Mag One BPR 40 Service Manual
  1. Manuals
  2. Brands
  3. Mag One Manuals
  4. Transceiver
  5. BPR 40
  6. Service manual

Mag One BPR 40 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Summary of Contents for Mag One BPR 40

  • Page 3: Computer Software Copyrights

    Computer Software Copyrights The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in any form, the copyrighted computer program.
  • Page 4 Notes...

  • Page 5: Document History

    DOCUMENT HISTORY The following major changes have been implemented in this manual since the previous edition: Edition Description Date 6816986H01-A Initial edition Mar. 2006 6816986H01-B Section 1 Introduction: June 2007 Updated Radio Model Information Section 2 Maintenance: Updated mechanical parts list. Section 5 Accessories: Updated items listed under Carry Accessories, Chargers, Publications and Batteries.
  • Page 6 Notes...

  • Page 7: Safety Information

    Safety Information Product Safety and RF Energy Exposure Booklet for Portable Two-Way Radios The information provided in this document supersedes the general safety information contained in user guides published prior to February 2002. BEFORE USING THIS RADIO, READ THE FOLLOWING INFORMATION WHICH CONTAINS IMPORTANT OPERATING INSTRUCTIONS FOR SAFE USAGE AND RF ENERGY AWARENESS AND CONTROL INFORMATION AND OPERATIONAL INSTRUCTIONS FOR COMPLIANCE WITH RF ENERGY EXPOSURE LIMITS IN APPLICABLE NATIONAL AND INTERNATIONAL STAN-...

  • Page 8: Operating Instructions

    Exposure awareness can be facilitated by the use of a product label directing users to specific user awareness information. Your Motorola two-way radio has a RF exposure product label. Also, your Motorola user manual, or separate safety booklet includes information and operating instructions required to control your RF exposure and to satisfy compliance requirements.

  • Page 9: Additional Information

    • When worn on the body, always place the radio in a Motorola-approved clip, holder, holster, case, or body harness for this product. Using approved body-worn accessories is important because the use of non-Motorola-approved accessories may result in exposure levels, which exceed the FCC occupational/controlled environment RF exposure limits.
  • Page 10 viii Hearing Aids Some digital wireless radios may interfere with some hearing aids. In the event of such interference, you may want to consult your hearing aid manufacturer to discuss alternatives. Other Medical Devices If you use any other personal medical device, consult the manufacturer of your device to determine if it is adequately shielded from RF energy.
  • Page 11 Operational Warnings For vehicle with air bags Refer to vehicle manufacturer's manual prior to installation of electronic equipment to avoid interference with air bag wiring. Do not place a portable radio in the area over an air bag or in the air bag deployment area. Air bags inflate with great force.
  • Page 12 Operational Cautions for Intrinsic Safe Equipment • Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualified (for example, FM, UL, CSA, ATEX, IEC approved). An explosion or fire may result. • Do not operate a radio unit that has been approved as intrinsically safe product in a hazardous atmosphere if it has been physically damaged (for example, cracked housing).
  • Page 13 Do Not Substitute Options or Accessories The Motorola communications equipment certified as intrinsically safe by the approving agency, (FM, UL, CSA,ATEX, IEC) is tested as a complete system which consists of the listed agency Approved portable, Approved battery, and Approved accessories or options, or both. This Approved portable and battery combination must be strictly observed.
  • Page 14 Notes...

  • Page 15: Table Of Contents

    xiii Table of Contents Document History.................... iii Safety Information ....................v Section 1 INTRODUCTION 1.0 Scope of Manual....................1-1 2.0 Warranty and Service Support................1-1 2.1 Warranty Period and Return Instructions ............1-1 2.2 After Warranty Period..................1-1 2.3 Piece Parts ......................1-2 2.4 Technical Support ...................1-2 2.5 Further Assistance From Motorola ..............1-2 3.0 Radio Model Information..................1-3 4.0 Radio Features .....................1-4...
  • Page 16 Section 3 RADIO TUNING 1.0 Introduction ......................3-1 2.0 Hardware Tuning Setup and Procedure ..............3-2 2.1 Tuning Frequency ...................3-2 2.2 Preparation Before Tuning (refer to Figure 3-1) ..........3-2 2.3 Transmitter Tuning ..................3-3 2.4 Receiver Tuning ....................3-5 Section 4 RADIO PROGRAMMING 1.0 Introduction ......................4-1 2.0 Programming Your Radio ..................4-1 2.1 Overview of the Programming Process............4-1 2.2 Cloning Radio Parameters to User Radios .............4-1...

  • Page 17: Introduction

    This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the Mag One™ by Motorola Series radio described and is current as of the printing date. Changes which occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions.

