Motorola Astro Xts5000 Detailed 6881094c31 E Manual

							November 16, 20066881094C31-E
3-42Theory of Operation: Encryption Module
The radio power-down sequence begins by opening the radio On/Off switch, which removes the 
B+SENSE signal from the VOCON board. This does not immediately remove power because the 
GCAP II IC has control of Q502 through Vref, and U301 through WDI maintains the GCAP II IC in an 
active state. Both the MCU and Flipper IC monitor B+SENSE. After B+SENSE is removed, the 
Flipper IC waits 125 ms. before releasing WDI to allow for software cleanup; however, the software 
has the ability to prolong this time if it was necessary to complete its operations. When WDI is 
released, the GCAP II IC shuts down its supplies and the rest of the radio through Q501. In 
NNTN5567 VOCON board, the radio power-down sequence begins by opening the radio On/Off 
switch, causing the MECH_SW pin to transition high. This causes the MAKO IC to start an internal 
125ms watchdog timer and drive the INT_X interrupt output pin low. The dual-core processor then 
determines (through communication on the SPI bus) that it must initiate the power-down sequence. 
At this point, the watchdog timer can be kept alive by the dual-core processor (via the SPI bus) 
allowing for software cleanup. Upon expiration of the watchdog timer, the MAKO IC asserts the 
RESETX pin and turns off all DC regulators including SW_B+ (Q500 turns off when the MAKO IC 
drives the FET_ENX pin high).
3.3 Encryption Module
The encryption module (secure models only) connects directly to the VOCON board and interfaces 
directly with the vocoder digital circuitry. It contains an independent microcontroller and two custom 
ICs to perform digital, numerical, encryption algorithms.
The encryption modules are designed to digitally encrypt and decrypt voice and ASTRO data in 
ASTRO XTS 5000 radios. This section covers the encryption modules, hardware kits NTN9738 and 
NNTN5032.
NOTE:The encryption modules are NOT serviceable. The information contained in this section is 
only intended to help determine whether a problem is due to a encryption module or the radio 
itself.
The encryption module uses a custom encryption IC and an encryption key variable to perform its 
encode/decode function. The encryption key variable is loaded into the encryption module, via the 
radios universal (side) connector, from a hand-held, key variable loader (KVL). The encryption IC 
corresponds to the particular encryption algorithm purchased. Table 3-6 lists the encryption 
algorithms and their corresponding kit numbers.
The encryption module operates from two power supplies (UNSW_B+ and SW_B+). The SW_B+ is 
turned on and off by the radios On/Off switch. The UNSW_B+ provides power to the encryption 
module as long as the radio battery is in place.Table 3-6.  Encryption Module Software Kits and Algorithms
Software
Kit NumberAlgorithm
NNTN4006 DES, DES-XL, DES-OFB 
NTN9837 DES, DES-XL, DES-OFB WITH DVP-XL 
NTN9838 DVI-XL 
NTN9839 DVP-XL 
NNTN4197 AES
NNTN4198 AES with DES, DES-XL, DES-OFB 
						

							6881094C31-ENovember 16, 2006
Theory of Operation: Encryption Module3-43
Key variables are loaded into the encryption module through connector J701, pin 1. Depending on 
the type of encryption module, up to 16 keys can be stored in the module at a time. The key can be 
infinite key retention or 30-seconds key retention, depending on how the codeplug is set up.
The radio s host processor communicates with the encryption module on the Synchronous Serial 
Interface (SSI) bus. The SSI bus consists of five signal lines. A communications failure between the 
host processor and the secure module will be indicated as an ERROR 09/10 message on the 
display.
To troubleshoot the encryption module, refer to the flowcharts in Chapter 5 “Troubleshooting Charts.” 
						

