astro digital saber portable radios basic service...

ASTRO Digital SABERPortable Radios

Basic Service Manual

*68P81076C05*

FOREWORD

The information contained in this manual relates to all ASTRO Digital SABER radios, unless otherwisespecified.

SAFETY INFORMATIONThe Federal Communications Commission (FCC), with its action in General Docket 79-144, March 13, 1985,

has adopted a safety standard for human exposure to radio frequency (RF) electromagnetic energy emitted byFCC-regulated equipment. Motorola subscribes to the same safety standard for the use of its products. Properoperation of this radio will result in user exposure substantially below FCC recommended limits.

• DO NOT hold the radio with the antenna very close to, or touching, exposed parts of the body, especially theface, ears, or eyes, while transmitting. Hold the radio in a vertical position with the microphone two to threeinches away from the lips.

• DO NOT hold the transmit switch (PTT) on when not actually desiring to transmit.

• DO NOT allow children to play with any radio equipment containing a transmitter.

• DO NOT operate this equipment near electrical blasting caps or in an explosiveatmosphere. Under certain conditions, radios can interfere with blasting operations.When you are in the vicinity of construction work, look for, and observe, signs cautioningagainst radio transmissions. If radio transmission is prohibited, you must not transmit untilout of the area. Furthermore, you must turn off your radio to prevent any accidentaltransmission.

• DO NOT replace or charge batteries in a hazardous atmosphere. Contact sparking mayoccur while installing or removing batteries and cause an explosion.

• TURN THE RADIO OFF when removing or installing a battery.

Anyone intending to use a radio in a hazardous area is advised to become familiar with the subject of intrinsicsafety and with Section 70 of the National Fire Code, which is commonly referred to as Article 500 of the NationalElectric Code. Use of anything but factory supplied components may affect the approval and safety of the radio.Likewise, it is advised that servicing should be performed only by qualified personnel who adhere to the followingFactory Mutual (FM) required warning:

MANUAL REVISIONSChanges which occur after this manual is printed are described in “FMRs.” These FMRs provide complete

information on changes including pertinent parts listing data.

COMPUTER SOFTWARE COPYRIGHTSThe 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 certainexclusive rights for copyrighted computer programs, including the exclusive right to copy or reproduce in any form thecopyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the Motorolaproducts described in this manual may not be copied or reproduced in any manner without the express writtenpermission of Motorola. Furthermore, the purchase of Motorola products shall not be deemed to grant either directlyor 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.

MAEPF-1781MAEPF-17813-A

WARNING Modification of FM approved intrinsically safe radios will negate Factory Mutual ResearchCorporation (FMRC) approval.

Basic Service Manual68P81076C05-O

CONTENTS

© 1993 by Motorola, Inc., Radio Products Group8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322Printed in U.S.A. 5/93. All Rights Reserved.

, Motorola, ASTRO, SABER, FLASHport, SMARTNET, Stat-Alert, SABER SI, CoveragePLUS, Private-Line, and Digital Private Line are trademarks of Motorola, Inc.

TITLE PAGE

FOREWORD...................................................................................................................................................inside front coverLIST OF TABLES .....................................................................................................................................................................iiLIST OF ILLUSTRATIONS.......................................................................................................................................................iiRELATED PUBLICATIONS AVAILABLE SEPARATELY.........................................................................................................iiPORTABLE RADIO MODEL NUMBERING SYSTEM.............................................................................................................iiiSPECIFICATIONS FOR VHF RADIOS ...................................................................................................................................ivSPECIFICATIONS FOR UHF RADIOS....................................................................................................................................vSPECIFICATIONS FOR 800MHz RADIOS.............................................................................................................................vi

SECTION I. INTRODUCTIONA. General ...........................................................................................................................................................1B. Radio Description............................................................................................................................................1C. ...............................................................................................................................................1

SECTION II. BASIC MAINTENANCEA. Introduction to This Section ............................................................................................................................3B. Preventive Maintenance .................................................................................................................................3C. Handling Precautions......................................................................................................................................3

SECTION III. RECOMMENDED TEST EQUIPMENT, SERVICE AIDS, AND TOOLS

A. Recommended Test Equipment .....................................................................................................................5B. Service Aids and Recommended Tools..........................................................................................................6C. Field Programming Equipment .......................................................................................................................6

SECTION IV. PERFORMANCE CHECKSA. Introduction to This Section ............................................................................................................................7B. Setup...............................................................................................................................................................7C. Test Mode .......................................................................................................................................................7

SECTION V. RADIO ALIGNMENT PROCEDUREA. Introduction to This Section ..........................................................................................................................11B. General .........................................................................................................................................................11C. Reference Oscillator Alignment ....................................................................................................................13D. Transmit Power Alignment............................................................................................................................14E. Transmit Deviation Balance (Compensation) Alignment ..............................................................................15F. Transmit Deviation Limit Alignment ..............................................................................................................16G. Front-End Filter Alignment (VHF/UHF Only).................................................................................................17

SECTION VI. DISASSEMBLY/REASSEMBLY PROCEDURESA. Disassembly..................................................................................................................................................19B. Servicing Major Subassemblies....................................................................................................................21C. Reassembly ..................................................................................................................................................22

™ Digital SABER™

Portable Radios

TM

TM

RELATED PUBLICATIONS AVAILABLE SEPARATELY

ASTRO Digital SABER User’s Guide ..........................................................................................................................68P81072C80ASTRO Digital SABER Portable Radios Detailed Service Manual .............................................................................68P81076C10

TABLE TITLE PAGE

FIGURE TITLE PAGE

TYPE OF MANUAL MANUAL NUMBER

LIST OF TABLES

LIST OF ILLUSTRATIONS

1 Radio Alignment Test Setup ................................................................................................................................112 RSS Service Menu Layout ...................................................................................................................................123 Softpot Concept ...................................................................................................................................................124 Reference Oscillator Alignment Screen............................................................................................................135 Transmit Power Alignment Screen ...................................................................................................................146 Transmit Deviation Balance (Compensation) Alignment Screen......................................................................157 Transmit Deviation Limit Alignment Screen......................................................................................................168 Front-End Filter Alignment Screen ...................................................................................................................179 Functional Block Diagram.................................................................................................................................2910 Connector Location Details...............................................................................................................................3011 Control Top/PTT Flex and Connector Information............................................................................................3112 Display Flex and Connector Information...........................................................................................................3113 Speaker/Microphone Flex and Connector Information .....................................................................................3214 Universal Flex and Connector Information .......................................................................................................3215 Controller Board/RF Board Connector Information...........................................................................................3316 Controller Board/Encryption Board Connector Information ..............................................................................3317 Exploded View Diagram and Parts List ............................................................................................................34

SECTION VII. BASIC THEORY OF OPERATIONA. Introduction to This Section ..........................................................................................................................23B. General Overview .........................................................................................................................................23C. Analog Mode of Operation ............................................................................................................................23D. ASTRO Mode of Operation...........................................................................................................................23E. RF Board Basic Theory of Operation............................................................................................................23F. Controller Board Basic Theory of Operation .................................................................................................24

SECTION VIII. BOARD-LEVEL TROUBLESHOOTINGA. Introduction to This Section ..........................................................................................................................25B. Replacement Board Procedures...................................................................................................................25C. Power-Up Error Codes..................................................................................................................................25D. Operational Error Codes ...............................................................................................................................26

REPLACEMENT PARTS ORDERING ...........................................................................................................inside back cover

CONTENTS (cont.)

TITLE PAGE

ii

1 ASTRO Digital SABER Basic Features..................................................................................................................12 Recommended Test Equipment.............................................................................................................................53 Service Aids for Board-Level Troubleshooting.......................................................................................................64 Recommended Tools for Board-Level Troubleshooting.........................................................................................65 Initial Equipment Control Settings ..........................................................................................................................76 Test Environments .................................................................................................................................................77 Test Frequencies ...................................................................................................................................................88 Receiver Performance Checks ..............................................................................................................................99 Transmitter Performance Checks ........................................................................................................................1010 Reference Oscillator Alignment............................................................................................................................1311 Transmit Power Setting........................................................................................................................................1412 Transmit Deviation Limit.......................................................................................................................................1613 Torque Specifications...........................................................................................................................................2214 Local Oscillator and First IF Frequencies.............................................................................................................2415 Power-Up Error Code Displays ............................................................................................................................2516 Operational Error Code Displays .........................................................................................................................2617 Receiver Troubleshooting Chart ..........................................................................................................................2618 Transmitter Troubleshooting Chart ......................................................................................................................27

iii

Typical Model Number: H 0 4 U C F 9 P W 7 A N S P 0 1Position: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Position 1 - Type of UnitH=Hand-Held Portable

Positions 2 & 3 - Model Series04=ASTRO

Position 4 - Frequency BandA=Less than 29.7MHz P=336 to 410MHzB=29.7 to 35.99MHz Q=403 to 437MHzC=36 to 41.99MHz R=438 to 482MHzD=42 to 50MHz S=470 to 520MHzF=66 to 80MHz T=Product SpecificG=74 to 90MHz U=806 to 870MHzH=Product Specific V=825 to 870MHzJ=136 to162MHz W=896 to 941MHzK=146 to178MHz Y=1.0 to 1.6GHzL=174 to 210MHz Z=1.5 to 2.0GHzM=190 to 235MHz

* Values given represent range only; they arenot absolute.

