CM Series/CM Radios Detailed Service Manual 6866545D30 O

User Manual: -CM Series/CM Radios Detailed service manual 6866545D30-O

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ELM_DSM_%20545D30
Sect1_Service%20Maint
Section2_Controlheads
Section3_UHF2
Section4_VHF2
Sect5_MB
Section6_UHF2_HP
Section7_VHF2_HP

Commercial Series

CM Radios

Detailed Service Manual

6866545D30-O

WLS EMEA Publications Department, Jays Close, Viables Industrial Estate, Basingstoke, Hampshire, RG22 4PD, UK.

Issue : December 2003 iii

Commercial Series

CM Radios

Detailed Service Manual

6866545D30-O

Contents

Section 1 Service Maintainability

Section 2 Controlhead Service Information

Section 3 UHF2 Service Information

Section 4 VHF2 Service Information

Section 5 Midband Service Information

Section 6 UHF2 High Power Service Information

Section 7 VHF2 High Power Service Information

Commercial Series

CM Radios

Service Maintainability

Issue: December 2003

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored

in semiconductor memories or other media. Laws in the United States and other countries preserve for

Motorola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or

reproduce in any form, the copyrighted computer program. Accordingly, any copyrighted Motorola computer

programs contained in the Motorola products described in this manual may not be copied or reproduced in

any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola

products shall not be deemed to grant, either directly or by implication, estoppel or otherwise, any license

under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive

royalty-free license to use that arises by operation of law in the sale of a product.

iii

Table of Contents

Chapter 1 INTRODUCTION

1.0 Scope of Manual..................................................................................................1-1

2.0 Warranty and Service Support.............................................................................1-1

2.1 Warranty Period and Return Instructions .......................................................1-1

2.2 After Warranty Period.....................................................................................1-1

2.3 European Radio Support Centre (ERSC).......................................................1-2

2.4 Parts Identification and Ordering ....................................................................1-2

2.5 EMEA Test Equipment Support......................................................................1-2

2.6 Technical Support...........................................................................................1-3

2.7 Related Documents ........................................................................................1-3

3.0 Radio Model Information......................................................................................1-4

Chapter 2 MAINTENANCE

1.0 Introduction ..........................................................................................................2-1

2.0 Preventive Maintenance ......................................................................................2-1

2.1 Inspection .......................................................................................................2-1

2.2 Cleaning .........................................................................................................2-1

3.0 Safe Handling of CMOS and LDMOS..................................................................2-2

4.0 General Repair Procedures and Techniques.......................................................2-2

5.0 Notes For All Schematics and Circuit Boards ......................................................2-5

Chapter 3 SERVICE AIDS

1.0 Recommended Test Tools...................................................................................3-1

2.0 Test Equipment....................................................................................................3-2

SAFETY INFORMATION

Read this information before using your radio.

PRODUCT SAFETY AND RF EXPOSURE FOR MOBILE TWO-WAY RADIOS

INSTALLED IN VEHICLES OR AS FIXED SITE CONTROL STATIONS.

This document provides information and instructions for the safe and efficient operation of Motorola

Mobile Two-Way Radios. The information provided in this document supersedes information

contained in user guides published prior to February 2002.

COMPLIANCE WITH RF ENERGY EXPOSURE STANDARDS

Note:This Radio is intended for use in occupational/controlled applications, where users have been

made aware of the potential for exposure and can exercise control over their exposure. This radio

device is NOT authorized for general population, consumer or similar use.

This user safety booklet includes useful information about RF exposure and helpful instructions on

how to control your RF exposures.

Your Motorola radio is designed and tested to comply with a number of national and international

standards and guidelines regarding human exposure to radio frequency electromagnetic energy. This

radio complies with IEEE and ICNIRP exposure limits for occupational/controlled RF exposure

environments at usage factors of up to 50% talk–50% listen. In terms of measuring RF energy for

compliance with the IEEE/ICNIRP exposure guidelines, your radio radiates measurable RF energy

only while it is transmitting (during talking), not when it is receiving (listening) or in standby mode.

Your Motorola two-way radio complies with the following RF energy exposure

standards and guidelines:

●United States Federal Communications Commission, Code of Federal Regulations; 47 CFR part 2

sub-part J

●American National Standards Institute (ANSI) / Institute of Electrical and Electronic Engineers

(IEEE) C95. 1-1992

●Institute of Electrical and Electronic Engineers (IEEE) C95.1-1999 Edition

●International Commission on Non-Ionizing Radiation Protection (ICNIRP) 1998

●Ministry of Health (Canada) Safety Code 6. Limits of Human Exposure to Radiofrequency Electro-

magnetic Fields in the Frequency Range from 3 kHz to 300 GHz, 1999

●Australian Communications Authority Radiocommunications (Electromagnetic Radiation - Human

Exposure) Standard 2001

●ANATEL, Brasil Regulatory Authority, Resolution 256 (April 11, 2001) “additional requirements for

SMR, cellular and PCS product certification.”

COMPLIANCE AND CONTROL GUIDELINES AND OPERATING INSTRUCTIONS FOR

MOBILE TWO-WAY RADIOS INSTALLED IN VEHICLES

To control your exposure and ensure compliance with the occupational/controlled environment

exposure limits, always adhere to the following procedures:

●To transmit (talk), push the Push-To-Talk (PTT) button; to receive, release the PTT button. Transmit

only when people outside the vehicle are at least the minimum lateral distance away from a properly

installed, externally-mounted antenna. Table 1 lists the minimum distance for bystanders in an

uncontrolled environment from the transmitting antenna at several different ranges of rated radio

power for mobile radios installed in a vehicle..

