Motorola Cdm And Pro Series Detailed 68p81091c63 O Manual

							CDM
ª
and PRO SERIES
ª
Mobile Radios
contact
control
Detailed
Service Manual
Professional Radio
CA, Motorola, Professional Radio, CDM Series and CDM
Model numbers, PRO Series and PRO Series Model num-
bers are trademarks of Motorola.
© 1999 Motorola, Inc. All rights reserved. Printed in USA.*6881091C63*68P81091C63-O
contact
CDM
ª
and PRO SERIES
ª
Mobile Radios
control
PRO7100
As Dedicated As You Are 
						

							 
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 cer-
tain exclusive rights for copyrighted computer programs, including the exclusive right to copy or reproduce in any 
form, the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in 
the Motorola products described in this manual may not be copied or reproduced in any manner without the 
express written permission of Motorola. Furthermore, the purchase of Motorola products shall not be deemed to 
grant, either directly or by implication, estoppel or otherwise, any license under the copyrights, patents or patent 
applications of Motorola, except for the normal non-exclusive royalty-free license to use that arises by operation of 
law in the sale of a product. 
						

							Safety-1
SAFETY INFORMATION
Important information on safe and efficient operation is included in this manual. Read this information before 
using your radio.
SAFE AND EFFICIENT OPERATION OF MOTOROLA TWO-WAY RADIOS
This document provides information and instructions for the safe and efficient operation of Motorola Portable and 
Mobile Two-Way Radios.
The information provided in this document supercedes the general safety information contained in user guides 
published prior to 1st. January 1998. 
For information regarding radio use in hazardous areas, please refer to the Factory Mutual (FM) approval manual 
supplement or Instruction Card which is included with radio models that offer this capability.
EXPOSURE TO RADIO FREQUENCY ENERGY
Your Motorola Two-Way Radio, which generates and radiates radio frequency (RF) electromagnetic energy 
(EME) is designed to comply with the following National and International Standards and Guidelines regarding 
exposure of human beings to radio frequency electromagnetic energy:
lFederal Communications Commission Report and Order No. FCC 96-326 (August 1996)
lAmerican National Standards Institute (C95.1 - 1992)
lNational Council on Radiation Protection and Measurements (NCRP-1986)
lInternational Commission on Non-Ionizing Radiation Protection (ICNRP- 1986)
lEuropean Committee for Electrotechnical Standardisation (CENELEC):
To assure optimal radio performance and to ensure that your exposure to radio frequency electromagnetic energy 
is within the guidelines in the above standards, always adhere to the following procedures:
PORTABLE RADIO OPERATION AND EME EXPOSURE
lWhen transmitting with a portable radio, hold radio in a ver tical position with the 
microphone 2.5 to 5 centimeters (one or two inches) away from the mouth. Keep 
antenna at least 2.5 centimeters (one inch) from your head or body when transmit-
ting. 
lIf you wear a portable Two-Way radio on your body, ensure that the antenna is at 
least 2.5 centimeters (one inch) from the body when transmitting.
ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY
lTo avoid electromagnetic interference and/or compatibility conflicts, turn off your radio in any facility where 
posted notices instruct you to do so. Hospital or health facilities may be using equipment that is sensitive to 
external RF energy.
lWhen instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in accor-
dance with airline regulations or crew instructions.ENV 50166-1 1995 E Human exposure to electromagnetic fields Low 
frequency (0 Hz to 10 kHz) 
ENV 50166-2 1995 E Human exposure to electromagnetic fields High 
frequency (10 kHz to 300 GHz)
Proceedings of SC211/B 1996 “Safety Considerations for Human Exposure to EMFs from 
Mobile Telecommunication Equipment (MTE) in the Fre-
quency Range 30MHz - 6 GHz.” (EMF - Electro-Magnetic 
Fields)
NOTE
Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inade-
quately shielded, designed or otherwise configured for electromagnetic compatibility
MAN WITH RADIO 
						

							Safety-2
OPERATIONAL WARNINGS   
Vehicles with an air bag
lDo not place a por table radio in the area over an air bag or in the air bag deployment area. Air bags inflate with 
great force. If a portable radio is placed in the air bag deployment area and the air bag inflates, the radio may 
be propelled with great force and cause serious injury to occupants of vehicle.
