Motorola Astro Digital Mobile Radio Xtl5000 Detailled 6881096c74 B Manual

							6881096C74-BMay 25, 2005
Theory of Operation: Controller Section3-75
Figure 3-50.  XTL 5000 TX Signal Path
After the DSP has finished its processing, filtering, and signaling on the audio data samples, it then 
sends this data to the modulation DAC (U0900) on the BBP SSI port, where it is converted to the 
analog modulation signal. The data is clocked over to the modulation DAC at a 2.4 MHz bit rate, with 
a frame sync (representing the transmit data sample rate) of 48 kHz. Both of these clocks are 
generated by the Urchin IC (U0901).
The modulation DAC audio output signal is sent to a switched capacitor low-pass filter (FL0900) that 
performs anti-aliasing filtering. The filter output is sent through a multiplexer switch, U0902, and 
finally on to the FGU/LV Frac-N synthesizer for modulation of the RF carrier signal.
3.8.12 Flash Programming
When the radio needs new program code, this can often be done by reflashing the FLASH ROM 
(U102) located on the daughtercard. Reflashing is accomplished by using a programming cable 
(HKN6155 for Mid Power or HKN6183 for High Power) and the Motorola Customer Programming 
Software (CPS) FLASHport tool. The technique to flash the radio is the same as when using CPS or 
the TUNER software to change features on your radio. Two data lines are utilized on the 
programming cable to allow the computer to communicate with the microcontroller. These two lines 
are called BOOT TX (J0401-25), and BOOT RX (J0401-26) (see Figure 3-51).
Figure 3-51.  Boot RX and Boot TX Data Lines
Patriot
U100
SPI
SAPBBP
CODEC
U0200URCHIN Clock
IC
U0901
Modulation DAC
U0900
Gain/Attenuation
Stages (U0201, U202)Low Pass Filter
FL0900
MODIN
MIC_HI
SCKA
SRDA
SCKASCKB
STDB
SC2B S PI_SC
SPI_MOSI
SPI_MISO
MCLK
DT
FSRTG2.4MHz
MOD Data
48kHzSCK
STD
SFSFM OUTInputOutput
(To LV FRACN)
(J0401-4) 512kHz
TX Data
8kHz48kHz 2.4MHz
MAEPF-27890-O
Computer
(male) pin 2
(RX_DTE)
Computer
(male) pin 3
(TX_DTE)9 pin cable
(female) pin 2
(TX_DCE)
9 pin cable
(female) pin 3
(RX_DCE)Tout
14
13
RinTin
11
12
Rout RS232 IC10 pin cable
(female) pin 10
(TX_DCE)
10 pin cable
(female) pin 2
(RX_DCE)Controlhead
plug P104
or
Remote Mount
faceplate
plug P506Boot_TX
Boot_RX
MAEPF-27815-OHKN6155 
						

							May 25, 20056881096C74-B
3-76Theory of Operation: Controller Section
The standard method of upgrading a radios software and communicating between a computer and 
the radio microcontroller involves the use of the UART path via the programming cable. The radio is 
placed in a bootstrap mode whenever the programming cable is inserted into either the control- head 
microphone connector (P104) or the remote-mount interconnect board data connector (P506). This 
cable applies SW_B+ to the MIC_HI line (J0401-4), which forward biases Q0404 and asserts the 
CABLE_DET* input low to the Patriot microprocessor. This tells the processor to switch MUX U0401 
to route the BOOT_TX line to J0401-25, rather than the default mode, which routes KEYFAIL* to the 
pin. This allows the level-shifted BOOT_TX data signal to route directly from the processors UART 
port thru U0308 and out J0401-25 to the microphone/programming connector and to the PC.
On the BOOT_RX side, the CABLE_DET* input also drives BOOT_DATA_EN* low, which switches 
off buffers U0303-4 and U0303-3, routing the level-shifted BOOT_RX data from J0401-26 and to the 
processors UART port. This data is level-shifted from 5 V to 2.85 V through U0303-2.
When interfacing with CPS, the TUNER software, and during a flash operation, the control-head 
display does not go blank. SB9600 messaging continues and, upon removal of the programming 
cable, the radio usually undergoes a reset operation as part of the normal cable detection and 
removal process.
High power is different from the mid power radios in several ways. High power is always configured 
for remote and on the remote TIB there is a GCAI connector instead of a programming port (P104). 