●Install mobile antennas at the centre of the roof and centre of the trunk deck. These mobile installa-

tion guidelines are limited to metal body vehicles. The antenna installation must additionally be in

accordance with:

a. The requirements of the antenna manufacturer/supplier

b. Instructions in the Radio Installation Manual.

●Use only Motorola-approved supplied or replacement antenna. Use of non–Motorola - approved

antennas, modifications, or attachments could damage the radio and may violate IEEE/ICNIRP regu-

lations. For a list of Motorola-approved antennas please see your dealer. Your nearest dealer can

be found at the following web site :

http://www.motorola.com/cgiss/emea/dealerlocator.html

For additional information on exposure requirements or other training information, visit

http://www.motorola.com/rfhealth.

COMPLIANCE AND CONTROL GUIDELINES AND OPERATING INSTRUCTIONS FOR

MOBILE TWO-WAY RADIOS INSTALLED AS FIXED SITE CONTROL STATIONS

If mobile radio equipment is installed at a fixed location and operated as a control station or as a fixed

unit, the antenna installation must comply with the following requirements in order to ensure optimal

performance and compliance with the RF energy exposure in the standards and guidelines listed

above:

●The antenna must be mounted outside the building on the roof or a tower if at all possible.

●As with all fixed site antenna installations, it is the responsibility of the licensee to manage the site in

accordance with applicable regulatory requirements and may require additional compliance actions

such as site survey measurements, signage, and site access restrictions in order to insure that

exposure limits are not exceeded.

Table 1: Rated Power and Distance

Rated Power of Vehicle-Installed

Mobile Two-Way Radio

Minimum Distance from

Transmitting Antenna

Less than 7Watts 20 cm (8 Inches)

7 to 15 Watts 30.5 cm (1 Foot)

16 to 50 Watts 61 cm (2 Feet)

51 to 110 Watts 91.5 cm (3 Feet)

vii

ELECTROMAGNETIC INTERFERENCE/COMPATIBILITY

NOTE: Nearly every electronic device is susceptible to electromagnetic interference (EMI) if

inadequately shielded, designed or otherwise configured for electromagnetic compatibility. It may be

necessary to conduct compatibility testing to determine if any electronic equipment used in or around

vehicles or near fixed site antenna is sensitive to external RF energy or if any procedures need to be

followed to eliminate or mitigate the potential for interaction between the radio transmitter and the

equipment or device.

Facilities

To avoid electromagnetic interference and/or compatibility conflicts, turn off your radio in any

facility where posted notices instruct you to do so. Hospitals or health care facilities may be

using equipment that is sensitive to external RF energy.

Vehicles

To avoid possible interaction between the radio transmitter and any vehicle electronic control

modules, for example, ABS, engine, or transmission controls, the radio should be installed only by an

experienced installer and that the following precautions be used when installing the radio:

1. Refer to the manufacturer’s instructions or other technical bulletins or recommendations on radio installation.

2. Before installing the radio, determine the location of the electronic control modules and their harnesses in

the vehicle.

3. Route all radio wiring, including the antenna transmission line, as far away as possible from the electronic

control units and associated wiring.

Driver Safety

Check the laws and regulations on the use of radios in the area where you drive. Always obey them.

When using your radio while driving, please:

●Give full attention to driving and to the road.

●Pull off the road and park before making or answering a call if driving conditions so require.

OPERATIONAL WARNINGS

For Vehicles With An Air Bag

Do not mount or place a mobile radio in the area over an air bag or in the air bag deployment area. Air

bags inflate with great force. If a radio is placed in the air bag deployment area and the air bag

inflates, the radio may be propelled with great force and cause serious injury to occupants of the

vehicle.

Potentially Explosive Atmospheres

Turn off your radio prior to entering any area with a potentially explosive atmosphere. Sparks in a

potentially explosive atmosphere can cause an explosion or fire resulting in bodily injury or even

death.

The areas with potentially explosive atmospheres referred to above include fuelling areas such as

below decks on boats, fuel or chemical transfer or storage facilities, areas where the air contains

chemicals or particles, such as grain, dust or metal powders. Areas with potentially explosive

atmospheres are often but not always posted.

Blasting Caps And Areas

To avoid possible interference with blasting operations, turn off your radio when you are near

electrical blasting caps, in a blasting area, or in areas posted:

"Turn off two-way radio". Obey all signs and instructions.

viii

For radios installed in vehicles fueled by liquefied petroleum gas, refer to the (U.S.) National Fire

Protection Association standard, NFPA 58, for storage, handling, and/or container information. For a

copy of the LP-gas standard, NFPA 58, contact the National Fire Protection Association, One Battery

Park, Quincy, MA.

Chapter 1

INTRODUCTION

1.0 Scope of Manual

This manual is intended for use by service technicians familiar with similar types of equipment. It

contains service information required for the equipment described and is current as of the printing

date. Changes which occur after the printing date may be incorporated by a complete Manual

revision or alternatively as additions.

2.0 Warranty and Service Support

Motorola offers long term support for its products. This support includes full exchange and/or repair

of the product during the warranty period, and service/ repair or spare parts support out of warranty.

Any "return for exchange" or "return for repair" by an authorised Motorola Dealer must be

accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an

Authorised Motorola Dealer.