Position 5 - Power LevelA=0 to 0.7 WattsB=0.7 to 0.9 WattsC=1.0 to 3.9 WattsD=4.0 to 5.0 WattsE=5.1 to 6.0 WattsF=6.1 to 10 Watts

Position 6 - Physical PackagesA=RF Modem OperationB=Receiver OnlyC=Standard Control; No DisplayD=Standard Control; With DisplayE=Limited Keypad; No DisplayF=Limited Keypad; With DisplayG=Full Keypad; No DisplayH=Full Keypad; With DisplayJ=Limited Controls; No DisplayK=Limited Controls; Basic DisplayL=Limited Controls; Limited DisplayM=Rotary Controls; Standard DisplayN=Enhanced Controls; Enhanced DisplayP=Low Profile; No DisplayQ=Low Profile; Basic DisplayR=Low Profile; Basic Display, Full Keypad

Position 7 - Channel Spacing1=5kHz 5=15kHz2=6.25kHz 6=20/25kHz3=10kHz 7=30kHz4=12.5kHz 9=Variable/Programmable

Position 8 - Primary OperationA=Conventional/SimplexB=Conventional/DuplexC=Trunked Twin TypeD=Dual Mode TrunkedE=Dual Mode Trunked/DuplexF=Trunked Type IG=Trunked Type IIH=FDMA* Digital Dual ModeJ=TDMA** Digital Dual ModeK=Single SidebandL=Global Positioning Satellite CapableM=Amplitude Companded Sideband (ACSB)P=Programmable* FDMA=Frequency Division Multiple Access**TDMA=Time Division Multiple Access

Position 9 - Primary System TypeA=ConventionalB=Privacy Plus®C=Clear SMARTNET™D=Advanced Conventional Stat-Alert™E=Enhanced Privacy Plus®F=Nauganet 888 SeriesG=Japan Specialized Mobile Radio (JSMR)H=Multi-Channel Access (MCA)J=CoveragePLUS™K=MPT1327*-PublicL=MPT1327*-PrivateM=RadiocomN=Tone SignallingP=Binary SignallingQ=Phonenet®W=ProgrammableX=Secure ConventionalY=Secure SMARTNET™* MPT=Ministry of Posts and Telecommunications

Position 10 - Feature Level1=Basic 6=Standard Plus2=Limited Package 7=Expanded Package3=Limited Plus 8=Expanded Plus4=Intermediate 9=Full Feature/5=Standard Package Programmable

Position 11 - VersionVersion Letter (Alpha)-Major Change

Position 12 - Unique Model Variations

C=CenelecN=Standard Package

Positions 13 - 16“SP” Model Suffix

PORTABLE RADIO MODEL NUMBERING SYSTEM

SPECIFICATIONS FOR VHF RADIOSAll specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.

RF Power:

136-174MHz 1Watt/5 Watts


Frequency Range: 136–178MHz†

Frequency Stability

(–30 to +60°C; 25°C ref.): ± .00025%

Emission (Conducted and Radiated): –66dBw

FM Hum and Noise

(Companion Receiver): –45dB Typical

Distortion: 3% Typical

Modulation Limiting: ±5kHz

Emissions Designators:

20K0F1E, 16K0F3E, 15K0F2D,

15K0F1D, and 8K10F1E

Frequency Range: 136–178MHz

Bandwidth: 42MHz

Quieting Sensitivity (20dBQ): 0.5µV Max.

Usable Sensitivity

(12dB SINAD): 0.35µV Max.

Intermodulation: –70dB

Selectivity

(30kHz Adjacent Channel): –70dB

Spurious Rejection: –70dB

Frequency Stability

(–30 to +60°C; 25°C reference): ± .00025%

Rated Audio: 500mW

Distortion (At Rated Audio): 3% Typical

Channel Spacing: 30kHz

GENERAL RECEIVER TRANSMITTER

Specifications subject to change without notice.

FCC Designation: AZ489FT3770

Temperature Range:Operating: –30°C to +60°CStorage: –40°C to +85°C

Power Supply: Nickel-Cadmium Battery (NiCd)or Nickel-Metal-Hydride Battery (NiMH)

Battery Voltage:Nominal: 7.5 VoltsRange: 6 to 9 Volts

Recommended Battery:

Medium Capacity NiCd: NTN4593**

or Ultra –High Capacity NiCd: NTN4595**

or Medium Capacity NiMH: NTN7014

or High Capacity NiMH: NTN7251

Optional FM (Factory Mutual) Battery :

High Capacity FM: NTN4538*/**

or Ultra-High Capacity FM: NTN4596*/**

* FM Intrinsically Safe: Class I, II, III, Division 1,

Groups D, F, and G

** FM Nonincendive: Class I, Division 2,

Groups A, B, C, and D

Dimensions (H x W x D)Note: 2.64" = width at PTT; 2.94" = width at top

Less Battery:5.20" x 2.64"/2.94"x 1.23"

(131.32mm x 67.05/74.67mm x 31.24mm)With Medium Capacity NiCd Battery:

8.34" x 2.94" x 1.28"(211.82mm x 74.67mm x 31.24mm)

With Ultra-High Capacity NiCd Battery:9.10" x 2.94" x 1.23"

(231.12mm x 74.67mm x 31.24mm)With High Capacity NiMH Battery:

8.34" x 2.94" x 1.23"(211.82mm x 74.67mm x 31.24mm)

Weight: (w/Helical Antenna)Less Battery: 12.8oz. (366gm)With Medium Cap. NiCd : 26.81oz. (759gm)With Ultra-High Cap. NiCd: 29.95oz. (849gm)With High Cap. NiMH: 26.3oz. (746gm)

iv

SPECIFICATIONS FOR UHF RADIOSAll specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.

RF Power:



Frequency Range: 450-520MHz†

Frequency Stability

(–30 to +60°C; 25°C ref.): ± .00025%


FM Hum and Noise

(Companion Receiver): –45dB Typical




20K0F1E, 16K0F3E, 15K0F2D,


Frequency Range: 403-520MHz

Bandwidth: 70MHz Max.


Usable Sensitivity(12dB SINAD): 0.35µV Max.


Selectivity(25kHz Adjacent Channel): –70dB

Spurious Rejection:450-512MHz –70dB 512-520MHz –65dB

Frequency Stability(–30 to +60°C; 25°C reference): ± .00025%

Rated Audio: 500mW












Optional FM (Factory Mutual) Battery :




Groups D, F, and G




Less Battery:5.20" x 2.64"/2.94"x 1.23"


8.34" x 2.94" x 1.28"(211.82mm x 74.67mm x 31.24mm)



8.34" x 2.94" x 1.23"(211.82mm x 74.67mm x 31.24mm)




v

SPECIFICATIONS FOR 800MHz RADIOSAll specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.

RF Power: 3 Watts


851–870MHz

Frequency Stability

(–30 to +60°C; 25°C ref.): ± .00015%


FM Hum and Noise

(Companion Receiver): –40dB



(821-824MHz): ±4kHz


20K0F1E, 16K0F3E, 15K0F2D,



Bandwidth: 19MHz


Usable Sensitivity

(12dB SINAD): 0.35µV Max.


Selectivity

(25kHz Adjacent Channel): –70dB

Spurious Rejection: –70dB

Frequency Stability

(–30+60°C; 25°C reference): ±.00015%

Rated Audio: 500mW












Optional FM (Factory Mutual) Battery:




Groups D, F, and G




Less Battery:5.20" x 2.64"/2.94"x 1.23"


8.34" x 2.94" x 1.28"(211.82mm x 74.67mm x 31.24mm)



8.34" x 2.94" x 1.23"(211.82mm x 74.67mm x 31.24mm)




vi

A. General

This manual includes all the information necessaryto maintain peak product performance and maximumworking-time using the board-replacement serviceapproach. This basic level of service (board-level) istypical of some local service centers, self-maintainedcustomers, and some distributors. Included in thismanual are: radio specifications for each frequencyband; a general description of ASTRO™ DigitalSABER™ models; basic theory of operation; recom-mended test equipment, service aids, and tools; radioalignment procedures; fundamental disassembly/reassembly procedures; general maintenance recom-mendations; board-level troubleshooting information;functional block diagram, connector information; andan exploded view diagram with parts list of the ASTRODigital SABER portable radio. For details on the oper-ation of the radio or component-level troubleshooting,refer to the applicable manuals available separately.To help you with your selection, a list is provided inthis manual, titled “Related Publications AvailableSeparately.”

Throughout the text in this publication, you willnotice the use of warnings, cautions, and notes. Thesenotations are used to emphasize that safety hazardsexist, and care must be taken and observed.

NOTEAn operational procedure, practice, or condition,etc., which is essential to emphasize.

B. Radio Description

The ASTRO Digital SABER radios are among themost sophisticated two-way radios available. They areavailable on VHF, UHF, and 800MHz bands.

One of the newest in a long l ine of quality Motorola products, the ASTRO Digital SABER radioprovides improved voice quality across more coveragearea. The digital process called “embedded signalling”intermixes system signalling information with digitalvoice, resulting in improved system reliability and thecapability of supporting a multitude of advanced fea-tures. Such features add up to better, morecost-effective two-way radio communications.

ASTRO Digital SABER radios are available inthree basic models. Table 1 provides a description oftheir basic features.

C.