  • Page 18: Piece Parts

    Warranty and Service Support Piece Parts Please refer to "Appendix A Replacement Parts Ordering" on page A-1 of this manual for further information. Technical Support Technical support is available to assist the dealer/distributor in resolving any malfunction which may be encountered. For service, contact the Service Depot in your area. If your area does not have a depot, please contact your Business Development Manager, Distributor, or contact Motorola Technical Support.

  • Page 19: Radio Model Information

    Power Physical Channel Feature Model Model Serie Protocol Band Level Packages Spacing Level Revision Package Unit (150–174 12.5/ Conventional BPR 40 MHz) Channel (NiMH) Navy (450–470 BPR 40 MHz) Channel (LiIon) Navy H = Portable AA = Motorola Internal Use...

  • Page 20: Radio Features

    Radio Features Radio Features The following are features your radio has. Normal Operation Rx Frequency Rx/Tx • • Tx Frequency Radio-CPS-Radio Cloning • • RX TPL/DPL/IDPL Radio-to-Radio Cloning • • TX TPL/DPL/IDPL Factory Reset • • User Defined PL (TPL1, TPL2, TPL3) Low Battery Indication •...

  • Page 21: Maintenance

    Section 2 MAINTENANCE Introduction This chapter provides details about the following: Preventive Maintenance • Safe Handling of CMOS and LDMOS Devices • General Repair Procedures and Techniques • Disassembling and Reassembling the Radio • Preventive Maintenance Periodic visual inspection and cleaning is recommended. Inspection Check that the external surfaces of the radio are clean, and that all external controls and switches are functional.

  • Page 22: Safe Handling Of Cmos And Ldmos Devices

    Safe Handling of CMOS and LDMOS Devices Cleaning Internal Circuit Boards and Components Isopropyl alcohol (100%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the dislodged material out and away from the inside of the radio.

  • Page 23: Repair Procedures And Techniques - General

    Repair Procedures and Techniques – General Repair Procedures and Techniques – General NOTE Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit boards — examples shown below) were developed and assembled using environmen- tally preferred components and solder assembly techniques to comply with the Euro- pean Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC.
  • Page 24 Repair Procedures and Techniques – General Flexible Circuits The flexible circuits are made from a different material than the rigid boards, and require different soldering techniques. Excessive prolonged heat on a flexible circuit can damage the material. Therefore, avoid excessive heat and excessive bending. For parts replacement, use the ST-1087 Temperature-Controlled Solder Station with a 600-700 degree F tip, and use small diameter solder such as ST-633.

  • Page 25: Disassembling And Reassembling The Radio - General

    Disassembling and Reassembling the Radio – General Disassembling and Reassembling the Radio – General For disassembly or reassembly of the radio, it is important to pay particular attention to all the snaps and tabs, and how parts align with each other. The following tools are required for disassembling the radio: Phillips screwdriver •...

  • Page 26: Radio Disassembly - Detailed

    Radio Disassembly – Detailed Radio Disassembly – Detailed Front Cover from Chassis Disassembly Turn off the radio. Unlatch the battery latch at the bottom of the radio (see “Figure 2-1”). Remove the battery by gently lifting the hilt of the battery, nearest to the battery latch, away from the housing. 2a 3 Figure 2-1 Slide the battery downwards to remove the battery.
  • Page 27 Radio Disassembly – Detailed Insert the Chassis Opener at the bottom of the radio, between the chassis and housing (see “Figure 2-2”). Lift the chassis gently. Be careful not to damage the housing or the O-ring underneath. Lift rear chassis away from the front cover. Be careful not to damage the speaker wire under- neath.
  • Page 28 Radio Disassembly – Detailed 12. Slide the battery latch shaft out from the latch. Figure 2-5 Proceed to perform steps 13, 14, and 15 only if there is a need to replace the speaker, NOTE speaker bracket or speaker felt. 13.

  • Page 29: Pc Board Disassembly

    Radio Reassembly – Detailed PC Board Disassembly Remove the audio jack seal. Remove the 10 screws which hold the PC board to the diecast. Next, remove the 2 nuts on the On/Off Volume and Channel knobs shafts with the Crab Eye Nut Opener.