2.1 Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or

Reseller contract. These conditions may change from time to time and the following notes are for

guidance purposes only.

In instances where the product is covered under a "return for replacement" or "return for repair"

warranty, a check of the product should be performed prior to shipping the unit back to Motorola.

This is to ensure that the product has been correctly programmed or has not been subjected to

damage outside the terms of the warranty.

Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact

Customer Resources (Please see page 2 and page 3 in this Chapter). All returns must be

accompanied by a Warranty Claim Form, available from your Customer Services representative.

Products should be shipped back in the original packaging, or correctly packaged to ensure no

damage occurs in transit.

2.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.

1. Motorola's Radio Aftermarket and Accessory Division (AAD) offers a repair service to both

end users and dealers at competitive prices.

2. AAD supplies individual parts and modules that can be purchased by dealers who are

technically capable of performing fault analysis and repair.

NOTE Before operating or testing these units, please read the Safety Information Section in the

front of this manual.

1-2 INTRODUCTION

2.3 European Radio Support Centre (ERSC)

The ERSC Customer Information Desk is available through the following service numbers:

Austria: 08 00 29 75 41 Italy: 80 08 77 387

Belgium: 08 00 72 471 Luxemburg: 08 00 23 27

Denmark: 80 88 05 72 Netherlands: 08 00 22 45 13

Finland: 08 00 11 49 910 Norway: 80 01 11 15

France: 08 00 90 30 90 Portugal: 08 00 84 95 70

Germany: 08 00 18 75 240 Spain: 90 09 84 902

Greece: 00 80 04 91 29 020 Sweden: 02 07 94 307

UK : 08 00 96 90 95 Switzerland: 08 00 55 30 82

Ireland: 18 00 55 50 21 Iceland: 80 08 147

Or dial the European Repair and Service Centre:

Tel: +49 30 6686 1555

Please use these numbers for repair enquiries only.

2.4 Piece Parts

Some replacement parts, spare parts, and/or product information can be ordered directly. If a

complete Motorola part number is assigned to the part, it is available from Motorola Radio

Aftermarket and Accessory Division (AAD). If no part number is assigned, the part is not normally

available from Motorola. If the part number is appended with an asterisk, the part is serviceable by

Motorola Depot only. If a parts list is not included, this generally means that no user-serviceable

parts are available for that kit or assembly.

All part orders should be directed to :

Motorola GmbH

Customer Care

AM Borsigturm 130

13507 Berlin

Germany.

2.5 EMEA Test Equipment Support

Information related to support and service of Motorola Test Equipment is available via Motorola

Online (Extranet), through the Customer Care organisation of Motorola’s local area representation

or by calling the the European Repair and Service Centre: Tel: +49 30 6686 1555

Warranty and Service Support 1-3

2.6 Technical Support

Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions

which may be encountered.

UK/Ireland - Richard Russell

Telephone: +44 (0) 1256 488 082

Fax: +44 01256 488 080

Email: BRR001@email.mot.com

Central/East Europe - Siggy Punzenberger

Telephone: +49 (0) 6128 70 2342

Fax: +49 (0) 6128 95 1096

Email: TFG003@email.mot.com

Scandinavia

Telephone: +46 8 735 9282

Fax: +46 8 735 9280

Email: C14749@email.mot.com

Germany -Customer Connect Team

Telephone: +49 (0) 6128 70 2248

Fax: +49 (0) 6128 95 1082

Email: cgiss.emea@europe.mot.com

France - Lionel Lhermitte

Telephone: +33 1 6929 5722

Fax: +33 1 6929 5904

Email: TXE037@email.mot.com

Italy - Ugo Gentile

Telephone: +39 0 2822 0325

Fax: +39 0 2822 0334

Email: C13864@email.mot.com

Africa & Middle East - Armand Roy

Telephone: +33 1 6929 5715

Fax: +33 1 6929 5778

Email: armand.roy@Motorola.com

2.7 Related Documents

The following documents are directly related to the use and maintainability of this product.

Title Language Part Number

CM Series Product Manual English GMLN1062_

German GMLN1063_

French GMLN1064_

Italian GMLN1065_

Spanish GMLN1066_

Russian GMLN1067_

1-4 INTRODUCTION

3.0 Radio Model Information

The model number and serial number are located on a label attached to the back of your radio. You

can determine the RF output power, frequency band, protocols, and physical packages. The

example below shows one mobile radio model number and its specific characteristics.

Table 1-1 Radio Model Number (Example: MDM50FNC9AN2_N)

Type of

Unit

Model

Series

Freq.

Band

Power

Level

Physical

Packages

Channel

Spacing Protocol Feature

Level

Model

Revision

Model

Package

MD M 50 F

Midband

(66-

88MHz)

VHF1

(136-

162MHz)

VHF2

(146-

174MHz)

1-25W

CM140

CM340

Program-

mable

Conven-

tional

MDC

Connector :

Mini-UHF

UHF1

(403-

430MHz)

25-40W

CM160

CM360

5 Tone

Connector :

BNC

UHF2

(438-

470MHz)

25-45W

UHF3

(465-

495MHz)

MD = Motorola Internal Use

M = Mobile

Chapter 2

MAINTENANCE

1.0 Introduction

This chapter of the manual describes:

■preventive maintenance

■safe handling of CMOS devices

■repair procedures and techniques

2.0 Preventive Maintenance

The radios do not require a scheduled preventive maintenance program; however, periodic visual

inspection and cleaning is recommended.