The ASTRO Digital SABER radio uti l izes Motorola’s revolutionary FLASHport technology.FLASHport makes it possible to add software thatdrives the radio’s capabilities both at the time of pur-chase and later on. Previously, changing a radio’sfeatures and capabilities meant significant modifica-tions, or buying a new radio. But now, similar to how acomputer can be loaded with different software, theradio’s features and capabilities can be upgraded withFLASHport software.

1

SECTION I. INTRODUCTION

Display none 2 lines/ 2 lines/

14 characters 14 characters

per line LCD per line LCD

Keypad none 3 x 2 button 3 x 6 button

Channel Capability 16/32 255 255

Dialing From not available available available

Prestored List

Programmable not available available available

Soft Keys

Feature Model I Model II Model III

Table 1. ASTRO Digital SABER Basic Features

WARNINGAn operational procedure, practice, or condi-tion, etc., which may result in injury or deathif not carefully observed.

CAUTIONAn operational procedure, practice, or condition,etc., which may result in damage to the equip-ment if not carefully observed.

TM

2

NOTES

A. Introduction to This Section

This section of the manual describes preventivemaintenance, handling precautions, and some basicrepair procedures and techniques. Each of these top-ics provides information vital to the successfuloperation and maintenance of your radio.

B. Preventive Maintenance

The ASTRO Digital SABER radios do not require a scheduled preventive maintenance program; howev-er, periodic visual inspection and cleaning isrecommended.

1. Inspection

Check that the external surfaces of the radio areclean, and that all external controls and switchesare functional. A detailed inspection of the interiorelectronic circuitry is not needed.

2. Cleaning

The following procedures describe the recom-mended cleaning agents and the methods to beused when cleaning the external and internal sur-faces of the radio. External surfaces include thefront cover, housing assembly, and battery case.These surfaces should be cleaned whenever aperiodic visual inspection reveals the presence ofsmudges, grease, and/or grime. Internal surfacesshould be cleaned only when the radio is disas-sembled for servicing or repair.

The only recommended agent for cleaning theexternal radio surfaces is a 0.5% solution of a milddishwashing detergent, such as JOY®, in water.The only factory recommended liquid for cleaningthe printed circuit boards and their components isisopropyl alcohol (70% by volume).

a. Cleaning External Plastic Surfaces

(The detergent-water solution should beapplied sparingly with a stiff, non-metallic,short-bristled brush to work all loose dirt awayfrom the radio. A soft, absorbent, lintless clothor tissue should be used to remove the solu-tion and dry the radio. Make sure that nowater remains entrapped near the connectors,cracks, or crevices.

b. Cleaning Internal Circuit Boards and Components

Isopropyl alcohol may be applied with a stiff,non-metallic, short-bristled brush to dislodgeembedded or caked materials located in hard-to-reach areas. The brush stroke should directthe dislodged material out and away from theinside of the radio.

Alcohol is a high-wetting liquid and can carrycontamination into unwanted places if anexcessive quantity is used. Make sure thatcontrols or tunable components are notsoaked with the liquid. Do not use high-pres-sure air to hasten the drying process, sincethis could cause the liquid to puddle and col-lect in unwanted places.

Upon completion of the cleaning process, usea soft, absorbent, lintless cloth to dry the area.Do not brush or apply any isopropyl alcohol tothe frame, front cover, or back cover.

NOTEAlways use a fresh supply of alcohol and aclean container to prevent contamination bydissolved material (from previous usage).

C. Handling Precautions

Complementary metal-oxide semiconductor(CMOS) devices, and other high-technology devices,are used in this family of radios. While the attributes ofthese devices are many, their characteristics makethem susceptible to damage by electrostatic discharge(ESD) 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, trou-bleshooting, and repair. Handling precautions aremandatory for this radio, and are especially importantin low-humidity conditions. DO NOT attempt to disas-semble the radio without observing the followinghandling precautions.

1. Eliminate static generators (plastics, Styrofoam,etc.) in the work area.

2. Remove nylon or double-knit polyester jackets, rollup long sleeves, and remove or tie back loosehanging neckties.

3. Store and transport all static-sensitive devices inESD-protective containers.

4. Disconnect all power from the unit before ESD-sensitive components are removed or insertedunless otherwise noted.

3

SECTION II. BASIC MAINTENANCE

CAUTIONThe effects of certain chemicals and theirvapors can have harmful results on certain plas-tics. Aerosol sprays, tuner cleaners, and otherchemicals should be avoided.

5. Use a static-safeguarded workstation, which canbe accomplished through the use of an anti-statickit (Motorola part number 01-80386A82). This kitincludes a wrist strap, two ground cords, a static-control table mat and a static-control floor mat. Foradditional information, refer to Service and RepairNote SRN-F1052, “Static Control Equipment forServicing ESD Sensitive Products,” available fromLiterature Distribution.

MotorolaLiterature Distribution2290 Hammond DriveSchaumburg, IL 60173

(708) 576-2826

When these items are not readily available,observing the following techniques will minimizechance of damage.

• If a static-sensitive device is to be temporarilyset down, use a conductive surface for place-ment of the device.

• Make skin contact with a conductive work sur-face first and maintain this contact when thedevice is set down or picked up.

6. Always wear a conductive wrist strap when servic-ing this equipment. The Motorola part number fora replacement wrist strap that connects to thetable mat is 42-80385A59.

4

A. Recommended Test Equipment

The list of equipment contained in Table 2 includesall of the standard test equipment required for servic-ing two-way portable radios, as well as several uniqueitems designed specifically for servicing this family of

radios. The “Characteristics” column is included sothat equivalent equipment may be substituted; howev-er, when no information is provided in this column, thespecific Motorola model listed is either a unique itemor no substitution is recommended.

5

SECTION III. RECOMMENDED TEST EQUIPMENT, SERVICE AIDS, AND TOOLS

Table 2. Recommended Test Equipment

Motorola Model Number Description Characteristics Application

R2600 System Analyzer This monitor will substitute Frequency/deviation meter and signalfor items with an asterisk (*). generator for wide-range

troubleshooting and alignment

R1049A* Digital Multimeter Recommended for ac/dc voltageand current measurements

R1150C* Code Synthesizer Injection of audio and digital signalling codes

S1053D* AC Voltmeter 1mV to 300V, 10-MegohmSKN6008A* Power Cable for Meter input impedance Audio voltage measurementsSKN6001A* Test Leads for Meter

R1094A Dual-Trace 20MHz bandwidth Waveform measurementsOscilloscope 5mV to 5V/division

S1350C* Wattmeter 50-ohm, ±5% accuracy Transmitter power outputST1213B (VHF)* Plug-In Element 10 watts, maximum measurementsST1223B (UHF)* RF Dummy Load 0-1000MHz, 300W

R1065 Load Resistor 10-watt Broadband For use with wattmeter

S1339A RF Millivolt Meter 100µV to 3V RF RF-level measurements10kHz to 1.2GHz

R1013A* SINAD Meter Receiver sensitivitymeasurements

S1347D or DC Power Supply 0-20Vdc, 0-5 Amps Bench supply for 7.5VdcS1348D (programmable) current limited

* Any of the R2600 series system analyzers will substitute for items with an asterisk (*).

B. Service Aids and Recommended Tools

Refer to the following tables, “Service Aids forBoard-Level Troubleshooting” and “RecommendedTest Tools for Board-Level Troubleshooting,” for a list-ing and description of the service aids and toolsdesigned specifically for servicing this family of radios,as well as the more common tools required to disas-semble and properly maintain the radio. These kitsand/or parts are available from the Motorola PartsDivision offices listed in the “Replacement PartsOrdering” section located on the inside back cover ofthis manual.

The following table lists service aids recommend-ed for working on this family of radios. While all ofthese items are available from Motorola, most arestandard shop equipment items, and any equivalentitem capable of the same performance may be substi-tuted for the item listed.

C. Field Programming Equipment

This family of radios can be aligned and pro-grammed in the field. This requires specific equipmentand special instructions. Refer to the applicable “RadioService Software User's Guide” for complete fieldprogramming information.

6

RKN-4046A RIB/Radio/Test Set Cable Connects radio to RTX-4005B Test Box and RIB.

RTL-4224A Battery Eliminator Interconnects radio to power supply.

REX-4200A Housing Eliminator/ Provides for troubleshooting of the radio when the housing

(contains REN-4014A Test Fixture is removed. If you have REN-4011A or the

and REN-4011A) REX-4194A (SABER SITM Housing Eliminator), order REN-4014A only.

RTX-4005B or both Portable Test Set Enables connection to the universal connector.

RTX-4005A and RPX-4665A Allows switching for radio testing.

Field Modification Kit

RLN-4008B Radio Interface Box Enables communications between the radio and the

computer's serial communications adapter.

01-80357A57 Wall-Mounted Power Supply Used to supply power to the RIB (120 Vac).

01-80358A56 Wall-Mounted Power Supply Used to supply power to the RIB (220 Vac).

30-80369B71 Computer Interface Cable Use B72 for the IBM PC AT. All other IBM models use B71.

or Connects the computer's serial communications adaptor

30-80369B72 to the RIB.

RVN-4100A Radio Service Software Software on 3-1/2 in. and 5-1/4 in. floppy disks.

58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test equipment.

Motorola Part Number Description Application

Motorola Part Number Description Application

01-80386A82 Anti-Static Used during radio assembly and disassembly procedures.