The GCAI connector is the only USB port on a high power “brick” and unlike mid power, it shares 
these lines with BOOT_RX and BOOT_TX. For this reason, there is no U0401 MUX and Keyfail is 
not shared by any other line. The GCAI standard requires that the type of cables are determined by 
a one-wire memory device, so “CABLE_DET” is not connected to the MIC_HI line. On all radios the 
default condition of the UART is four-wire RS232 either through the rear J2 connector on mid power 
or J6 on the TIB of all remote configurations. For this reason, data cables can also be used with 
CPS. High power does not have a rear connector so the only way to access USB is through the 
GCAI connector. USB is the default condition of the GCAI, but one-wire is always read any time that 
a cable is detected.
Programming high power with a GCAI RS232 cable is done the following way. The cable is detected 
by grounding GP1O0 on the GCAI connector and in turn the processor reads the one-wire memory 
in the same attached cable. If it determines from one-wire that a two-wire RS232 cable is attached, 
GCAI_USB-RS232 is lowered to allow 5 volt power on the TIB to supply current to USB_PWR on the 
GCAI and to turn off the passive FET Q801 which normally allows power to be supplied to the USB 
interface. On the “brick”, GCAI_USB-RS232 line also drives CABLE_DET and BOOT_DATA_EN*. 
This line also drives U0303-2, which has now been enabled to receive BOOT_RX on the USB-line. 
With USB_PWR off U0308 is allowed to drive the BOOT_TX on the USB+ line.
3.8.13 Reflashing/Upgrading Firmware
The FLASH IC is the firmware storage IC. Programming this IC is accomplished using one of the 
following input paths:
• Two-wire RS-232 directly from a computer’s srial port to the radio’s rear connector data cable 
HKN6160 (Mid Power only)
• Two-wire RS-232 through an HKN6155 programming cable at the control head’s 10-pin 
microphone port (Mid Power only)
• Two-wire RS-232 through an HKN6155 programming cable at the Remote Mount Interconnect 
board’s 10-pin flash port (Mid Power only)
• Two-wire RS-232 through an HKN6183 programming cable at the High Power Remote Mount 
Interconnect board’s 10-pin GCAI port (High Power only) 
						

							6881096C74-BMay 25, 2005
Theory of Operation: Controller Section3-77
For a list of all available programming cables, refer to the table below.
NOTE:In remote-mount configurations, the control head 10-pin microphone port is disabled for any 
kind of programming.
NOTE:FLASH IC replacement is not supported as a field repair option. If the FLASH IC is removed, 
the radio cannot be reflashed by a customer or radio depot. This is because the FLASH IC 
must be hard-boot loaded at the factory to allow the programming of a unique file.Table 3-17.  Programming Cables
Motorola
Part NumberDescriptionApplication
HKN6155 Programming Flash Cable Used with Tuner software, Customer Programming 
Software (CPS), and FLASHport
RVN4185 Customer Programming Software and 
Tuner SoftwareProgramming and radio alignment software on CD
HKN6182 High Power GCAI Cable Adapter for 
KeyloaderUsed for keyloading XTL 5000 High Power
HKN6183 High Power GCAI to RS232 
Programming CableUsed for programming XTL 5000 High Power
HKN6184 High Power GCAI to USB Programming 
CableUsed for programming XTL 5000 High Power
HKN6122 4-wire data cable, J6 remote TIB Used for programming XTL 5000 
HKN6160 Cable Kit 6’ Dash Mount Data (RS232) Used for programming XTL 5000 Mid Power
If you choose to reflash the radio (reflash the IC), DO NOT interrupt the 
process; otherwise, you might corrupt the FLASH IC and need advanced 
technical support to revive your radio.
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3-78Theory of Operation: Controller Section
Notes 
						

							Chapter 4 Troubleshooting Procedures
4.1 Introduction
This section will aid you in troubleshooting a malfunctioning XTL 5000 radio. It is intended to be 
detailed enough to localize the malfunctioning circuit and isolate the defective component.
4.2 Handling Precautions
Complementary metal-oxide semiconductor (CMOS) devices and other high-technology devices, are 
used in the XTL 5000 radio. While the attributes of these devices are many, their characteristics 
make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges. 
Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special 
precautions must be taken to prevent device damage during disassembly, troubleshooting, and 
repair. Handling precautions are mandatory for this radio, and are especially important in low-
humidity conditions. DO NOT attempt to disassemble the radio without observing the following 
handling precautions.
1. Eliminate static generators (plastics, Styrofoam, etc.) in the work area.
2. Remove nylon or double-knit polyester jackets, roll up long sleeves, and remove or tie back 
loose hanging neckties.
3. Store and transport all static-sensitive devices in ESD-protective containers.
4. Disconnect all power from the unit before ESD-sensitive components are removed or inserted 
unless otherwise noted.
