Kit Starter Pack (TPK-SV-004) ■...
Page 78 The assembly toolkit (TPK-SV-003) provides the special drivers and bits needed to disassemble and reassemble the radio. The assembly toolkit is included in both TP8100 service kits and can also be ordered separately. See Table 4.2 on page Table 4.2...
Page 79 (negative) cable into the plated through hole near the top of the RF board. Figure 4.3. Notice If the RF board is still attached to the chassis, make sure that the cables do not make contact with the chassis. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 80 Do not apply more than is indicated. To obtain Loctite 248, order the TP8100 Channel / Volume Pot / UI Assembly Spares Kit (TPK-SP-005) or any of the reskinning spares kits listed Table 7.2 on page...
Page 81 For details of how to apply the thermal products see Task 20 “Attach the RF Board and Internal Options Board to the Chassis” on page 148. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 82 Shielding Cans and Connectors All shielding cans used in the TP8100 are press fit shields. Figure 4.4 identifies the cans and connectors on both sides of the RF board. Figure 4.4 Cans and connectors on the RF board antenna SMA...
Page 83 Notice A hot air gun provides little control and can damage a board. Even in skilled hands, a hot air gun causes rapid uncontrolled rises in component temperature, both under the can that is being removed and under adjacent cans. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 84 To add solder, pre-fill the lands with solder wire and apply the ■ soldering iron. Using too little solder will prevent the can staying secured. See “Achieving Quality Solder Joints” on page General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 85 Clean the area thoroughly afterwards to remove all traces of solder balls. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 86 67. Attempting a repair without the necessary training, tools, and equipment can cause permanent damage to the radio. The most cost-effective way to resolve a problem with a TP8100 PCB or SMT component may be to replace the board. See “Replacing the Control...
Page 87 Technical notes are published on the Tait Technical Resources website. Consult the Technical Notes Before ordering a replacement component, consult all technical notes that apply to the board. They may provide technical details that are not yet in the manuals.
Page 88 See also “Repair Categories” on page Follow these specific repair guidelines in addition to the standard repair techniques that apply to the replacement of SMT components. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 89 Relative to leaded solder joints, lead-free solder joints look dull and ■ grainy. This is a cosmetic difference only. All acceptance criteria remain the same. For the standards see the IPC A-610D Acceptability of Electronic Assemblies. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 90 Notice Do not overheat the component. Shield any heat-sensitive components. You can use a slightly thicker can for this, such as the VCO can from a Tait Orca portable radio. Adjust the hot air gun to the correct temperature and set the airflow to 1.
Page 91 When the solder starts to melt, remove the hot air gun and allow the component to cool slightly. Remove the pair of tweezers, apply flux, and then apply the heat again for only a few seconds. The component self-aligns. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 92 “Setting Up the Radio Test Equipment” on page 93. To test and maintain the radio using a Test Unit (TOPA-SV-024) see Chapter 14, TOPA-SV-024 Test Unit. See also “Vacuum and Pressure Testing” on page General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 93 Notice Insert a calibration low pass filter (TPK-SV-103) between the calibration adapter (TPK-SV-101) and the Test Unit (TOPA-SV-024). The calibration low pass filter is part of both the TP8100 Service Kit and the TP8100 Service Kit Starter Pack. Figure 4.6...
Page 94 Pack. See “Servicing Precautions” on page 71. If using a TP8100 encryption module programming adapter (TPK-SV-008) to connect the radio to the test computer, you can use a Tait TP8100 programming adapter (TPK-SV-100) and omit the following items: Tait Test Unit (TOPA-SV-024) ■...
Page 95 Vacuum and Pressure Testing Opening the radio (to replace a board, for example) invalidates the IP67 and IP65 ratings possessed by a TP8100 radio when it leaves the factory. Before opening the radio, record what the customer’s requirements are regarding the verification of IP67 and IP65 ratings after servicing. See “Complete the Initial Administration”...
Page 96 Tait office. The equipment required to validate the environment water sealing on a TP8100 radio is the Vacuum and Pressure Tester (TA2893-xx). The tester is provided with comprehensive documentation, and training is available.
Page 97 ‘^’ 0x5E. 4.11.1 Placing the Radio in Computer-Controlled Test Mode The easiest way to enter CCTM is from the TP8100 calibration application: Install the calibration application on the test computer. See “Programming and Calibration Applications” on page Connect the radio to the computer and then start the calibration application.
Page 98 Within half a second, enter the character %. The character – appears and Test Mode appears on the radio display. If this does not happen, repeat Step 5 until the radio enters CCTM. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 99 For example, to enter ‘52>1’, type 52 press the spacebar and then type 1. To enter a CCTM command from a terminal program: Enter the command number. ■ TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 100 In this service manual, a > in a number sequence indicates that you must enter one space. For example, to enter ‘52>1’, type 52 press the spacebar and then type 1. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 101 SET LCD VLCD where x is 0 to 63 Control the LCD and keypad backlighting 58>x None BACKLIGHTING CONTROL where x is the backlighting status 1 = on 0 = off TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 102 0 = invalid valid IS CAL DATABASE VALID 1 = valid To display the radio firmware version, see also “Pressing Keys When Turning On the Radio” on page 117. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 103 ANR - set to on None SET ANR ON ANR - set to off None SET ANR OFF Reciprocal gain - set None SET RECIPROCAL GAIN DSP - unmute None UNMUTE THE DSP TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 104 0 to 255 Volume setting - read 0 to 255 READ VOLUME SETTING The radio has a combined speaker-microphone. Use CCTM commands to control the speaker and microphone functions independently. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 105 CODEC - set to idle or normal 159>x None mode SET CODEC IDLE MODE where x = 1 sets CODEC to idle x = 0 sets CODEC to normal mode TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 106 0 = low (off), 1 = high (on) SYN EN Set synthesizer charge pump 105>x None gain SET SYNTH CHARGE PUMP GAIN where x is the required gain: 0 = low, 1 = high General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 107 FORCE CTCSS SIGNALLING DCS - set modulation 121>x None SET DCS MODULATION where x = 0 to 32767 DCS - force signalling None Forces to DCS 023 FORCE DCS SIGNALLING TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 108 Selcall - set modulation None SET SELCALL MODULATION where x = 0 to 32767 Selcall - force signalling None Forces to 2000Hz for 2 seconds FORCE SELCALL SIGNALLING conventional radio only General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 109 SET ALC ENABLE ALC - disable None SET ALC DISABLE For details of signalling and modes supported by the TP8100 please refer to the TP8100 Specifications Manual (MPC-00025-xx). For an explanation of MDC1200 signalling refer to Technical Note TN-1490. Table 4.10...
