Motorola Portable Radio Ep450 Basic Hkln4215a Manual
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December 3, 2003HKLN4215A 3-2Test Equipment, Service Aids, and Service Tools: Service Aids 3.2 Service Aids Ta b l e 3 - 2 lists service aids recommended for working on the EP450 Radios. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. Table 3-2. Service Aids Motorola Part No.Description Application RLN4460Portable Test SetEnables connection to the audio/accessory jack. Allows switching for radio testing. RLN4510 Battery Interface Regulates DC current and voltage between radio and power supply. RVN4195Customer Programming Soft- ware and Tuner Software on CD ROMProgram customer option and channel data. AAPMKN4004 Programming Test Cable Connects radio to RIB (RLN4008). AAPMKN4003Radio to Radio Cloning CableAllows a radio to be duplicated from a master radio by transferring programmed data from the master radio to the other. RLN4008 Radio Interface Box Enables communications between the radio and the computer’s serial communications adapter. 5886564Z01RF AdaptorAdapts radio’s antenna port to BNC cabling of test equipment. 0180305K08 Shop Battery Eliminator Interconnects radio to power supply. HSN9412Wall-Mounted Power SupplyUsed to supply power to the RIB (120 VAC). 3080369B71 or 3080369B72Computer Interface Cable Use B72 for the IBM PC AT or newer (9-pin serial port). Use B71 for older models (25-pin serial port). Connects the computer’s serial communications adapter to the RIB (PLN4008). 6686533Z01Knob Remover/Chassis OpenerUsed to remove the front cover assembly. HKN9216 IBM Computer Interface Cable Connection from computer to RIB. 8180384N65Housing EliminatorAllows testing of the radio outside of the housing. RLN5583 Flashing Adapter Flashing/CPS cable for authorized service centers. Table 3-3. Recommended Service Tools Motorola Part No.Description Application RSX4043TORX screwdriverTighten and remove chassis screws 6680387A70 T6 TORX bit Removable TORX screwdriver bit R1453Digital readout solder stationDigitally controlled soldering iron RLN4062 Hot air workstation, 120 V Tool for hot air soldering/desoldering of surface mounted integrated circuits
HKLN4215ADecember 3, 2003 Test Equipment, Service Aids, and Service Tools: Service Aids 3-3 0180386A78Illuminated magnifying glass with lens attachment Illumination and magnification of components 0180302E51 Master lens system 0180386A82Anti-static grounding kitUsed during all radio assembly and disassembly pro- cedures 6684253C72 Straight prober 6680384A98Brush 1010041A86 Solder (RMA type), 63/67, 0.5mm diameter, 1 lb. spool 0180303E45SMD tool kit (included with R1319A) R1319 ChipMaster (110 V) Surface mount removal and assembly of surface mounted integrated circuits and/or rework station shields. Includes 5 nozzles. R1321ChipMaster (220 V) ChipMaster Nozzles: 6680332E83PLCC-28* nozzle Soldering and Un-soldering IC’s 6680332E82 PLCC-44* nozzle 6680332E94PLCC-52 nozzle 6680332E96 PLCC-84 nozzle 6680334E67QFP-160 nozzle 6680333E46 SOL-18 nozzle 6680332E84SOIC-20 nozzle 6680332E87 SOL-20J nozzle 6680333E45SOL-24 nozzle 6680333E55 TSOP-64 nozzle * Included with ChipMaster packages Table 3-3. Recommended Service Tools (Continued) Motorola Part No.Description Application
December 3, 2003HKLN4215A 3-4Test Equipment, Service Aids, and Service Tools: Service Aids Programming/Test Cable Figure 3-1. Programming/Test Cable Figure 3-2. Wiring of the Connectors 25 POSITION FEMALE CONNECTOR 25 POSITION MALE CONNECTOR 36.0” CABLE 36.0” CABLE P1 P2 P3 P2 25 pin Male D Connector Components molded inside 1 5 24 7 20 8 15 16 9 47 ohm 33K + 1UF,16V 5% Orange Blue White Spiral Yellow P1 2.5mm stereo and 3.5mm 1 2 5 3 4 3.5mm Tip (Speaker +) 3.5mm Sleeve 2.5mm Tip (Microphone) 2.5mm 2.5mm Center P3 25 pin Female D Connector 1 15 4 11 1 2 3 4 5 3.5mm mono 2.5mm stereo To Test Box To Test Box