							November 16, 20066881094C31-E
3-44Theory of Operation: Encryption Module 
						

							Chapter 4 Troubleshooting Procedures
The purpose of this chapter is to aid in troubleshooting problems with the ASTRO XTS 5000 radio. It 
is intended to be detailed enough to localize the malfunctioning circuit and isolate the defective 
component. It also contains a listing of service tools recommended for PC board repair at the 
component level.
4.1 Handling Precautions
Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices, 
are used in this family of radios. 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.Most of the ICs are static sensitive devices. Do not attempt to 
disassemble the radio or troubleshoot a board without first 
referring to the following Handling Precautions section.
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							November 16, 20066881094C31-E
4-2Troubleshooting Procedures: Recommended Service Tools
4.2 Recommended Service Tools
Table 4-1 lists recommended service tools that can be used for PC board repairs at the component 
level. For listings of additonal service tools, service aids, and test equipment that are recommended 
for all levels of service, refer to the XTS 5000 basic service manual (see “ Related Publications” on 
page xii).
Table 4-1.  Recommended Service Tools
Motorola
Part NumberDescriptionApplication
R1453 Digital-readout solder station Digitally controlled soldering iron
RLN4062 Hot-air workstation, 120V Tool for hot-air soldering/desoldering of 
surface-mounted integrated circuits
0180386A78 Illuminated magnifying glass with 
lens attachmentIllumination and magnification of 
components
0180302E51 Master lens system
0180386A82 Anti-static grounding kit Used during all radio assembly and 
disassembly procedures
6684253C72 Straight prober
6680384A98 Brush
1010041A86 Solder (RMA type), 63/67, 0.5 mm 
diameter, 1 lb. spool
0180303E45 SMD tool kit (included with 
R1319A)
R1319 ChipMaster (110V) Surface-mount removal and assembly of 
surface-mounted integrated circuits and/or 
rework station shields. Includes 5 nozzles. R1321 ChipMaster (220V)
R1364 Digital heated tweezer system Chip component removal
R1427 Board preheater Reduces heatsink on multi-level boards
6680309B53 Rework equipment catalog Contains application notes, procedures, 
and technical references used to rework 
equipment
ChipMaster Options:
6680370B54 0.710” x 0.710” Heat-focus heads for R1319 workstation
6680370B57 0.245” x 0.245”
6680370B58 0.340” x 0.340”
6680371B15 0.460” x 0.560” 
						