Page 110 READ LAST SYSTEM ERROR where x is the error number and Y is the associated data (such as a firmware file and line reference) Initialize all RAM 253>PASSWORD None INITIALIZE ALL RAM General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 111 Step 2 R is the RX channel spacing used in that step: enter 1 if you used 6.25kHz in the calculation ■ enter 0 if you used 5kHz ■ TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 112 To enter CCTM command 101 using the values derived above, enter 101>64000>1>56784>1>1 For conventional radios only. CCTM Command 41 The TP8100 internal options interface includes a number of audio input and output signals: DIG OPT RX POST VOL is active when the radio is unmuted and in receive ■...
Page 113 The audio path changes caused by CCTM 41 take effect only once the radio has completed a Tx/Rx cycle. The radio reverts to normal audio behavior after CCTM 41 is used. There is no need to reset the radio. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 114 The radio has not responded within the specified time. Re-enter the CCTM command. The firmware is corrupt. Download and reinstall the firmware. If the error persists, contact your regional Tait office. The flash needs to be replaced. Internal RAM in the microprocessor has failed.
Page 115 4.12 Key Simulation On a conventional radio (TP8120, TP8115, or TP8110) you can use the Tait-proprietary Computer Controlled Data Interface (CCDI) protocol to simulate key presses. Where the instruction below is to ‘press a key’, it means ‘enter the equivalent simulation character’.
Page 116 2 channel 3 channel 4 channel 5 channel 6 channel 7 channel 8 channel 9 channel 10 channel 11 channel 12 channel 13 channel 14 channel 15 channel 16 General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 117 The following table identifies typical behavior of the LED status indicator. Additional information about a condition is often provided by audible indicators, and icons and/or messages on the LCD screen. TP8100 Service Manual General Servicing Information © Tait Limited July 2014...
Page 118 If this LED behavior is accompanied by System Error H04 and the radio serial number is lower than 25066994, please refer to Technical Note TN-1405 See also “Pressing Keys When Turning On the Radio” on page 117. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 119 (audible tones are off until ■ the radio user turns them on using the function key) select which tone set of audible indicators is used: ‘MPT 1343’ or ‘Tait’ ■ In the programming application, access the Audible Tones field from the General Options form.
Page 120 For more information see ‘Search Alert’ in the Help of the programming application. See also “How Man Down Functionality Works” on page 215. General Servicing Information TP8100 Service Manual © Tait Limited July 2014...
Page 121 Chapter 4, General Servicing Information describes advanced disassembly and reassembly techniques, some of which may be specific to the TP8100. Pay special attention to any techniques and precautions that are unfamiliar to you. This chapter describes how to completely disassemble and reassemble the radio, but full disassembly of a TP8100 is neither recommended nor supported.
Page 122 Figure 4.5 on page 83 Information about how items are numbered ■ IPNs, Product Codes, and Type Codes on page 207 ■ An explanation of what the numbers mean Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 123 1, 7 (Step 2 only) chassis (including battery connectors, battery connector block) 1, 2, 3, 4, chassis spring 1, 2, 3, channel switch see top UI switch assembly TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 124 1, 2, 4, SMA connector 1, 10 (Step 4only) speaker-microphone (‘speaker’) see front panel assembly thermal gap filler and thermal grease 1, 2, 4, top key 1, 2, 5, Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 125 Read the important safety information in the Li-ion Battery Safety Information document (MPC-00006-xx). The document is on the Product Support CD and is also available from the TP8100 area of the Tait Technical Resources website, http://support.taitradio.com. Figure 5.1 Removing the belt clip...
Page 126 Notice If the battery catch is broken in such a way that you cannot remove the battery, it is extremely difficult to open the radio without causing further damage. Contact your regional Tait office for assistance. Optional. Remove the antenna by turning it counter-clockwise. It is easier to service the radio if the antenna is removed.
Page 127 “Attaching a Customized Chassis or Battery Label” on page 183. Notice Engraving of the aluminum TP8100 chassis is discouraged but does not significantly reduce the mechanical strength of the chassis. Do not replace a chassis simply because it has been engraved.
Page 128 Starting at the edge furthest from the SMA connector, smoothly lift the rear panel , together with the battery catch , from the chassis in one continuous movement. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 129 Figure 5.3. Do not scratch the chassis. b. Without twisting or bending the chassis spring, lift it from the chassis wall. TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 130 If an internal options board is fitted, disconnect the white 26-way FPC cable from J7 on the control board. Two internal options boards are available: Midian TVS-2-TP8 encryption board ■ Tait Man Down board see Chapter 8, Man Down Options Board ■ Disassembly and Reassembly TP8100 Service Manual...
Page 131 Instead, remove the black foam from the new LCD assembly and trim it so that it will provide only what is missing from the old foam. TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 132 Make sure that this was removed with the volume knob, or remove it separately. If you remove either knob from a TP8100, best practice is to replace both knobs with new knobs when reassembling the radio. Use the volume/channel nut driver tool (355-00002-xx) to remove the nut that secures the channel switch.
Page 133 If the flexible accessory board is undamaged, replace the cover and ■ proceed to the next task. If the flexible accessory board is damaged, continue with the ■ current task. TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 134 Use your fingers to press down on the round plastic posts that project from the PTT frame into the front panel. This releases the PTT frame from the front panel. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 135 (x2) PTT frame and PTT keypad (underneath) are wedged against the ESD mat PTT retainer clip (x2) PTT actuators (x2) TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 136 Use a Torx T6 driver to remove the five screws that secure the RF board to the chassis. This is easier if the driver has a magnetic tip. See “Screws” on page 138. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 137 Task 11 — Remove the Vent Patch from the Chassis Use your finger to lift out the damaged vent patch, which is not glued to the chassis. Discard the vent patch. TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 138 5.3.2 Tools and Torque All screws used in the TP8100 radio require a Torx T6 driver. See also Driver “Assembly Toolkit” on page Secure each screw or nut to the exact torque specified in Table 5.4 on...