5. Use a static-safeguarded workstation, which can be accomplished through the use of an anti-
static kit (Motorola part number 01-80386A82). This kit includes a wrist strap, two ground 
cords, a static-control table mat and a static-control floor mat.
6. Always wear a conductive wrist strap when servicing this equipment. The Motorola part 
number for a replacement wrist strap that connects to the table mat is 42-80385A59.
4.2.1 Parts Replacement and Substitution
Special care should be taken to ensure that a suspected component is actually the one at fault. This 
special care will eliminate unnecessary unsoldering and removal of parts, which could damage or 
weaken other components or the printed circuit board (PCB) itself.
When damaged parts are replaced, identical parts should be used. If the identical replacement 
component is not locally available, check the parts list for the proper Motorola part number and order 
the component from the nearest Motorola Communications Parts facility. Most of the ICs are static-sensitive devices. Do not attempt 
to troubleshoot or disassemble a board without first referring 
to the following Handling Precautions section.
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							May 25, 20056881096C74-B
4-2Troubleshooting Procedures: Handling Precautions
4.2.2 Rigid Circuit Boards
The XTL 5000 radio uses bonded, multi-layer, printed circuit boards. Since the inner layers are not 
accessible, special considerations are required when soldering and unsoldering components. The 
printed-through holes might interconnect multiple layers of the printed circuit. Therefore, care should 
be exercised to avoid pulling the plated circuit out of the hole.
When soldering near module socket pins, be careful to avoid accidentally getting solder in the 
socket. Also, be careful not to form solder bridges between module socket pins. Closely examine 
your work for shorts caused by solder bridges. When removing modules with metal enclosures, be 
sure to unsolder the enclosure ground tabs as well as the module parts.
4.2.3 Heat-Related Precautions
During all repair procedures, heating neighboring components can be minimized by:
• Using upper heat only
• Using the correct size of heat-focus head, which should be approximately the same size as the 
carrier being replaced
• Keeping the heat-focus head approximately 1/8 in. (3-6 mm) above the printed circuit board 
when removing or replacing the device
4.2.4 Daughtercard Module
The daughtercard module can be removed by desoldering. However, this only should be done as a 
last resort since the module cannot be reliably reattached to the main board, except with a new 
module, and contains extremely small parts that can be easily lost. Therefore, it is recommended 
that when troubleshooting an XTL 5000 radio, avoid removing and replacing large sections for an 
expected quick fix.
4.2.4.1  SRAM
Each of the daughtercard module’s three sections are attached to the module using BGA (Ball Grid 
Array) solder-attachment technology, and once removed, cannot be reliably reattached. Also, 
because of the dense grouping of the solder balls, heating of the part and doing a slight tap to fix 
presumed cold-solder joints usually only results in smearing the solder and shorting the solder balls.
4.2.4.2  Testing
The daughtercard module is tested prior to placement on the main board. However, this is done with 
proprietary software that is not available outside Motorola. Also, because of the high density of the 
solder balls, the pins of the three ICs are not exposed to the outside world for test probing.Moisture-sensitive devices (MSD) are subject to die-bond (or other 
interface) delamination if heated above 185°C. To ensure that 
delamination does not occur, the PCB should be baked for eight 
hours at 125°C prior to repair if an adjacent MSD could potentially 
be exposed to 185°C or greater temperature during repair. Use 
0.250 in. as the determining distance between the component being 
repaired and the MSD.
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							6881096C74-BMay 25, 2005
Troubleshooting Procedures: Voltage Measurement and Signal Tracing 4-3
4.3 Voltage Measurement and Signal Tracing
In most situations, the problem circuit may be identified using a DC voltmeter, RF millivoltmeter, and 
oscilloscope (preferably with 100 MHz bandwidth or more). The “Recommended Test Equipment, 
Service Aids, and Tools” section in the ASTRO Digital XTL 5000 VHF/UHF Range 1/UHF Range 2/
700–800 MHz Mobile Radio Basic Service Manual (6881096C73) outlines the recommended tools 
and service aids which would be useful. Of special note are:
• 30-80370E06 Extender Cable which provides an extension cable for VOCON board connector 
J501 and command board connector P501
• RPX-4725C Command and Control Service Cable Kit which provides extension cables for 
servicing digital and analog circuits
• RPX-4724B RF Service Cable Kit which provides interface cables needed to service the RF 
boards
In some cases DC voltages at probe points are shown in red on the schematics. In other areas 
diagrams are included to show time-varying signals, which should be present under the indicated 
circumstances. It is recommended that a thorough check be made prior to replacement of any IC or 
part. If the probe point does not have a signal reasonably close to the indicated one, a check of the 
surrounding components should be made prior to replacing any parts.