							6881094C31-ENovember 16, 2006
Troubleshooting Procedures: Voltage Measurement and Signal Tracing 4-3
4.3 Voltage Measurement and Signal Tracing
It is always a good idea to check the battery voltage under load. This can be done by checking the 
OPT_B+_VPP pin at the side connector (pin 4). The battery voltage should remain at or above 
7.0 Vdc. If the battery voltage is less than 7.0 Vdc, then it should be recharged or replaced as 
necessary prior to analyzing the radio.
In most instances, the problem circuit may be identified using a multimeter, an RF millivoltmeter, 
oscilloscope (preferably with 100 MHz bandwidth or more), and a spectrum analyzer.
ChipMaster Nozzles:
6680333E28 PA nozzle Soldering and unsoldering ICs
6680332E83 PLCC-28* nozzle
6680332E93 PLCC-32 nozzle
6680332E82 PLCC-44* nozzle
6680332E94 PLCC-52 nozzle
6680332E95 PLCC-68* nozzle
6680332E96 PLCC-84 nozzle
6680332E89 QFP-80 nozzle
6680332E90 QFP-100* nozzle
6680332E91 QFP-132* nozzle
6680334E67 QFP-160 nozzle
6680332E86 SOIC-14/SOL-16J nozzle
6680333E46 SOL-18 nozzle
6680332E84 SOIC-20 nozzle
6680332E87 SOL-20J nozzle
6680333E45 SOL-24 nozzle
6680332E88 SOL-28J nozzle
6680333E54 TSOP-32 nozzle
6680333E55 TSOP-64 nozzle
* Included with ChipMaster packages
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.  Recommended Service Tools (Continued)
Motorola
Part NumberDescriptionApplication
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							November 16, 20066881094C31-E
4-4Troubleshooting Procedures: Standard Bias Table
4.4 Standard Bias Table
Table 4-2 outlines some standard supply voltages and system clocks which should be present under 
normal operation. These should be checked as a first step to any troubleshooting procedure.
Table 4-2.  Standard Operating Bias
Signal NameNominal ValueTo l e r a n c eVOCON Board Source
13 MHz 13 MHz ±1000 ppm C303 (NTN9564)
C339 (NNTN4563, NNTN4819 & 
NNTN4717)
FLIP_32K 32.768 kHz ±400 ppm U302, pin2
(under shield SH102
on NNTN4563, NNTN4819 & 
NNTN4717)
SINE32K 32.768 kHz ±400 ppm C313 (NTN9564)
C306 (NNTN4563, NNTN4819 & 
NNTN4717)
CKIH 16.8 MHz R452
(under shield SH101 on NNTN4563, 
NNTN4819 & NNTN4717 or 
test fixture pin 7 on the
board-to-board connector)
16_8MHz 16.8 MHz C452
(under shield SH101
on NNTN4563, NNTN4819 & 
NNTN4717)
POR 3.0 Vdc ±5% POR test point
RESET_OUT 3.0 Vdc ±5% RESET_OUT test point (NTN9564)
D401, pin 3 (NNTN4563, NNTN4819 & 
NNTN4717)
VSW1 3.85 Vdc ±5% R502
VSW2 1.85 Vdc ±5% R501
FILT_B+ 7.5 Vdc 6.0-9.0 Vdc C523
V2 3.0 Vdc*
2.9 Vdc**±5% R560
GCAP_B+ 7.5 Vdc 6.0-9.0 Vdc R581
UNSW_B+ 7.5 Vdc 6.0-9.0 Vdc B104
SW_B+ 7.5 Vdc 6.0-9.0 Vdc R587
VCC5 5.0 Vdc ±5% R503
VSW_1_55 V 1.55 Vdc ±5% R407 (NNTN4717 VOCON kit only)
* = NTN9564, NNTN4563, & NNTN4819 VOCON kits
** = NNTN4717 VOCON kit 
						

							6881094C31-ENovember 16, 2006
Troubleshooting Procedures: Power-Up Self-Check Errors 4-5
4.5 Power-Up Self-Check Errors
Each time the radio is turned on, the MCU and DSP perform a series of internal diagnostics. These 
diagnostics consist of checking such programmable devices as the FLASH ROMs, the EEPROM, 
and SRAM devices.
Problems detected during the power-up self-check routines are presented as error codes on the 
radio’s display. For non-display radios, the problem is presented at power up by a single, low-
frequency tone. Table 4-4 lists possible error codes, a description of each error code, and a 
recommended corrective action.Table 4-3.  Standard Operating Bias (only for kit NNTN5567_)
Signal NameNominal 
Va l u eTo l e r a n c eVOCON Board Source
Gated_32_CLK 32.768KHz ± 400ppm R543
CKIH 16.8MHz R457
16.8_MHz 16.8MHz C450
POR 2.9Vdc ±5% R725
MAKO_RESET 2.9Vdc ±5% TP_MAKO_RESET
VSW1 3.6Vdc ±5% R511
VSW2 2.3Vdc ±5% C515
V_2.9 2.9Vdc ±5% C523
UNSW_B+ 7.5Vdc 6.0-9.0Vdc R525
SW_B+ 7.5Vdc 6.0-9.0Vdc R517
VCC5 5.0Vdc ±5% L505
VSAVE 2.5Vdc ±5% C504
RF_SW_B+ 7.5Vdc 6.0-9.0Vdc C530
Table 4-4.  Power-Up Self-Check Error Codes
Error 
CodeDescriptionCorrective Action
01/02 FLASH ROM codeplug Checksum Non-Fatal Error Reprogram the codeplug
01/12 Security Partition Checksum Non-Fatal Error Send radio to depot
01/20 ABACUS Tune Failure Non-Fatal Error Turn radio off, then on
01/22 Tuning Codeplug Checksum Non-Fatal Error Send radio to depot
01/81 Host ROM Checksum Fatal Error Send radio to depot
01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug 
						