  • Page 30: Chassis And Front Cover Reassembly

    2-10 Radio Reassembly – Detailed Chassis and Front Cover Reassembly Proceed to perform steps 1, 2, 3 and 4 only if there is a need to replace the speaker, NOTE speaker bracket or speaker felt. Place the speaker felt onto the grille area (see “Figure 2-8”) . Place the speaker on top of the felt.
  • Page 31 Radio Reassembly – Detailed 2-11 Figure 2-10 With the battery latch placed on the housing, push the shaft in the housing slot to the left (see “Figure 2-11”). Figure 2-11 Place the small latch pad onto the right slot space (see “Figure 2-11”).
  • Page 32 2-12 Radio Reassembly – Detailed Connect the internal speaker connector to the PC board (“see “Figure 2-12”). Speaker Connector Figure 2-12 10. Place the diecast into the front housing (see “Figure 2-13”). Figure 2-13 11. Snap the front housing cover firmly into place on the rear diecast . 12.

  • Page 33: Mechanical View And Parts List

    Exploded View and Parts List 19 20 30 Figure 2-14 Exploded View Table 2-1 Parts List Reference Part No Part Name § PMDN4001_R Front Housing § Lightpipe PMDN4002_R Mag One By Motorola Nameplate PMDN4005_R BPR 40 Nameplate PMDN4008_R PTT Escutcheon PMDN4007_R PTT Rubber...
  • Page 34 2-14 Mechanical View and Parts List Table 2-1 Parts List Reference Part No Part Name PMDN4010_R PTT Bezel § PMDN4011_R Speaker & Cable (non-EPP) PMDN4067_R Speaker & Cable (EPP) PMDN4012_R Speaker Bracket § Speaker Bracket Screw § § PMDN4013_R Speaker Poron Pad §...
  • Page 35 PMDN4036_R Speaker Connector PMDN4037_R Pogo Pin Seal Pogo Pin Housing Pogo Pin PMAD4051_R Mag One™ 150 – 174 MHz Antenna PMAE4020_R Mag One™ 450 – 470 MHz Antenna PMLN4743_ Mag One™ Spring Belt Clip PMNN4071_R Mag One™ NiMH Battery 1200mAh PMNN4075_R Mag One™...

  • Page 36: Service Aid

    Service Aid Service Aid Table 2-2 lists service aids recommended for working on the Mag One by Motorola Radios. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed.

  • Page 37: Test Equipment

    Test Equipment 2-17 10.0 Test Equipment Table 2-3 lists test equipment required to service the Mag One by Motorola Radios and other two-way radios. Table 2-3 Recommended Test Equipment Motorola Description Characteristics Application Part No. R2600 Communication Frequency/deviation meter and signal...

  • Page 38: Cloning Cable (Pmdn4060_R)

    2-18 Cloning Cable (PMDN4060_R) 12.0 Cloning Cable (PMDN4060_R) Figure 2-16 Cloning Cable Schematic 13.0 Test Box (PMDN4040_R) Figure 2-17 Test Box Schematic...

  • Page 39: Radio Tuning

    RADIO TUNING Introduction This chapter provides an overview of the hardware tuning for this Mag One by Motorola Series radio. There is no software tuning required. In order to perform the manual tuning procedures, the radio needs to be disassembled to the PC Board.

  • Page 40: Hardware Tuning Setup And Procedure

    Hardware Tuning Setup and Procedure Hardware Tuning Setup and Procedure Tuning Frequency Table 3-1 Frequencies Used for Tuning. Band Tuning Parameter Frequency (MHz) PLL Synthesizer 173.975 VHF 150 – 174 MHz Transmitter 150.025 Receiver 150.025 PLL Synthesizer 469.975 UHF 450 – 470 MHz Transmitter 450.025 Receiver...

  • Page 41: Transmitter Tuning

    Hardware Tuning Setup and Procedure Transmitter Tuning 2.3.1 High Power Connect the radio to power meter. Set the radio to the appropriate tuning frequency (refer to Table 3-1). Key up the radio. Using the ceramic tool, adjust R425 to tune high power (refer to Figure 3-2). R425 R426 R216...
  • Page 42 Hardware Tuning Setup and Procedure Using the ceramic tool, adjust R174 to tune to 100% of the maximum deviation (refer to Figure 3-3). R159 R174 R172 Figure 3-3 Top Side of PCB 2.3.5 Maximum Modulation Set the radio to the appropriate tuning frequency (refer to Table 3-1). On the test equipment, set the following configurations: Audio bandwidth: 0.25Hz to 15,000Hz De-emphasis: Off...

  • Page 43: Receiver Tuning

    Hardware Tuning Setup and Procedure Receiver Tuning 2.4.1 Wide Band Sinad Tuning Set the radio to the appropriate tuning frequency (refer to Table 3-1). Set RF Signal Generator level to -47dBm at 1 kHz tone, 60% of the deviation. Find the SINAD level 7 of the radio to decrease RF Signal Generator level. Using the ceramic tool, adjust R215 clockwise to off the audio output.
  • Page 44 Hardware Tuning Setup and Procedure Tx PLL Frequency Tuning Set the radio to the appropriate tuning frequency (refer Table 3-1). Detect output voltage at test point TP1. Using the ceramic tool, adjust C722 to tune the voltage below 5.0V +/-0.1V (refer to Figure 3-4).

