Motorola Mototrbo Dr3000 Repeater Basic 6866576d03 A Manual
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Chapter 3 Transceiver Performance Testing 3.1 General The MOTOTRBO Repeater meets published specifications through their manufacturing process by utilizing high-accuracy laboratory-quality test equipment. The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule. NOTE:Although these radios function in digital and analog modes, all testing is done in analog mode. 3.2 Setup Supply voltage is 120/240 VAC. The equipment required for alignment procedures is connected as shown in the Repeater Tuning Equipment Setup Diagram, Figure 4-2. Initial equipment control settings should be as indicated in Table 3-1. Table 3-2 lists Receiver Performance Checks information. Table 3-1. Initial Equipment Control Settings Service Monitor Test Set Monitor Mode: Power MonitorSpeaker set: A RF Attenuation: -70 Speaker/load: Speaker AM, CW, FM: FMPTT: OFF Oscilloscope Source: Mod Oscilloscope Horizontal: 10 mSec/Div Oscilloscope Vertical: 2.5 kHz/Div Oscilloscope Trigger: Auto Monitor Image: Hi Monitor Bandwidth: Narrow Monitor Squelch: middle setting Monitor Vol: 1/4 setting
February 21, 20076866576D03-A 3-2Transceiver Performance Testing: Setup Table 3-2. Receiver Performance Checks Test NameCommunications AnalyzerRadio Test Set Comment Rated AudioMode: GEN Output level: 1.0 mV RF 4th channel test frequency* Mod: 1kHz tone at 3 kHz deviation Monitor: DVM: AC VoltsUse tuner tool to program repeater to an appropriate test frequency with carrier squelch.PTT to OFF (center), meter selector to Audio PASet volume to 7.75 Vrms via tuner tool. Distortion As above, except to distortionAs above As above Distortion
Chapter 4 Repeater Tuning and Programming 4.1 Introduction This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as well as the Tuner application, which are all designed for use on Windows 2000/XP operating system. These programs are available in one kit as listed in the Table 4-1. An Installation Guide is also included with the kit. NOTE:Refer to the appropriate program on-line help files for the programming procedures. Table 4-1. Repeater Software Program Kits 4.2 Customer Programming Software Setup The Customer Programming Software setup, shown in Figure 4-1 is used to program the repeater. NOTE:Refer to the appropriate program on-line help files for the programming procedures.Description Kit Number MOTOTRBO CPS, Tuner and AirTracer Applications CDGMVN5141_ Figure 4-1. Customer Programming Software Setup from Rear Accessory Connector AC ACCRear Accessory Connector 120 / 240 VAC USB Repeater Tx Port Rx PortMobile & Repeater Rear Programming Cable PMKN4010_
February 21, 20076866576D03-A 4-2Repeater Tuning and Programming: Repeater Tuning Setup 4.3 Repeater Tuning Setup A personal computer (PC), Windows 2000/XP and a tuner program (which is available as part of the MOTOTRBO CPS kit) are required to tune the repeater. To perform the tuning procedures, the repeater must be connected to the PC and test equipment setup as shown in Figure 4-2. Figure 4-2. Repeater Tuning Equipment Setup WATT meter Audio Generator SINAD Meter AC Voltmeter 30 dB PadAudio In Tx Rx RF Generator RLN4460_ Te s t B o x Service Monitor 120 / 240 VAC AC ACCMobile & Repeater Rear Programming, Testing & Alignment Cable PMKN4016_ USB Tx Tx Tx Port Rx Port
Chapter 5 Disassembly/Reassembly Procedures 5.1 Introduction This chapter provides details about the following: • Preventive maintenance (inspection and cleaning). • Safe handling of CMOS and LDMOS devices. • Disassembly and reassembly of the repeater. • Disassembly and reassembly of the Transmit and Receive radios. • Repair procedures and techniques. 5.2 Preventive Maintenance Periodic visual inspection and cleaning is recommended. 5.2.1 Inspection Check that the external surfaces of the repeater are clean, and that all external controls and switches are functional. It is not recommended to inspect the interior electronic circuitry. 5.2.2 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 repeater. External surfaces include the top cover and repeater enclosure. Periodically clean smudges and grime from exterior enclosure. Use a soft, non-abrasive cloth moistened in a mild soap and water solution. Rinse the surface using a second cloth moistened in clean water, and clean any dirt or debris from the fan grill and louvers on the front side. NOTE:Internal surfaces should be cleaned only when the repeater is disassembled for service or repair. The only recommended agent for cleaning the external repeater 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 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 repeater. 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. Once the cleaning process is complete, use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the top cover and repeater enclosure. NOTE:Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage).