Grounding Kit

RSX-4043A Roto-Torq Adjustable Used during radio assembly and disassembly procedures.

Torque Screwdriver

66-80370B89 Slotted-Spanner Used during radio assembly and disassembly procedures.

Nut Bit

66-80321B86 #0 Phillips Bit Used during radio assembly and disassembly procedures.

66-80321B79 #1 Phillips Bit Used during radio assembly and disassembly procedures.

66-80371B03 Spanner Nut Bit Used during radio assembly and disassembly procedures.

66-80371B34 Spanner Nut Bit Used during radio assembly and disassembly procedures.

Table 3. Service Aids for Board-Level Troubleshooting

Table 4. Recommended Tools for Board-Level Troubleshooting

SECTION IV. PERFORMANCE CHECKS

7


This section covers performance checks used toverify the radio meets published specifications. Therecommended test equipment listed in the previoussection approaches the accuracy of the manufactur-ing equipment, with a few exceptions. Accuracy of theequipment must be maintained in compliance with themanufacturer’s recommended calibration schedule.

B. Setup

Supply voltage can be connected from the batteryeliminator. The equipment required for alignment pro-cedures is connected as shown in the “RadioAlignment Test Setup” diagram.

Initial equipment control settings should be asindicated in the following table, and should hold for allalignment procedures except as noted in Table 5.

Table 5. Initial Equipment Control Settings

C. Test Mode

1. RF Test Mode

When the ASTRO Digital SABER radio is operat-ing in its normal environment, the radio'smicrocomputer controls the RF channel selection,transmitter key-up, and receiver muting. Howev-er, when the unit is on the bench for testing,alignment, or repair, it is removed from its normalenvironment. It cannot receive commands fromits system and, therefore, the internal microcom-puter will not key the transmitter nor unmute thereceiver. This prevents the use of normal tune-upprocedures. To solve this problem a special rou-tine, called TEST MODE or “air test,” has beenincorporated in the radio.

To enter the test mode:

a. Turn the radio on and adjust the volume for acomfortable llistening level. The volume levelremains constant once in the test mode.

b. Within 10 seconds after the “Self Test” iscomplete, press side button 3 five times insuccession.

c. After “RF TEST” appears, press the top pro-grammable button (normally programmed asthe emergency button) once. “1 CSQ”appears, indicating: test frequency 1, carriersquelch mode.

d. Each additional press of side button 3 willadvance to the next test channel. (Refer toTable 7.)

e. Pressing side button 2 will scroll through and access test environments as shown inTable 6.

NOTETransmit into a load when keying a radiounder test.

Table 6. Test Environments

2. Control Top and Keypad Test Mode

To check the display, the buttons, and the switch-es, perform the following tests:

a. Turn the radio on and adjust the volume for acomfortable llistening level. The volume levelremains constant once in the test mode.

b. Within 10 seconds after the “Self Test” iscomplete, press side button 3 five times insuccession.

c. After “RF TEST” appears on the display,press side button 1 once, “CH TEST” (14-character radio) appears on the display.

d. Next, press and hold the top programmablebutton; all segments on the display will light,and the LED on the control top will illuminatea red color.

e. Release the top programmable button; “3/0”appears, which indicates that the top pro-grammable button is in the open condition.

Monitor Mode: Pwr Mon Spkr set: A Voltage: 7.5Vdc

RF Attn: –70dB Spkr/load: DC on/standby:Speaker Standby

AM, CW, FM: FM PTT: OFF Volt Range: 10Vdc(center)

O'scope Source: Mod Current: 2.5AmpsO'scope Horiz: 10mSec/DivO'scope Vert: 2.5kHz/DivO'scope Trig: AutoMonitor Image: HiMonitor BW: NarMonitor Squelch: mid CWMonitor Vol: 1/4 CW

CSQ Carrier Squelch RX:unsquelch if carrier detectedTX: mic audio

TPL Tone RX:unsquelch if carrier and tonePrivate-Line (192.8 Hz) detected

TX: mic audio + tone (192.8 Hz)

AST ASTRO RX:noneTX: 1200Hz tone *

System Analyzer Test Set Power Supply Display Description Function

* All deviation values are based on deviation tuning of this mode.

f. Press the top programmable button again;“3/1” appears, which indicates that the top programmable button is in the closed condition.

g. Rotate the mode/zone selector switch; “4/0”through “4/15” appears, which indicates thatthe selector switch is in mode/zone position 1 through 15.

h. Rotate the two-position (A/B) switch; “65/0”and “65/1” appears.

i. Rotate the two-position programmable switch(concentric with the top programmable but-ton); “67/3” and “67/0” appear.

j. Rotate the volume control; “2/0” through“2/255” appear.

k. Press side button 1, “96/1” appears; release,“96/0” appears.

l. Press side button 2, “97/1”appears; release,“97/0” appears.

m. Press side button 3, “98/1”appears; release,“98/0” appears.

n. Press the PTT switch, “1/1” appears; release,“1/0” appears.

Keypad Checks:

• Press 0, “48/1” appears; release, “48/0”appears.










• Press *, “58/1” appears; release, “58/0”appears.

• Press #, “59/1” appears; release, “59/0”appears.

• Press , “128/1” appears; release,

“128/0” appears.

• Press HOME, “129/1” appears; release,“129/0” appears.

• Press , “130/1” appears; release, “130/0”appears.

• Press the left-hand • key on the top row ofkeys, “131/1” appears; release, “131/0”appears.

• Press the center • key, “132/1” appears;release, “132/0” appears.

• Press the right-hand • key, “133/1” appears;release, “133/0” appears.

8

TX #1 136.025 403.100 450.025 806.0125

RX #1 136.075 403.150 450.075 851.0625

TX #2 142.125 424.850 465.225 815.0125

RX #2 142.075 424.900 465.275 860.0625

TX #3 154.225 438.050 475.225 824.9875

RX #3 154.275 438.100 475.275 869.9375

TX #4 160.125 444.050 484.975 851.0125

RX #4 160.175 444.100 485.025 851.0625

TX #5 168.075 456.350 500.275 860.0125

RX #5 168.125 456.400 500.225 860.0625

TX #6 173.975 463.700 511.975 869.9875

RX #6 173.925 463.750 511.925 869.9375

TX #7 177.975 469.650 519.975 None

RX #7 177.925 469.700 519.925 None

Table 7. Test Frequencies

Test Channel VHF UHF Band 1 UHF Band 2 800MHz

9

Reference Mode: PWR MON TEST MODE, PTT to continuous Frequency error to be ≤ ±600HzFrequency 4th channel test frequency❖ 4 CSQ (during the

Monitor: Frequency error output at performance check)Input at RF In/Out antenna

Rated Audio Mode: GEN TEST MODE, PTT to OFF (center), Set volume control toOutput level: 1.0mV RF 4 CSQ meter selector to 3.74Vrms4th channel test frequency❖ Audio PAMod: 1kHz tone at3kHz deviationMonitor: DVM: ac Volts

Distortion As above, except to As above As above Distortion < 3.0%distortion

Sensitivity As above, except SINAD, As above PTT to OFF (center) RF input to be < 0.35µV(SINAD) lower the RF level for 12dB

SINAD

Noise Squelch RF level set to 1mV RF As above PTT to OFF (center), Set volume control toThreshold meter selection to 3.74Vrms(only radios with Audio PA, spkr/loadconventional to speakersystem needto be tested) As above, except change Out of TEST As above Unsquelch to occur at < 0.25µV

frequency to a conventional MODE; select a system. Raise RF level from conventional zero until radio unsquelches. system Preferred SINAD = 8-10dB

Table 8. Receiver Performance Checks

❖ (See Table 7.)

Test SystemName Analyzer Radio Test Set Comments Name

10

Reference Mode: PWR MON TEST MODE, PTT to continuous Frequency error to be ≤ ±600Hz.Frequency 4th channel test frequency❖ 4 CSQ (during the

Monitor: Frequency error performance check).Input at RF In/Out

Power RF As above As above, 4 CSQ As above Refer to Maintenance Specifica-tions page in front of manual.

Voice Mode: PWR MON As above, 4 CSQ As above, meter Deviation:Modulation 4th channel test frequency❖ selector to mic VHF, UHF, and 800MHz:

atten to –70, input to RF In/Out, ≥ 3.6kHz but ≤ 5.0kHzMonitor: DVM, ac VoltsSet 1kHz Mod Out level for0.025Vrms at test set,80mVrms at ac/dc test set jack

Voice Mode: PWR MON TEST MODE, Remove modulation Press PTT switch on radio.Modulation 4th channel test frequency❖ 4 CSQ, input Say “four” loudly into the(internal) atten to –70, input to RF In/Out output at antenna radio mic. Measure deviation:

VHF, UHF, and 800MHz:≥ 3.8kHz but ≤ 5.0kHz

PL Change frequency to a Conventional coded As above Deviation:Modulation conventional transmit squelch personality VHF, UHF, and 800MHz:(radios with frequency, BW to narrow (clear mode ≥ 500Hz but ≤ 1000Hzconventional, operation)clear mode, 4 TPLcoded squelchoperation only)

Talkaround Change frequency to conven- Conventional As above Deviation:Modulation tional talk-around frequency. talk-around UHF and 800MHz: ≥ 3.8kHz(radios with Mode: PWR MON personality but ≤ 5.0kHzconventional, deviation, attenuation to –70, (clear modeclear mode, input to RF In/Out operation)talk-around Monitor: DVM, ac volts 1 CSQoperation only) Set 1kHz Mod Out level for

25mVrms at test set.