Page 139 Table 5.4 Screws in the TP8100 radio Description Pos. Purpose Torque 1.8mm x 5mm self-tapping screw, 349-00030-02 (x6) secure the control board 0.2N·m 1& Pan head. Bright zinc finish. Thread to the front panel (2lbf·in) suitable for use into plastic.
Page 140 Use your fingers to smooth the seal down in a succession of firm and even presses. If the radio has an accessory connector cover, install the cover and use a coin to fasten the screw. Do not overtighten. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 141 Select a flat-headed screwdriver. The head should be as wide as, or slightly wider than, a PTT retainer clip. b. Orient a PTT retainer clip correctly. See the Note above. TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 142 Slide the PTT retainer clip into place. The clip clicks onto a notch on the corresponding post. e. Repeat the process to install the other PTT retainer clip. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 143 IPN. To seal the channel switch properly, the O-ring must lie flat on top of the channel switch and fit into a notch on the switch. If necessary, use the TP8100 channel O-ring assimilator tool (355-00004-xx) to seat the O-ring correctly.
Page 144 New knobs fit firmly and may be hard to pull off: each time they are removed and replaced, the fit naturally becomes less firm. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 145 FPC cable of the flexible accessory board out of the way. The speaker fits above the control board, in a cut-away area of the board. A replacement control board is supplied with an LCD already fitted. TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 146 Where the FPC cable turns, fold it up and over towards the J1 connector on the control board. See Figure 4.5 on page c. Make sure that the contacts are against the control board and then close the connector. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 147 The battery catch will then fail, making it extremely difficult to re-open the radio without causing damage. If the springs become trapped, contact your regional Tait office for assistance. Press the rear panel down onto the chassis, securing the SMA side first.
Page 148 Press down evenly on the patch until the patch attaches to the chassis. Notice Thermal gap filler 418 (TIM Putty) and thermal grease are both essential to the proper operation of a TP8100 radio. Do not omit them. For more information about these products see “Consumables” on...
Page 149 “Screws” on page 138. Using the 2.5lbf·in (0.3N·m) Torx T6 driver, torque to 2.5lbf·in (0.3N·m). Securing these screws now. This prevents stress to the solder joints later in the reassembly. TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 150 Torx T6 driver, torque to 2.5lbf·in (0.3N·m). A new encryption board is supplied with default settings. ■ To customize the settings, use the TP8100 Encryption Module Programming Adapter (TPK-SV-008) and follow the instructions (402-00062-xx) supplied with the adapter. If you reinstall an existing encryption board, you will need to reconfigure the custom encryption settings.
Page 151 A square lug at the top right corner of the main seal fits into a gap in the wall of the seal groove, below the SMA connector. curve TP8100 Service Manual Disassembly and Reassembly © Tait Limited July 2014...
Page 152 Attach the FPC cable to P1 on the internal options board. b. Attach the FPC cable to J7 on the control board. c. Make sure that both connector clips are firmly in place. Disassembly and Reassembly TP8100 Service Manual © Tait Limited July 2014...
Page 153 It is possible to fit a belt clip to a battery even if the battery was supplied without one. The 55mm belt clip used with a TP8100 radio is compatible with the Tait TP8100/TP9100 belt clip adapter (TPA-CA-208).
Page 155 Servicing Procedures Notice Before starting to service a TP8100 radio read Chapter 4, General Servicing Information. For procedures that are specific to this radio, follow the instructions provided below. These include: Basic Faultfinding ■ Upgrading the Radio Firmware ■ Type Changing the Radio ■...
Page 156 Notice If verification of the IP ratings is required by the customer and the radio will be opened during servicing, complete the initial vacuum and pressure tests now and record the results. Before opening a TP8100 radio see “Vacuum and Pressure Testing” on page...
Page 157 (PIN) to the radio, ENTER CODE flashes on the LCD. Enter the PIN. By default, the LCD displays TAIT TP8100 RADIO SERIES, followed ■ by the idle screen. If the radio is programmed to display radio information, the LCD displays that information.
Page 158 Always read the programming file before starting to service the radio. It is Task 4 — Read the Programming File especially important to do this if replacing or installing a board. Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 159 Inspect the flexible accessory board, including the FPC cable. If ■ the flexible accessory board appears to be damaged, replace it. Repeat Step 1 above: If the application reads the programming file, save a copy of the ■ TP8100 Service Manual Servicing Procedures © Tait Limited July 2014...
Page 160 If the volume works correctly, jump to Step 4 of the current task. ■ If the volume control works intermittently or does not work at all, ■ first go to Step 3 of the current task. Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 161 If the radio is programmed to have LCD and keypad backlighting on, check the backlighting. Use CCTM command 58>1 to activate the backlighting and CCTM command 58>0 to turn off backlighting. TP8100 Service Manual Servicing Procedures © Tait Limited July 2014...
Page 162 Repair or replace any damaged parts. Retest the radio and record ■ whether the repair was successful. If the problem is solved go straight to “Final Tasks” on page 167. Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 163 ■ the incorrect frequency was entered when the radio was programmed ■ there is no modulation, indicating a problem with the CODEC-audio ■ circuitry or with the speaker TP8100 Service Manual Servicing Procedures © Tait Limited July 2014...
Page 164 Tasks” on page 167. If no audio is being transmitted, check the microphone (the round ‘speaker’ in the TP8100 is a combined speaker-microphone): a. Use one of the following methods to eliminate the microphone as the source of the problem: Instead of using the microphone that is built into the radio, use an ■...
Page 165 If the returned value is not 0, the frequency synthesizer is in lock ■ as it should be. Continue with Step 3 of the current task (below). If the returned value is 0, the frequency synthesizer is not in lock. ■ TP8100 Service Manual Servicing Procedures © Tait Limited July 2014...
Page 166 All receive signalling must be disabled before the squelch will open. If there is no audio output, check the speaker (the round ‘speaker’ in the TP8100 is a combined speaker-microphone): a. Use one of the following methods to eliminate the speaker as the...
Page 167 For example, if you replaced a board, you have already loaded the programming file and recalibrated the radio. Do not omit the final administration. TP8100 Service Manual Servicing Procedures © Tait Limited July 2014...