Potentially explosive atmospheres
lTurn off your Two-Way radio when you are in any area with a potentially explosive atmosphere, unless it is a 
radio type especially qualified for use in such areas (e.g. FM or Cenelec approved). Sparks in a potentially 
explosive atmosphere can cause an explosion or fire resulting in bodily injury or even death.
Batteries
l Do not replace or recharge batteries in a potentially explosive atmosphere. Contact sparking may occur while 
installing or removing batteries and cause an explosion.
Blasting caps and areas
lTo avoid possible interference with blasting operations, turn off your radio when you are near electrical blasting 
caps. In a “
blasting area” or in areas posted “turn off two-way radio”, obey all signs and instructions.
OPERATIONAL CAUTIONS   
Damaged antennas
lDo not use any portable Two-Way radio that has a damaged antenna. If a damaged antenna comes into con-
tact with your skin, a minor burn can result.
Batteries
lAll batteries can cause property damage and/or bodily injury such as burns if a conductive material such as 
jewelery, keys or beaded chains touch exposed terminals. The conductive material may complete an electrical 
circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, par ticularly when 
placing it inside a pocket, purse or other container with metal objects.
INTRINSICALLY SAFE RADIO INFORMATION
FMRC Approved Equipment
Anyone intending to use a radio in a location where hazardous concentrations of flammable material 
exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and 
with the National Electric Code NFPA 70 (National Fire Protection Association) Ar ticle 500 (hazardous 
[classified] locations).
An Approval Guide, issued by Factory Mutual Research Corporation (FMRC), lists manufacturers and 
the products approved by FMRC for use in such locations. FMRC has also issued a voluntary 
approval standard for repair service (“Class Number 3605”).
FMRC Approval labels are attached to the radio to identify the unit as being FM Approved for 
specified hazardous atmospheres. This label specifies the hazardous Class/Division/Group along 
with the par t number of the battery that must be used. Depending on the design of the portable unit, 
NOTEThe areas with potentially explosive atmospheres referred to above include fuelling areas 
such as: below decks on boats; fuel or chemical transfer or storage facilities; areas where 
the air contains chemicals or particles, such as grain, dust or metal powders; and any other 
area where you would normally be advised to turn off your vehicle engine. Areas with poten-
tially explosive atmospheres are often but not always posted.
!
W A R N I N G
!
!
C a u t i o n 
						

							Safety-3
this FM label can be found on the back of the radio housing or the bottom of the radio housing.Their 
Approval mark is shown below.
Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability 
and FM Approval labeling. Radios will not be “upgraded” to this capability and labeled in the field.
A modification changes the unit’s hardware from its original design configuration. Modifications can 
only be done by the original product manufacturer at one of its FMRC audited manufacturing facilities.
Unauthorized or incorrect modification of an FMRC Approved Product unit will negate the Approval 
rating of the product.
Repair of FMRC Approved Products
REPAIRS FOR MOTOROLA FMRC APPROVED PRODUCTS ARE THE RESPONSIBILITY OF THE 
USER.
You should not repair or relabel any Motorola manufactured communication equipment bearing the 
FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC 
Approval standard for repairs and service (“Class Number 3605).
You may want to consider using a repair facility that operates under 3605 repair service approval.
WARNING: Do not operate radio communications equipment in a hazardous atmosphere 
unless it is a type especially qualified (e.g. FMRC Approved) for such use. An explosion or 
fire may result.
WARNING: Do not operate the FMRC Approved Product in a hazardous atmosphere if it has 
been physically damaged (e.g. cracked housing). An explosion or fire may result.
WARNING: 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.
WARNING: 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.
WARNING: Do not operate the FMRC Approved Product unit in a hazardous location with the 
accessory contacts exposed. Keep the connector cover in place when accessories are not 
used.