2.1 Inspection

Check that the external surfaces of the radio are clean, and that all external controls and switches

are functional. It is not recommended to inspect the interior electronic circuitry.

2.2 Cleaning

The following procedures describe the recommended cleaning agents and the methods to be

used when cleaning the external and internal surfaces of the radio. External surfaces include the

front cover, housing assembly, and battery case. These surfaces should be cleaned whenever a

periodic visual inspection reveals the presence of smudges, grease, and/or grime.

The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild

dishwashing detergent in water. The only factory recommended liquid for cleaning the printed

circuit boards and their components is isopropyl alcohol (70% by volume).

1. Cleaning External Plastic Surfaces

The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-

bristled brush to work all loose dirt away from the radio. A soft, absorbent, lintless cloth or

tissue should be used to remove the solution and dry the radio. Make sure that no water

remains entrapped near the connectors, cracks, or crevices.

2. Cleaning Internal Circuit Boards and Components

Isopropyl alcohol may be applied with a stiff, non-metallic, short-bristled brush to dislodge

embedded or caked materials located in hard-to-reach areas. The brush stroke should

direct the dislodged material out and away from the inside of the radio. Make sure that

controls or tunable components are not soaked with alcohol. Do not use high-pressure

air to hasten the drying process since this could cause the liquid to collect in unwanted

places. Upon completion of the cleaning process, use a soft, absorbent, lintless cloth to

dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or

back cover.

NOTE Internal surfaces should be cleaned only when the radio is disassembled for servicing or

repair.

CAUTION: The effects of certain chemicals and their vapors can have harmful results on

certain plastics. Aerosol sprays, tuner cleaners, and other chemicals should be avoided.

2-2 MAINTENANCE

3.0 Safe Handling of CMOS and LDMOS

Complementary metal-oxide semiconductor (CMOS) devices are used in this family of radios.

CMOS characteristics make them susceptible to damage by electrostatic or high voltage

charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore,

special precautions must be taken to prevent device damage during disassembly,

troubleshooting, and repair.

Handling precautions are mandatory for CMOS circuits and are especially important in low

humidity conditions. DO NOT attempt to disassemble the radio without first referring to the CMOS

CAUTION paragraph in the Disassembly and Reassembly section of the manual.

4.0 General Repair Procedures and Techniques

IC Pre-Baking

No pre-baking of components is required in the repair of this product.

Parts Replacement and Substitution

When damaged parts are replaced, identical parts should be used. If the identical replacement

component is not locally available, check the parts list for the proper Motorola part number and

order the component from the nearest Motorola Communications parts center listed in the “Piece

Parts” section of this manual.

Rigid Circuit Boards

The family of radios uses bonded, multi-layer, printed circuit boards. Since the inner layers are

not accessible, some special considerations are required when soldering and unsoldering

components. The through-plated holes may interconnect multiple layers of the printed circuit.

Therefore, care should be exercised to avoid pulling the plated circuit out of the hole.

When soldering near the 18-pin and 40-pin connectors:

■avoid accidentally getting solder in the connector.

■be careful not to form solder bridges between the connector pins

■closely examine your work for shorts due to solder bridges.

NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by

dissolved material (from previous usage).

General Repair Procedures and Techniques 2-3

Chip Components

Use either the RLN4062 Hot-Air Repair Station or the Motorola 0180381B45 Repair Station for

chip component replacement. When using the 0180381B45 Repair Station, select the TJ-65 mini-

thermojet hand piece. On either unit, adjust the temperature control to 370 °C (700 °F), and

adjust the airflow to a minimum setting. Airflow can vary due to component density.

■To remove a chip component:

1. Use a hot-air hand piece and position the nozzle of the hand piece approximately 0.3 cm

(1/8") above the component to be removed.

2. Begin applying the hot air. Once the solder reflows, remove the component using a pair

of tweezers.

3. Using a solder wick and a soldering iron or a power desoldering station, remove the

excess solder from the pads.

■To replace a chip component using a soldering iron:

1. Select the appropriate micro-tipped soldering iron and apply fresh solder to one of the

solder pads.

2. Using a pair of tweezers, position the new chip component in place while heating the

fresh solder.

3. Once solder wicks onto the new component, remove the heat from the solder.

4. Heat the remaining pad with the soldering iron and apply solder until it wicks to the

component. If necessary, touch up the first side. All solder joints should be smooth and

shiny.

■To replace a chip component using hot air:

1. Use the hot-air hand piece and reflow the solder on the solder pads to smooth it.

2. Apply a drop of solder paste flux to each pad.

3. Using a pair of tweezers, position the new component in place.

4. Position the hot-air hand piece approximately 0.3 cm (1/8” ) above the component and

begin applying heat.

5. Once the solder wicks to the component, remove the heat and inspect the repair. All

joints should be smooth and shiny.

2-4 MAINTENANCE

Shields

Removing and replacing shields will be done with the R1070 station with the temperature control

set to approximately 215°C (415°F) [230°C (445°F) maximum].

■To remove the shield:

1. Place the circuit board in the R1070 circuit board holder.

2. Select the proper heat focus head and attach it to the heater chimney.

3. Add solder paste flux around the base of the shield.

4. Position the shield under the heat-focus head.

5. Lower the vacuum tip and attach it to the shield by turning on the vacuum pump.

6. Lower the focus head until it is approximately 0.3 cm (1/8”) above the shield.

7. Turn on the heater and wait until the shield lifts off the circuit board.

8. Once the shield is off, turn off the heat, grab the part with a pair of tweezers, and turn off

the vacuum pump.