Page 168 If the radio will be returned to a Tait dealer or distributor, or ■ directly to a customer who has programming facilities, advise them that they will need to reprogram the radio.
Page 169 ■ the reported fault, and a description of the repair action to date. (If you are at a regional Tait office, send the radio and details to the Global Repair Centre.) Regard a repair as ‘not successful’ if, for example: You cannot locate the fault within a reasonable and economic period of ■...
Page 170 Best practice is to record test results on a separate sheet and to provide the customer with a copy of the sheet as confirmation of the repair. For detailed radio specifications please refer to the TP8100 Specifications Specifications Manual (MPC-00025-xx) on the TP8100 Product Support CD (406-00059-xx).
Page 171 <5% ■ ■ 1kHz at 3.0kHz deviation (wide band) <5% CTCSS deviation ■ Narrow band 250 to 500Hz ■ Medium band 400 to 800Hz ■ Wide band 500 to 1000Hz TP8100 Service Manual Servicing Procedures © Tait Limited July 2014...
Page 172 117. From the relevant programming application, select Radio > Interrogate. ■ The screen that appears displays the product code, radio band and model, and firmware, hardware and database version numbers. Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 173 6.2.2 Downloading Firmware To download a firmware upgrade: Log into the secured area of the Tait Technical Resources website. From the product Firmware area, download the latest conventional or trunked firmware as appropriate. Choose a different version of the firmware (a version other than the latest version) only if that other version is specifically required.
Page 174 Group Select User Defined Menu Type Changing the Radio For the step-by-step instructions needed to type change a TP8100 radio, log into the secured area of the Tait Technical Resources website (http://support.taitradio.com) and download the latest version of Technical Note T/N-1298. The technical note also provides detailed instructions for upgrading firmware (see above).
Page 175 178. Download and install the latest radio firmware version: a. Log into the secured area of the Tait Technical Resources website. b. Download the latest conventional or trunked firmware as appropriate. Choose a different version of the firmware (not the latest version) only if that different version is specifically required.
Page 176 If returning the radio to a Tait dealer or distributor or to a ■ customer who has programming facilities, advise them that they will need to reprogram the radio.
Page 177 Use the programming application to view the Specifications form. Note the values in the three fields in the ESN panel. b. Supply the new ESN to the trunked network provider. No Software Feature Enabling (SFE) codes are required for a TP8100 radio. SFE Codes 6.5.1...
Page 178 See Figure 6.1. If R43 is in good condi- tion, it too can be re-used. Figure 6.1 Locating R43 on the discarded control board (primary side, K5) Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 179 Install the C62 capacitor at right-angles to its earlier position. Fit C62 between the right-hand pad that was one of its original pads and the nearest via. See Figure 6.4. TP8100 Service Manual Servicing Procedures © Tait Limited July 2014...
Page 180 Figure 6.3 Cutting the track and ground plane Figure 6.4 Fitting C62 to its new location position of C62 after the modification Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 181 Reassembly. The radio can remain open at this stage. Notice Thermal gap filler 418 (TIM Putty) and thermal grease are both essential to the proper operation of a TP8100 radio. Do not omit them. For more information about these products see “Consumables”...
Page 182 If returning the radio to a Tait dealer or distributor or to a ■ customer who has programming facilities, advise them that they will need to reprogram the radio. Make a full and final inspection of the radio exterior as described in “Perform a Visual Inspection”...
Page 183 Attaching a Label Follow these guidelines to attach a customized label or a replacement label to a TP8100 radio or battery. 6.7.1 Attaching a Customized Chassis or Battery Label To ensure that the battery fits securely to the radio, the fit between battery and chassis is intentionally firm.
Page 184 53mm(2.1in) from top of chassis label max. 31mm W x 25mm H (1.2in x 0.9 in) keep clear 10mm (0.4in) from bottom of chassis label Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 185 If you install a new radio chassis using spares kit TPK-SP-004, a new chassis label (365-01820-xx) is included in the kit. A regional Tait office can print the original radio details to the new label if necessary. Attach the label as described below.
Page 186 Read the important safety information in the Li-ion Battery Safety Information document (MPC-00006-xx) that is on the TP8100 Product Support CD and on the Tait Technical Resources website http://support.taitradio.com under TP8100 user documentation.
Page 187 (Man Down or Encryption) to the radio does not significantly increase the drain on the battery. For more information about battery shift life, log into the secured area of the Tait Technical Resources website (http://support.taitradio.com) and download Technical Note TN-1320. TP8100 Service Manual Servicing Procedures ©...
Page 188 6.8.3 Battery Safe Operating Temperature This table shows the safe operating temperature range for a TP8100 battery. 1880mAh 2400mAh 1800mAh ‘standard’ ‘performance’ Intrinsically Safe Li-ion battery Li-ion battery Li-ion battery T03-00011-Axxx T03-00011-Cxxx T03-20011-Axxx Safe operating –22°F to +140°F –4°F to +104°F temperature range (–30 °C to +60°C)
Page 189 6.8.6 Battery Safe Charging Temperature This table shows the safe charging temperature range for a TP8100 battery. 1880mAh 2400mAh 1880mAh ‘standard’ ‘performance’ Intrinsically Safe Li-ion battery Li-ion battery Li-ion battery T03-00011-Axxx T03-00011-Cxxx T03-20011-Axxx Safe charging +5°C to +40 °C (+41°F to +104°F)
Page 190 TYPE. See Figure 6.7. The resistance should be 10kΩ (±100Ω is acceptable). If the resistance is too high or too low, the Type resistor is faulty. Install a new battery. Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 191 If it is necessary to replace a battery, discard the old battery in accordance with the Li-ion Battery Safety Information document (MPC-00006-xx) that is on the TP8100 Product Support CD and available from the Tait Technical Resources website (http://support.taitradio.com). Handle the battery as described in the Li-ion Battery Safety Information document (MPC-00006-xx).
Page 192 Before using a new battery for the first time, fully charge the battery. Full initial charging typically take 1.5 hours to 2 hours. See “Charging a Battery” on page 235. Servicing Procedures TP8100 Service Manual © Tait Limited July 2014...
Page 193 Spare Parts This chapter identifies serviceable parts in a TP8100 radio and, where applicable, shows which spares kit provides each part. A list of spares kits is provided, with order numbers. Detailed instructions describe how to order a replacement PCB. Use the compatibility tables to ensure that a replacement control board or RF board is compatible with the other board in the radio.