WARNING: Turn radio off before removing or installing a battery or accessory.
WARNING: Do not disassemble the FMRC Approved Product unit in any way that exposes 
the internal electrical circuits of the unit.
WARNING: Failure to use an FMRC Approved Product unit with an FMRC Approved battery 
or FMRC Approved accessories specifically approved for that product may result in the dan-
gerously unsafe condition of an unapproved radio combination being used in a hazardous 
location.
WARNING: Incorrect repair or relabeling of any FMRC Approved Product unit could 
adversely affect the Approval rating of the unit.
WARNING: Use of a radio that is not intrinsically safe in a hazardous atmosphere could 
result in serious injury or death.
FM
APPROVED
!
W A R N I N G
!
!
W A R N I N G
!
!
W A R N I N G
! 
						

							Safety-4
FMRC’s Approval Standard Class Number 3605 is subject to change at any time without notice to 
you, so you may want to obtain a current copy of 3605 from FMRC. Per the December, 1994 
publication of 3605, some key definitions and service requirements are as follows:
Repair
A repair constitutes something done internally to the unit that would bring it back to its original 
condition Approved by FMRC. A repair should be done in an FMRC Approved facility.
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 which exposes the internal electrical 
circuits of the unit. You do not have to be an FMRC Approved Repair Facility to perform these actions.
Relabeling
The repair facility shall have a method by which the replacement of FMRC Approval labels are 
controlled to ensure that any relabeling is limited to units that were originally shipped from the 
Manufacturer with an FM Approval label in place. FMRC Approval labels shall not be stocked by the 
repair facility. An FMRC Approval label shall be ordered from the original manufacturer as needed to 
repair a specific unit. Replacement labels may be obtained and applied by the repair facility providing 
satisfactory evidence that the unit being relabeled was originally an FMRC Approved unit. Verification 
may include, but is not limited to: a unit with a damaged Approval label, a unit with a defective housing 
displaying an Approval label, or a customer invoice indicating the serial number of the unit and 
purchase of an FMRC Approved model.
Do Not Substitute Options or Accessories
The Motorola communications equipment cer tified by Factory Mutual is tested as a system and 
consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or 
options, or both. This Approved por table 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 in the FM Approval 
guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped with FM 
Approved radio and battery combination from the manufacturer. The Approval guide, or the Approval 
standard Class Number 3605 document for repairs and service, can be ordered directly through 
Factory Mutual Research Corporation located in Norwood, Massachusetts. 
						

							i
TABLE OF CONTENTS
Chapter 1Introduction
1.1 Scope of Manual  ........................................................................................................................... 1-1
1.2 Warranty and Service Support ...................................................................................................... 1-1
1.2.1 Warranty Period  ..................................................................................................................... 1-1
1.2.2 Return Instructions  ................................................................................................................. 1-1
1.2.3 After Warranty Period  ............................................................................................................ 1-1
1.3 Related Documents  ...................................................................................................................... 1-2
1.4 Technical Support  ......................................................................................................................... 1-2
1.5 Warranty and Repairs .................................................................................................................... 1-2
1.6 Radio Model Chart and Specifications .......................................................................................... 1-4
1.7 Radio Model Information ............................................................................................................... 1-4
Chapter 2Theory of Operation
2.1 Overview .......................................................................................................................................  2-1
2.2 Controller Section  ......................................................................................................................... 2-1
2.2.1 Radio Power Distribution .......................................................................................................  2-2
2.2.2 Automatic On/Off ...................................................................................................................  2-3
2.2.3 Emergency .............................................................................................................................  2-4
2.2.4 Mechanical On/Off .................................................................................................................  2-4
2.2.5 Ignition ...................................................................................................................................  2-4
2.2.6 Microprocessor Clock Synthesizer.........................................................................................  2-5
2.2.7 Serial Peripheral Interface (SPI) ............................................................................................  2-5
2.2.8 SBEP Serial Interface ............................................................................................................  2-6
2.2.9 General Purpose Input/Output ............................................................................................... 2-6
2.2.10 Normal Microprocessor Operation .........................................................................................  2-7
2.2.11 Static Random Access Memory (SRAM) ...............................................................................  2-8