9. Remove the circuit board from the R1070 circuit board holder.

■To replace the shield:

1. Add solder to the shield if necessary, using a micro-tipped soldering iron.

2. Next, rub the soldering iron tip along the edge of the shield to smooth out any excess

solder. Use solder wick and a soldering iron to remove excess solder from the solder

pads on the circuit board.

3. Place the circuit board back in the R1070 circuit board holder.

4. Place the shield on the circuit board using a pair of tweezers.

5. Position the heat-focus head over the shield and lower it to approximately 0.3 cm (1/8”)

above the shield.

6. Turn on the heater and wait for the solder to reflow.

7. Once complete, turn off the heat, raise the heat-focus head and wait approximately one

minute for the part to cool.

8. Remove the circuit board and inspect the repair. No cleaning should be necessary.

Notes For All Schematics and Circuit Boards 2-5

5.0 Notes For All Schematics and Circuit Boards

* Component is frequency sensitive. Refer to the Electrical Parts List for value and usage.

1. Unless otherwise stated, resistances are in Ohms (k = 1000), and capacitances are in picofarads

(pF) or microfarads (µF).

2. DC voltages are measured from point indicated to chassis ground using a Motorola DC

multimeter or equivalent. Transmitter measurements should be made with a 1.2 µH choke in

series with the voltage probe to prevent circuit loading.

3. Interconnect Tie Point Legend:

Signal Name Signal Description

16_8MHz 16.8MHz Reference Frequency from Synthesizer to ASFIC

3V 3V RF regulator

5V 5V RF regulator

5V_CH Optional 5V for Control Head

9V Regulated 9.3V Supply Voltage

9R 9V to enable RX_INJ when RX_EN is active

ASFIC_CS ASFIC Chip Select

B+ 13.8V Supply Voltage

BATT_SENSE Battery Voltage Sense Line

BOOT_EN_IN_CH Boot Mode Select

BW_SEL Select BW (12.5 KHz, 25 KHz)

CH_ACT Channel Activity Indicator Signal (Fast Squelch)

COMM_DATA_SEL_CH Display Driver Command/ Data Select

D3_V3 Regulated 3.3V supply voltage for Voice Storage

DEMOD Audio Output Signal from the Receiver IC

DETECTOR_AUDIO_SEND_BRD Flat Audio to Option Board

DISPLAY_CS_CH Control Head Chip Select

EMERGENCY_ACCES_CONN Emergency line to switch on the radio voltage regulators

EMERGENCY_SENSE Emergency sense to µP

EXTERNAL_MIC_AUDIO ACCES_CONN External (from accessory connector) microphone input

F1200 Interrupt line from ASFIC CMP

FILT_SW_B+ Switched 13.8 V supply voltage

FLAT_TX_AUDIO_INPUT_ACCESS_CONN Flat TX input from accessory connector

HANDSE RX_AUDIO_CH Handset Audio Output

HOOK_CH Hang-up switch input

HSIO High Speed Clock In / Data Out

IGNITION Ignition Line to switch on he radio’s voltage regulator

KEYPAD_COL_CH Keypad Matrix Column

LOC_DIST Enable Attenuator for RX line

LSIO Low Speed Clock In / Data Out

MIC_AUDIO_CH Microphone Input

2-6 MAINTENANCE

MIC_PTT_CH Microphone PTT Input

MOD_IN Modulation Signal from ASFIC

MOD_OUT Modulation Signal to the Synthesizer

ONOFF_SENSE On off sense switch

OPT_DATA_R_OPRD DATA/Ready Request from Option Board

OPT_EN_OPBD Option Board Chip Select

PA_BIAS PA Control bias voltage

PA_CURRENT Not used

POST_LIMITER_TX

AUDIO_RETURN_OPT_BRD

Flat TX Input from Option Board

PROG x IN ACC y General Purpose Input x accessory connector Pin y

PROG x INOUT ACC y General Purpose Input/Output x accessory connector Pin y

PROG x OUT ACC y General Purpose Input x accessory connector Pin y

PWR_SET PA Power Control Voltage

RESET Reset Line

RSSI Received Signal Strength Indicator

RX RX signal

RX AUD RTN Option Board Input/Output of Receiver Audio Path

RX_AUDIO_OUTPUT_ACCESS_CONN Flat or filtered audio to accessory connector

RX_EN Enable Receiving

RX_INJ RF signal from VCO into the Receiver

SCI_CH Bi-directional serial communication line

SHIFT_R_CS SPI Chip select for the Control Head

SPI_CLK Serial peripheral interface bus CLOCK

SPI_MISO Serial peripheral interface bus data IN

SPI_MOSI Serial peripheral interface bus data OUT

SPKR- Negative Audio PA Speaker Output

SPKR+ Positive Audio PA Speaker Output

SQ_DET Squelch Detect Signal

SYNTH_CS Synth Chip Select

SYNTH_LOCK µP Clock Lock Signal

TX AUDIO_RETURN_OPT_BRD Option Board Output to Transmit Audio Path

TX AUDIO_SEND_OPT_BRD Microphone Audio to Option Board

TX_INJ RF signal from the VCO to transmitter PA

TX_EN Enable transmitting

UNMUTED RX_AUDIO_SEND_OPT_BRD Unmuted filtered audio to option board

uP_CLK µP Clock signal

VoL_INDIRECT Volume Pot Input

VOX Voice operated transmit level

Notes For All Schematics and Circuit Boards 2-7

VS AUDIO_SEL Switch signal to Enable option board audio output signal

VS GAIN_SEL Voice Storage Gain Select line

VS_MIC Voice Storage Audio Signal to microphone path

VS_INT Voice Storage Interrupt line

VS_RAC Voice storage Row Address Clock Signal

VSTBY 3.3 V supply for µP when the radio is switched off

2-8 MAINTENANCE

Chapter 3

SERVICE AIDS

1.0 Recommended Test Tools

Table 3.1 lists the service aids recommended for working on the radio. While all of these items are

available from Motorola, most are standard workshop equipment items, and any equivalent item

capable of the same performance may be substituted for the item listed.