Page 194 316-06034-xx not in a spares kit Intrinsically Safe red 4-key 316-06033-xx not in a spares kit ■ ■ Intrinsically Safe red without a 316-06032-xx not in a spares kit display Spare Parts TP8100 Service Manual © Tait Limited July 2014...
Page 195 Table 7.1 Serviceable parts in the radio (Continued) Pos. Description IPN or product code Spares kit(s) TP8100 series label for 16-key or 365-01802-xx not in a spares kit 4-key radio PTT frame 306-01053-xx ■ TPK-SP-008 PTT keypad 306-01026-xx ■ TPK-SP-001 ■...
Page 196 ■ TPK-SP-004 2& chassis 303-10005-xx TPK-SP-004 chassis label not a separate item (supplied with chassis) chassis spring 303-50134-xx vent patch 362-01083-xx TPK-SP-004 antenna ring 316-02629-xx SMA connector, with seal 240-06026-xx Spare Parts TP8100 Service Manual © Tait Limited July 2014...
Page 197 (optional, not shown) TPA-CA-208 friction seal for volume knob 362-01146-xx ■ TPK-SP-005 TPK-SP-009 ■ ■ TPK-SP-011 ■ TPK-SP-001 ■ TPK-SP-002 ■ TPK-SP-003 PTT switch 232-00010-41 not in a spares kit TP8100 Service Manual Spare Parts © Tait Limited July 2014...
Page 198 138. A chassis (303-10005-xx) is supplied with the battery connector block assembly (240-10018-xx) already installed. Two screws (349-00030-02) are included in the assembly. Order the TP8100 Chassis Assembly Spares Kit (TPK-SP-004). Two chassis labels are supplied on a single adhesive backing. See also “Labels”...
Page 199 Figure 7.1 Serviceable parts in the radio Table 7.1 on page 194 as the key to this figure. TP8100 Service Manual Spare Parts © Tait Limited July 2014...
Page 200 List of Spares Kits Table 7.2 lists the spare part kits currently available for the TP8100 radio. Table 7.2 TP8100 spares kits Description Order code PCBs (Star Ground) see Table 7.6 on page 206 TP8100 Spares Kit - Control Board Star Ground TPK-SP-013 TP8100 Spares Kit - RF Board 136–174MHz Star Ground (B1)
Page 201 TP8100 spares kits (Continued) Description Order code ■ orange front panel TP8100 Spares Kit - TP8120/TP8140 orange 16 Key Reskin Kit TPK-SP-030 TP8100 Spares Kit - TP8115/TP8135 orange 4 Key Reskin Kit TPK-SP-029 TP8100 Spares Kit - TP8110 orange No Key Reskin Kit TPK-SP-028 ■...
Page 202 This is the T03 number of the board that is not being replaced. c. Note the T03 number of the compatible board. Example: control board, T03-00102-CBAA. This T03 number identifies the required replacement board. Spare Parts TP8100 Service Manual © Tait Limited July 2014...
Page 203 Finding the Hardware Version Number There are various ways to determine the hardware version of the PCBs in the radio. If possible, use the TP8100 Programming Application (Conventional or Interrogate the Radio Trunked as appropriate) to interrogate the radio under repair: Select Radio >...
Page 204 Control board and RF board Version 01 hardware is From not used in K6 radios S: 25 104 870 Control board and RF board Version 01 hardware is From not used in L3 radios S: 25 095 575 Spare Parts TP8100 Service Manual © Tait Limited July 2014...
Page 205 “Modifying a Replacement Control Board (C0 Only)” on page 178. The modification effectively changes the board from a T03-00103-ABAA board (which you need to order) to a T03-00103-ABAB board (which you cannot order). TP8100 Service Manual Spare Parts © Tait Limited July 2014...
Page 206 For information about the letters and numbers (for example, ‘L3’) used to identify frequency bands see “Frequency Bands” on page 26. For an explanation of the T03 product code see “T03-nnnnn-XXXX Numbering” on page 208. Spare Parts TP8100 Service Manual © Tait Limited July 2014...
Page 207 IPNs, Product Codes, and Type Codes A 10-digit number in the format xxx-xxxxx-xx identifies a Tait Internal Quoting an IPN Part Number (IPN). Although you can quote an IPN to order a part, it is usually best to order the spares kit that contains that part. For example, a top key (311-03023-xx) is available in the spares kits TPK-SP-001, TPK-SP-003, and TPK-SP-005.
Page 208 The terms ‘TP8100’ and ‘TPC’ refer to the same series of Tait analog TP8100, TPC, T03 portable radios: ‘TP8100’ is the term used in marketing literature and user ■ documentation. ‘TPC’ is largely internal to Tait Communications, and is the term used ■...
Page 209 Table 7.7 -nnnnn- in the TP8100 product range Product code Product T03-00001-XXXX RADIO, Conventional without a display (TP8110) T03-00002-XXXX RADIO, Conventional 4-key (TP8115) T03-00003-XXXX RADIO, Conventional 16-key (TP8120) T03-00005-XXXX RADIO, Trunked 4-key (TP8135) T03-00006-XXXX RADIO, Trunked 16-key (TP8140) T03-00102-XXXX RADIO PBA, RF board...
Page 210 PBA is certified Intrinsically Safe (IS). See “Servicing Intrinsically Safe (IS) Equipment” on page 76. For example, T03-00006-XXXX is the product code for a TP8140 and T03-20006-XXXX is the product code for an Intrinsically Safe TP8140. Spare Parts TP8100 Service Manual © Tait Limited July 2014...
Page 211 01 hardware and version 03 hardware. The control board is not identical in all radios. For important information about ordering a replacement control board see “Choosing a Replacement Board” on page 202. TP8100 Service Manual Spare Parts © Tait Limited July 2014...
Page 212 221. A Standard A Standard Example: T03-00012-ACAA is a single battery charger for a TP8100 Li-ion battery, suitable for use in the UK. In the single battery charger (‘desktop charger’), the PBA product code -XXXX for a Single...
Page 213 -Xxxx What PBA is for AAAA Multicharger for Li-ion batteries The antennas used with a TP8100 radio are not assigned a ‘T03’ product Antenna Numbering code. Because many of them can also be used with a TP9100 radio, the antennas follow the TPA-AN-xxx numbering schema: An antenna with the order code ...
