94C09_XTS2500_BSM XTS Series/XTS2500 Basic Service Manual 6881094C09 B XTS2500
User Manual: -XTS Series/XTS2500 Basic service manual 6881094C09-B
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XTS™2500 XTS™1500 MT 1500 700 - 800 MHz Digital Portable Radios Basic Service Manual Foreword This manual covers all models of the ASTRO™ Digital XTS 2500® Portable Radio, unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum working time, using the pass/fail service approach. This basic level of service is typical of some local service centers, self-maintained customers, and some distributors. Included in this manual are: radio specifications for the 700/800 MHz frequency bands; a general description of ASTRO Digital XTS 2500 models; recommended test equipment, service aids, and tools; radio alignment procedures; fundamental disassembly/reassembly procedures; and general maintenance recommendations. For details on the operation of the radio, or board or component-level troubleshooting, refer to the applicable manuals, available separately. To help you with your selection, a list is provided under “Related Publications” at the front of this manual. Safety Before operating an ASTRO XTS 2500 Radio, please read the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 68P81095C98) to ensure compliance with RF energy exposure limits. Manual Revisions Changes which occur after this manual is printed are described in “FMRs.” These FMRs provide complete information on changes, including pertinent parts list data. 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, but not limited to, 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, reproduced, modified, reverse-engineered, or distributed 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 license to use that arises by operation of law in the sale of a product. Table of Contents ➠ List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Commercial Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Portable Radio Model Numbering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Specifications for 700 MHz/800 MHz Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiv ASTRO Digital XTS 2500 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv ASTRO XTS 1500/MT 1500 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv 1 - Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Notations Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Radio Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FLASHport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 - Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning External Plastic Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 - Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Analog Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transmitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ASTRO Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 RF Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 VOCON Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4 - Recommended Test Equipment and Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Field Programming Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5 - Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Display Radio Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Entering Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 RF Test Mode (Display Radio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 i Table of Contents Control Top and Keypad Test Mode (Display Radio). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering Non-Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF Test Mode (Non-Display Radio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Top and Keypad Test Mode (Non-Display Radio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 15 15 15 16 6 - Radio Alignment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radio Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmit Power Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmit Deviation Balance Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmit Deviation Limit Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front End Filter Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure for 700 MHz Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure for 800 MHz Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure for UHF/VHF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bit Error Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bit Error Rate Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmitter Test Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmitter Test Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 19 21 21 23 25 27 28 28 28 28 28 29 29 29 31 31 31 7 - XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XTS 2500/XTS 1500/MT 1500 Model I Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XTS 2500 Model II Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XTS 2500 Model III Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 33 34 35 8 - Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attach the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attach the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attach the Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attach the Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Speaker Microphone Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attach the Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radio Disassembly—Detailed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover from Chassis Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backup Battery Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keypad and Keypad/Option Board Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speaker, Microphone, and Universal Connector Flex Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTT Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radio Reassembly—Detailed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 37 37 37 37 38 38 38 39 39 39 40 40 40 41 41 41 42 42 42 45 46 47 49 50 51 52 ii Table of Contents PTT Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Keypad and Keypad Option Board Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Display Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Speaker, Microphone, and Universal Connector Flex Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Chassis Assembly Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Backup Battery Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Chassis and Front Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 9 - Radio-Level Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Power-Up Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Operational Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 10 - Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Antennas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Headsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Earpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Remote Speaker Microphones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Surveillance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Belt Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Carrying Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Charger Mounting Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Enhanced and Multi-Unit Line Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 iii Table of Contents iv List of Figures List of Figures Figure 1. XTS 2500 Overall Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Figure 2. Receiver Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Figure 3. RF Block Diagram (Power and Control Omitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Figure 4. Radio Alignment Test Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 5. Tuner Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Figure 6. Typical Softpot Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Figure 7. Radio Information Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Figure 8. Reference Oscillator Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Figure 9. Transmit Power Alignment Screen (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Figure 10. Transmit Deviation Balance Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Figure 11. Transmit Deviation Limit Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Figure 12. Front End Filter Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 13. Bit Error Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Figure 14. Transmitter Test Pattern Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 15. Attaching the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 16. Removing the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 17. Step 1, Attaching the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 18. Step 2, Attaching the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 19. Step 1, Removing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 20. Step 2, Removing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 21. Attaching the Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 22. Removing the Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 23. Removing the Universal Connector Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Figure 24. Attaching the Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Figure 25. Removing the RSM Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 26. Step 1, Attaching the RSM Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 v List of Figures Figure 27. Step 2, Attaching the RSM Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 28. Knob Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 29. Chassis Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 30. Chassis Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Figure 31. Unlatching the Flex Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Figure 32. Removing the Main Board from the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 33. Remove the Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Figure 34. Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 35. Keypad Retainer and Boards Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 36. Display Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Figure 37. Speaker-Microphone Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Figure 38. PTT Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 39. Lock Retainer Catches to Radio Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 40. Reassemble the Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 41. Fastening the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 vi List of Tables List of Tables Table 1.ASTRO XTS 2500 Basic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Table 2.Local Oscillator and First IF Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Table 3.Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Table 4.Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Table 5.Initial Equipment Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Table 6.Front-Panel Access Test-Mode Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Table 7.Test Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Table 8.Test Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Table 9.Receiver Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Table 10.Transmitter Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Table 11.Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Table 12.Transmit Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Table 13.Model I Exploded View Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Table 14.Model II Exploded View Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Table 15.Model III Exploded View Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Table 16.Front Cover from Chassis Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Table 17.Chassis Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Table 18.Backup Battery Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Table 19.Keypad and Keypad/Option Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Table 20.Display Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Table 21.Speaker, Microphone, and Universal connector Flex Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Table 22.PTT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Table 23.Power-Up Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Table 24.Operational Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Table 25.Receiver Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Table 26.Transmitter Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 vii Related Manuals Related Manuals ASTRO XTS 2500 Digital Portable Radio Model I User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C04 ASTRO XTS 2500 Digital Portable Radio Model II User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C05 ASTRO XTS 2500 Digital Portable Radio Model III User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C06 ASTRO XTS 2500 Digital Portable Radio Detailed Service Manual. . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C10 ASTRO XTS 1500 Digital Portable Radio Model 1 User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P04113J52 ASTRO MT 1500 Analog Portable Radio Model 1 User Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P04113J71 viii ➠ Commercial Warranty Limited Warranty MOTOROLA COMMUNICATION PRODUCTS I. What This Warranty Covers And For How Long MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication Products listed below (“Product”) against defects in material and workmanship under normal use and service for a period of time from the date of purchase as scheduled below: ASTRO Digital XTS2500 Portable Units One (1) Year Product Accessories One (1) Year Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period. All replaced parts of Product shall become the property of MOTOROLA. This express limited warranty is extended by MOTOROLA to the original end user purchaser only and is not assignable or transferable to any other party. This is the complete warranty for the Product manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or modifications to this warranty unless made in writing and signed by an officer of MOTOROLA. Unless made in a separate agreement between MOTOROLA and the original end user purchaser, MOTOROLA does not warrant the installation, maintenance or service of the Product. MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by MOTOROLA which is attached to or used in connection with the Product, or for operation of the Product with any ancillary equipment, and all such equipment is expressly excluded from this warranty. Because each system which may use the Product is unique, MOTOROLA disclaims liability for range, coverage, or operation of the system as a whole under this warranty. ix Commercial Warranty II. General Provisions This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product. Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW. III. State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY. This warranty gives specific legal rights, and there may be other rights which may vary from state to state. IV. How To Get Warranty Service You must provide proof of purchase (bearing the date of purchase and Product item serial number) in order to receive warranty service and, also, deliver or send the Product item, transportation and insurance prepaid, to an authorized warranty service location. Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada. V. What This Warranty Does Not Cover A) Defects or damage resulting from use of the Product in other than its normal and customary manner. B) Defects or damage from misuse, accident, water, or neglect. C) Defects or damage from improper testing, operation, maintenance, installation, alteration, modification, or adjustment. D) Breakage or damage to antennas unless caused directly by defects in material workmanship. E) A Product subjected to unauthorized Product modifications, disassemblies or repairs (including, without limitation, the addition to the Product of non-Motorola supplied equipment) which adversely affect performance of the Product or interfere with Motorola's normal warranty inspection and testing of the Product to verify any warranty claim. F) Product which has had the serial number removed or made illegible. G) Rechargeable batteries if: •any of the seals on the battery enclosure of cells are broken or show evidence of tampering. •the damage or defect is caused by charging or using the battery in equipment or service other than the Product for which it is specified. H) Freight costs to the repair depot. x Commercial Warranty I) A Product which, due to illegal or unauthorized alteration of the software/firmware in the Product, does not function in accordance with MOTOROLA's published specifications or the FCC type acceptance labeling in effect for the Product at the time the Product was initially distributed from MOTOROLA. J) Scratches or other cosmetic damage to Product surfaces that does not affect the operation of the Product. K) Normal and customary wear and tear. VI. Patent And Software Provisions MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the extent that it is based on a claim that the Product or parts infringe a United States patent, and MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in any such suit which are attributable to any such claim, but such defense and payments are conditioned on the following: A) that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such claim; B) that MOTOROLA will have sole control of the defense of such suit and all negotiations for its settlement or compromise; and C) should the Product or parts become, or in MOTOROLA's opinion be likely to become, the subject of a claim of infringement of a United States patent, that such purchaser will permit MOTOROLA, at its option and expense, either to procure for such purchaser the right to continue using the Product or parts or to replace or modify the same so that it becomes noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and accept its return. The depreciation will be an equal amount per year over the lifetime of the Product or parts as established by MOTOROLA. MOTOROLA will have no liability with respect to any claim of patent infringement which is based upon the combination of the Product or parts furnished hereunder with software, apparatus or devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary equipment or software not furnished by MOTOROLA which is attached to or used in connection with the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of patents by the Product or any parts thereof. Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute copies of such Motorola software. MOTOROLA software may be used in only the Product in which the software was originally embodied and such software in such Product may not be replaced, copied, distributed, modified in any way, or used to produce any derivative thereof. No other use including, without limitation, alteration, modification, reproduction, distribution, or reverse engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent rights or copyrights. VII. Governing Law This Warranty is governed by the laws of the State of Illinois, USA. xi Commercial Warranty Notes xii ➠ Specifications Portable Radio Model Numbering System Typical Model Number: H Position: 1 4 2 6 3 U 4 C 5 Position 1 - Type of Unit H = Hand-Held Portable 9 7 P 8 W 9 7 10 A 11 N 12 S 13 P 14 0 15 1 16 Positions 13 - 16 SP Model Suffix Position 12 Unique Model Variations C = Cenelec N = Standard Package Positions 2 & 3 - Model Series 46 = XTS 2500 66 = XTS 1500 67 = MT 1500 Position 4 - Frequency Band A = Less than 29.7MHz P = B = 29.7 to 35.99MHz Q= C = 36 to 41.99MHz R= D = 42 to 50MHz S = F = 66 to 80MHz T = G = 74 to 90MHz U= H = Product Specific V = J = 136 to 162MHz W= K = 146 to 178MHz Y = L = 174 to 210MHz Z = M = 190 to 235MHz H 6 336 to 410MHz 403 to 437MHz 438 to 482MHz 470 to 520MHz Product Specific 764 to 870MHz 825 to 870MHz 896 to 941MHz 1.0 to 1.6GHz 1.5 to 2.0GHz Values given represent range only; they are not absolute. Position 5 - Power Level A = 0 to 0.7 Watts B = 0.7 to 0.9 Watts C = 1.0 to 3.9 Watts D = 4.0 to 5.0 Watts E = 5.1 to 6.0 Watts F = 6.1 to 10 Watts Position 6 - Physical Packages A = RF Modem Operation B = Receiver Only C = Standard Control; No Display D = Standard Control; With Display E = Limited Keypad; No Display F = Limited Keypad; With Display G = Full Keypad; No Display H = Full Keypad; With Display J = Limited Controls; No Display K = Limited Controls; Basic Display L = Limited Controls; Limited Display M = Rotary Controls; Standard Display N = Enhanced Controls; Enhanced Display P = Low Profile; No Display Q = Low Profile; Basic Display R = Low Profile; Basic Display, Full Keypad Position 7 - Channel Spacing 1 = 5kHz 5 = 15kHz 2 = 6.25kHz 6 = 20/25kHz 3 = 10kHz 7 = 30kHz 4 = 12.5kHz 9 = Variable/Programmable Position 11 - Version Version Letter (Alpha) - Major Change Position 10 - Feature Level 1 = Basic 6 = Standard Plus 2 = Limited Package 7 = Expanded Package 3 = Limited Plus 8 = Expanded Plus 4 = Intermediate 9 = Full Feature/ 5 = Standard Package Programmable Position 9 - Primary System Type A = Conventional B = Privacy Plus C = Clear SMARTNET D = Advanced Conventional Stat-Alert E = Enhanced Privacy Plus F = Nauganet 888 Series G = Japan Specialized Mobile Radio (JSMR) H = Multi-Channel Access (MCA) J = CoveragePLUS K = MPT1327* - Public L = MPT1327* - Private M = Radiocom N = Tone Signalling P = Binary Signalling Q = Phonenet W = Programmable X = Secure Conventional Y = Secure SMARTNET * MPT = Ministry of Posts and Telecommunications Position 8 - Primary Operation A = Conventional/Simplex B = Conventional/Duplex C = Trunked Twin Type D = Dual Mode Trunked E = Dual Mode Trunked/Duplex F = Trunked Type I G = Trunked Type II H = FDMA* Digital Dual Mode J = TDMA** Digital Dual Mode K = Single Sideband L = Global Positioning Satellite Capable M = Amplitude Companded Sideband (ACSB) P = Programmable * FDMA = Frequency Division Multiple Access ** TDMA = Time Division Multiple Access MAEPF-27327-A xiii Specifications Specifications for 700 MHz/800 MHz Radios All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted GENERAL RECEIVER FCC ID: 700/800 MHz: Temperature Range: Operating: Storage: AZ489FT5804 –30°C to +60°C –40°C to +85°C Power Supply: Nickel-Cadmium Battery (NiCd) or Nickel-Metal-Hydride Battery (NiMH) Battery Voltage Nominal: Range: Transmit Current Drain (Typical): Receive Current Drain (Rated Audio): Standby Current Drain: Recommended Battery: High-Capacity NiCd: or Ultra-High-Capacity NiMH: or High-Capacity NiCd FM: or Ultra–High-Capacity NiMH FM: Optional FM (Factory Mutual) Battery: * FM Intrinsically Safe: Class I, II, III 7.5 Volts 6 to 9 Volts 1250mA 220mA 70mA NTN9815 NTN9858 NTN9816* NTN9857* Height x Width x Depth Radio Less Battery: 6.0" x 2.3" x 1.5" With NiCd Ultra-High Cap.: 6.0" x 2.3" x 2.0" With NiMH Ultra-High Cap.: 6.0" x 2.3" x 2.0" xiv 764 to 767; 773 to 776 MHz 851 to 870 MHz Quieting Sensitivity (typical) (20dBQ): 0.23µV Usable Sensitivity (typical) (12dB SINAD): 0.25µV Intermodulation (typical): –74dB Selectivity (typical) (25kHz Channel): (12.5kHz Channel): –72dB –63dB Spurious Rejection (typical): –75dB 11.0 oz. 20.0 oz. 20.5 oz. RF Power 806 - 870 MHz: 764 - 806 MHz: Frequency Stability (typical) (–30 to +60°C; 25°C ref.): FM Hum and Noise (typical) (25 kHz channel): (12.5 kHz channel): Distortion (typical): Rated Audio: 500mW Modulation Limiting: Channel Spacing: –47dB –40dB 2.5% 12.5/20/25 kHz 1.5ppm Emission (typical conducted): 1.5ppm FM Hum and Noise (typical) (25kHz channel): (12.5kHz channel): 3 Watts 2.5 Watts Frequency Range: 700 MHz: 764 to 767; 773 to 776; 794 to 797; 803 to 806 MHz 800 MHz: 806 to 824; 851 to 870 MHz Frequency Stability (–30+60°C; 25°C reference): Distortion (At Rated Audio; typical): Dimensions Weight Radio Less Battery: With NiCd Ultra-High Capacity: With NiMH Ultra-High Capacity: Frequency Range: 700 MHz: 800 MHz: TRANSMITTER Emissions Designators: -75dBc<1GHz –43dB –40dB 2% 25 kHz chnls ±5.0kHz 20 kHz chnls ±4.0kHz 12.5 kHz chnls ±2.5kHz 16K0F3E,11K0F3E, 8K10F1D, and 8K10F1E Specifications ASTRO Digital XTS 2500 Model Chart MODEL NUMBER H46UCC9PW5AN H46UCF9PW6AN H46UCH9PW7AN ITEM NUMBER X X X 1505579Z01 4385665D01 X X X X X X NTN9815 X X X NAF5037 HLN6853 X X X X NTN9637 X NTN9638 X NTN9639 X X X NUF6541 X 6881094C04 X 6881094C05 X 6881094C06 DESCRIPTION 700/800 MHz, 1-3 Watts, ASTRO Digital XTS 2500 Model I 700/800 MHz, 1-3 Watts, ASTRO Digital XTS 2500 Model II 700/800 MHz, 1-3, Watts ASTRO Digital XTS 2500 Model III DESCRIPTION Cover, Dust, Accessory Connector Adapter, Remote Speaker Microphone Hi Capacity NiCd Battery 1/2 Wave Whip Antenna, 800 MHz 2.250 inch Belt Clip Front Cover Kit, Model I Front Cover Kit, Model II Front Cover Kit, Model III RF/VOCON Board Kit User’s Guide, Model I User’s Guide, Model II User’s Guide, Model III Notes:X=Item Included ASTRO XTS 1500/MT 1500 Model Chart MODEL NUMBER H66UCC9PW5AN H67UCC9PW5AN ITEM NUMBER X X 1585746D04 X X 4385665D01 X X NTN9815_ X X NAF5037_ X X HLN6853_ X PMTN4080_ X PMTN4079_ X X PMUF6541_ X 6804113J52 X 6804113J71 DESCRIPTION 700/800 MHz, 1-3 Watts, ASTRO Digital XTS 1500 Model l 700/800 MHz, 1-3, Watts ASTRO Analog MT 1500 Model I DESCRIPTION Cover, Dust, Accessory Connector Adapter, Remote Speaker Microphone Hi Capacity NiCd Battery 1/2 Wave Whip Antenna, 800 MHz 2.250 inch Belt Clip Front Cover Kit, XTS1500 Model I Front Cover Kit, MT1500 Model I RF/VOCON Board Kit User’s Guide, XTS1500 Model I User’s Guide, MT1500 Model I Notes:X=Item Included xv Specifications Notes xvi 1 Introduction General This manual covers information needed for level one and two troubleshooting. Level one troubleshooting consists of radio programming, tuning (via CPS/tuner), knobs replacement, and installation and removal of antenna, belt clip, battery, and universal connector cover. Level two troubleshooting consists of everything listed in level one, plus the identification and replacement of Field Replaceable Units (FRUs). No soldering will be allowed; only board swapping. Included in this manual are radio specifications for the 700/800 MHz frequency bands, a general description of ASTRO Digital XTS 2500 models, recommended test equipment, service aids, radio alignment procedures, general maintenance recommendations, and procedures for basic assembly and disassembly. Notations Used in This Manual Throughout the text in this publication, you will notice the use of warnings, cautions, and notes. These notations are used to emphasize that safety hazards exist, and care must be taken and observed. NOTE: An operational procedure, practice, or condition, etc., which is essential to emphasize. ! CAUTION indicates a potentially hazardous situation which, if not avoided, may result in equipment damage. Caution ! WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury. WARNING ! DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury. DANGER 1 Introduction Radio Description The ASTRO Digital XTS 2500 radios are among the most sophisticated two-way radios available. One of the newest in a long line of quality Motorola products, the ASTRO Digital XTS 2500 radio provides improved voice quality across more coverage area. The digital process, called “embedded signalling,” intermixes system signalling information with digital voice, resulting in improved system reliability, and the capability of supporting a multitude of advanced features. Such features add up to better, more cost-effective two-way radio communications. ASTRO Digital XTS 2500 radios are available in three basic models. Table 1 describes their basic features. Table 1. ASTRO XTS 2500 Basic Features Feature Model I Model II Model III Display None LCD 6 lines/ 12 characters per line LCD 6 lines/ 12 characters per line Keypad None 3 x 2 button with 4-Position Navigation button 3 x 6 button with 4-Position Navigation button Channel Capability 48 160 160 Dialing from Prestored List No Yes Yes Programmable Softkeys No Yes Yes FLASHport 2 The ASTRO® Digital XTS 2500 radio utilizes Motorola’s revolutionary FLASHport™ technology. FLASHport makes it possible to add software that drives the radio’s capabilities both at the time of purchase and later on. Previously, changing a radio’s features and capabilities meant significant modifications, or buying a new radio. But now, just as a computer can be loaded with different software, the radio’s features and capabilities can be upgraded with FLASHport software. Basic Maintenance 2 Introduction to This Section This section of the manual describes preventive maintenance and handling precautions. Each of these topics provides information vital to the successful operation and maintenance of your radio. Preventive Maintenance ASTRO Digital XTS 2500 radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. Inspection Check that the external surfaces of the radio are clean, and that all external controls and switches are functional. A detailed inspection of the interior electronic circuitry is not needed. Cleaning The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external surfaces of the radio. External surfaces include the 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, such as JOY®, in water. ! Caution Cleaning External Plastic Surfaces 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. The detergent-water solution should be applied sparingly with a stiff, non-metallic, shortbristled 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. 