Chapter 4 Performance Checks 4.1 General These radios meet published specifications through their manufacturing process by utilizing high- accuracy laboratory-quality test equipment. The recommended field service equipment is as accurate as the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule. 4.2 Power-Up Self Test Applying power to the radio by using the on/off volume control, starts a self-test routine which checks the RAM, EEPROM hardware and EEPROM checksum. Pressing and holding SB1 while turning on the radio causes the self-test routine to check for the ROM checksum as well. If these checks are successfully completed, the radio will generate the Self-Test Pass Tone. If the self-test is not successful, a Self-Test Fail Tone is heard.Figure 4-1. Radio Tuning Setup Service Monitor or Counter Wattmeter Audio Generator Sinad Meter AC Voltmeter 30 dB Pad 30 dB Pad Battery Eliminator Powe r Supply Audio In Tx Rx Receive Tr a n s m i t RF Generator BNC RF Adaptor 5886564Z01 RIB RLN4008 RIB Power Supply RLN4460Te s t B o xRx GndData Tx Data Radio Computer Interface Cable Program/ Test Cable AAPMKN4004 RLN5410Power Ca ble
December 3, 2003HKLN4215A 4-2Performance Checks: RF Test Mode Supply voltage can be connected from the battery eliminator. The equipment required for alignment procedures is connected as shown in the Radio Performance Checks Setup diagram (Figure 4-1). Initial equipment control settings should be as indicated in Table 4-1 and should be the same for all performance checks and tuner alignment procedures. 4.3 RF Test Mode When the EP450 radio is operating in its normal environment, the radios microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer code plug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment using a special routine, called RF TEST MODE. This mode allows bench testing of the radio at various test frequencies across the entire band, at both high and low transmit power (if applicable), at various channel spacings, and with different coded or carrier squelch types. Any customer specific programming in the radio will not be changed or affected by use of the RF Test Mode. Figure 4-2. Side Button Locations Table 4-1. Initial Equipment Control Settings Service Monitor Test Set Power Supply Monitor Mode: Power MonitorSpkr set: CVoltage: 7.5 Vdc RF Attenuation: -70 Spkr/load: LoadDC on/standby: Standby AM, CW, FM: FMPTT: OFF Volt Range: 10 V Oscilloscope Source: Mod Oscilloscope Horiz: 1 0 mSec/Div Oscilloscope Vert: 2.5kHz/Div Oscilloscope Trig: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: mid CW Monitor Vol: 1/4 CWCurrent: 2.5 A P1 P2 123 456 789 *0 # Side Button 1 Side Button 2
HKLN4215ADecember 3, 2003 Performance Checks: RF Test Mode4-3 To enter test mode: 1.Turn the radio on. Within ten seconds after the self test is complete (self test tone is heard), press SB2 (Side Button 2 in Figure 4-2) five times in succession. If the self test complete tone is not heard, see Error Codes information in Chapter 8. Entry into the test mode is indicated by a positive indicator tone followed by a good key chirp (GKC). Upon entering test mode, the radio is in the carrier squelch mode. 2.Press SB1 (Side Button 1) and scroll through and access test environments as shown in Table 4-2. 3.Press SB2 and scroll through the channel spacing available as shown in Table 4-3. 4.Turn the channel selector knob to change the test channel for that environment as shown in Table 4-4. 5.Press the PTT on a test channel to cause the radio to transmit at the test frequency for the channel. Table 4-2. Test Environments No. of BeepsDescription Function 1 GKC*Carrier SquelchRX: unsquelch if carrier detected TX: mic audio 1 BKC*Tone Private-Line RX: unsquelch if carrier and tone (192.8 Hz) detected TX: mic audio + tone (192.8 Hz) 2 BKCDigital Private-LineRX: unsquelch if carrier and digital code (131) detected TX: mic audio + digital code (131) 3 BKCDual-Tone Multiple FrequencyRX: unsquelch if carrier detected TX: selected DTMF tone pair 5 BKCUnsquelch OpenRX: constant unsquelch TX: mic audio 9 BKCHigh-Speed Signal- ingRX: unsquelch if carrier detected TX: 1500 Hz tone * “BKC” means Bad Key Chirp (low-pitched tone), “GKC” means Good Key Chirp (high-pitched only). Table 4-3. Test Channel Spacing No. of BKC Channel Spacing 125 kHz 2 12.5 kHz 320 kHz