Page 214 There is no immediate or obvious association between the characters used for x and yy, and the attributes they signify. They are simply a code. Spare Parts TP8100 Service Manual © Tait Limited July 2014...
Page 215 Man Down Options Board Man Down functionality is optional in a TP8100 radio. If present, the functionality is provided by a Man Down internal options board. How Man Down Functionality Works A radio equipped with Man Down functionality is programmed to raise an...
Page 216 “Choosing a Replacement Board” on page 202. To install Man Down functionality in a TP8100 radio not already equipped with it, or to replace a damaged Man Down board, order the following from your regional Tait office: TP8100 OPT TPC Mandown (T03-00116-AAAA) ■...
Page 217 To replace or install a Man Down internal options board: Procedure Complete the standard steps required when servicing a TP8100 radio. “Basic Faultfinding” on page 155. Read the programming file and the calibration file that is currently in the radio and save the files to the computer.
Page 218 Down functionality in the radio. If this error message appears, the Man Down board is not yet calibrated. Restore the original calibration file, calibrate horizontal and vertical as described above, then program the radio. Man Down Options Board TP8100 Service Manual © Tait Limited July 2014...
Page 221 T03-00012-xxxx Desktop Charger Use a TP8100 desktop charger (T03-00012-xxxx/TPK-CH-1xx) to charge a TP8100 Lithium-ion battery. The desktop charger is supplied as part of a kit that includes the desktop charger, a power adapter, and the multilingual Battery Charging Guide (MPD-00002-xx).
Page 222 Before charging the battery, read the important safety information in the Li-ion Battery Safety Information document (MPC-00006-xx). The document is on the TP8100 Product Support CD and on the Tait Technical Resources website http://support.taitradio.com (look under TP8100 user documentation).
Page 223 Once you have identified the source of the problem, complete the relevant steps described in “Faultfinding” on page 224. If the problem persists, contact your regional Tait office. Troubleshooting Table 9.1 Desktop charger symptoms and solutions Symptom Possible reasons and solutions The charger does not turn on.
Page 224 9.1. If the power connector is faulty, replace it. If the fault persists, replace the charger board. Figure 9.1 Fuse (F1) and power connector (J1) fuse F1 (265-10300-10) power connector J1 R100 T03-00012-xxxx Desktop Charger TP8100 Service Manual © Tait Limited July 2014...
Page 225 To reassemble the charger, complete the disassembly steps but in the reverse Reassembly order. Use the tools and torque specified above. TP8100 Service Manual T03-00012-xxxx Desktop Charger © Tait Limited July 2014...
Page 226 T03-00107-AAAA. The PCB used in this issue of the board is IPN 220-01769-05. The component values listed in the circuit diagram on page 232 indicative only. For actual component values see the parts list page 227. T03-00012-xxxx Desktop Charger TP8100 Service Manual © Tait Limited July 2014...
Page 227 RES 0402 1K0 1% 1/16W 041-15100-10 RES 0402 10K 1% 1/16W 041-13100-10 RES 0402 100R 1% 1/16W 041-14100-10 RES 0402 1K0 1% 1/16W 041-15470-10 RES 0402 47K 1% 1/16W (continues on next page) TP8100 Service Manual T03-00012-xxxx Desktop Charger © Tait Limited July 2014...
Page 228 RES 0402 47K 1% 1/16W 938-10001-01 FLAG paste print leadfree SAC 002-10003-24 IC LM324 quad OP-amp SO14 002-10494-90 IC L4949ED 5V rgltr LDO SO8 002-12954-00 IC BQ2954 chgr Li-Ion PWM SO16 T03-00012-xxxx Desktop Charger TP8100 Service Manual © Tait Limited July 2014...
Page 229 1D13 1D14 1:G6 1J12 1:E7 1:G6 1H11 1:C3 1F9 1E8 1:H6 1J12 1:C3 1E7 1F7 1:H6 1J12 1:E5 1:H6 1H12 1:D3 1:H4 1H12 1:B6 1:H4 1H12 1:B6 1:B2 1F12 TP8100 Service Manual T03-00012-xxxx Desktop Charger © Tait Limited July 2014...
Page 230 R109 Tip: For an enlarged view of the figures in this section, open the PDF of the service manual that is on the TP8100 Product Support CD. You can then use the zoom feature to magnify the images. T03-00012-xxxx Desktop Charger TP8100 Service Manual ©...
Page 232 9.8.5 Circuit Diagram – Desktop Charger Component values in this circuit diagram are indicative only. For actual component values see the parts list on page 227. T03-00012-xxxx Desktop Charger TP8100 Service Manual © Tait Limited July 2014...
Page 233 10.2 Description Use a multicharger (T03-00013-xxxx/TPK-CH-15x) to charge up to six rechargeable TP8100 Lithium-ion batteries at once. The charger has two identical main PCBs, each of which supports three slots. Each slot has the same circuitry as the desktop charger TPK-CH-100/T03-00012-AAAA.
Page 234 Plug the mains cable into the charger. The mains cable must be appropriate for use in your country. Apply power to the charger. For two seconds, the fan runs and the LEDs are lit. T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 235 Before charging the battery, read the important safety informa- tion in the Li-ion Battery Safety Information document (MPC-00006-xx). The document is on the TP8100 Product Support CD and on the Tait Technical Resources website http://support.taitradio.com(look under TP8100 user docu- mentation).
Page 236 Complete the relevant steps described in “Faultfinding” on page 238. Always use a known good battery when checking a charger. If the problem persists, contact your regional Tait office. 10.7 Troubleshooting Table 10.1 Multicharger symptoms and solutions...