Table 3-1 Service Aids

Motorola Part

No. Description Application

RLN4460_ Portable Test Set Enables connection to audio/accessory jack.

Allows switching for radio testing.

GMVN5034_ Customer Programming

Software (CPS) and Tuner

CDROM (MDC)

Programs customer options and channel data.

Tunes hardware parameters, front end,

power, deviation etc.

GMVN5033_ Customer Programming

Software (CPS) and Tuner

CDROM (5-Tone)

Programs customer options and channel data.

Tunes hardware parameters, front end,

power, deviation etc.

RKN4081_ Programming Cable with

Internal RIB

Includes radio interface box (RIB) capability.

FKN8096_ Data/Flash Adapter Key Used with RKN4081 (10 to 8 pin adapter for

front Telco connector with Data/Flash switch).

RKN4083_ Mobile Programming/Test Cable Connects radio to RIB (RLN4008_).via rear

accessory connector

FKN8113_ Adapter Cable Used with RKN4083 (20 to 16 pin adapter for

rear accessory connector).

GTF374_ Program Cable Connects RIB to Radio microphone input.

RLN4008_ Radio Interface Box Enables communications between radio and

computer’s serial communications adapter.

HLN8027_ Mini UHF to BNC Adaptor Adapts radio antenna port to BNC cabling of

test equipment.

GPN6133_ Power Supply Provides the radio with power when bench

testing.

EPN4040_ Wall-Mounted Power Supply Used to supply power to the RIB (UK).

EPN4041_ Wall-Mounted Power Supply Used to supply power to the RIB (Euro).

8180384N64 Housing Eliminator (25W) Test Fixture used to bench test the radio pcb.

3080369B71 Computer Interface Cable Connects the RIB to the Computer (25-pin).

3-2 SERVICE AIDS

3080369B72 Computer Interface Cable Connects the RIB to the Computer (9-pin)

(Use for IBM PC AT - other IBM models use

the B71 cable above).

6686119B01 Removal Tool Assists in the removal of radio control head.

6680334F39 Hex Tool Assists in the removal of antenna connector.

WADN4055A Portable Soldering Station Digitally controlled soldering iron.

6604008K01 0.4mm Replacement Tip For WADN4055A Soldering iron.

6604008K01 0.8mm Replacement Tip For WADN4055A Soldering iron.

0180386A82 Anti-static Grounding Kit Used for all radio assembly/disassembly

procedures.

6684253C72 Straight Prober

6680384A98 Brush

1010041A86 Solder (RMA type) 63/37, 0.5mm diameter, 1lb. spool.

Table 3-1 Service Aids

Motorola Part

No. Description Application

Test Equipment 3-3

2.0 Test Equipment

Table 3-2 lists test equipment required to service the radio and other two-way radios.

Table 3-2 Recommended Test Equipment

Motorola Part

No. Description Characteristics Application

R2600_NT Comms System

Analyzer (non MPT)

This monitor will

substitute for items with

an asterisk *

Frequency/deviation meter

and signal generator for wide-

range troubleshooting and

alignment

*R1072_ Digital Multimeter AC/DC voltage and current

measurements

*R1377_ AC Voltmeter 100 µV to 300 V,

5Hz-1MHz,

10 Megohm input

impedance

Audio voltage

measurements

WADN4133 Delay

Oscilloscope

2 Channel 40 MHz

bandwidth,

5 mV/cm - 20 V/cm

Waveform measurements

R1440_

0180305F17

0180305F31

0180305F40

RLN4610_

T1013_

Wattmeter,

Plug-in Elements

Carry case

RF Dummy Load

Thruline 50-Ohm,

±5% accuracy

10W, 25 - 60 MHz

10W, 100 - 250 MHz

10W, 200 - 500 MHz

Wattmeter and

6 elements

Transmitter power output

measurements

S1339_ RF Millivolt Meter 100mV to 3 VRF,

10 kHz to 1.2 GHz

RF level measurements

R1011_/220V 220V Power

Supply

0-40V, 0-40A Programmable

3-4 SERVICE AIDS

Commercial Series

CM Radios

Controlhead

Service Information

Issue: December 2003

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored

in semiconductor memories or other media. Laws in the United States and other countries preserve for

Motorola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or

reproduce in any form, the copyrighted computer program. Accordingly, any copyrighted Motorola computer

programs contained in the Motorola products described in this manual may not be copied or reproduced in

any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola

products shall not be deemed to grant, either directly or by implication, estoppel or otherwise, any license

under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive royalty-

free license to use that arises by operation of law in the sale of a product.

iii

Table of Contents

Chapter 1 MODEL OVERVIEW

1.0 CM140/CM340 Models ........................................................................................1-1

2.0 CM160/CM360 Models ........................................................................................1-1

Chapter 2 THEORY OF OPERATION

1.0 Introduction ..........................................................................................................2-1