December 3, 2003HKLN4215A 4-4Performance Checks: RF Test Mode Table 4-4. Test Frequencies Channel Selector Switch PositionTe s t C h a n n e lVHF R2 (MHz)UHF R1 (MHz)UHF R2 (MHz)UHF R3 (MHz) 1 Low Power 8 High PowerTX#1 or #8 RX#1 or #8146.625403.625438.625465.625 2 Low Power 9 High PowerTX#2 or #9 RX#2 or #9150.775 409.775 443.775 470.775 3 Low Power 10 High PowerTX#3 or #10 RX#3 or #10155.275415.275448.275475.275 4 Low Power 11 H i g h P o w e rTX#4 or #11 RX#4 or #11160.125 421.125 454.125 480.125 5 Low Power 12 High PowerTX#5 or #12 RX#5 or #12164.475427.475459.475485.475 6 Low Power 13 High PowerTX#6 or #13 RX#6 or #13169.475 433.475 464.475 490.475 7 Low Power 14 High PowerTX#7 or #14 RX#7 or #14173.875439.875469.875494.875 Table 4-5. Receiver Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference FrequencyMode: PWR MON 4th channel test frequency * Monitor: Frequency error Input at RF In/Out *. See Table 4-4 TEST MODE, Test Channel 4 carrier squelch output at antennaPTT to continu- ous (during the performance check)Frequency error to be ±200 Hz VHF ±500 Hz UHF Rated Audio Mode: GEN Output level: 1.0m V RF 4th channel test frequency * Mod: 1 kHz tone at 3 kHz deviation Monitor: DVM: AC VoltsTEST MODE Test Channel 4 carrier squelchPTT to OFF (center), meter selector to Audio PASet volume control to 3.24Vrms DistortionAs above, except to distortionAs aboveAs aboveDistortion
HKLN4215ADecember 3, 2003 Performance Checks: RF Test Mode4-5 Table 4-6. Transmitter Performance Checks Test Name Communications Analyzer Radio Test Set Comments Reference FrequencyMode: PWR MON 4th channel test frequency * Monitor: Frequency error Input at RF In/Out *. See Table 4-4 TEST MODE, Test Channel 4 carrier squelch Output at antennaPTT to continu- ous (during the performance check)Frequency error to be ±200 Hz VHF ±500 Hz UHF Power RF As above As above As above Refer to Maintenance Specifications Vo i c e ModulationMode: PWR MON 4th channel test frequency * atten to -70, input to RF In/ Out Monitor: DVM, AC Volts Set 1 kHz Mod Out level for 0.025 Vrms at test set, 80m Vrms at AC/DC test set jack As aboveAs above, meter selector to micDeviation: VHF, UHF ≥ 4.0 kHz but ≤ 5.0 kHz (25 kHz Ch Sp). Vo i c e Modulation (internal)Mode: PWR MON 4th channel test frequency * atten to -70, input to RF In/ OutTEST MODE, Test Channel 4 carrier squelch Output at antennaRemove modula- tion inputPress PTT switch on radio. Say “four” loudly into the radio mic. Measure deviation: VHF, UHF ≥ 4.0 kHz but ≤ 5.0 kHz (25 kHz Ch Sp) DTMF ModulationAs above, 4th channel test frequency * TEST MODE, Test Channel 4 DTMF Output at antennaAs aboveDeviation: VHF, UHF ≥ 3.05 kHz but ≤ 3.45 kHz (25 kHz Ch Sp) PL/DPL ModulationAs above 4th channel test frequency * BW to narrowTEST MODE, Test Channel 4 TPL DPLAs above Deviation: VHF, UHF ≥ 500Hz but ≤ 1000 Hz (25 kHz Ch Sp).
December 3, 2003HKLN4215A Notes: 4-6Performance Checks: RF Test Mode
Chapter 5 Radio Alignment Procedures 5.1 Introduction This chapter provides an overview of the Commercial Series Customer Programming Software (CPS) and the Global Tuner as designed for use in a Windows® 98/NT4/2000/ME/XP environment. Both cover all the functions of the traditional Radio Service Software (RSS) package. They are both available in the CPS Tuner (CD ROM) Kit (RVN4195). 5.2 CPS Programming Setup Refer to online help files for the CPS Programming procedures. (See Figure 5-1 for CPS Programming Setup). Figure 5-1. CPS Programming Setup RIB RLN4008 RIB Power Supply RLN4460Te s t B o xRx GndData Tx Data Radio Battery Computer Interface Cable Program/ AAPMKN4004 Te s t C a b l e