Page 237 ■ To permanently solve the problem, upgrade the charger control PCB (220-01777-xx) to issue 04 or later. For details please refer to TIMS 68954. TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 238 Make sure that the screw terminals are tight. Warning HIGH VOLTAGES - MAINS POWER! Risk of elec- trical shock. Before completing the next step, make sure that the charger has been disconnected from all power sources. T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 239 Three Charger Slots PCB and the power supply unit. If the cable is faulty, install a new cable. Make sure that the screw terminals on the power supply unit are tight. TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 240 C20_1 U1_1 R50_1 R18_1 R15_1 R56_1 R55_1 Q3_1 R66_1 R17_1 R52_1 R46_1 R90_1 R115_1 TP6_1 Q9_1 R13_1 R11_1 R12_1 R83_1 Q5_1 R33_1 Q13_1 R81_1 TP5_1 R87_1 R98_1 DS1_1 DS2_1 DS3_1 T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 241 P/H T20 BZ Mc stud (136 cN·m) Spring washer, metric M4. 353-00010-23 Same screw and washer 1& Bright zinc finish. WSHR M4 spr (continues on next page) TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 242 Notice Do not pinch or over-extend the cables in the next step. b. Pulling the front and back sides of the cover slightly outwards, lift the cover from the base assembly. T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 243 Remove the cover from the terminal block b. Refer to Table 10.3 on page 244. Then unscrew and remove the seven cables from the power supply unit. TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 244 Remove the power supply unit. Remove the IEC connector: a. Remove the two screws that attach the IEC connector to the charger base. b. Remove the IEC connector and remove the mains cables. T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 245 352-00010-29 For details of the top assembly and the PCBs items Table 10.5 on page 246. For detailed descriptions of screws, nuts, and washers see Table 10.2 on page 241. TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 246 353-00010-23 cradle assembly (x6) T03-00109-AAAA nut, M3 (x4) 352-00010-08 screw, (x3 per cradle assembly) part of cradle assembly Items through listed here are shown in Table 10.4 on page 245. T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 247 Use a P2 driver tip and torque to 6.5lbf·in (73cN·m). When inserting the main boards, fit them into the guides in the top of the Fitting the Main Boards charger cover. TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 248 _3 is a part for Slot 3. Each slot provides the circuitry for one cradle. Tip: For an enlarged view of the figures in this section, open the PDF of the service manual that is on the TP8100 Product Support CD. You can then use the zoom feature to magnify the images.
Page 249 CAP cer 0402 10n 25V X7R 10% DS3_2 008-10008-00 LED 1206 org RA 2V2 28MCD C19_3 031-15100-10 CAP cer 0402 10n 25V X7R 10% DS3_3 008-10008-00 LED 1206 org RA 2V2 28MCD TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 250 RES 0402 100K 1% 1/16W Q15_3 000-10085-70 XSTR BC856 PNP dual SOT363 R15_2 041-16100-10 RES 0402 100K 1% 1/16W Q16_1 000-10084-72 XSTR BC847BS NPN Dual SOT363 R15_3 041-16100-10 RES 0402 100K 1% 1/16W T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 251 RES 0402 47K 1% 1/16W R43_3 041-15470-10 RES 0402 47K 1% 1/16W R70_1 041-17100-10 RES 0402 1M0 1% 1/16W R44_1 041-15470-10 RES 0402 47K 1% 1/16W R70_2 041-17100-10 RES 0402 1M0 1% 1/16W TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 252 RES 0402 100R 1% 1/16W R94_3 041-13100-10 RES 0402 100R 1% 1/16W R95_1 041-16100-10 RES 0402 100K 1% 1/16W R95_2 041-16100-10 RES 0402 100K 1% 1/16W R95_3 041-16100-10 RES 0402 100K 1% 1/16W T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 253 4E14 Q13_1 1:E1 2C13 2E13 R11_3 1:S2 C19_1 1:E7 2J13 DS3_1 1:D1 2C10 Q13_2 1:L1 3E13 3C13 1:W2 C19_2 1:L7 3J13 DS3_2 1:M1 3C10 Q13_3 1:U1 4E13 4C13 R12_1 1:C2 TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 254 1:K3 3A11 R35_3 1:S3 R63_1 1:E4 R88_2 1:M2 R113_3 1:S3 4A11 R36_1 1:D2 R63_2 1:L4 R88_3 1:U2 R114_1 1:D3 2B11 R36_2 1:K2 R63_3 1:U4 R89_1 1:E4 2J12 R114_2 1:K3 3B11 T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 255 U1_1 1:C2 2B4 2C4 2E4 2B13 U1_2 1:J2 3B13 3B4 3E4 3C4 U1_3 1:S2 4E4 4B4 4B13 4C4 U2_1 1:C4 U2_2 1:K4 U2_3 1:S4 U3_1 1:F4 U3_2 1:M4 U3_3 1:V4 TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 256 10.10.3 PCB Layout – Top fan controller circuit for details see Figure 10.1 slot 1 of 3 for details see Figure 10.3 on page 240 T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 258 10.10.5 Circuit Diagram – Multicharger Component values in the circuit diagram are indicative only. For actual component values see the parts list on page 249. T03-00013-xxxx Multicharger TP8100 Service Manual © Tait Limited July 2014...
Page 259 This is the circuit diagram for slot 1. Use this diagram for slots 2 and 3, but for suffix _1, substitute_2 for slot 2 and _3 for slot 3. Component values in the circuit diagram are indicative only. TP8100 Service Manual T03-00013-xxxx Multicharger © Tait Limited July 2014...
Page 261 Use a Hirose accessory adapter (T03-00119-XAAA) to connect the audio accessories listed in Table 11.1 to a TP8100 radio. Table 11.1 Compatible Hirose accessories IPN or product code...
Page 262 Interface Specification Figure 11.1 shows the pins and signals used in the interface between the Hirose adapter and the accessory connector on the TP8100 radio. Table 11.2 describes the signals. For more information about the accessory connector contacts and signals, “Accessory Connector”...
Page 263 7.62 mm Notice The T03-00119-XBAA adapter is not guaranteed waterproof and is not recommended for mission-critical situations. If a waterproof connection is needed, use a TP8100 accessory that connects directly to the radio. See “Accessory Connector” on page TP8100 Service Manual T03-00119-XBAA 7.5mm Accessory Adapter...
Page 264 The speaker in the radio is not muted when you connect the adapter to the radio. The speaker is muted only once you have connected an acces- sory to the adapter. T03-00119-XBAA 7.5mm Accessory Adapter TP8100 Service Manual © Tait Limited July 2014...
Page 265 Use an accessory connector kit (TPB-AA-005) to connect the TP8100 radio to a compatible third-party external accessory, such as a speaker- microphone or headset.