Talkaround Change frequency to conven- Conventional As above Deviation:Modulation tional talk-around frequency. talk-around UHF and 800MHz: ≥ 3.6kHz(radios with Mode: PWR MON personality but ≤ 4.4kHzconventional, deviation, attenuation to –70, (secure modesecure mode, input to RF In/Out operation)talk-around Monitor: DVM, ac volts Load key intooperation only) Mod: 1kHz out level for radio(**) 25mVrms at test set. 1 sec.

Table 9. Transmitter Performance Checks

* 800MHz radios only** The secure mode, talkaround modulation test is only required for trac mode radios which do not have clear mode talkaround capability.❖ See Table 7.

Test SystemName Analyzer Radio Test Set Comments Name


This section describes both receiver and transmit-ter radio alignment procedures.

B. General

An IBM personal computer (PC) and radio servicesoftware (RSS) are required to align the radio. Referto the applicable RSS manual for installation andsetup procedures for the software. To perform thealignment procedures, the radio must be connected tothe PC, radio interface box (RIB), and a universal testset as shown in Figure 1.

11

SECTION V. RADIO ALIGNMENT PROCEDURE

BNC

RIBRLN-4008B

RIB POWER SUPPLY01-80357A57 (120V)

COMPUTER INTERFACECABLE

30-80369B7130-80369B72 (IBM "AT" ONLY)

DATABUSYGND

COMPUTER

AUDIO GENERATOR

SINAD METER

AC VOLTMETER

TX

RX

30 dB PAD

30 dB PAD

RF GENERATOR

SYSTEM ANALYZEROR COUNTER

WATTMETER

BATTERYELIMINATORRTL-4224A

TRANSMIT

RECEIVE

TEST SETRTX-4005B

RADIO

PROGRAM/TEST CABLERKN-4046A

AUDIO IN

SET TO APPROX. 450mV FOR Tx

MEASURE 80mV FOR Tx

SMA-BNC58-80348B33

Figure 1. Radio Alignment Test Setup

MAEPF-23413-O

All service and tuning procedures are performedfrom the SERVICE menu, which is selected by press-ing F2 from the MAIN MENU. Figure 2 illustrates howthe RSS alignment SERVICE screens are organized.

Figure 2. RSS Service Menu Layout

All SERVICE screens read and program the radiocodeplug directly; you do NOT have to use the RSSGET/SAVE functions to use the SERVICE menus.

The SERVICE screens introduce the concept ofthe “softpot,” an analog SOFTware controlled POTen-tiometer used for adjusting all transceiver alignmentcontrols.

Each SERVICE screen provides the capability toincrease or decrease the ‘softpot’ value with the keyboard UP/DOWN arrow keys respectively. Agraphical scale is displayed indicating the minimum,maximum, and proposed value of the softpot, asshown in Figure 3.

Figure 3. Softpot Concept

Adjusting the softpot value sends information tothe radio to increase (or decrease) a dc voltage in thecorresponding circuit. For example, pressing the UParrow key at the Reference Oscillator screen instructsthe radio’s microcomputer to increase the voltageacross a varactor in the reference oscillator, whichincreases the frequency.

In ALL cases, the softpot value is just a relativenumber corresponding to a digital-to-analog (D/A)generated voltage in the radio.

12

REFERENCE OSCILLATOR ALIGNMENT

TRANSMIT POWER ALIGNMENT

TRANSMITTER ALIGNMENT MENU

TRANSMIT DEVIATION BALANCE (COMPENSATION) ALIGNMENT

TRANSMIT DEVIATION LIMIT ALIGNMENT

F2 -

F2 -

F3 -

F4 -

F5 -

RECEIVER ALIGNMENT MENUF3 -

FRONT END BANDPASS FILTER ALIGNMENTF2 -

SERVICE

HELPF1 -

EXIT, RETURN TO SERVICE MENUF10 -

MAEPF-23414-O

CAUTIONDo NOT switch radios in the middle of any SER-VICE procedure. Always use the EXIT key toreturn to the MAIN menu screen before discon-necting the radio. Improper exits from theSERVICE screens may leave the radio in animproperly configured state and result in seri-ously degraded radio or system performance.

MAEPF 22858 O

Min.Value

Max.Value

0 15

MAEPF-22858-O

Perform the following procedures in thesequence indicated.

NOTESome of the following screens may vary dependingupon the radio under test and the version of radioservice software you are using. Refer to your radioservice software user’s guide.

C. Reference Oscillator Alignment

Adjustment of the reference oscillator is critical forproper radio operation. Improper adjustment will resultnot only in poor operation, but also in a misalignedradio that will interfere with other users operating onadjacent channels. For this reason, the referenceoscillator should be checked every time the radio isserviced. The frequency counter used for this proce-dure must have a stability of 0.1 ppm (or better).

1. From the SERVICE MENU, press F2 to select theTRANSMITTER ALIGNMENT MENU.

2. Press F2 again to select the REFERENCEOSCILLATOR alignment screen. See Figure 4.

3. Press Tab (or Enter or Return ) to select a fre-quency field (starting with the highest frequencyshown). Then, press F6 to key the radio. Thescreen will indicate that the radio is transmitting.

4. Measure the transmit frequency on your servicemonitor.

5. Use the UP/DOWN arrow keys to adjust the refer-ence oscillator softpot value. See Table 10.

6. Press F6 again to dekey the radio.

7. Press F8 to program the new softpot value.

8. Repeat steps 3-7 for the remaining frequencies.

9. Press F10 once to return to the TRANSMITTERALIGNMENT MENU, or press F10 twice to returnto the SERVICE MENU.

13

MOTOROLA Radio Service SoftwareASTRO Model: H04UCH9PW7AN

MAIN:SERVICE:TX ALIGN:REF OSC

Use UP/DOWN Arrows To Adjust Softpot.

F1HELP

F2 F3 F4 F5 F6TOGGLE

PTT

F7 F8PROGRAM

VALUE

F9 F10EXIT

REFERENCE OSCILLATOR

Frequency Current Value

869.9875 150 New Softpot Value ....................150

Transmitter........On0

Min255Max

Figure 4. Reference Oscillator Alignment Screen

Band Target

VHF ±150Hz

UHF ±150Hz

800MHz ±150Hz

Table 10. Reference Oscillator Alignment

D. Transmit Power Alignment

NOTE• All power measurements are to be made at the

antenna port.

• The transmitter power setting keeps the radiat-ed power at or below the level specified in theexclusionary clause for low power devices ofIEEE Standard C95.1-1991.


2. Press F3 to select the TRANSMIT POWER align-ment screen. The screen will indicate the transmitfrequencies to be used. See Figure 5.

3. Press Tab (or Enter or Return ) to select a fre-quency field (starting with the highest frequencyshown). Then, press F6 to key the radio. Thescreen will indicate that the radio is transmitting.

4. Use the UP/DOWN arrow keys to adjust the trans-mit power per the values shown in Table 11.

5. Press F6 to dekey the radio.

6. Press F8 to program the value.



14

TRANSMIT POWER

Current Value New Softpot ValueFrequency High Pwr Low Pwr High Pwr Low Pwr806.00000 35 35 10 23815.00000 42 42 11 28824.00000 50 50 20 33851.00000 60 60 33 40860.00000 70 70 43 45869.00000 80 80 58 58

Transmitter..........On


MAIN:SERVICE:TX ALIGN:TX POWER


F1HELP


PTT

F7 F8PROGRAM

VALUE

F9 F10EXIT

0Min

127Max

Figure 5. Transmit Power Alignment Screen

Table 11. Transmit Power Setting

Test Frequencies

VHF Power Level 136-174MHz 174-178MHz

1W 1.2 -1.4 1.2 - 1.4

5W 5.2 - 5.4 4.2 - 4.4

1W 1.2 -1.4 1.2 - 1.4

4W 4.2 - 4.4 3.2 - 3.4

3W 3.2 -3.4

Test Frequencies

UHF Power Level 450-512MHz 512-520MHz

800MHz Power Level All Test Frequencies

E. Transmit Deviation Balance (Compensation) Alignment

Compensation alignment balances the modulationsensitivity of the VCO and reference modulation (syn-thesizer low-frequency port) lines. The compensationalgorithm is critical to the operation of signallingschemes that have very-low-frequency components(for example, DPL) and could result in distorted wave-forms if improperly adjusted.


2. Press F4 to select the TRANSMIT DEVIATIONBALANCE (COMPENSATION) alignment screen.The screen will indicate the transmit frequenciesto be used. See Figure 6.

3. Press Tab (or Enter or Return ) to select a fre-quency field (starting with the lowest frequencyshown).

4. Press F4. This will cause the radio to key and theradio’s DSP IC to inject an 80Hz tone into the RFboard.

5. Measure the deviation and record this value.

6. Press F4 to dekey the radio.

7. Press F6. This will cause the radio’s DSP IC tochange the injection tone to 3kHz, 100mVrms.Use the UP/DOWN arrow keys to adjust the devia-tion to within ±2% of the value recorded in step 5.