2.3 Controller Board Audio and Signalling Circuits  .............................................................................2-8
2.3.1 Audio Signalling Filter IC with Compander (ASFIC CMP)  ..................................................... 2-8
2.3.2 Transmit Audio Circuits ..........................................................................................................  2-9
2.3.3 Microphone Input Path  ........................................................................................................... 2-9
2.3.3.1 PTT Sensing and TX Audio Processing  ........................................................................ 2-10
2.3.3.2 TX Secure Audio (optional)  ........................................................................................... 2-10
2.3.3.3 Option Board Transmit Audio  ........................................................................................ 2-10
2.3.4 Transmit Signalling Circuits .................................................................................................  2-11
2.3.4.1 Sub-Audible Data (PL/DPL)  .......................................................................................... 2-11
2.3.4.2 High Speed Data  ........................................................................................................... 2-12
2.3.4.3 Dual Tone Multiple Frequency (DTMF) Data  ................................................................ 2-12
2.3.5 Receive Audio Circuits .........................................................................................................  2-13
2.3.5.1 Squelch Detect  .............................................................................................................. 2-13
2.3.5.2 Audio Processing and Digital Volume Control ............................................................... 2-14
2.3.5.3 Audio Amplification Speaker (+) Speaker (-)  ................................................................. 2-14
2.3.5.4 Handset Audio  ............................................................................................................... 2-15
2.3.5.5 Filtered Audio and Flat Audio  ........................................................................................ 2-15
2.3.5.6 RX Secure Audio (Optional)  .......................................................................................... 2-15 
						

							ii
2.3.5.7 Option Board Receive Audio  2-15
2.3.6 Receive Signalling Circuits...................................................................................................  2-16
2.3.6.1 Sub-audible Data (PL/DPL) and High Speed Data Decoder  ........................................ 2-16
2.3.6.2 Alert Tone Circuits ......................................................................................................... 2-16
2.3.6.3 Voice Storage (Optional)  .............................................................................................. 2-17
2.4 UHF (403-470 MHz) Receiver Front-End  ................................................................................... 2-17
2.4.1 Front-End Band-Pass Filters & Pre-Amplifier.......................................................................  2-19
2.4.2 First Mixer and 1st Intermediate Frequency (IF) ................................................................... 2-19
2.4.3 2nd Intermediate Frequency (IF) and Receiver Back-End ...................................................  2-19
2.5 Transmitter Power Amplifier (PA) 40 W  ......................................................................................2-20
2.5.1 Power Controlled Stage .......................................................................................................  2-20
2.5.2 Pre-Driver Stage ..................................................................................................................  2-20
2.5.3 Driver Stage .........................................................................................................................  2-21
2.5.4 Final Stage ...........................................................................................................................  2-21
2.5.5 Bi-Directional Coupler ..........................................................................................................  2-21
2.5.6 Antenna Switch ....................................................................................................................  2-21
2.5.7 Harmonic Filter ...................................................................................................................... 2-21
2.5.8 Power Control ....................................................................................................................... 2-21
2.6 Frequency Synthesis  .................................................................................................................. 2-22
2.6.1 Reference Oscillator.............................................................................................................  2-22
2.6.2 Fractional-N Synthesizer ......................................................................................................  2-22
2.6.3 Voltage Controlled Oscillator (VCO) ....................................................................................  2-23
2.6.4 Synthesizer Operation..........................................................................................................  2-25
2.7 VHF (136-174MHz) Receiver Front-End ..................................................................................... 2-26
2.7.1 Front-End Band-Pass Filters and Pre-Amplifier ...................................................................  2-27
2.7.2 First Mixer and 1st Intermediate Frequency (IF) ..................................................................  2-27
2.7.3 2nd Intermediate Frequency (IF) and Receiver Back-End ...................................................  2-27
2.8 Transmitter Power Amplifier (PA) 45 W  ......................................................................................2-28
2.8.1 Power Controlled Stage .......................................................................................................  2-28
2.8.2 Pre-Driver Stage ..................................................................................................................  2-28
2.8.3 Driver Stage .........................................................................................................................  2-29
