Motorola Bpr40 Magone 6816986h01 B Manual
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vii Operational Cautions Intrinsically Safe Radio Information The Intrinsically safe approval unit refers to a product that has been approved as intrinsically safe by an approval agency (for example FM Approvals, CSA, UL, or Cenelec) and certifies that a particular product meets the Agencys applicable intrinsic safety standards for specific types of hazardous classified locations. A portable radio that has been approved for intrinsic safety will have Approval label attached to the radio to identify the unit as being Approved for specified hazardous atmospheres. This label specifies the hazardous Class/Division/Group along with the part number of the battery that must be used. The intrinsically safe approval label will be located on the portable radio unit. Operational Cautions for Intrinsic Safe Equipment Warnings for Radios Approved as Intrinsically Safe Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and the intrinsic safety approval labelling (FM, UL, CSA, CENELEC). Radios will not be upgraded to this capability and labeled once they have been shipped to the field. Antennas Do not use any portable radio that has a damaged antenna. If a damaged antenna comes into contact with your skin, a minor burn can result. Batteries All batteries can cause property damage and/or bodily injury, such as burns, if a conductive material such as jewelry, keys, or beaded chains touches exposed terminals. The conductive material may complete an electrical circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, particularly when placing it inside a pocket, purse, or other container with metal objects. • Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualified (for example, FM, UL, CSA, or CENELEC 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). An explosion or fire may result. • Do not replace or charge batteries in a hazardous atmosphere. Contact sparking may occur while installing or removing batteries and cause an explosion or fire.
viii A modification changes the units hardware from its original design configuration. Modifications can only be made by the original product manufacturer. Repair A repair constitutes something done internally to the unit that would bring it back to its original condition. Items not considered as repairs are those in which an action is performed on a unit which does not require the outer casing of the unit to be opened in a manner that exposes the internal electrical circuits of the unit. Do Not Substitute Options or Accessories The Motorola communications equipment certified as intrinsically safe by the approving agency, (FM, UL, CSA, CENELEC) 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. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit. Approved configurations are listed by the Approving Agency (FM, UL, CSA, CENELEC). The intrinsically safe Approval label affixed to radio refers to the intrinsically safe classification of that radio product, and the approved batteries that can be used with that system. The manual PN referenced on the intrinsically safe approval label identifies the approved Accessories and or options that can be used with that portable radio unit. Using a non Motorola intrinsically safe battery and or accessory with the Motorola approved radio unit will void the intrinsically safe approval of that radio unit. • Do not replace or change accessories in a hazardous atmosphere. Contact sparking may occur while installing or removing accessories and cause an explosion or fire. • Turn the radio off before removing or installing a battery or accessory. • Do not disassemble an intrinsically safe product in any way that exposes the internal circuits of the unit. • Failure to use an intrinsically safe approved battery or Approved accessories specifically approved for the radio unit may result in the dangerously unsafe condition of an unapproved radio combination being used in a hazardous location. • Unauthorized or incorrect modification of the intrinsically safe approved Product will negate the approval rating of the product. • Incorrect repair or relabeling of any intrinsically safe Agency approved radio could adversely affect the Approval rating of the unit. • Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in serious injury or death. REPAIRS FOR MOTOROLA PRODUCTS WITH INTRINSICALLY SAFE APPROVAL ARE THE RESPONSIBILITY OF THE USER. • Repairs to a Motorola FM approved radio product should only be done at a location that has been FM audited under the FM 3605 repairs and service standard. • Contact Motorola for assistance regarding repairs and service of Motorola intrinsically safe equipment.