2.0 Controlhead Model for CM140 and CM340 .........................................................2-1

2.1 Power Supplies...............................................................................................2-1

2.2 Power On / Off................................................................................................2-1

2.3 Microprocessor Circuit....................................................................................2-1

2.4 SBEP Serial Interface.....................................................................................2-1

2.5 Keypad Keys ..................................................................................................2-1

2.6 Status LED and Back Light Circuit..................................................................2-3

2.7 Microphone Connector Signals ......................................................................2-3

2.8 Speaker ..........................................................................................................2-4

2.9 Electrostatic Transient Protection...................................................................2-4

3.0 Controlhead Model for CM160 andCM360 ..........................................................2-4

3.1 Power Supplies...............................................................................................2-4

3.2 Power On / Off................................................................................................2-4

3.3 Microprocessor Circuit....................................................................................2-5

3.4 SBEP Serial Interface.....................................................................................2-5

3.5 Keypad Keys ..................................................................................................2-6

3.6 Status LED and Back Light Circuit..................................................................2-6

3.7 Liquid Crystal Display (LCD) ..........................................................................2-6

3.8 Microphone Connector Signals ......................................................................2-6

3.9 Speaker ..........................................................................................................2-7

3.10 Electrostatic Transient Protection ...................................................................2-8

Chapter 3 TROUBLESHOOTING CHARTS

1.0 Troubleshooting Chart for Controlhead CM140/340 ...........................................3-1

1.1 On/Off ............................................................................................................3-1

1.2 Microprocessor ..............................................................................................3-2

2.0 Troubleshooting Chart for Controlhead CM160/360 ............................................3-3

2.1 On/Off ............................................................................................................3-3

2.2 Microprocessor ..............................................................................................3-4

2.3 Display ...........................................................................................................3-5

2.4 Backlight ........................................................................................................3-6

Chapter 4 CONTROLHEAD PCB/SCHEMATICS/PARTS LISTS

1.0 Allocation of Schematics and Circuit Boards .......................................................4-1

2.0 Controlhead CM140/340 - PCB 8488998U01 Schematics..................................4-3

2.1 Controlhead PCB 8488998U01 - Parts List....................................................4-5

3.0 Controlhead CM160/360 - PCB 8489714U01 Schematics .................................4-6

3.1 Controlhead PCB 8489714U01 - Parts List ...................................................4-8

Chapter 1

OVERVIEW

1.0 CM140/CM340Models

The Controlhead contains the internal speaker, the on/off/volume knob, the microphone connector,

several buttons to operate the radio, three indicator Light Emitting Diodes (LED) to inform the user

about the radio status, and a single character 7-segment display for numeric information e.g.

channel number.

2.0 CM160/CM360Models

The Controlhead contains the internal speaker, the on/off/volume knob, the microphone connector,

several buttons to operate the radio, three indicator Light Emitting Diodes (LED) to inform the user

about the radio status, and an 8 character Liquid Crystal Display (LCD) for alpha - numerical

information e.g. channel number or call address name.

1-2 OVERVIEW

Chapter 2

THEORY OF OPERATION

1.0 Introduction

This Chapter provides a detailed theory of operation for the Controlhead circuits. For details of the

trouble shooting refer to the related chapter in this section.

2.0 Controlhead Model for CM140 and CM340

The controlhead contains the internal speaker, the on/off/volume knob, the microphone connector,

several buttons to operate the radio and three indicator Light Emitting Diodes (LED) to inform the

user about the radio status and a 7-segment display for numeric information.

2.1 Power Supplies

The power supply to the control head is taken from the host radio’s 9.3V via connector J803-9, The

9.3V is used for the LEDs and back light, the 5V is used for the LCD driver and level shifter. The

stabilized 3V is used for the other parts.

2.2 SPI Interface

The host radio (master) communicates with the control head through its SPI bus. Three lines are

connected to the shift register (U801):SPI clock (J803-17), SPI MOSI (J803-16) and shift register

chip select (J803-15).

Shift

BCD To

7-segment

Mux.

Control

Keypads

DTMF

Resistors

PTT

circuit

2pinspeaker

connector

7-segment

display

9.3V

Keypad

Backlight

9.3VRow/Column

Control line

Boot_res / SCI

DTMF

Row/Column

Boot_res (DTMF-

Column)/ SCI

(DTMF-Row)

Shift

BCD To

7-segment

Mux.

Control

Keypads

DTMF

Resistors

PTT

circuit

2pinspeaker

connector

7-segment

display

9.3V

Keypad

Backlight

9.3VRow/Column

Control line

Boot_res / SCI

DTMF

Row/Column

Boot_res (DTMF-

Column)/ SCI

(DTMF-Row)

2-2 THEORY OF OPERATION

When the host radio needs to send date to the shift register, the radio asserts the shift register chip

select and the data is loaded to the shift register. For example, the host radio sends data to change

display channel or change LED status.

2.3 Keypad Keys

The control head keypad is a four-key design. All keys are configured as two analog lines read by

µP. The voltage on the analog lines varies between 0V and 3.3 V depending on which key is

pressed. If no key is pressed, the voltage at both lines is 3.3V. The key configuration can be thought

of as a matrix where the two lines represent one row and one column. Each line is connected to a

resistive divider powered by 3.3V. If a button is pressed, it will connect one specific resistor of each

divider line to ground level and thereby reduce the voltages on the analog lines. The voltages of the

lines are A/D converted inside the µP (ports PE 6 - 7) and specify the pressed button. To determine

which key is pressed, the voltage of both lines must be considered.