3 Basic Maintenance Handling Precautions Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices, are used in this family of radios. While these devices have many attributes, their characteristics make them susceptible to damage by electrostatic discharge (ESD) or highvoltage 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 this radio, and are especially important in low-humidity conditions. Never heat the RF PA above 210°C while performing repair or rework procedures to maintain its integrity. Utilizing a Chipmaster (R1319 or R1321) top-side set point of 215°C and a Dragon (R1427) bottom-side pre-heat set point of 180°C has proven to satisfy this condition during the rework of the RF PA (note: the RF PA temperature does not reach the Chipmaster’s internal set point temperature). All other parts on the transceiver board can be reworked with Chipmaster top-side heat alone. 4 3 Basic Theory of Operation General Overview The ASTRO Digital XTS 2500 radio is a wideband, synthesized, fixed-tuned radio available in the 700/800 MHz bands. All XTS 2500 radios are capable of both analog operation (12.5 kHz or 25 kHz bandwidths) and digital ASTRO mode operation (12.5 kHz only). The ASTRO Digital XTS 2500 radio includes the following major assemblies (see Figure 1): • Main Board: contains the microcontrol unit (MCU) and its associated memory and memory management integrated circuit (IC), the audio power amplifier, and a switching regulator. The board also contains the digital signal processor (DSP) and its support IC and associated memories. It further contains all transmit, receive, and frequency generation circuitry, including the digital receiver back-end IC and the reference oscillator. • Universal Flex: contains the universal connector, speaker, and microphone. • Display (Models II and III only): a six-line, 12-character, liquid-crystal display (LCD). • Keypad (Models II and III only): - Model II: a 3 x 2 keypad - Model III: a 3 x 6 keypad. Universal Flex 13 Antenna 20 J650 (Side Connector, Controls, LEDs, Speaker, Microphone) J101 Main Board 45 Keypad 3 J601 B500 20 Note: indicates 20 wires 7.5V Battery 22 Display Figure 1. XTS 2500 Overall Block Diagram 5 Basic Theory of Operation Analog Mode of Operation Receiving When the radio is receiving (see Figure 2), the signal comes from the antenna connector to the radio board, passes through the RX/TX antenna switch and into the receiver front end. A 15dB step attenuator is included in the front end to provide additional protection against strong signals. The attenuator is controlled by a DSP based algorithm that continuously monitors signal strength. When the ON threshold is exceeded (approximately -95dBm), the attenuator is activated via a DAC in the PCIC by the host. The attenuator remains activated until the signal drops below the OFF threshold (approximately -115dBm including the 15dB attenuation). Hysterisis and timer functions are included in the algorithm to enhance performance. The algorithm controlling the attenuator is enabled via the CPS for each personality. When the algorithm is disabled, the attenuator is essentially a short circuit from input to output.The signal is then filtered, amplified, and mixed with the first localoscillator signal generated by the voltage-controlled oscillator (VCO). RX Front End RF Input Harmonic Filter Antenna Switch Tuneable Preslector Attenuator RF Amp Tuneable Preselector Filter 1st LO 1st Mixer ABACUS III - RX Back End XTAL Filter 3 ADC LO RX_SSI_ DATA to VOCON Board CKO MAEPF-27278-O Figure 2. Receiver Block Diagram The resulting intermediate frequency (IF) signal is fed to the IF circuitry, where it is again filtered and amplified. This amplified signal passes to the digital back-end IC, where it is mixed with the second local oscillator to create the second IF at 450 kHz. It is then converted to a digital bit stream and mixed a third time to produce a baseband signal. This signal is passed to the VOCON circuitry through a current-driven differential output. In the VOCON circuitry, the digital-signal processor (DSP) support IC digitally filters and discriminates the signal, and passes it to the DSP. The DSP decodes the information in the signal and identifies the appropriate destination for it. For a voice signal, the DSP routes the digital voice data to the CODEC for conversion to an analog signal. The CODEC then presents the signal to the audio power amplifier, which drives the speaker. For signalling information, the DSP decodes the message and pass it to the microcontrol unit. Transmitting 6 When the radio is transmitting (see Figure 3), microphone audio is passed through gain stages to the CODEC where the signal is digitized. The CODEC passes digital data to the DSP where pre-emphasis and low-pass (splatter) filtering are done. The DSP passes this signal to a digital-to-analog (D/A) converter where it is reconverted into an analog signal and scaled for application to the voltage-controlled oscillator as a modulation signal. Basic Theory of Operation Loop Filter EPIC Y200 Power Module Q101 TX TX Driver VCOBIC Buffer Amplifier U250 Q216 U101 Reference Oscillator VCO Directional Coupler U106 RF Power Detector D103 FracN U201 Antenna Switch VCO 3 MOD IN From TX_SSI PCIC U102 LPF FL200 DAC U203 VCO Harmonic Filter To Antenna ABACUS III U401 3 To RX_SSI Crystal Filter FL3 Sample Clk Mixer U1 Preselector Filter FL2 RX LNA Q1 Attenuator Preselector Filter FL1 2ND LO MAEPF-27322-O Figure 3. RF Block Diagram (Power and Control Omitted) Transmitted signalling information is accepted by the DSP from the microcontrol unit, coded appropriately, and passed to the D/A converter, which handles it the same as a voice signal. Modulation information is passed to the synthesizer along the modulation line. A modulated carrier is provided to the RF PA, which transmits the signal under dynamic power control. ASTRO Mode of Operation In the ASTRO mode (digital mode) of operation, the transmitted or received signal is limited to a discrete set of deviation levels, instead of continuously varying. The receiver handles an ASTRO-mode signal identically to an analog-mode signal up to the point where the DSP decodes the received data. In the ASTRO receive mode, the DSP uses a specifically defined algorithm to recover information. In the ASTRO transmit mode, microphone audio is processed identically to an analog mode with the exception of the algorithm the DSP uses to encode the information. This algorithm will result in deviation levels that are limited to discrete levels. RF Basic Theory of Operation The receiver front end consists of a preselector, an RF amplifier, a second preselector, and a mixer. Both preselectors are varactor-tuned, two-pole filters, controlled by the microcontroller unit through the D/A IC. The RF amplifier is a dual-gate, gallium-arsenidebased IC. The mixer is a double-balanced, active mixer, coupled by transformers. Injection is provided by the VCO through an injection filter. See Table 2 for local oscillator (LO) and first IF information. Table 2. Local Oscillator and First IF Frequencies LO Frequency Range First IF Frequency 700 MHz 800 MHz -- -- 109.65 MHz 109.65 MHz The frequency generation function is performed by three ICs and associated circuitry. The reference oscillator provides a frequency standard to the synthesizer/prescaler IC, which controls the VCOB IC. The VCOB IC actually generates the first LO and transmit-injection 7 Basic Theory of Operation signals and buffers them to the required power level. The synthesizer/prescaler circuit module incorporates frequency-division and comparison circuitry to keep the VCO signals stable. The synthesizer/prescaler IC is controlled by the microcontrol unit through a serial bus. The receiver back end consists of a two-pole crystal filter, an IF amplifier, a second twopole crystal filter, and the digital back-end IC. The two-pole filters are wide enough to accommodate 4 kHz modulation. Final IF filtering is done digitally in the DSP. The digital back-end IC consists of an amplifier, the second mixer, an IF analog-to-digital converter, a baseband down-converter, and a 2.4 MHz synthesis circuit to provide a clock to the DSP-support IC on the VOCON circuitry. The second LO is generated by discrete components external to the IC. The output of the digital back-end IC is a digital bit stream that is current driven on a differential pair for a reduction in noise generation. The transmitter consists of an RF driver IC that gets an injection signal from the VCO and a final-stage power amplifier. Transmit power is controlled by a power-control IC that monitors the output of a directional coupler and adjusts PA control voltages correspondingly. The signal passes through a RX/TX switch that uses PIN diodes to automatically provide