Table of Contents Document History.............................................................................................. i Safety Information ........................................................................................... iii Section 1INTRODUCTION 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 Section 2MAINTENANCE 1.0 Introduction ............................................................................................................2-1 2.0 Preventive Maintenance ........................................................................................2-1 2.1 Inspection ........................................................................................................2-1 2.2 Cleaning Procedures .......................................................................................2-1 3.0 Safe Handling of CMOS and LDMOS Devices ......................................................2-2 4.0 Repair Procedures and Techniques — General ....................................................2-3 5.0 Disassembling and Reassembling the Radio — General ......................................2-5 6.0 Radio Disassembly — Detailed .............................................................................2-6 6.1 Front Cover from Chassis Disassembly ..........................................................2-6 6.2 PC Board Disassembly ...................................................................................2-9 7.0 Radio Reassembly — Detailed ..............................................................................2-9 7.1 PC Board Reassembly ....................................................................................2-9 7.2 Chassis and Front Cover Reassembly .........................................................2-10 8.0 Mechanical View and Parts List ...........................................................................2-13 8.1 Exploded View and Parts List........................................................................2-13 9.0 Service Aid...........................................................................................................2-16 10.0 Test Equipment....................................................................................................2-17 11.0 Programming Cable (PMDN4043_R) .................................................................2-17 12.0 Cloning Cable (PMDN4060_R) ............................................................................2-18 13.0 Test Box (PMDN4040_R) ....................................................................................2-18
Section 3RADIO 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 4RADIO 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 2.3 Parameters which are cloned ..........................................................................4-1 2.4 Parameters which are not cloned....................................................................4-1 2.5 To Clone a Radio ............................................................................................4-1 2.6 Error Conditions ..............................................................................................4-2 3.0 CPS Programming .................................................................................................4-2 3.1 To Read Radio Data to a PC...........................................................................4-3 3.2 To Write Data to a Radio .................................................................................4-3 4.0 Factory Reset ........................................................................................................4-3 Section 5ACCESSORIES 1.0 Antennas................................................................................................................5-1 2.0 Carry Accessories..................................................................................................5-1 3.0 Carry Cases ...........................................................................................................5-1 4.0 Chargers ................................................................................................................5-1 5.0 Publications ...........................................................................................................5-1 6.0 Batteries.................................................................................................................5-1 7.0 Audio Accessories .................................................................................................5-2 8.0 Service Kits ............................................................................................................5-2 Replacement Parts Ordering ........................................................................ A-1 Motorola Service Centers ............................................................................. B-1 Glossary of Terms ........................................................................................G-1
Scope of Manual1-1 Section 1 INTRODUCTION 1.0 Scope of Manual 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. 2.0 Warranty and Service Support Motorola offers long term support for its products. This support includes full exchange and/or repair of the product during the warranty period, and service/ repair or spare parts support out of warranty. Any return for exchange or return for repair by an authorized Motorola Dealer must be accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer. 2.1 Warranty Period and Return Instructions The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or Reseller contract. These conditions may change from time to time and the following notes are for guidance purposes only. In instances where the product is covered under a return for replacement or return for repair warranty, a check of the product should be performed prior to shipping the unit back to Motorola. This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty. Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact Customer Resources. All returns must be accompanied by a Warranty Claim Form, available from your Customer Services representative. Products should be shipped back in the original packaging, or correctly packaged to ensure no damage occurs in transit. 2.2 After Warranty Period After the Warranty period, Motorola continues to support its products in two ways. 1. Motorolas Radio Parts and Service Group offers a repair service to both end users and dealers at competitive prices. 2. Motorola Customer Care and Services Division (CCSD) supplies individual parts and modules that can be purchased by dealers who are technically capable of performing fault analysis and repair. NOTEBefore operating or testing these units, please read the Safety Information Section in the front of this manual.