4.4 Power-Up Self-Check Errors
When the radio is turned on (power-up), the radio performs cursory tests to determine if its basic 
electronics and software are in working order. Problems detected during these tests are presented 
as error codes on the radio’s display. The presence of an error should prompt the user that a 
problem exists and that a service technician should be contacted.
Self-test errors are classified as either fatal or non-fatal. Fatal errors inhibit user operation; non-fatal 
errors do not. Table 4-1 will aid in understanding particular power-up error code displays. When checking a transistor or module, either in or out of 
circuit, do not use an ohmmeter having more than 1.5 Vdc 
appearing across test leads or use an ohms scale of less than 
x100.
Table 4-1.  Power-Up Self-Check Error Codes
Error CodeDescriptionError TypeCorrective Action
ERROR 01/02 FLASH ROM Codeplug 
ChecksumNON-FATAL Re-flash the entire codeplug.
ERROR 01/12 Security Partition 
ChecksumNON-FATAL Re-flash the codeplug sections.
ERROR 01/20 ABACUS Tune Failure NON_FATAL • Turn the radio off, then on.
• Re-flash tuning (codeplug).
• Replace ABACUS IC / resolder.
ERROR 01/22 Tuning Codeplug 
ChecksumNON-FATAL • Re-flash tuning (codeplug).
• Retune the radio using CPS.
FAIL 01/81 FLASH ROM Checksum FATAL Re-flash the firmware.
FAIL 01/82 FLASH ROM Codeplug 
ChecksumFATAL Re-flash the codeplug or 
firmware.
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							May 25, 20056881096C74-B
4-4Troubleshooting Procedures: Power-Up Self-Check Errors
FAIL 01/88 External RAM Error FATAL • Turn the radio off, then on.
• Hard bootstrap and flash the 
firmware.
• Replace the daughtercard.
FAIL 01/90 General Hardware FATAL • Turn the radio off, then on.
• Replace the control head or flex.
FAIL 01/92 Security Partition 
ChecksumFATAL Re-flash the codeplug sections.
FAIL 01/93 FlashPORT AUTHENT 
CODE FailureFATAL Re-flash the appropriate base 
codeplug to match the radio 
feature set.
FAIL 01/98 Internal RAM Failure FATAL • Turn the radio off, then on.
• Hard bootstrap and flash the 
firmware.
• Replace the daughtercard.
FAIL 01/AO ABACUS IC Failure/Wrong 
ABACUS IC VersionFATAL • Re-flash tuning (codeplug).
• Retune the radio using CPS.
FAIL 01/A2 Tuning Codeplug 
ChecksumFATAL • Re-flash tuning (codeplug).
• Retune the radio using CPS.
FAIL 02/81 DSP ROM Checksum FATAL• Turn the radio off, then on.
• Re-flash the DSP firmware 
(DSP is processor-dependent).
FAIL 02/88 DSP RAM Error FATAL • Turn the radio off, then on.
• Re-flash the DSP firmware 
(DSP is processor-dependent).
FAIL 02/90 General DSP Hardware 
FailureFATAL • Turn the radio off, then on.
• Re-flash the DSP firmware 
(DSP is processor-dependent).
• Replace daughtercard.
FAIL 02/CO Wrong Microprocessor 
Ve r s i o nFATAL • Re-flash the firmware.
• Hard bootstrap and flash the 
firmware.
• Replace the daughtercard.
ERROR 05/10 Control Head Hardware 
ErrorNON-FATAL • Turn the radio off, then on.
• Replace the control head or flex.
FAIL 05/81 Control Head ROM 
Checksum ErrorFATAL Replace the control head.
ERROR 06/10 Aux Control Head 
Hardware ErrorNON-FATAL • Turn the radio off, then on.
• Replace the control head or flex.
FAIL 06/81 Aux Control Head ROM 
Checksum ErrorFATAL Replace the auxiliary control 
head.
ERROR 08/10 Siren Hardware Error NON-FATAL • Turn the radio off, then on.
• Check the siren cable 
connection.
FAIL 08/81 Siren ROM Checksum 
ErrorFATAL Replace the siren.
ERROR 09/10 Secure Hardware Error NON-FATAL Replace the secure module.
Table 4-1.  Power-Up Self-Check Error Codes (Continued)
Error CodeDescriptionError TypeCorrective Action 
						

							6881096C74-BMay 25, 2005
Troubleshooting Procedures: Operational Error Codes 4-5
4.5 Operational Error Codes
During radio operation, the radio performs dynamic tests to determine if the radio is working properly. 