February 21, 20076866576D03-A 5-2Disassembly /Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices 5.3 Safe Handling of CMOS and LDMOS Devices Complementary metal-oxide semiconductor (CMOS) devices are used in this family of repeaters, 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 repeater without first referring to the following CAUTION statement. This repeater contains static-sensitive devices. Do not open the repeater unless y ou 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 (part number 0180386A82), 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 4280385A59). • 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. ! C a u t i o n
6866576D03-AFebruary 21, 2007 Disassembly /Reassembly Procedures: Repair Procedures and Techniques — General 5-3 5.4 Repair Procedures and Techniques — General Any rework or repair on Environmentally Preferred Products must be done using the appropriate lead-free solder wire and lead-free solder paste as stated in the following table: Parts Replacement and Substitution When damaged parts are replaced, identical parts should be used. If the identical replacement part is not locally available, check the parts list for the proper Motorola part number and order the part from the nearest Motorola Radio Products and Solutions Organization listed in Appendix A of this manual. Rigid Circuit Boards This repeater uses bonded, multi-layer, printed circuit boards. Since the inner layers are not accessible, some special considerations are required when soldering and unsoldering components. The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, exercise care to avoid pulling the plated circuit out of the hole. When soldering near connector: • Avoid accidentally getting solder in the connector. • Be careful not to form solder bridges between the connector pins. • Examine your work closely for shorts due to solder bridges. NOTE Environmentally Preferred Products (EPP) (refer to the marking on the printed circuit boards — examples shown below) were developed and assembled using environmen- tally preferred components and solder assembly techniques to comply with the Euro- pean Union’s Restriction of Hazardous Substances (ROHS) Directive 2002/95/EC and Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC. To maintain product compliance and reliability, use only the Motorola specified parts in this manual. Table 5-1. Lead Free Solder Wire Part Number List Motorola Part NumberAlloy Flux TypeFlux Content by WeightMelting PointSupplier Part numberDiameter Weight 1088929Y0195.5Sn/3.8Ag/0.7CuRMA Version2.7-3.2%217C521710.015”1lb spool 1088929Y02 95.5Sn/3.8Ag/0.7Cu RMA Version 2.7-3.2% 217C 52170 0.010” 0.5lb spool 1088929Y0395.5Sn/3.8Ag/0.7CuRMA Version2.7-3.2%217C521730.032”1lb spool Table 5-2. Lead Free Solder Paste Part Number List Motorola Part NumberManufacturer Part NumberViscosity Type Composition & Percent MetalLiquid Temperature 1085674C03NC-SMQ230900-1000KCPs Brookfield (5rpm)Type 3 (-325/+500)(95.5%Sn-3.8%Ag-0.7%Cu) 89.3%217°C
February 21, 20076866576D03-A 5-4Disassembly /Reassembly Procedures: Disassembling and Reassembling the Repeater — General 5.5 Disassembling and Reassembling the Repeater — General The following tools are required for disassembling the repeater: • Small Flat Blade Screwdriver • TORX™ T30 Driver Bit • TORX™ T25 Driver Bit • TORX™ T20 Driver Bit • TORX™ T15 Driver Bit • TORX™ T10 Driver Bit • 7 mm Magnetic Socket Driver (extension of >150 mm) • 16 mm Deep Well Socket Driver • 19 mm Deep Well Socket Driver If a unit requires more complete testing or service than is customarily performed at the basic level, please send repeater to a Motorola Service Center listed in Appendix A. The following disassembly procedures should be performed only if necessary. 5.6 Disassembly Procedures — Detailed The following are typical procedures to remove and replace the Transmit radio, Receive radio, Repeater Indicator Board, connector board assembly and other miscellaneous parts. 1. Power cord and all external cables must be disconnected before opening up repeater. 2. Take the proper grounding precautions as stated in Section 5.3: Safe Handling of CMOS and LDMOS Devices on page 5-2. 3. When disassembling repeater, retain all screws for reuse. 5.6.1 Disassembly of Cover 1. Remove the five screws that retain the cover to the housing as shown in Figure 5-1 using a T20 TORX™ driver. Figure 5-1. Removing Top Cover of Repeater Enclosure Front View of RepeaterBack View of Repeater Screws Top Cover
6866576D03-AFebruary 21, 2007 Disassembly /Reassembly Procedures: Disassembly Procedures — Detailed 5-5 5.6.2 Disassembly of Repeater Indicator Board (Refer to Figure 5-2 and Figure 5-3) 1. Disconnect the blue ethernet cable from the ethernet connector on the Repeater Indicator Board. 2. Disconnect flex cable from 30-position connector on Repeater Indicator Board, noting orientation of cable which is identified with a solid black line. This is important for reassembly. Figure 5-2. Disconnecting Ethernet Cable and Flex Cable 3. Detach the front panel by removing the four M6 screws located on the front face of panel using a T30 TORX™ driver. 4. Place the front panel on a flat surface with the Repeater Indicator Board facing up. 5. Detach the Repeater Indicator Board from front panel by removing the four M3 screws using a T10 TORX™ driver. 6. Hold the Repeater Indicator Board on its outer edge with your finger tips, squeeze together the catch of each clip and slightly press them through the board to remove the light guide. Control Head Flex Repeater, LED Ethernet Connector and USB Converter Board
February 21, 20076866576D03-A 5-6Disassembly /Reassembly Procedures: Disassembly Procedures — Detailed 7. Store Repeater Indicator Board in an anti-static bag when it is not being serviced. Figure 5-3. Repeater Indicator Board Disassembly 5.6.3 Disassembly of Fan 1. Unplug the fan cable from the mating connector on the connector board assembly. 2. Detach the fan assembly by removing the four screws that secure the fan grill and fan assembly to the back of the enclosure using a T15 TORX™ driver. 3. Carefully remove fan, noting position of arrow which identifies direction of air flow. This is important for reassembly. Figure 5-4. Fan Orientation Repeater Indicator Board Light Guide Front Panel M3 Screws (4) M6 Screws (4) Screws Back of Enclosure Position of arrow Fan