Motorola Pr400 Basic 6881096c24 A Manual
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6881096C24-AAugust, 2004 Model Charts and Test Specifications: MIL Standards 1-9 1.9 MIL Standards Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications (8.2 and 8.4) Military Standards 810 C, D, E, & F: Parameters/Methods/Procedures 810C810D810E810F Applicable MIL-STDMethods Procedures Methods Procedures Methods Procedures Methods Procedures Low Pressure500.11500.22500.32500.41 High Temper- ature501.1 1,2 501.2 1,2 501.3 1,2 501.4 1,2 Low Temperature502.11502.21,2502.31,2501.41,2 Temperature Shock503.1 1 503.2 1 503.3 1 503.4 1 Solar Radia- tion505.11505.21505.31505.41 Rain 506.1 1,2 506.2 1,2 506.3 1,2 506.4 1 Humidity507.12507.22,3507.32,3507.43 Salt Fog 509.1 1 509.2 1 509.3 1 509.4 1 Dust 510.11510.21510.31510.41 Vibration 514.2 8,10 514.3 1 514.4 1 514.5 1 Shock516.21,2,5516.31,4516.41,4516.51
August, 20046881096C24-A This Page Intentionally Left Blank 1-10Model Charts and Test Specifications: MIL Standards
Chapter 2 Theory Of Operation 2.1 Introduction This chapter provides a basic theory of operation for the radio components. 2.2 Major Assemblies • Transceiver Board – contains all transmit, receive, and audio circuitry. • Display (Limited and Full Keypad models only) – 8 characters (14 segments star burst) and 10 icons with backlighting, liquid-crystal display (LCD). Keypad Board (Limited and Full Keypad models only) – Limited Keypad: a 2-button menu keypad with 2-way navigation button, Full Keypad: a 2-button menu keypad with 2-way navigation button, and a 3 x 4 alphanumeric keypad.Transceiver Board (Figure 2-1). 2.2.1 Receiver Incoming RF signals from the antenna are first routed through the harmonic filter and antenna switch, part of the transmitter circuitry, before being applied to the receiver front end. The receiver front end consists of a preselector filter, RF amplifier, interstage filter, and a double-balanced first mixer (Figure 2-2). The mixer output is applied to a diplexer network which matches the 44.85 MHz IF signal to the crystal filter, and terminates the mixer into 50 ohms at all other frequencies. The receiver back-end is a dual conversion design. High IF selectivity is provided by a 4-pole fundamental mode 44.85 MHz crystal filter. The output is matched to an IF amplifier stage. The output of the IF amplifier is applied to the input of the receiver IFIC.Figure 2-1. Major Assemblies Block Diagram Antenna M140 Transceiver BoardBoard BatteryJ301 J491 J470J460 Spkr MicKeypad J2 3 2 2 28 J1Display
July, 20046881096C24-A 2-2Theory Of Operation: Major Assemblies The IFIC is a low-voltage monolithic FM IF system incorporating a mixer/oscillator, two limiting IF amplifiers, quadrature detector, logarithmic received signal strength indicator (RSSI), voltage regulator and audio, and RSSI Op Amps. The second LO frequency, 44.395 MHz, is determined by a crystal oscillator. The second mixer converts the 44.85 MHz high IF frequency to 455 kHz. Additional IF selectivity is provided by two ceramic filters. The first ceramic filter is a 4-pole filter used between the second mixer and IF amp. The second ceramic filter is a 6-pole filter and is used between the IF amp and the limiter input. For the second ceramic filter, a wider filter is used for 20/25 kHz channel spacing, and a narrower filter is used for 12.5 kHz channels. A ceramic resonator provides phases vs. frequency characteristic required by the quadrature detector, with 90 degree phase shift occurring at 455 kHz. The output of the IFIC is the recovered audio signal which is fed to the audio IC for amplification and signal conditioning. The output of the audio IC is injecting into the audio PA which drives the 24 Ohm speaker. 2.2.2 Transmitter • When the radio is transmitting, microphone audio is passed through the audio IC, where pre- emphasis and low-pass (splatter) filtering are done. The output of the audio IC is used to modu- late the TX VCO, which creates the modulated carrier. The modulated carrier is then amplified by the pre-driver and power amplifier circuit, which transmits the signal under dynamic power control Figure 2-2. Transceiver Block Diagram Crystal Filter Filter Filter Filter Mixer IF Amp VCOBIC Loop Filter Rx VCO Circuit Tx VCO Circuit Ref. Osc. Rx Out Tx Out Audio IC MicAudio PA SpkrPredriver SwitchT/R Rx Tx ModulePA Demodulator Recovered Audio RSSI Ceramic ResonatorCer FltrSwitching4E 6E6G BW_SELPreselector Frac N Mod Power Cntr Harmonic LNA Image IF IC
Chapter 3 Test Equipment, Service Aids, and Service Tools 3.1 Test Equipment Table 3-1 lists test equipment required to service the PR400 Radios. Table 3-1. Recommended Test Equipment Motorola Part No. Description Characteristics Application R2600 seriesSystem analyzerThis item will substitute for items with an asterisk (*)Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment *R1074A Fluke 87 digital multi- meterTrue RMS metering, 200 kHz frequency counter, 32-segment bar graph with backlit displayDigital voltmeter is recom- mended for AC/DC voltage and current measurements Fluke 85 RF probe500 MHz, 30 VAC maxUse with Fluke 87 digital multi- meter for RF voltage measure- ments. *R1377A AC voltmeter 1 mV to 300 mV, 10 mega- ohm input impedanceAudio voltage measurements R1611ADual channel 100 MHz oscillo- scope (Agillent)Two-channel, 100 MHz bandwidth, 200 M sample rate/sec, 2 MB memory/ channelWaveform measurements S1339A RF millivolt meter 100 µV to 3V RF, 10 kHz to 1 GHz frequency rangeRF level measurements *R1013B or *R1370ASINAD meter or SINAD meter with RMSWithout RMS audio voltme- ter or With RMS audio voltmeterReceiver sensitivity measure- ments
July 21, 20046881096C24-A 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 PR400 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 RLN4460Po r ta ble Tes t Se tEnables connection to the audio/accessory jack. Allows switching for radio testing. RLN4510 Battery Interface Regulates DC current and voltage between radio and power supply. RVN4191Customer Programming Soft- ware and Global Tuner Software on CD RomProgram customer option and channel data. AAPMKN4004 Programming Test Cable Connects radio to RIB (PLN4008). 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. Table 3-3. Recommended Service Tools Motorola Part No.Description Application RSX4043ATORX screwdriverTighten and remove chassis screws 6680387A70 T6 TORX bit Removable TORX screwdriver bit R1453ADigital readout solder stationDigitally controlled soldering iron RLN4062A Hot air workstation, 120 V Tool for hot air soldering/desoldering of surface mounted integrated circuits
6881096C24-AJuly, 2004 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) R1319A ChipMaster (110 V) Surface mount removal and assembly of surface mounted integrated circuits and/or rework station shields. Includes 5 nozzles. R1321AChipMaster (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
July 21, 20046881096C24-A 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 Performance Checks Setup RIB RLN4008 RIB Power Supply Rx GndData Tx Data Radio Computer Interface Cable Program/ Test Cable PMKN4004
July, 20046881096C24-A 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 PR400 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 codeplug 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: AVoltage: 7.5 Vdc RF Attenuation: -70 Spkr/load: SpeakerDC 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