8. Repeat steps 4-7 until the 3kHz tone deviation iswithin ±2% of the 80Hz tone deviation.





15


MAIN:SERVICE:TX ALIGN:BAL ATTN


F1HELP

F2 F3 F4TOGGLE LOW

TONE PTT

F5 F6TOGGLE HIGH

TONE PTT

F7 F8PROGRAM

VALUE

F9 F10EXIT

TRANSMIT DEVIATION BALANCE (COMPENSATION)

CurrentFrequency Value New Softpot Value

450.62500 30 30465.22500 30 30475.22500 30 30484.97500 45 45500.27500 45 45511.97500 45 45

Transmitter ..............Off

0Min

63Max

Figure 6. Transmit Deviation Balance (Compensation) Alignment Screen

F. Transmit Deviation Limit Alignment

IMPORTANT NOTEPut the radio in the RF test mode and scroll to theASTRO test environment, indicated by “AST” onthe display (refer to the "Performance Checks" sec-tion for details). All other deviation values arederived from the ASTRO test environment modetransmit deviation limit.


2. Press F5 to select the TRANSMIT DEVIATIONLIMIT alignment screen. The screen will indicatethe transmit frequencies to be used. See Figure 7.

3. Press Tab (or Enter or Return ) to select a fre-quency field (starting with the lowest frequencyshown).

4. Press F6 to key the radio. Then use theUP/DOWN arrow keys to adjust for a deviation perthe values shown in Table 12.


6. Press F8 to program the softpot value.



16


MAIN:SERVICE:TX ALIGN:VCO ATTN


TRANSMIT DEVIATION LIMIT

CurrentFrequency Value New Softpot Value

450.02500 175 175465.22500 175 175475.22500 180 180484.97500 180 180500.27500 180 180511.97500 180 180

Transmitter ..............Off

F1HELP


PTT

F7 F8PROGRAM

VALUE

F9 F10EXIT

0Min

255Min

Figure 7. Transmit Deviation Limit Alignment Screen

Table 12. Transmit Deviation Limit

VHF 2785-2885

UHF 2785-2885

800MHz 2785-2885

Band Deviation (Hz)

G. Front-End Filter Alignment (VHF/UHF Only)

NOTEThis procedure is only required for tuning the front-end filter varactors in the VHF and UHF models.The 800MHz models utilize a fixed front-end filter.

1. From the SERVICE MENU, press F3 to select theRECEIVER ALIGNMENT MENU.

2. Press F2 to select the FRONT END FILTERALIGNMENT screen. The screen will indicate thereceive frequencies at which the filter is to bealigned. See Figure 8.

3. Press Tab (or Enter or Return ) to select a fre-quency field.

4. Set the RF test generator to the first receive frequency +150Hz. Set the RF level at the radio standard antenna port to 4.0µV with no modulation.

5. Adjust the UP/DOWN arrow keys to obtain a peakvalue in the RSSI (receive signal strength indica-tor) field. Note F4 must be pressed to obtain eachRSSI reading after adjustment.



8. Press F10 once to return to the RECEIVERALIGNMENT MENU, or press F10 twice to returnto the SERVICE MENU.

17


MAIN:SERVICE:RX ALIGN:FE FL


FRONT END FILTER ALIGNMENT

CurrentFrequency Value New Softpot Value RSSI. . . .0

450.02500 0 0465.22500 0 0475.22500 0 0484.97500 0 0500.27500 0 0511.97500 0 0519.97500 0 0

F1HELP

F2 F3 F4READRSSI

F5F6 F7 F8

PROGRAMVALUE

F9 F10EXIT

0Min

255Max

Figure 8. Front-End Filter Alignment Screen

18

NOTES

A. Disassembly

(Refer to the following diagrams and the explodedview diagram located in the back of this manual.)

1. Turn off the radio by rotating the on/off/volumecontrol fully counterclockwise until you hear aclick. Remove the accessory connector cover orany accessory connected to the radio beforebeginning disassembly.

2. Remove the battery from the baseplate on thebottom of the radio housing by pushing the spring-loaded battery latch toward the top of the radio,and sliding the battery away from the latch until itclears the baseplate.

3. Loosen the two slotted-spanner nuts on the bottom of the radio using the ROTO-TORQadjustable torque screwdriver with bit No. 66-80370B89. When loosened, the slotted-span-ner nuts are captive and will spin freely withoutseparating from the baseplate.

4. Remove the chassis from the radio housing bygrasping the antenna at its base and pulling itgently upward. Do not depress the PTT switchduring removal and do not push on the slotted-spanner nuts to remove the chassis.

19

SECTION VI. DISASSEMBLY/REASSEMBLY PROCEDURES

CAUTIONBefore attempting any disassembly or reassem-bly of the radio, observe the handlingprecautions described in the “Basic Mainte-nance” section of this manual.

A B

ON/OFF/VOLUMECONTROL

ILLUSTRATOR ENDATE

LETTERINGREQUIRES

EDITOR CHDATE

EH 11/10/92

11/20/92JWB

MAEPF-23372-O

BATTERYLATCH

REMOVALDIRECTION

INSERTIONDIRECTION

BATTERY

BASEPLATE

MAEPF-20185-O

66-80370B89SLOTTED-SPANNER NUT BIT

SLOTTED-SPANNERNUTS

RSX-4043AROTO-TORQ ADJUSTABLETORQUE SCREWDRIVER

DESCRIPTION

DRAWN: AISSLETTERING SIZE:

REQUIRES:RE

MA

O

SYSTEM ASTRO DIGITAL SABERUHF LOOSEN SPANNER NUTS

MAEPF-23373-O

MAEPF-23373-O created

MAEPF-23373-O

BASE OFANTENNA

LETTERING SIZREQUIRES:

MAEPF-23374-O

5. Gently push the center bottom edge of the frontshield assembly and lift it away from the bottomof the chassis. If necessary, use a small slottedscrewdriver to disengage the two retaining clipsnear the bottom outer edges. Next, pull the frontshield assembly out from under the plastic toppanel. Be careful not to pull against the flexible cir-cuits connecting to the controller board.

6. Disconnect the display flexible circuit (Models IIand III only) and the speaker/microphone flexi-ble circuit from the controller board by pulling therespective connector plugs out and away from thecontroller board and shield assembly. The connec-tor plugs are covered with a protective rubberizedpad. Also, disconnect the control top/PTT flexi-ble circuit from the controller board by pulling upand rotating the flex connector plug out and awayfrom the controller board and shield assembly.The connector plug is covered with a protectiverubberized pad.

7. Using a ROTO-TORQ adjustable screwdriver toolwith a Phillips bit #0 point size (Motorola part num-ber 66-80321B86), remove the four controllershield screws. Next, gently pry the controllershield up and out of the chassis by inserting thetip of a thin slotted screwdriver between the chas-sis and the controller shield at each of the threethin-walled chassis points (see diagram below).

After the controller shield is freed, remove the controller board from the chassis by gentlyapplying upward pressure on the black 15-pin connector.

20

CHASSISASSEMBLY

TOP PANELFRONT SHIELD

ASSEMBLY

MAEPF-23375-O

DISPLAY FLEXIBLE CIRCUITCONNECTOR PLUG (MODELS II AND III)

SPEAKER/MICROPHONEFLEXIBLE CIRCUITCONNECTOR PLUG

CONTROL TOP/ PTTFLEXIBLE CIRCUITCONNECTOR PLUG

MAEPF-23376-O

CAUTIONTo avoid damage to the control top/PTT flexiblecircuit, DO NOT insert the screwdriver tip nearthe flexible circuit connector or the dual-functionswitch. Insert the tip of the slotted screwdriveronly at the thin-walled chassis points shownbelow.

CHASSISCASTING THIN

WALL POINTS (3)

CONTROLLERBOARD

(UNDER SHIELD)

DUAL-FUNCTIONSWITCH HOUSING

MAE

CONTROLLER SHIELDSCREWS (4)

CONTROLLERSHIELD

66-80321B86PHILLIPS BIT

15-PINCONNECTOR

(THIS END)

MAEPF-23377-O

8. Remove the center shield from the chassis byinserting a thin slotted screwdriver between eachof five center-shield release clips and the corre-sponding chassis-retaining tabs.

Once freed from the chassis at the five releasepoints, the center shield can be removed and theRF board can be removed from the chassis.

B. Servicing Major Subassemblies

Refer to the exploded view diagram at the back ofthis manual before attempting further disassembly orrepair.

1. Baseplate

• All repairs to the baseplate assembly can, andshould, be made with the radio chassis insidethe radio.

• After the slotted-spanner nuts are loosened,the baseplate is held in place by the powercontact screw.

• The retainers holding the slotted-spanner nutsin place are not reusable. Replacement of theretainers requires special insertion proce-dures; refer to the instruction sheet providedwith the slotted-spanner nut kit.

• The "O-ring" portion of the elastomer sealmust be fully seated on the threaded bushingbefore the baseplate is reassembled (thebushing is part of the housing assembly).

2. Housing Assembly

• The housing assembly includes many partsthat are not replaceable or repairable.

• The insulator on the universal connector can,and should, be replaced if the old insulatorhas been torn. When replacing the insulatortake care to keep it out of the main-seal O-ring's seating area.

• The PTT lever can be replaced by prying outthe old part with a soft plastic tool. The plastichousing around the lever may be damaged ifa harder tool is used.