an appropriate interface to transmit or receive signals. Antenna selection is done mechanically in the control top. VOCON Basic Theory of Operation The vocoder and controller (VOCON) circuitry contains the radio’s microcontrol unit with its memory and support circuits, the DSP, its memory devices, and the DSP-support IC, voltage regulators, audio, and power control circuits. Connected to the VOCON circuitry are the display board, RF circuitry, keypad board, and controls/universal flex. The microcontrol unit controls receive/transmit frequencies, power levels, display, and other radio functions, using either direct logic control or serial communications paths to the devices.The microcontrol unit executes a stored program located in the FLASH ROM. Data is transferred to and from memory by the microcontrol unit data bus. The memory location from which data is read, or to which data is written, is selected by the address lines. The DSP-support IC is supplied with a 16.8 MHz clock from the RF circuitry. Both the DSP and the microprocessor have their clocks generated by the DSP-support IC. They can both be adjusted so that the harmonics do not cause interference with the radio’s receive channel. The regulator and power-control circuits include 3.3-volt analog, 3.3-volt digital, and 5volt regulators. The audio PA is sourced from 7.5V. The regulator’s power-down mode is controlled by the microcontrol unit, which senses the position of the on/off switch. The 5volt regulator has an error pin for low-voltage resets. The DSP performs signalling and voice encoding and decoding, as well as audio filtering and volume control. This IC performs Private-Line®/Digital Private Line™ (PL/DPL) encode and alert-tone generation. The IC transmits pre-emphasis on analog signals and applies a low-pass (splatter) filter to all transmitted signals. It requires a clock on the EXTAL pin. An 8 kHz interrupt signal generated by the DSP-support IC is also required for functionality. It is programmed using parallel programming from the microcontrol unit. The audio CODEC performs analog-to-digital (A/D), and digital-to-analog conversions on audio signals. The DSP controls squelch, deviation, and executes receiver and transmitter filtering. The DSP-support IC receives a 2.4 MHz clock, and also receives data, which it formats for the DSP. 8 Recommended Test Equipment and Service Aids Recommended Test Equipment 4 The list of equipment contained in Table 3 includes all of the standard test equipment required for servicing two-way portable radios, as well as several unique items designed specifically for servicing this family of radios. The “Characteristics” column is included so that equivalent equipment may be substituted; however, when no information is provided in this column, the specific Motorola model listed is either a unique item or no substitution is recommended. Table 3. Recommended Test Equipment Motorola Model Number Description Characteristics This monitor will substitute for items with an asterisk (*). Application R2600 Series Communications System Analyzer Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment. Fluke 8012 Digital Multimeter Recommended for ac/dc voltage and current measurements R1150_* Code Synthesizer Injection of audio and digital signalling codes R1377_* AC Voltmeter 1mV to 300V, 10-Megohm input impedance Audio voltage measurements R1094_ Dual-Trace Oscilloscope 20 MHz bandwidth 5mV to 5V/ division Waveform measurements S1350_* Wattmeter 50-ohm, ±5% accuracy ST1213_ (VHF)* Plug-In Element 10 watts, maximum Transmitter power output measurements ST1223_ (UHF)* RF Dummy Load 0-1000 MHz, 300W R1065_ Load Resistor 10-watt Broadband For use with wattmeter S1339_ RF Millivolt Meter 100µV to 3V RF RF-level measurements R1013_* SINAD Meter S1347_ or S1348_ (programmable) DC Power Supply Receiver sensitivity measurements 0-20Vdc, 0-5 Amps current limited Bench supply for 7.5Vdc *The R2600 Series monitor will substitute for these items. 9 Recommended Test Equipment and Service Aids Service Aids Refer to Table 4., “Service Aids,” for a listing and description of the service aids designed specifically for servicing this family of radios. These kits and/or parts are available from the Motorola Parts Division offices listed in the “Replacement Parts Ordering” section located on the inside back cover of this manual. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. Table 4. Service Aids Motorola Part Number Description Application 6685666D01 Chassis Opener Tool Used to remove radio knobs and to separate chassis from Front Cover. RKN-4106_ RS232/Radio/Test Set Cable Connects radio to RLN4460 Test Box and to RS232 computer connector (DB9). 0180305G54 Battery Eliminator Interconnects radio to power supply. RLN-4460 Portable Test Set Enables connection to the universal connector. Allows switching for radio testing. RVN-4181_ Customer Programming Software Customer Programming Software (CPS)/Tuner on one CD-ROM. 58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test equipment. RKN4105 USB/Radio/Test Set Cable Connects radio to RLN4460 test box and to USB computer connector. 8180384M37 Test Fixture Provides for troubleshooting the radio board when the back casting is removed. NOTE: Field Programming Equipment 10 The Radio Interface Box (RIB), Smart Radio Interface Box (SRIB), and any cables that connect with those boxes are incompatible with the XTS 2500 radio and should NOT be used. This family of radios can be aligned and programmed in the field. This requires specific equipment and special instructions. Refer to the applicable “CPS On-line Help” for complete field programming information. 5 Performance Checks Introduction to This Section This section covers performance checks used to verify that the radio meets published specifications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule. Checks should be performed if radio performance degradation is suspected. Setup Supply voltage can be connected from the battery eliminator. The equipment required for alignment procedures is connected as shown in the “Radio Alignment Test Setup” diagram (Figure 4). 30 dB PAD SYSTEM ANALYZER OR COUNTER 30 dB PAD WATTMETER TRANSMIT SMA-BNC 58-80348B33 BATTERY ELIMINATOR 0180305G54 BNC RF GENERATOR RECEIVE SET TO APPROX. 450mV FOR Tx RADIO AUDIO IN TX TEST SET RLN-4460 RX AUDIO GENERATOR SINAD METER AC VOLTMETER COMPUTER PROGRAM/TEST CABLE RKN4106 MEASURE 80mV FOR Tx Figure 4. Radio Alignment Test Setup 11 Performance Checks Initial equipment control settings should be as indicated in the Table 5, and should hold for all alignment procedures except as noted. Table 5. Initial Equipment Control Settings System Analyzer Test Set Power Supply Monitor Mode: Pwr Mon Spkr Set: A Voltage: 7.5Vdc RF Attn: –70dB Spkr/Load: Speaker DC On/Standby: Standby AM, CW, FM: FM PTT: OFF (center) Volt Range: 10Vdc O'scope Source: Mod O'scope Horiz: 10mSec/Div O'scope Vert: 2.5 kHz/Div O'scope Trig: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: Mid CW Monitor Vol: 1/4 CW Current: 2.5Amps Display Radio Test Mode Entering Display Radio Test Mode 1. Turn the radio on. 2. Within 10 seconds after “Self Test” is complete, press Side button 3 five times in succession. 3. The radio will show a series of displays that will give information regarding various version numbers and subscriber specific information. The displays are described in Table 6. Table 6. Front-Panel Access Test-Mode Displays Name of Display Description Appears “SERVICE” The literal string indicates the radio has entered test mode. Always. Host Software Version The version of host firmware. Always. DSP Software Version The version of DSP firmware. Always. Model Number The radio’s model number as programmed in the codeplug. Always. Serial Number The radio’s serial number as programmed in the codeplug. Always. ROM Size The memory capacity of the host FLASH part. Always. FLASHcode The FLASH codes as programmed in the codeplug. Always. NOTE: 12 All displays are temporary and will disappear without any user intervention. If information is longer than the physical length of the radio’s display, the information will wrap around to the next display. After the last display, “RF TEST” will be displayed. For non-display radios, refer to the CPS Radio Information Screen. Performance Checks 4a. Press Side Button 1 to stop the displays and put the radio into the Control Top and Keypad test mode (display radio). The test mode menu “CH TEST” will be displayed. Go to the “Control Top and Keypad Test Mode (Display Radio)” section on page 14. NOTE: Each press of Side Button 1 will toggle between “CH TEST” and “RF TEST.” OR 4b. Press the Top Programmable Button to stop the displays and put the radio into the RF test mode (display radio). The test mode menu “1 CSQ.” will be displayed, indicating test frequency 1, Carrier SQuelch mode. Go to “RF Test Mode (Display Radio)” in the next section. RF Test Mode (Display Radio) When the ASTRO Digital XTS 2500 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment via a special routine, called TEST MODE or “air test.” 1. Each additional press of Side Button 3 will advance to the next test channel. (Refer to Figure 7.) 