							November 16, 20066881094C31-E
4-6Troubleshooting Procedures: Power-Up Self-Check Diagnostics and Repair (Not for Field Use)
4.6 Power-Up Self-Check Diagnostics and Repair (Not for Field Use)
Table 4-5 lists additional action items that can be used for the diagnosis and resolution of the error 
codes listed in Table 4-4 on page 4-5.
01/88 External RAM Fatal Error — Note: Not a checksum error Send radio to depot
01/90 General Hardware Failure Fatal Error Turn radio off, then on
01/92 Security Partition Checksum Fatal Error Send radio to depot
01/93 FLASHport Authentication Code Failure Send radio to depot
01/98 Internal RAM Fail Fatal Error Send radio to depot
01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot
02/81 DSP ROM Checksum Fatal Error Send radio to depot
02/88 DSP RAM Fatal Error — Note: Not a checksum error Turn radio off, then on
02/90 General DSP Hardware Failure (DSP startup message not 
received correctly)Turn radio off, then on
09/10 Secure Hardware Failure Turn radio off, then on
09/90 Secure Hardware Fatal Error Turn radio off, then on
Table 4-5.  Power-Up Self-Check Diagnostic Actions
Error 
CodeDiagnostic Actions
01/02 This non-fatal error will likely recover if the radios power is cycled. In the event that this 
does not resolve the issue, the radio should be reflashed. As a last resort, the FLASH 
ROM U402 should be replaced.
01/12 The radio should be sent to the depot for reflashing of the security codeplug.
01/20 Cycling radio power should resolve this issue. 
01/22 The radio should be sent to the depot for reflash of the tuning codeplug followed by 
retuning of the radio.
01/81 The radio should be sent to the depot for reflashing of the host code.
01/82 The radio should be sent to the depot for reflashing of the radio codeplug.
01/88 Reflashing of the radio should first be performed. If this fails to resolve the issue, then 
replacement of the SRAM U403 is necessary.
01/90 Cycle power to radio. Continued failure indicates a likely IC failure (GCAP, PCIC, 
FLIPPER, ABACUS). In this event, radio should be sent to the depot for isolation and 
repair of the problem IC.
Table 4-4.  Power-Up Self-Check Error Codes (Continued)
Error 
CodeDescriptionCorrective Action 
						

							6881094C31-ENovember 16, 2006
Troubleshooting Procedures: Power-Up Self-Check Diagnostics and Repair (Not for Field Use) 4-7
01/92 The radio should be sent to the depot for reprogramming of the security codeplug.
01/93 The radio should be sent to the depot for reflashing of the host code.
01/98 Send radio to the depot for replacement of the SRAM U403.
01/A2 The radio should be sent to the depot for reflashing of the tuning codeplug followed by 
re-tuning of the radio.
02/81 The radio should be sent to the depot for examination and/or replacement of either the 
FLASH U402, or the PATRIOT MCU/DSP U401.
02/88 Cycle power to the radio. If this does not fix the problem, then the radio should be sent 
to the depot for reflashing of the DSP code. Continued failure requires examination and/
or replacement of the SRAM U403.
02/90 Cycle power to the radio. If this fails to fix the problem, then the radio should be sent to 
the depot for reflashing of the DSP code. Continued failure may require replacement of 
U401, the PATRIOT MCU/DSP.
09/10 Cycle power to the radio. If this fails then follow instructions in the secure hardware 
failure troubleshooting flowchart.
09/90 Cycle power to the radio. If this fails then follow instructions in the secure hardware 
failure troubleshooting flowchart.
Table 4-5.  Power-Up Self-Check Diagnostic Actions (Continued)
Error 
CodeDiagnostic Actions