3. Control Top Panel

The control top panel is fastened to the chassis bythe on/off/volume control, mode/zone selectorswitch, programmable switch, and antenna switch;it should be removed from the chassis only ifabsolutely necessary.

4. Front Shield/Display Board Assembly

The ASTRO Digital SABER radio's display boardcan be replaced, but the comments and cautionsin this manual must be strictly followed. To removethe display board from the front shield assembly:

a. ensure that all static safeguards are in effect;

b. turn the front shield/display board assemblyface down;

c. with slight upward pressure on the LCD bezel,bend back each of the two plastic tabs thathold the display board in place, and the bot-tom of the LCD will come loose;

d. push the LCD from its secured posit ionenough to grasp its edges, then pull firmly upand out on the front shield/display boardassembly.

5. Chassis

If you must lift or remove the control top/PTT flexi-ble circuit for any reason, do not re-adhere it to thechassis; the flexible circuit must be replaced.

6. Dual-Function Switch and Actuator Assembly

• Before removing the switch, remove the knobby gently separating the two arms of theswitch bracket (located between the switchand the main O-ring seal) and pulling upwardon the knob.

• Before re-inserting the knob, ensure that theslot in the switch is properly aligned with theblade on the knob's shaft.

21

CAUTIONUse extreme caution to ensure that the releaseclips are only deflected enough to disengagethe clip from the chassis. Too much pressure onthe clips could permanently damage the retain-ing feature.

CHASSIS WITHRF BOARD ASSEMBLY

MAEPF-23378-O

CENTER SHIELDRELEASE POINTS

(5)

CENTER SHIELD (UNDERNEATH)

MAEPF-23378-O

CAUTIONThe RF and ground contacts at the top of the RFboard are exposed when the board is removedfrom the chassis. Special care must be taken toavoid accidental damage to these contacts.

CAUTIONBe very careful not to damage the keyswitchoverlay which is adhesively attached to theLCD bezel.

• When the knob is properly inserted, the armsof the switch bracket will snap into position(approximately 0.2 inches apart), the knob willnot be loose in the switch bracket, and thebracket will hold the switch firmly against theinside of the top control panel. If this is not thecase, replace the switch bracket.

C. Reassembly

Reassemble the radio in the reverse order of disassembly, referring to "Servicing Major Subassem-blies" (paragraph B) and making certain:

1. that the protruding block that functions as the PAheatsink (inside back casting), is coated with athin film of thermal compound (Motorola part num-ber 11-10022A55), which helps provide maximumheat transfer;

2. that the RF board is properly seated in the chas-sis, and that when inserted, the five locking tabson the center shield are engaged with the chassis;

3. that when the controller board is reinstalled overthe center shield and mated to the RF board, theconnector plug of the controller is pressed firmlyinto the connector jack of the RF board (the twoboards should snap together);

4. that when installed, the four controller shieldscrews are torqued per specifications;

5. that the control top/PTT flex plug, speaker/micro-phone flex plug, and display flex plug have allproperly mated with their corresponding connectorjacks;

6. that the keyswitch overlay is pressed firmlyagainst the LCD metal bezel of the front shieldassembly;

7. that there is no foreign material on the main O-ringor stud seals;

8. to properly orient the completed chassis assemblybefore inserting it into the radio housing;

9. that the PTT switch and monitor button are notdepressed while the chassis is being inserted intothe housing;

10. that the slotted-spanner nut closest to the batterylatch is torqued first, then torque the other to theproper specification listed in Table 13.

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CAUTIONInspect the chassis stud seals and the controltop panel O-ring and replace if any damageexists.

Table 13. Torque Specifications

Application Torque Torque Torque(in -lbs) (N•m) Bit Part No.

RX/TX Switch Spanner Nut 20 2.27 66-80371B34Frequency Switch Spanner Nut 8 0.91 66-80371B03Power Contact Screws 2.5 0.28 66-80321B79Slotted-Spanner Nut (Baseplate) 6 0.68 66-80370B89Volume Pot Spanner Nut 8 0.91 66-80371B03Controller Shield Screws 2.8 0.32 66-80321B86

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SECTION VII. BASIC THEORY OF OPERATION


The following theory will help isolate the problemto a particular board. Using circuit board replacementas the basic service approach will maximize working-time of the radio.

B. General Overview

The ASTRO Digital SABER radio is a wideband,synthesized, f ixed-tuned radio available in the VHF, UHF, and 800MHz bands. All ASTRO DigitalSABER radios are capable of both analog operation and ASTRO mode (digital) in 12.5kHz or 25kHz bandwidths.

The ASTRO Digital SABER radio consists of fourmajor assemblies. They are:

• Controller Board - contains the microcontrol unit(MCU) and its associated memory and memorymanagement integrated circuit (IC), the digital sig-nal processor and its associated memories andsupport IC, the audio power amplifier, and aswitching regulator.

• RF Board - contains all transmit, receive, and fre-quency generation circuitry including the digitalreceiver back-end IC and the reference oscillator.

• Display/Keypad Assemblies - contain the inter-nal microphone and speaker, a two-line liquidcrystal display (LCD), and a 3 x 6 keypad.

• Control Top - contains switches for volume andmode selection, push-to-talk (PTT), monitor, andseveral function-selectable switches.

C. Analog Mode of Operation

When the radio is receiving, the signal comes fromthe antenna/antenna-switch connector to the RFboard, passes through the RX/TX switch and thereceiver front end. The signal is then filtered, ampli-fied, and mixed with the first local-oscillator signalgenerated by the voltage-controlled oscillator (VCO).The resulting intermediate frequency (IF) signal is fedto the IF circuitry, where it is again filtered and ampli-fied. This amplified signal is passed to the digitalback-end IC, where it is mixed with the second localoscillator to create the second IF at 450kHz. It is thenconverted to a digital bit stream and mixed a third timeto produce a baseband signal. This signal is passed tothe controller board through a current-driven differen-tial output. On the controller board, the digital-signal-processor-support IC digitally filters and dis-

criminates the signal, and passes it to the digital-signalprocessor (DSP). The DSP decodes the information inthe signal and identifies the appropriate destination forit. For a voice signal, the DSP will route the digitalvoice data to the DSP-support IC for conversion to ananalog signal. The DSP-support IC will then presentthe signal to the audio power amplifier, which drivesthe speaker. For signall ing information, the DSP will decode the message and pass it to themicrocontrol unit.

When the radio is transmitting, microphone audiois passed from the audio power amplifier (PA) to theDSP-support IC, where the signal is digitized. TheDSP-support IC passes digital data to the DSP, wherepre-emphasis and low-pass (splatter) filtering aredone. The DSP returns this signal to the DSP-supportIC, where it is reconverted into an analog signal andscaled for application to the voltage-controlled oscilla-tor as a modulation signal. Transmitted signallinginformation is accepted by the DSP from the micro-control unit, coded appropriately, and passed to theDSP-support IC, which handles it the same as a voicesignal. Modulation information is passed to the synthe-sizer along the modulation line. A modulated carrier isprovided to the RF PA, which transmits the signalunder dynamic power control.

D. ASTRO Mode of Operation

In the ASTRO mode (digital mode) of operation,the transmitted or received signal is limited to a dis-crete set of deviation levels, instead of continuouslyvarying. The receiver handles an ASTRO-mode signalidentically to an analog-mode signal up to the pointwhere the DSP decodes the received data. In theASTRO receive mode, the DSP uses a specificallydefined algorithm to recover information. In theASTRO transmit mode, microphone audio is pro-cessed identically to an analog mode with theexception of the algorithm the DSP uses to encode theinformation. This algorithm will result in deviation lev-els that are limited to discrete levels.

E. RF Board Basic Theory of Operation

The receiver front end consists of a preselector,an RF amplifier, a second preselector, and a mixer.Both preselectors in the VHF and UHF radios are var-actor-tuned, two-pole f i l ters controlled by themicrocontrol unit through the digital/analog (D/A) IC.On the 800MHz receiver front end, these filters arefixed-tuned. The RF amplifier is a dual-gate, gallium-arsenide based IC. The mixer is a double-balanced,

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active mixer coupled by transformers. Injection is pro-vided by the VCO through an injection filter. See Table14 for local oscillator (LO) and first IF information.

The frequency generation function is performed bythree ICs and associated circuitry. The reference oscil-lator provides a frequency standard to thesynthesizer/prescaler IC, which controls the VCO IC.The VCO IC actually generates the first LO and trans-mit-injection signals and buffers them to the requiredpower level. The synthesizer/prescaler circuit moduleincorporates frequency-division and comparison cir-cuitry to keep the VCO signals stable. Thesynthesizer/prescaler IC is controlled by the microcon-trol unit through a serial bus. Most of the synthesizercircuitry is enclosed in rigid metal cans on the RFboard to reduce microphonic effects.

The receiver back end consists of a two-pole crys-tal filter, an IF amplifier, a second two-pole crystalfilter, and the digital back-end IC. The two-pole filtersare wide enough to accommodate 5kHz modulation.Final IF filtering is done digitally in the DSP-supportIC.

The digital back-end IC consists of an amplifier,the second mixer, an IF analog-to-digital converter, abaseband down-converter, and a 2.4MHz synthesiscircuit to provide a clock to the DSP-support IC on thecontroller board. The second LO is generated by dis-crete components external to the IC. The output of thedigital back-end IC is a digital bit stream that is currentdriven on a differential pair for a reduction in noisegeneration.