Problems detected during these tests are presented as error codes on the radio’s display. The 
presence of an error code should prompt a user that a problem exists and that a service technician 
should be contacted. Table 4-2 will aid in understanding particular operational error codes.
4.6 VHF (136–174 MHz) Band Main Board Troubleshooting
This information will help you troubleshoot the RF section of the VHF (136–174 MHz) band 
XTL 5000 radio. Use this information, along with the theory of operation and troubleshooting charts, 
to diagnose and isolate the cause of failures.
Prior to troubleshooting, it is important to review the theory of operation, including specific 
precautions and troubleshooting methods. Because much of the radios circuitry operates at high 
frequencies, measurements must be taken very carefully. Notes and cautions are added to the text 
to alert you to this need in areas of greatest sensitivity. However, the need for extreme care does 
exist in all measurements and tests.
4.6.1 Display Flashes “FAIL 001”
This display indicates a synthesizer out-of-lock condition. The following information will help to 
trouble shoot the frequency generation unit to the component level. Perform the following checks to 
determine the mode of the Fail 001:
1. Determine if the out-of-lock condition occurs in either receive mode, transmit mode, or both. 
Also, check other frequencies programmed in the unit if available.
FAIL 09/90 Secure Hardware Fatal 
ErrorFATAL Replace the secure module.
ERROR 12/10 VRS Hardware Error NON-FATAL • Turn the radio off, then on.
• Check the VRS cable 
connection.
FAIL 12/81 VRS ROM Checksum Error FATAL Replace the VRS.
ERROR 1C/10 Tone Remote Control 
(TRC) Hardware ErrorNON-FATAL • Turn the radio off, then on.
• Check the TRC cable 
connection.
FAIL 1C/81 TRC ROM Checksum Error FATAL Replace the TRC.
Note:
• Firmware=Radio HOST and DSP software files
• Codeplug=Radio configuration software files.
Table 4-2.  Operational Error Codes
Error CodeDescriptionError TypeCorrective Action
FAIL 001 Synthesizer Out of Lock/
Radio band mismatchNON-FATAL • Re-flash the tuning (codeplug)
• Re-flash the entire codeplug.
• Replace the daughtercard.
FAIL 002 Personality Checksum or 
System Block ErrorNON-FATAL Re-flash the entire codeplug.
Table 4-1.  Power-Up Self-Check Error Codes (Continued)
Error CodeDescriptionError TypeCorrective Action 
						

							May 25, 20056881096C74-B
4-6Troubleshooting Procedures: VHF (136–174 MHz) Band Main Board Troubleshooting
2. To determine if the out-of-lock is frequency or VCO dependant, place the unit into RF TEST 
Mode, as described in the ASTRO Digital XTL 5000 VHF/UHF Range 1/UHF Range 2/700–
800 MHz Mobile Radio Basic Service Manual (6881096C73) and step through each test 
channel. Table 4-3 indicates the frequency and Aux logic level for each test mode channel. In 
addition, Table 4-4 provides information about the frequency of operation for each VCO.
3. Continue troubleshooting by using the Fail 001 troubleshooting chart in Chapter 5.
4.6.2 VCO Hybrid Assembly
The VCO hybrid substrate is glued to the carrier board. The hybrid is not a field-repairable assembly. 
If a failure is indicated in this assembly, replace the entire carrier board. Table 4-3.  Test Mode Channels
Test 
MODELV Frac-N
TX LogicTX Freq 
MHzLV Frac-N 
RX LogicRX Freq 
MHz
CHAN 1 AUX 2 136.0125 AUX 3 245.7125
CHAN 2 AUX 2 140.7625 AUX 3 250.4625
CHAN 3 AUX 2 145.5125 AUX 3 255.2125
CHAN 4 AUX 2 150.2625 AUX 3 259.9625
CHAN 5 AUX 2 154.9875 AUX 3 264.5875
CHAN 6 AUX 1 155.0125 AUX 4 264.7125
CHAN 7 AUX 1 159.7625 AUX 4 269.4625
CHAN 8 AUX 1 164.5125 AUX 4 274.2125
CHAN 9 AUX 1 169.2625 AUX 4 278.9625
CHAN 10 AUX 1 173.9875 AUX 4 283.5875
Table 4-4.  VCO Frequency and Switching Logic
MODEFrequency 
(MHz)AUX1AUX2AUX3AUX4
RX 245.65– 
264.65LOW LOW HIGH LOW
RX 264.65– 
283.65LOW LOW LOW HIGH
TX 155–174 HIGH LOW LOW LOW
TX 136–155 LOW HIGH LOW LOW