2. Pressing Side Button 2 will scroll through and access test environments as shown in Figure 8. NOTE: Transmit into a load when keying a radio under test. Table 7. Test Frequencies Frequency 700/800 MHz RX 700/800 MHz TX F1 764.0625 764.0125 F2 769.0625 769.0125 F3 775.9375 775.9875 F4 851.0625 794.0125 F5 860.0625 809.0125 F6 869.9375 823.9875 F7 851.0625 851.0125 F8 860.0625 860.0125 F9 869.9375 869.8875 13 Performance Checks Table 8. Test Environments No. of Beeps Display 1 CSQ Carrier Squelch RX: unsquelch if carrier detected TX: mic audio 3 TPL Tone Private-Line RX: unsquelch if carrier and tone (192.8 Hz) detected TX: mic audio + tone (192.8 Hz) 11 AST ASTRO RX: none TX: 1200Hz tone ** 12 USQ Carrier Unsquelch RX: unsquelch always TX: mic audio Description Function ** All deviation values are based on deviation tuning of this mode. Control Top and Keypad Test Mode (Display Radio) This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected. 1. Press and hold the Top Programmable Button; all segments on the display will light, and the LED on the control top will illuminate a red color. 2. Release the Top Programmable Button; “3/0” appears, indicating that the Top Programmable Button is in the open condition. 3. Press the Top Programmable Button again; “3/1” appears, indicating that the Top Programmable Button is in the closed condition. 4. Rotate the Mode/Zone Selector Switch; “4/0” through “4/15” appears, indicating that the selector switch is in mode/zone position 1 through 16. 5. Rotate the Three-Position Concentric Switch; “65/0” through “65/2” appear. 6. Cycle through the 16-Position Programmable Switch; “67/0,” “67/1,” and “67/2” appear. 7. Rotate the Volume Control; “2/0” through “2/255” appear. 8. Press Side Button 1; “96/1” appears; release, “96/0” appears. 9. Press Side Button 2; “97/1”appears; release, “97/0” appears. 10. Press Side Button 3; “98/1”appears; release, “98/0” appears. 11. Press the PTT Switch; “1/1” appears; release, “1/0” appears. 12. Keypad Checks: Model III Only— 14 - Press 0, “48/1” appears; release, “48/0” appears. - Press 1, “49/1” appears; release, “49/0” appears. - Press 2, “50/1” appears; release, “50/0” appears. - Press 3, “51/1” appears; release, “51/0” appears. - Press 4, “52/1” appears; release, “52/0” appears. - Press 5, “53/1” appears; release, “53/0” appears. - Press 6, “54/1” appears; release, “54/0” appears. Performance Checks - Press 7, “55/1” appears; release, “55/0” appears. - Press 8, “56/1” appears; release, “56/0” appears. - Press 9, “57/1” appears; release, “57/0” appears. - Press *, “58/1” appears; release, “58/0” appears. - Press #, “59/1” appears; release, “59/0” appears. All Display Models— - Press V, “128/1” appears; release, “128/0” appears. - Press h, “129/1” appears; release, “129/0” appears. - Press U, “130/1” appears; release, “130/0” appears. - Press the left-hand D key on the top row of keys, “131/1” appears; release, “131/ 0” appears. - Press the center E key, “132/1” appears; release, “132/0” appears. - Press the right-hand F key, “133/1” appears; release, “133/0” appears. - Press @ button, “134/1” appears; release, “134/0” appears. - Press X (up arrow), “135/1 appears; release, “135/0” appears. - Press Y (down arrow), “136/1” appears; release, “136/0” appears. Non-Display Radio Test Mode Entering NonDisplay Radio Test Mode 1. Turn the radio on. 2. Within 10 seconds after the top green LED turns off, press Side button 3 five times in succession. 3a. Press Side Button 1 to put the radio into the Control Top and Keypad test mode (nondisplay radio). Go to the “Control Top and Keypad Test Mode (Non-Display Radio)” section on page 16. NOTE: Each press of Side Button 1 will toggle between Control Top and Keypad test mode (non-display radio) and RF test mode (nondisplay radio). OR 3b. Press the Top Programmable Button to stop the displays and put the radio into the RF test mode (non-display radio). Go to “RF Test Mode (Non-Display Radio)” in the next section. RF Test Mode (NonDisplay Radio) When the ASTRO Digital XTS 2500 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting according to the customer codeplug configuration. However, when the unit is on the bench for testing, alignment or repair, it must be removed from its normal environment via a special routine, called TEST MODE or “air test.” 1. Each additional press of Side Button 3 will advance to the next test channel. (Refer to Table 7 on page 13.) The channel number is represented by the number of beeps 15 Performance Checks emitted by the radio after the button press (for example, five beeps indicates channel 5). 2. Pressing Side Button 2 will scroll through and access test environments as shown in Table 8 on page 14. The test environment is represented by the number of beeps emitted by the radio after the button press (for example, 11 beeps indicate AST). NOTE: Transmit into a load when keying a radio under test. Control Top and Keypad Test Mode (NonDisplay Radio) This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected. 1. Press and hold the Top Programmable Button; the LED on the control top lights red, and the radio beeps. 2. Release the Top Programmable Button; the radio beeps again. 3. Press the Top Programmable Button again; the radio beeps, indicating that the Top Programmable Button is in the closed condition. 4. Rotate the Three-Position Concentric Switch; the radio beeps in each switch position. 5. Rotate the Mode/Zone Selector Switch; the radio beeps in each switch position. 6. Cycle through the 16-Position Programmable Switch; the radio beeps in each switch position. 7. Rotate the Volume Control; the radio beeps at each new volume setting. 8. Press Side Button 1; the radio beeps. 9. Press Side Button 2; the radio beeps. 10. Press Side Button 3; the radio beeps. 16 Performance Checks Table 9. Receiver Performance Checks Test Name Reference Frequency System Analyzer Radio Test Set Comments Mode: PWR MON 4th channel test frequency* TEST MODE, 4 CSQ output at antenna PTT to continuous (during the performance check) Frequency error to be ≤ ±1.3 kHz TEST MODE, 4 CSQ PTT to OFF (center); meter selector to Audio PA Set volume control to 3.74Vrms Monitor: Frequency error. Input at RF In/Out Rated Audio Mode: GEN Output level: 1.0mV RF 4th channel test frequency* Mod: 1 kHz tone at 3 kHz deviation Monitor: DVM: ac Volts Distortion As above, except to distortion As above As above Distortion < 3.0% Sensitivity (SINAD) As above, except SINAD; lower the RF level for 12dB SINAD As above PTT to OFF (center) RF input to be < 0.35µV Noise Squelch Threshold (only radios with conventional system need to be tested) RF level set to 1mV RF As above PTT to OFF (center); meter selection to Audio PA; spkr/load to speaker Set volume control to 3.74Vrms As above, except change frequency to a conventional system. Raise RF level from zero until radio unsquelches. Out of TEST MODE; select a conventional system As above Unsquelch to occur at < 0.25µV. Preferred SINAD = 5-8dB *See Table 7 on page 13. 17 Performance Checks Table 10. Transmitter Performance Checks Test Name Reference Frequency System Analyzer Mode: PWR MON 4th channel test frequency* Radio Test Set TEST MODE, 4 CSQ PTT to continuous (during the performance check). Frequency error to be ≤ ±1.3 kHz. Monitor: Frequency error. Input at RF In/Out Comments Power RF As above As above, 4 CSQ As above Refer to Maintenance Specifications page in front of manual. Voice Modulation Mode: PWR MON 4th channel test frequency* atten to –70, input to RF In/ Out. As above, 4 CSQ As above, meter selector to mic Deviation: ≥ 4.1 kHz but ≤ 5.0 kHz Monitor: DVM, ac Volts. Set 1 kHz Mod Out level for 0.025Vrms at test set, 80mVrms at ac/dc test set jack Voice Modulation (internal) Mode: PWR MON 4th channel test frequency* atten to –70, input to RF In/ Out TEST MODE, 4 CSQ, output at antenna Remove modulation input Press PTT switch on radio. Say “four” loudly into the radio mic. Measure deviation: ≥ 4.1 kHz but ≤ 5.0 kHz PL Modu-lation (radios with conven-tional, clear mode, coded squelch oper-ation only) Change frequency to a conventional transmit frequency Conventional coded squelch personality (clear mode operation) 4 TPL As above Deviation: ≥ 500Hz but ≤ 1000Hz Talkaround Modulation (radios with conventional, clear mode, talk-around operation only) Change frequency to conventional talk-around frequency. Conventional talkaround personality (clear mode operation) 1 CSQ As above Deviation: ≥ 4.1 kHz but ≤ 5.0 kHz Mode: PWR MON deviation, attenuation to –70, input to RF In/Out. Monitor: DVM, ac volts Set 1 kHz Mod Out level for 25mVrms at test set. *See Table 7 on page 13 18 6 Radio Alignment Procedures Introduction to This Section This section describes both receiver and transmitter radio alignment procedures. General A personal computer (PC) and tuner software are required to align the radio. Refer to the applicable manual for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the PC and to a universal test set as shown in Figure 4. Radio Alignment Test Setup on page 11. ! Caution These procedures should only be attempted by qualified service personnel. Failure to perform alignment procedures properly may result in seriously degraded radio or system performance. Select Tuner from the START menu. To read the radio, use the File ➝ Read Device menu or click on . Figure 5 illustrates how the alignment screens are organized. To access a screen, double-click on the desired screen name in the Tuner menu. 123ABC1234 Radio Information Transmitter Alignments Reference Oscillator (page 21) Tx Power High (page 23) Tx Power Mid (page 23) Tx Power Low (page 23) Tx Deviation Balance (page 25) Tx Deviation Limit (page 27) Receiver Alignments Front End Filter (page 28) Performance Testing Bit Error Rate (page 29) Transmitter Test Pattern (page 31) Figure 5. Tuner Menu Layout 19 Radio Alignment Procedures The alignment screens introduce the concept of the “softpot,” an analog SOFTwarecontrolled POTentiometer used for adjusting all transceiver alignment controls. ! Caution