2.8.4 Final Stage ...........................................................................................................................  2-29
2.8.5 Directional Coupler...............................................................................................................  2-29
2.8.6 Antenna Switch ....................................................................................................................  2-29
2.8.7 Harmonic Filter .....................................................................................................................  2-29
2.8.8 Power Control ......................................................................................................................  2-30
2.9 Frequency Synthesis  .................................................................................................................. 2-30
2.9.1 Reference Oscillator.............................................................................................................  2-30
2.9.2 Fractional-N Synthesizer ......................................................................................................  2-30
2.9.3 Voltage Controlled Oscillator (VCO) ....................................................................................  2-32
2.9.4 Synthesizer Operation..........................................................................................................  2-33
2.10 Control Head (PRO3100, CDM750)  ........................................................................................... 2-34
2.10.1 Power Supplies ....................................................................................................................  2-34
2.10.2 Power On/Off .......................................................................................................................  2-34
2.10.3 Microprocessor Circuit .........................................................................................................  2-34
2.10.4 SBEP Serial Interface ..........................................................................................................  2-35
2.10.5 Keypad Keys ........................................................................................................................  2-35
2.10.6 Status LED and Back Light Circuit .......................................................................................  2-35
2.10.7 Microphone Connector Signals ............................................................................................  2-36
2.10.8 Speaker ................................................................................................................................. 2-36
2.10.9 Electrostatic Transient Protection ........................................................................................  2-36
2.11 Control Head (PRO5100, PRO7100, CDM1250, CDM1550)  ..................................................... 2-37
2.11.1 Power Supplies ....................................................................................................................  2-37
2.11.2 Power On / Off .....................................................................................................................  2-37 
						

							iii
2.11.3 Microprocessor Circuit .........................................................................................................  2-37
2.11.4 SBEP Serial Interface ..........................................................................................................  2-38
2.11.5 Keypad Keys ........................................................................................................................  2-38
2.11.6 Status LED and Back Light Circuit .......................................................................................  2-38
2.11.7 Liquid Crystal Display (LCD) ................................................................................................  2-39
2.11.8 Microphone Connector Signals ............................................................................................  2-39
2.11.9 Speaker................................................................................................................................  2-40
2.11.10 Electrostatic Transient Protection ........................................................................................  2-40
Chapter 3 Maintenance
3.1 Introduction ................................................................................................................................... 3-1
3.2 Preventive Maintenance  ............................................................................................................... 3-1
3.2.1 Inspection...............................................................................................................................  3-1
3.2.2 Cleaning .................................................................................................................................  3-1
3.3 Safe Handling of CMOS and LDMOS ........................................................................................... 3-2
3.4 General Repair Procedures and Techniques  ............................................................................... 3-2
3.5 Recommended Test Tools ............................................................................................................ 3-5
3.6 Transmitter Troubleshooting Chart ................................................................................................ 3-6
3.7 Receiver Troubleshooting Charts  ................................................................................................. 3-7
3.8 Synthesizer Troubleshooting Charts ............................................................................................. 3-9
3.9 VCO Troubleshooting Charts....................................................................................................... 3-11
Chapter 4Schematic Diagrams, Overlays, and Parts Lists
4.1 Introduction ................................................................................................................................... 4-1
4.1.1 Notes For All Schematics and Circuit Boards ........................................................................  4-1
List of Figures