1-2Warranty and Service Support 2.3 Piece Parts Please refer to Appendix A Replacement Parts Ordering on page A-1 of this manual for further information. 2.4 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. Initial contact should be by telephone wherever possible. When contacting Motorola Technical Support, be prepared to provide the product model number and the unit’s serial number. For service, do contact one of the service depots listed in Appendix B Motorola Service Centers on page B-1 of this manual. Please call and confirm your return before sending the unit to the depot for service. 2.5 Further Assistance From Motorola You can also contact the Customer Help Desk through the following Web Address. https://www.motorola.com/governmentandenterprise/contactus/ NOTEOnly Motorola Service Centers or Approved Motorola Service Dealers can perform these functions. Any tampering by non-authorized Motorola Service Centers voids the warranty of your radio. To find out more about Motorola and its approved Service Centers, please visit http://www.motorola.com/governmentandenterprise/public/functions/home/home.aspx
Radio Model Information1-3 3.0 Radio Model Information The model number and serial number are located on a label attached to the back of your radio. You can determine the RF output power, frequency band, protocols, and physical packages. The example below shows one portable radio model number and its specific characteristics. Table 1-1 Radio Model Number (Example: AAH84KDS8AA1AN) Ty p e of UnitModel SeriesFreq. BandPower LevelPhysical PackagesChannel Spa ci ngProtocolFeature LevelModel RevisionModel Package AAH84K (150- 174MHz)D 5WS 8 Channel Navy8 12.5/ 25KAA Conventional1 BPR 40 (NiMH)AN R (450- 470MHz)C 4WJ 16 Channel Navy2 BPR 40 (LiIon) AA = Motorola Internal UseH = Portable
1-4Radio Features 4.0 Radio Features The following are features your radio has. Normal Operation •Rx/Tx •Radio-CPS-Radio Cloning •Radio-to-Radio Cloning •Factory Reset •Low Battery Indication •Self Test Programable Button •High/Low Power •Vo l u m e S e t •Monitor •Sticky Monitor •Scan Activate •Nuisance Channel Delete •Repeater/Talkaround •PL/DPL •Button Lock •Battery Save Mode •Squelch •Unassigned CPS •Rx Frequency •Tx Frequency •RX TPL/DPL/IDPL •TX TPL/DPL/IDPL •User Defined PL (TPL1, TPL2, TPL3) •Squelch Type •Unmute/Mute Rules •Power Level (High/Low) •TPL Reverse Burst •Turn Off Code •Rx Only •Busy Channel Lock Out (BCLO) •Channel Spacing (22KHz / 12.5KHz) •Talkaround •Time Out TImer •Battery Save Mode •Quick Key Override •Password Protection •Scan List •Normal Scan •Priority Scan •Talkback Scan
2-1 Section 2 MAINTENANCE 1.0 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 2.0 Preventive Maintenance Periodic visual inspection and cleaning is recommended. 2.1 Inspection Check that the external surfaces of the radio are clean, and that all external controls and switches are functional. It is not recommended to inspect the interior electronic circuitry. 2.2 Cleaning Procedures The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external and internal surfaces of the radio. External surfaces include the front cover, housing assembly and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime. The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol (70% by volume). Cleaning External Plastic Surfaces Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices. NOTEInternal surfaces should be cleaned only when the radio is disassembled for service or repair. CAUTION: The effects of certain chemicals and their vapors can have harmful results on certain plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.
2-2 Safe Handling of CMOS and LDMOS Devices Cleaning Internal Circuit Boards and Components Isopropyl alcohol (70%) 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. Make sure that controls or tunable components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process since this could cause the liquid to collect in unwanted places. After completing of the cleaning process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or back cover. 3.0 Safe Handling of CMOS and LDMOS Devices Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios, and are susceptible to damage by electrostatic 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 CMOS circuits and are especially important in low humidity conditions. DO NOT attempt to disassemble the radio without first referring to the following CAUTION statement. NOTEAlways use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage). CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are properly grounded. Take the following precautions when working on this unit: •Store and transport all CMOS devices in conductive material so that all exposed leads are shorted together. Do not insert CMOS devices into conventional plastic “snow” trays used for storage and transportation of other semiconductor devices. •Ground the working surface of the service bench to protect the CMOS device. We recommend using the Motorola Static Protection Assembly, which includes a wrist strap, two ground cords, a table mat, and a floor mat. •Wear a conductive wrist strap in series with a 100k resistor to ground. (Replacement wrist straps that connect to the bench top covering are Motorola part number RSX-4015.) •Do not wear nylon clothing while handling CMOS devices. •Do not insert or remove CMOS devices with power applied. Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present. •When straightening CMOS pins, provide ground straps for the apparatus used. •When soldering, use a grounded soldering iron. •If at all possible, handle CMOS devices by the package and not by the leads. Prior to touching the unit, touch an electrical ground to remove any static charge that you may have accumulated. The package and substrate may be electrically common. If so, the reaction of a discharge to the case would cause the same damage as touching the leads.