Do NOT switch radios in the middle of any Alignment procedure. Always left-click the Close button on the screen to return to the MAIN menu screen before disconnecting the radio. Improper exits from the Alignment screens may leave the radio in an improperly configured state and result in seriously degraded radio or system performance. Each alignment screen provides the ability to increase or decrease the softpot value by using a slider or the screen’s UP/DOWN arrow keys (▲ ▼), or by entering the new value from the keyboard. A graphical scale on the display indicates the minimum, maximum, and proposed value of the softpot; see Figure 6. Figure 6. Typical Softpot Screen Adjusting the softpot value sends information to the radio to increase (or decrease) a voltage in the corresponding circuit. For example, left-clicking the UP arrow ▲ on the Reference Oscillator screen instructs the radio’s microcomputer to increase the voltage across a varactor in the reference oscillator, which increases the frequency. In ALL cases, the softpot value is just a relative number corresponding to a digital-toanalog (D/A) generated voltage in the radio. Perform the following procedures in the sequence indicated. NOTE: Some of the following screens may vary depending upon the radio under test and the version of tuner software you are using. Refer to the software’s on-line help. 20 Radio Alignment Procedures Radio Information Figure 7 shows a typical Radio Information screen. Figure 7. Radio Information Screen Reference Oscillator Alignment Adjustment of the reference oscillator is critical for proper radio operation. Improper adjustment will result not only in poor operation, but also in a misaligned radio that will interfere with other users operating on adjacent channels. For this reason, the reference oscillator should be checked every time the radio is serviced, or once a year, whichever comes first. The frequency counter used for this procedure must have a stability of 0.1 ppm (or better). NOTE: Reference oscillator alignment is required after replacing (or servicing) the transceiver board. This test can be done with either the R-2670 Communication Analyzer or the 8901_Modulation Analyzer. • • Initial setup using the R-2670 Communication Analyzer: - RF Control: MONITOR - B/W: WB - Freq: CPS frequency under test - Attenuation: 20dB - Mon RF in: RF I/O - Meter: RF Display - Mode: STD - Input Level: uV or W - Display: Bar Graphs - Squelch: Mid-range or adjust as necessary Initial setup using the 8901_ Series Modulation Analyzer: 21 Radio Alignment Procedures - Press the green Automatic Operation button on the analyzer. - Press the FREQ key. - Type 7.1 followed by SPCL button to set the 8901B_ modulation analyzer for maximum accuracy. To align the reference oscillator: 1. Select the Reference Oscillator alignment screen. See Figure 8. Figure 8. Reference Oscillator Alignment Screen 2. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting. 3. Measure the transmit RF frequency with your service monitor. 4. Adjust the reference oscillator’s softpot value until the measured value is as close as possible to the frequency shown on the screen. See Table 11. Table 11. Reference Oscillator Alignment Band Target VHF ±100 Hz UHF R1 (380-470 MHz) ±100 Hz 700 MHz/800 MHz ±100 Hz 5. Left-click the Program All button on the screen to dekey the radio and save the tuned values. 6. Left-click the Close button on the screen to return to the Transmitter Alignments menu. 22 Radio Alignment Procedures Transmit Power Alignment This alignment procedure adjusts the transmit power of the radio and must be performed for three different power levels (Low, Mid, High), at multiple frequencies for each power level, to allow for proper alignment across the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in each zone. NOTES: 1. • The same softpot attenuation value will result in DIFFERENT radio output power levels at different frequencies. • All power measurements are to be made at the antenna port. • Transmit Power alignment is required after replacing (or servicing) the transceiver board. Select the TX Power alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 9. 2. Left-click the desired frequency field (starting with the highest frequency shown). 3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting. 4. Measure the transmit power of the radio with a service monitor. 5. Adjust the softpot value until the required power, as shown in Table 12, is indicated on the service monitor. Table 12. Transmit Power Settings Test Frequencies Power Level 700/800 MHz Low (1 Watt) 1.2 - 1.4W Mid (2 Watts) 2.5W - 2.7W High (3 Watts) 3.2W - 3.4W 6. Repeat the above process for all frequencies and all power levels. 23 Radio Alignment Procedures 7. Left-click the Program All button on the screen to dekey the radio and save the tuned values. Left-click the Close button on the screen to return to the Transmitter Alignments menu. Figure 9. Transmit Power Alignment Screen (Typical) 24 Radio Alignment Procedures Transmit Deviation Balance Alignment This alignment procedure balances the modulation contributions of the low- and highfrequency portions of a baseband signal. Proper alignment is critical to the operation of signalling schemes that have very low frequency components (for example, DPL) and could result in distorted waveforms if improperly adjusted. This procedure needs to be performed at multiple frequencies to allow for proper alignment across the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in each zone. NOTE: This alignment is required after replacing (or servicing) the VOCON board or the transceiver board. Proper alignment requires a modulation analyzer or meter with a frequency response to less than 10 Hz modulating frequency. The modulation analyzer settings during this test should be set for average deviation, a 15 kHz low-pass filter, no de-emphasis, and no high-pass filter, if these settings are supported. This test can be done with either the R-2670 Communication Analyzer or the 8901_ Series Modulation Analyzer. The method of choice is the R-2670 analyzer. 1. Initial setup using the R-2670 Communication Analyzer: - Connect a BNC cable between the “DEMOD OUT” port and the “VERT/SINAD DIST/DMM COUNTER IN” port on the R-2670. - Press the SPF key on the R-2670 to display the “SPECIAL FUNCTIONS MENU.” Move the cursor to “High Pass,” and select 5 Hz on the soft key menu. Select 20 kHz for the “Low Pass” setting. - In the “RF Control” section of the R-2670, enter the frequency displayed on the RSS screen. Move the cursor to the “B/W” setting and select “WIDE +/- 100 kHz” on the soft key menu. - Place the R-2670 cursor in the “Display” zone. Select “AC VOLTS” on the soft key menu. Move the cursor to the “Range” setting and select “AUTO.” 2. Initial setup using the 8901_ Series Modulation Analyzer: - Press the FM MEASUREMENT button. (The “Error 03-input level too low” indication is normal until an input signal is applied.) - Simultaneously press the Peak – and Peak + buttons. Both LEDs on the buttons should light. - Press the 15 kHz LP filter key. 3. Select the TX Deviation Balance alignment screen. The screen indicates the transmit frequencies to be used. See Figure 10. 4. Left-click the desired frequency field (starting with the highest frequency shown). 5. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting. 25 Radio Alignment Procedures Figure 10. Transmit Deviation Balance Alignment Screen 6. Left-click the PTT Tone: Low button. 7. Left-click the PTT Toggle button on the screen to enable transmission. The screen indicates whether the radio is transmitting. Wait approximately 5 seconds until the voltage shown on R-2670, or the deviation shown on the 8901_ analyzer, stabilizes. 8. Measure and record the ac voltage value from the R-2670 analyzer or the deviation value from the 8901_ series analyzer. 9. Left-click the PTT Tone: High button. 10. Adjust the softpot value until the measured deviation/voltage, when using the high tone, is within +/- 1.5% of the value observed when using the low tone. 11. Repeat the above process for all frequencies. 12. Left-click the Program All button on the screen to dekey the radio and save the tuned values. 13. Left-click the Close button on the screen to return to the Transmitter Alignments menu. 26 Radio Alignment Procedures Transmit Deviation Limit Alignment This alignment procedure limits the modulation of a baseband signal. It is used for primary modulation limiting. This procedure needs to be performed at multiple frequencies to allow for proper alignment across the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in each zone. NOTE: This alignment is required after replacing (or servicing) the VOCON board or the transceiver board. 1. Select the TX Deviation Limit alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 11. Figure 11. Transmit Deviation Limit Alignment Screen 2. Left-click the desired frequency field (starting with the highest frequency shown). 3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting. 4. Measure the transmitted signal deviation of the radio with a service monitor. 5. Adjust softpot value until the measured deviation is as close as possible to 2.83 kHz. 6. Repeat the above process for all frequencies. 7. Left-click the Program All button on the screen to dekey the radio and save the tuned values. 