Page 266 Accessory Connector Contacts and Signals The accessory connector on the radio provides nine contacts. See Figure 13.3. Figure 13.3 Accessory connector contacts on TP8100 radio For a description of each contact see Table 13.1. TPB-AA-005 Accessory Connector Kit TP8100 Service Manual...
Page 267 2.5V. If the battery is flat, the switched off when voltage provided may decrease by 1.5V. the radio is powered off. Ground Ground Safe DC limit: –12V (minimum), +12V (maximum). TP8100 Service Manual TPB-AA-005 Accessory Connector Kit © Tait Limited July 2014...
Page 268 CMOS. is from the RS-232 compatible, with data polarity inverted computer to the relative to conventional UART behaviour. radio. Safe DC limit: –12 V (minimum), +12 V (maximum). TPB-AA-005 Accessory Connector Kit TP8100 Service Manual © Tait Limited July 2014...
Page 269 Fit the strain relief crimp to the accessory cable, immediately behind the heatshrink. Use a crimp tool or a small pair of pliers to tighten the crimp. The crimp provides strain relief for the solder joints. TP8100 Service Manual TPB-AA-005 Accessory Connector Kit © Tait Limited July 2014...
Page 270 The baseplate must sit cleanly in the main body. The PCB assembly holds the strain relief in place. You can now attach the accessory to the accessory connector on the radio. TPB-AA-005 Accessory Connector Kit TP8100 Service Manual © Tait Limited July 2014...
Page 271 265. Figure 13.7 Attaching a headset typical Electret mic capsule ACC MIC 3k3 470p MIC+470p ACC GPIO1 ACC PTT ACC SPKR SP 32Ω 100Ω ACC SPKR+ TP8100 Service Manual TPB-AA-005 Accessory Connector Kit © Tait Limited July 2014...
Page 273 Use a Tait Test Unit (TOPA-SV-024) to test and maintain a TP8100 radio. The Test Unit provides an interface between the radio, a test computer, and an RF communications test set. The Test Unit, which is part of the TP8100 Service Kit (TPK-SV-001), was previously called a Calibration Test Unit or Calibration Box.
Page 274 ■ Off (no signal) ■ The switch is not used when you calibrate a TP8100 radio. For normal transmit deviation tests, set the switch to Mic Audio: this routes the signals to EXT_MIC of the accessory connector. This two-way ‘hook’ switch toggles a 12kΩ resistor (R3) in or out of the Off Hook / On Hook MIC_PTT line.
Page 275 Unit, where it is terminated. No speakers are activated. If you are using a TOPA-SV-004 test unit, this switch sets the dummy load. 8Ω / 16Ω For a TP8100 radio, set the load to 16 Ω. 14.2 Calibration Tests For a comprehensive list of final calibration tests, please refer to the Help of the TP8100 calibration application.
Page 276 1D8 1E8 2:M5 2:K6 2:H1 2:K4 2:K4 2:D3 2:M7 2:K5 2:N7 2:P5 SPEAKER+ 2:H3 SPEAKER- 2:H7 1:P2 1D5 1G5 1:H4 1F3 1G4 1:L1 1:L4 1:J2 2:C1 2:C1 TRAN 2:F1 TOPA-SV-024 Test Unit TP8100 Service Manual © Tait Limited July 2014...
Page 279 14.3.5 Circuit Diagram – TOPA-SV-024 Test Unit TP8100 Service Manual TOPA-SV-024 Test Unit © Tait Limited July 2014...
Page 281 Notice Midian Electronics Inc. supplies the four default encryption codes that are preinstalled on the TPK-OP-101 encryption board. These codes are not unique to Tait radios, and may be present on other radios fitted with a Midian encryption board. Any radios that use the same encryption code on the same channel can decode all communications on that channel.
Page 282 “Vacuum and Pressure Testing” on page 95. If vacuum and pressure testing is required, ensure you are equipped to perform the test- ing, or send the radio for testing at a regional Tait office. The encryption options board RF board...
Page 283 Connect the radio to the computer. If loading custom codes to the encryption options board later, you can connect the radio to the computer using the TP8100 Encryption Mod- ule Programming Adapter (TPK-SV-008). Follow the instructions pro- vided with the adapter.
Page 284 The Display Active Encryption Code check box is cleared by default. TPK-OP-101 Encryption Options Board TP8100 Service Manual © Tait Limited July 2014...
Page 285 When a TP8100 is programmed to enable encryption, a small flashing key icon is visible at the bottom of the radio display. If the Display Active Encryption Code check box is selected, however, the radio displays additional encryption information. For example, when an encrypted channel is selected, the radio displays a large key icon;...
Page 286 1, 2, 3, or 4. For more information see the previous Note. Program the radio with the changes. You may need to switch the TP8100 radio off and then on again when reprogramming the radio. TPK-OP-101 Encryption Options Board TP8100 Service Manual...
Page 287 16.1 Installing the Driver Tait recommends that you install the driver from the CD before connecting the USB plug to the PC. Connecting the USB plug to the PC first will work, but will require you to browse the CD for the driver.
Page 288 Under Device Manager / Ports, right-click the Tait Pro- gramming Cable and select Properties. Then in the Port Settings tab select Advanced. If the Tait Programming Cable and the assigned port number do not appear in your Tait programming application, restart your computer. 16.3 More Information Refer to your radio provider for more information about this product.
Page 289 (iii) may contain one or more items of soft- “Designated Products” means products pro- ware owned by a third-party supplier. The term vided by Tait to Licensee with which or for which "Software" does not include any third-party soft- the Software and Documentation is licensed for ware provided under separate license or not use.
Page 290 Open Source grant to verify compliance with this Agreement. Software Licenses will take precedence. For infor- Tait, or a third party nominated by Tait, may mation about Open Source Components con- inspect Licensee’s premises, books and records,...
Page 291 Section 8 TERM AND TERMINATION the perceived defect reveals that no such defect in 8.1. Licensee’s right to use the Software and Doc- fact exists, Tait may recover its costs in respect of umentation will commence when the Designated such investigation from Licensee.
Page 292 11.5. THIRD-PARTY BENEFICIARIES. This Agreement is entered into solely for the benefit of Tait and Licensee. No third party has the right to make any claim or assert any right under this Agreement, and no third party is deemed a bene- ficiary of this Agreement.

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