The transmitter consists of an RF PA IC that getsan injection signal from the VCO. Transmit power iscontrolled by two custom ICs that monitor the output ofa directional coupler and adjust PA control voltagescorrespondingly. The signal passes through a RX/TXswitch that uses PIN diodes to automatically providean appropriate interface to transmit or receive signals.Antenna selection is done mechanically in the controltop.

F. Controller Board Basic Theory of Operation

The controller board contains the radio’s micro-control unit with its memory and support circuits,voltage regulators, audio, DSP, and power control cir-cuits. Connected to the controller board are thedisplay board, RF board, and control top.

The microcontrol unit controls receive/transmit fre-quencies, power levels, display, and other radiofunctions, using either direct logic control or serialcommunications paths to the devices.The microcontrolunit executes a stored program located in the FLASHROM. Data is transferred to and from memory by themicrocontrol unit data bus. The memory location fromwhich data is read, or to which data is written, isselected by the address lines.

The support-logic IC acts as an extension of themicrocontrol unit by providing logic functions such aslower address latch, reset, memory address decoding,and additional control lines for the radio. The micro-control unit controls the crystal-pull circuit to adjust thecrystal oscillator’s frequency on the microcontrol unit,so that the E-clock’ s harmonics do not cause interfer-ence with the radio’s receive channel.

The regulator and power-control circuits includean unswitched +5V discrete circuit and theregulator/power-control IC. Switched +5V is used forall circuits on the controller board except the audio PA,which is sourced from 7.5V. The regulator automati-cally provides 5V when the radio is turned on. Theregulator’s power-down mode is controlled by themicrocontrol unit, which senses the position of theon/off switch.

The DSP performs signalling and voice encodingand decoding as well as audio filtering and volumecontrol. This IC performs Private-Line®/Digital PrivateLine™ (PL/DPL) encode and alert-tone generation.The IC transmits pre-emphasis on analog signals andapplies a low-pass (splatter) filter to all transmitted sig-nals. It requires a 33MHz crystal to function. An 8kHzinterrupt signal generated by the DSP-support IC isalso required for functionality. It is programmed usingparallel programming from the microcontrol unit andthe DSP-support IC.

The DSP-support IC performs analog-to-digitaland digital-to-analog conversions on audio signals. Itcontains attenuators for volume, squelch, deviation,and compensation, and it executes receiver filteringand discrimination. The IC requires a 2.4MHz clock tofunction (generated by the digital back-end IC) and isprogrammed by the microcontrol unit SPI bus.

LO Frequency Range 181.15-223.15MHz 329.65-446.65MHz 732.65-796.65MHz

First IF Frequency 45.15MHz 73.35MHz 73.35MHz

VHF UHF 800MHz

Table 14. Local Oscillator and First IF Frequencies


This section of the manual contains troubleshoot-ing charts, error codes, a functional block diagram,interconnect diagrams, and flexible circuit information.This section will help you isolate a problem to theboard level. Board-level troubleshooting does notattempt to isolate problems to the component level.Component-level service information can be found inthe “ASTRO Digital SABER Portable Radios DetailedService Manual.” (Refer to “Related Publications Avail-able Separately” list located in the front section of thismanual.)

NOTETo access the various connector pins, use thehousing eliminator/test fixture along with the dia-grams found in this section of the manual. (Refer tothe “Service Aids for Board-Level Troubleshooting”table for the appropriate Motorola housing elimina-tor/test fixture part number.)

B. Replacement Board Procedures

Once a problem has been narrowed down to aspecific board, it is important to get the customer’sradio back in service as quickly as possible. This canbe done several ways:

1. Install a good board from your inventory into thecustomer’s radio.

2. Order a replacement board from Worldwide Sys-tem and Aftermarket Products Division at1-800-422-4210.

3. Troubleshoot the defective board using the“ASTRO Digital SABER Portable Radios DetailedService Manual.” (Refer to the “Related Publica-tions Available Separately” list located in the frontsection of this manual for the specific manualnumber.)

C. Power-Up Error Codes

When the radio is turned on (power-up), the radioperforms cursory tests to determine if its basic elec-tronics and software are in working order. Problemsdetected during these tests are presented as errorcodes on the radio’s display. The presence of an errorshould prompt the user that a problem exists and thata service technician should be contacted.

Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit user operation; non-fatalerrors will not. Use Table 15 to aid in understandingparticular power-up error code displays.

SECTION VIII. BOARD-LEVEL TROUBLESHOOTING

Table 15. Power-Up Error Code Displays

Note: If the corrective action does not fix the failure, replace the controller board.

Error Code Description Corrective Action

01/81 ROM Checksum Failure Reprogram the FLASH memory.

01/02 External EEprom Checksum Non-Fatal Error Reprogram codeplug.

01/82 External EEprom Checksum Failure Reprogram the codeplug.

01/88 RAM Failure - Note: not a checksum failure Turn the radio off, then on.

01/90 General Hardware Failure Turn the radio off, then on.

01/92 Internal EEPROM Checksum Failure Reprogram the codeplug.

02/10 DSP support IC checksum Non-Fatal Error Turn the radio off, then on.

02/81 DSP ROM Checksum Failure Reprogram the FLASH memory.

02/88 DSP RAM Failure - Note: not a checksum failure Turn the radio off, then on.

02/90 General DSP Hardware Failure Turn the radio off, then on.

(DSP startup message not received correctly)

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D. Operational Error Codes

During radio operation, the radio performs dynam-ic tests to determine if the radio is working properly.Problems detected during these tests are presentedas error codes on the radio’s display. The presence of

an error code should prompt a user that a problemexists and that a service technician should be contact-ed. Use Table 16 to aid in understanding particularoperational error codes.

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Table 16. Operational Error Code Displays

Error Code Description Corrective Action

FAIL 001 Synthesizer Out-of-Lock a. Reprogram codeplug

b. Replace RF Board

FAIL 002 Selected Mode/Zone Codeplug Checksum Error Reprogram codeplug

Table 17. Receiver Troubleshooting Chart

Symptom Possible Cause Correction or Test (Measurements Taken at Room Temperature)

Radio Dead; 1. Dead Battery Replace with charged battery.Display Does 2. Blown Fuse Check see-through fuse on RF board near the B+ connector.Not Light Up 3. On/Off Switch With the radio on, check for B+ SENSE at P901 pin 10 of the control top/

PTT flex; if not there, check for UNSW B+ at pin 19 of RF board connector; if not there, replace the RF board; if there, replace the controller board.

4. Regulators Check for +5V at P901 pin 5 of the control top/PTT flex; if not there, replace the controller board.

Radio Dead; 1. Controller Check board for communication with RSS. If no communication,Display Board replace controller board.

Lights Up 2. RF Board Check the ODC (output data clock) at pin 8 of the RF board connector for 2.4MHz. If not there, replace RF board.

No Receiver 1. Programming a. Does the transmitted signal match the receiver Audio or configuration (PL, DPL, etc.)?Receiver Does b. With the monitor function enabled, can the radio be unmuted?Not Unmute

Audio Distorted 1. Synthesizer Check synthesizer frequency by measuring the transmitter frequency; or Not Loud Not On if off by more than ±250Hz, realign.Enough Frequency

RF Sensitivity 1. Synthesizer Check synthesizer frequency by measuring the transmitter frequency;Poor Not On if off by more than ≤ ±600Hz, realign.

Frequency

2. Antenna Switch Visually check for proper mechanical positioning of the antenna switchto the RF board; re-position if necessary. Then, check for electricalcontinuity between the center pin of the antenna connector and theRF board; replace defective item.

3. Receiver Check RF front-end tuning for optimum sensitivity using the RSS.Front-EndTuning(VHF/UHF only)

Radio Will 1. Controller Does B+ SENSE at P901 pin 10 of the control top/PTT flex switch on andNot Turn Off Board off as the on/off switch is operated? If not, replace the controller board.

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Symptom Possible Cause Correction or Test (Measurements Taken at Room Temperature)

No RF Power 1. TX Power Level Check TX power level and frequency programming (from RSS).Out or Frequency

2. No PTT From With the PTT switch depressed (radio transmitting/keyed), check for INT PTT Control Top at P901 pin 6 of the control top/PTT flex;

if not there, replace the control top/PTT flex.

3. No Injection To Check LOCK DETECT at pin 13 of the RF board connector; Power Amplifier if not between 1.0 and 4.5V, replace the RF board.

No Modulation; 1. Programming Check deviation and compensation settings using the RSS.

Distorted 2. Controller With a 1kHz tone at 80mVrms injected at the external microphone, is the Modulation Board output of the controller board to RF board connector pin 15 distorted?

If so, replace the controller board.

Bad Microphone 1. Check Realign if necessary.Sensitivity Deviation and

Compensation

2. Microphone Speaking loudly into the microphone, monitor the output voltage (INT MIC)at the speaker microphone flex connector, P701 pin 4. If not 2mVrms, replace the speaker/microphone and front shield assembly.

No/Low 1. CheckSignalling Programming

(PL, DPL, MDC) 2. Controller Check for proper modulation at the RF board to controller board Board connector pin 15; if not there, replace the controller board.

Can’t Set 1. RF Board If maximum deviation can be set to > 5.0kHz, but compensation Compensation cannot be set, replace the RF board.

Table 18. Transmitter Troubleshooting Chart

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NOTES

astro digital saber portable radios basic service...

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