The same analog lines also support a keypad microphone. A microphone key press is processed in

the same manner like a control head key press.

2.4 Status LED’s and Back Light Circuit

All indicator LEDs (red, yellow, and green) are driven by current sources. To change the LED status

the host radio sends a data message to the control head shift register via the SPI bus. The control

head shift register determines the LED status from the received data and switches the LEDs on or

off via Q5-Q7.

The back light for the keypad is always on. The back light current for the keypad is drawn from the

9.3 V source and controlled by two current sources. The LED current is determined by the resistor

at the emitter of the respective current source transistor.

2.5 Microphone Connector Signals

The MIC_PTT line (J802-3) is grounded when the PTT button on the microphone is pressed. When

released, this line is pulled to 9.3V by R805. Two transistor stages (Q802, Q801 and associated

parts) are used to level shift between 9.3V and 3.3V required for the uP while keeping the same

sense (active low for PTT pressed).

Two of the mic socket lines (J802-2,7) have dual functions depending on the type of microphone or

SCI lead connected. An electronic switch (U803) is used to switch these two lines between mic

keypad operation or SCI operation. The switch (mux) is controlled by the uP through J803-20 with

level shifting (and inversion) provided by transistor Q812. When MUX_CTRL (J803-20) is low the

electronic switch is in the mic keypad mode. The mic socket (J802) pin 2 is connected to the keypad

row line that goes to J803-13 and pin 7 is connected to the keypad column line that goes to J803-12.

When MUX_CTRL (J803-20) is high the electronic switch is in the SCI mode. The mic socket (J802

pin 2) is connected to the SCI line that goes to J803-4 and pin 7 is connected to the BOOT_RES line

that goes to J803-11.

The HOOK line (J802-6) is used to inform the uP which type of microphone or SCI lead is connected

to the microphone socket. The voltage of the HOOK line is monitored by the uP (port PE0,

MIC_SENSE) through a resistor divider on the main board. When the HOOK line is grounded (on

hook condition) or floating (2.8V nominal), the uP sets the mux (U803) for keypad operation to allow

the use of microphones with a keypad. When the HOOK line is connected to 9.3V, the uP sets the

mux for SCI operation. This mode is also used to select low cost mic operation where the gain of the

microphone path is increased (on the main board) to compensate for not having a pre-amp in the low

cost mic.

Controlhead Model for CM140 and CM340 2-3

If the BOOT_RES (J802-7) line is connected to >5V (e.g. 9.3V) at turn-on, the uP will start in boot

mode instead of normal operation. This mode is used to programme new firmware into the FLASH

memory (U404 mainboard).

2.6 Speaker

The controlhead contains a speaker for the receiver audio. The receiver audio signal from the

differential audio output of the audio amplifier located on the radio’s controller is fed via connector

J803-1, 2 to the speaker connector P801 pin 1 and pin 2. The speaker is connected to the speaker

connector P801. The controlhead speaker can be disconnected if an external speaker, connected on

the accessory connector, is used.

2.7 Electrostatic Transient Protection

Electrostatic transient protection is provided for the sensitive components in the controlhead by

diodes VR801, VR802, VR803 and VR804. The diodes limit any transient voltages to tolerable

levels. The associated capacitors provide Radio Frequency Interference (RFI) protection.

2-4 THEORY OF OPERATION

3.0 Controlhead Model for CM160 and CM360

The controlhead contains the internal speaker, the on/off/volume knob, the microphone connector,

several buttons to operate the radio, three indicator Light Emitting Diodes (LED) to inform the user

about the radio status, and an 8 character Liquid Crystal Display (LCD) for alpha - numerical

information e.g. channel number or call address name.

3.1 Power Supplies

The power supply to the control head is taken from the host radio’s 9.3V via connector J103-9, The

9.3V is used for the LEDs and back light, the 5V is used for the LCD driver (U3) and level shifter

(U4). The stabilized 3V is used for the other parts.

3.2 SPI Interface

The host radio (master) communicates with the control head through its SPI bus. Three lines are

connected to the shift register (U8):SPI clock (J103-17), SPI MOSI (J103-16), shift register chip

select (J103-15) and LCD driver chip select (J103-18).

When the host radio needs to send date to the shift register, the radio asserts the shift register chip

select and the data is loaded to the shift register. For example, the host radio sends data to change

display channel or change LED status.

8pinJACK

connector

9.3V LCD

Shift

Backlight

Control

Mux.

Control

Keypads

Keypad

Resistors

PTT

circuit

2-pin speaker

connector

9.3V

LED

Indicators

Row/Column

Control line

Boot_Res / SCI

DTMF

Row/Column

Boot_Res (DTMF-

Column)/ SCI

(DTMF-Row)

Level

Shifter

LCD

Driver

LED

Backlight

8pinJACK

connector

9.3V LCD

Shift

Backlight

Control

Mux.

Control

Keypads

Keypad

Resistors

PTT

circuit

2-pin speaker

connector

9.3V

LED

Indicators

Row/Column

Control line

Boot_Res / SCI

DTMF

Row/Column

Boot_Res (DTMF-

Column)/ SCI

(DTMF-Row)

Level

Shifter

LCD

Driver

LED

Backlight

Controlhead Model for CM160 and CM360 2-5

3.3 Keypad Keys