2-1 Controller Block Diagram ............................................................................................................... 2-1
2-2 DC Power Distribution Block Diagram ........................................................................................... 2-3
2-3 Transmit Audio Paths .................................................................................................................... 2-9
2-4 Transmit Signalling Paths ............................................................................................................ 2-11
2-5 Receive Audio Paths ................................................................................................................... 2-13
2-6 Receive Signalling Paths ............................................................................................................. 2-16
2-7 UHF Receiver Block Diagram ...................................................................................................... 2-18
2-8 UHF Transmitter Block Diagram .................................................................................................. 2-20
2-9 UHF Synthesizer Block Diagram ................................................................................................. 2-23
2-10 UHF VCO Block Diagram ............................................................................................................ 2-24
2-11 VHF Receiver Block Diagram ...................................................................................................... 2-26
2-12 VHF Transmitter Block Diagram .................................................................................................. 2-28
2-13 VHF Synthesizer Block Diagram ................................................................................................. 2-31
2-14 VHF VCO Block Diagram ............................................................................................................ 2-32
4-1 PRO3100/CDM750 Control Head Top Overlay ............................................................................  4-3
4-2  PRO3100/CDM750 Control Head Bottom Overlay  ....................................................................... 4-4
4-3  PRO3100CDM750 Control Head Schematic Diagram, Sheet 1  ................................................... 4-5
4-4  PRO3100CDM750 Control Head Schematic Diagram, Sheet 2  ................................................... 4-6 
						

							iv
4-5  PRO5100/PRO7100/CDM1250/CDM1550 Control Head Top 
Overlay .......................................................................................................................................... 4-9
4-6  PRO5100/PRO7100/CDM1250/CDM1550 Control Head Bottom 
Overlay ........................................................................................................................................ 4-10
4-7  PRO5100/PRO7100/CDM1250/CDM1550 Control Head 
Schematic Diagram ..................................................................................................................... 4-11
4-8  PRO5100/PRO7100/CDM1250/CDM1550 Control Head Keypad 
Schematic Diagram.....................................................................................................................  4-12
4-9  PRO5100/PRO7100/CDM1250/CDM1550 Control Head LCD 
Schematic ................................................................................................................................... 4-13
4-10  PRO5100/PRO7100/CDM1250/CDM1550 Control Head Display 
Schematic ................................................................................................................................... 4-14
4-11  Complete Controller Schematic Diagram ....................................................................................4-17
4-12  Controller Control  Schematic Diagram  ...................................................................................... 4-18
4-13  Controller I/O Schematic Diagram  .............................................................................................. 4-19
4-14  Controller Audio Schematic Diagram  .......................................................................................... 4-20
4-15  Controller Supply Voltage Schematic Diagram  ........................................................................... 4-21
4-16  UHF (403-470MHz) Voltage Controlled Oscillator Schematic Diagram ...................................... 4-25
4-17  UHF (403-470MHz) Fractal-N Schematic Diagram  .................................................................... 4-26
4-18  UHF (403-470MHz) Power Amplifier Schematic Diagram  .......................................................... 4-27
4-19  VHF (136-174MHz) Main Board Top Side PCB .......................................................................... 4-33
4-20  VHF (136-174MHz) Receiver Front End Schematic Diagram  .................................................... 4-34
4-21  VHF (136-174MHz) Receiver IF Schematic Diagram  ................................................................. 4-35
4-22  VHF (136-174MHz) Fractal-N Schematic Diagram ..................................................................... 4-36
4-23  VHF (136-174MHz) Voltage Controlled Oscillator Schematic Diagram  ...................................... 4-37
4-24  VHF (136-174MHz) Power Amplifier Schematic Diagram  .......................................................... 4-38
List of Tables
1-1 Radio Model Number ..................................................................................................................... 1-3
3-1 Recommended Test tools .............................................................................................................. 3-5
4-1 PRO3100/CDM750 Control Head Parts List .................................................................................. 4-7
4-2 PRO5100/PRO7100/CDM1250/CDM1550 Control Head Parts List ............................................ 4-15
4-3 Controller Parts List ..................................................................................................................... 4-22
4-4 UHF B1 Radio Parts List .............................................................................................................. 4-28
4-5 VHF (136-174MHz) Radio Parts List ...........................................................................................4-39