  • Page 45: Radio Programming

    Introduction Section 4 RADIO PROGRAMMING Introduction The radios can be programmed using the Customer Programming Software (CPS). Programming Your Radio Overview of the Programming Process To prepare properly programmed radios for your customers, you should program your radio with all the necessary parameters, as required by your customers, and then clone these parameters over to all your customer’s radios.

  • Page 46: Error Conditions

    Please disconnect the cloning cable from the radio. CPS Programming The CPS is designed for use in the Windows 98/NT/2000/XP and above environment. An Installation instruction manual is contained within each CPS kit. Description Kit Number Mag One Customer Programming Software (CD) RVN5081_...

  • Page 47: To Read Radio Data To A Pc

    CPS Programming Refer to the diagram below for the programming setup. Radio Programming Cable PMDN4043_R Comm Port Figure 4-1 CPS Programming Setup To Read Radio Data to a PC Turn off the radio. Connect the programming cable to the radio. Press and hold Programmable Button 1 (top side button on the radio), then turn on the radio.

  • Page 48: Serial Number Programming

    Serial Number Programming Serial Number Programming A Serial Number can be reprogrammed into units with replacement boards with the Dealer Serial Number Programming tool. See Figure 4-1 CPS Programming Setup. To read the Radio Serial Number to a PC Turn off the radio. Connect the programming cable to the radio.

  • Page 49: Factory Reset

    Factory Reset NOTE Make sure the replacement board can be reprogrammed by following the procedures at “To read the Radio Serial Number to a PC” on page 4-4. Take note of the 10-digit serial number found at the sticker at the radio’s chassis; look for the number following the “S/N”.
  • Page 50 Factory Reset Notes...

  • Page 51: Accessories

    Mag One Hard Leather Carry Case Chargers PMLN5041_R Mag One Tri-Chem Charger Base PMLN 5048_R Mag One Tri-Chem SUC with Switching PS, US 2-pin EPNN9288_ Switching Power Supply with AC Cord, US 2-pin, 90-264 VAC Publications 6881098C61 BPR 40 User Guide (English/French Canadian)

  • Page 52: Audio Accessories

    Mag One Remote Speaker Switch PMLN4442_ Mag One Earbud with in-line Microphone and PTT/VOX* Switch PMLN4443_B Mag One Ear Receiver with in-line Microphone and PTT/VOX* Switch PMLN4445_ Mag One Ultra Lightweight Headset with in-line PTT/VOX* Switch PMLN4294_ Earbud with Microphone and PTT Combined...

  • Page 53: Replacement Parts Ordering

    Appendix A Replacement Parts Ordering Basic Ordering Information When ordering replacement parts or equipment information, the complete identification number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufficient description of the desired component to identify it.
  • Page 54 Parts Identification Parts Identification Radio Products and Solutions Organization* (United States and Canada) 1-800-422-4210 Product Customer Service Radio Products and Solutions Organization (United States and Canada) 1-800-927-2744 * The Radio Products and Solutions Organization (RPSO) was formerly known as the Radio Products Services Division (RPSD) and/or the Accessories and Aftermarket Division (AAD).

  • Page 55: Motorola Service Centers

    Appendix B Motorola Service Centers Servicing Information If a unit requires further complete testing, knowledge and/or details of component level troubleshooting or service than is customarily performed at the basic level, please send the radio to a Motorola Service Center as listed below. Motorola Service Center 45D Butterfield Trail El Paso, TX 79906...
  • Page 56 Motorola Canadian Technical Logistics Center Notes...

  • Page 57: Glossary Of Terms

    GLOSSARY OF TERMS Term Definition Busy Channel If BCLO is activated, the radio will check for channel activity before transmit- Lockout (BCLO) ting. If activity is detected, transmission is prohibited. For carrier squelch mode, radio will not transmit, if it is receiving carrier. For coded squelch mode, it will not transmit, if it is receiving carrier with different PL/DPL code.
  • Page 58 Term Definition Reverse Burst / Causes a Tone Private Line (TPL) or Digital Private Line (DPL) code to be Turn Off Code transmitted at the end of a transmission - once PTT is released, and while op- erating on the current channel. This sub-audible tone causes the receiving ra- dio to mute its speaker before loss of a carrier is detected.

Table of Contents