27 Radio Alignment Procedures 8. Left-click the Close button on the screen to return to the Transmitter Alignments menu. Front End Filter Alignment ! Refer to your Radio Service Manual for alignment procedure details. This procedure should only be attempted by qualified service personnel. Caution Definition This alignment procedure adjusts the front end receiver bandpass filters for best receiver sensitivity and selectivity. It should be performed for all test frequencies to allow for proper software interpolation for frequencies in between the test frequencies in the band (see Figure 12). NOTE: Rx Front End Filter Alignment is required after replacing (or servicing) the transceiver board. Procedure for 700 MHz Frequencies 1. Left-click the desired frequency field. 2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency. 3. Start with a softpot value (approximately 10 or 20), increase softpot in ascending order, and note the RSSI values. The RSSI will reach a peak value and remain stable and then decrease. Allow the limits of the peak range to be defined as RSSI PEAK - 3. Choose the middle of the peak range and program the corresponding softpot value as the tuned softpot value. 4. Repeat the above process for all 700MHz frequencies. 5. Click on the “Program All” button to save the tuned values in the radio. Procedure for 800 MHz Frequencies 1. Left-click the desired frequency field. 2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency. 3. Start with a softpot value of 50, increase softpot in ascending order, and note the RSSI values. The RSSI will reach a peak value and remain stable and then decrease. Allow the limits of the peak range to be defined as RSSI PEAK - 3. Note the upper end of the peak range and program the corresponding softpot value as the tuned softpot value. 4. Repeat the above process for all 800MHz frequencies. 5. Click on the “Program All” button to save the tuned values in the radio. Procedure for UHF/ VHF 1. Left-click the desired frequency field. 2. Apply an RF signal with no modulation at -90 dBm on the current operating frequency. 3. Adjust the softpot value until the maximum RSSI value is found. 4. Repeat the above process for all frequencies. 28 Radio Alignment Procedures Click on the “Program All” button to save the tuned values in the radio. Figure 12. Front End Filter Alignment Screen Bit Error Rate Definition This screen is used to test the Bit Error Rate (BER) of the radio’s receiver at a desired frequency. Bit Error Rate Fields This screen contains the following fields: Rx Frequency: This field selects the Receive Frequency directly in MHz. Test Pattern: This field selects the Digital test pattern — TIA. Choices are: Standard Tone Test Pattern (framed 1011) and Standard Interface Test Pattern (CCITT V.52). Modulation Type: 29 Radio Alignment Procedures This field represents the digital modulation type of the incoming signal on which BER is to be calculated. Continuous Operation: This field allows the user to make the BER test repeat indefinitely. A selection of Yes will cause the radio to calculate BER on a continuous basis and update the results on this screen after each integration time. A selection of No will cause the BER test to execute for only one sample of the integration time and then update the display. Audio: This field allows the user to select the audio output during a test. Selecting Internal will cause the radio's built-in speaker to unmute to any signals at the desired frequency which are present during the test. Selecting External will route the same signal to the radio's accessory connector audio output. Selecting Mute will disable the audio output. Integration Time: This field represents the amount of time over which the Bit Error Rate is to be calculated. The range is from 0.360 to 91.8 seconds in increments of 0.360 seconds. NOTE: When Continuous Operation = Yes, all fields will be grayed out while test is in progress. They will be enabled when the STOP button is pressed. When Continuous Operation = No, a wait cursor will be displayed while the test is in progress and return to normal when the test is done. Figure 13. Bit Error Rate Screen 30 Radio Alignment Procedures Transmitter Test Pattern Definition This screen is used to transmit specific test patterns at a desired frequency so that the user can perform tests on the radio’s transmitter. Transmitter Test Fields This screen contains the following fields: Tx Frequency: This field selects the Transmit Frequency directly in MHz. Channel Spacing: This field allows the user to select the desired transmit deviation. Test Pattern Type: This field represents the type of test pattern which will be transmitted by the radio when “PTT TOGGLE” button is pressed. NOTE: Channel Spacing and Test Pattern Type fields will be grayed out while radio is transmitting. Figure 14. Transmitter Test Pattern Screen 31 Radio Alignment Procedures Notes 32 29 15 MAEPF-27251-O 27 13 XTS 2500/XTS 1500/MT 1500 Model I Exploded View 30 28 14 23 16 22 20 17 26 5 6 2 8 12 25 11 18 9 21 19 24 1 3 4 31 7 10 2785787C01 3285270D01 4285633D01 3680529Z01 3685779C01 6003710K08 4585782C01 7585382D01 3280534Z01 15 16 17 18 19 20 21 22 23 1505579Z01 1585405D01 14 25 0385563D01 13 Typical 3585339D01 12 24 3385511D01 11 Dust Cover, Universal Conn. Antenna Seal, Contact Pad, Thermal Lever, Concentric Switch Battery, Backup Knob, Frequency (W/D-Clip) Knob, Volume Retaining Clip Seal, Main O-ring Chassis Cover, Rear Shroud Screw Speaker Mesh Label, Bottom Nameplate, Front (MT1500) 3386597Z02 Nameplate, Front (XTS2500) Nameplate, Front (XTS1500) 3385466D01 10 Label, ABC Boot, Microphone Microphone Felt Retainer, Microphone Boot Retainer, Speaker Keypad, PTT/Side Controls Bezel, PTT Assembly, Speaker/Microphone/ Universal Connector Flex Cover, Front Assembly Kit (XTS1500/MT1500) Cover, Front Assembly Kit (XTS2500) Description 3386597Z01 1385855C01 1485218D01 3585469D01 9 8 7 4285632D01 4285446D01 5 6 7585959C01 1385149D01 8485939D01 1585746D04 1585746D01 Motorola Part Number 4 3 2 1 Item Number 31 30 29 28 27 26 Item Number 0485667D01 Typical Typical 4385665D01 Typical 2685785C01 Motorola Part Number Table 13. Model I Exploded View Parts List XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List Washer, Teflon Belt Clip Battery Adaptor, Remote Speaker Mic. Main Board Main Shield Description 7 33 37 20 35 34 XTS 2500 Model II Exploded View 38 36 21 22 28 26 23 19 12 29 3 MAEPF-27250-O 10 11 14 6 2 7 33 8 18 32 31 9 17 1 4 5 39 13 4285633D01 3680529Z01 3685779C01 6003710K08 4585782C01 7585382D01 3280534Z01 23 24 25 26 27 28 29 34 3285270D01 22 1585405D01 20 2785787C01 0385563D01 19 21 3585339D01 3385511D01 3385466D01 1385855C01 1485218D01 3585469D01 4385717D01 4285632D01 4285446D01 4285214D01 7585915C01 7585776C02 7285726C01 7585959C01 1385149D01 8485939D01 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 0185947D01 2 24 16 1585746D02 Motorola Part Number 1 Item Number 15 27 25 30 Seal, Contact Pad, Thermal Lever, Concentric Switch Battery, Backup Knob, Frequency (W/D-Clip) Knob, Volume Retaining Clip Seal, Main O-ring Chassis Cover, Rear Shroud Screw Speaker Mesh Label, Bottom Nameplate, Front Label, ABC Boot, Microphone Microphone Felt Spacer, Plastic Retainer, Microphone Boot Retainer, Speaker Retainer, Keypad Pad, Shock LCD Keypad, Limited Display Module Keypad, PTT/Side Controls Bezel, PTT Assembly, Speaker/Microphone/ Universal Connector Flex Board, Model II Cover, Front Assembly Kit Description 39 38 37 36 35 34 33 32 31 30 Item Number 0485667D01 Typical Typical 4385665D01 Typical 2685785C01 7585737D01 8485268D01 1505579Z01 Typical Motorola Part Number Table 14. Model II Exploded View Parts List XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List Washer, Teflon Belt Clip Battery Adaptor, Remote Speaker Mic. Main Board Main Shield Spacer Pad Board, Jumper Flex Dust Cover, Universal Conn. Antenna Description 37 21 26 34 XTS 2500 Model III Exploded View 38 36 20 22 28 35 23 19 12 10 3 MAEPF-27249-O 29 11 14 6 2 7 33 8 18 32 31 9 17 24 15 27 25 30 1 4 5 39 13 16 3685779C01 6003710K08 4585782C01 7585382D01 3280534Z01 25 26 27 28 29 4285633D01 23 3680529Z01 3285270D01 22 24 2785787C01 1585405D01 0385563D01 21 20 19 3585339D01 3385511D01 17 18 3385466D01 1385855C01 1485218D01 3585469D01 4385717D01 4285632D01 4285446D01 4285214D01 7585915C01 7585776C01 7285726C01 7585959C01 1385149D01 8485939D01 0185948D01 1585746D03 Motorola Part Number 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Item Number Seal, Contact Pad, Thermal Lever, Concentric Switch Battery, Backup Knob, Frequency (W/D-Clip) Knob, Volume Retaining Clip Seal, Main O-ring Chassis Cover, Rear Shroud Screw Speaker Mesh Label, Bottom Nameplate, Front Label, ABC Boot, Microphone Microphone Felt Spacer, Plastic Retainer, Microphone Boot Retainer, Speaker Retainer, Keypad Pad, Shock LCD Keypad, Full Display Module Keypad, PTT/Side Controls Bezel, PTT Assembly, Speaker/Microphone/ Universal Connector Flex Keypad Board, Model III Cover, Front Assembly Kit Description 39 38 37 36 35 34 33 32 31 30 Item Number 0485667D01 Typical Typical 4385665D01 Typical 2685785C01 7585737D01 8485268D01 1505579Z01 Typical Motorola Part Number Table 15. Model III Exploded View Parts List Washer, Teflon Belt Clip Battery Adaptor, Remote Speaker Mic. Main Board Main Shield Spacer Pad Board, Jumper Flex Dust Cover, Universal Conn. Antenna Description 35 XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List 36 XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List 8 Disassembly/Assembly Introduction to This Section This section contains basic procedures for removing and installing the following components of the XTS 2500 radio: • Antenna • Battery • Belt Clip • Universal Connector Cover • Remote Speaker Microphone Adapter • Radio Disassembly—Detailed • Radio Reassembly—Detailed Antenna Attach the Antenna With the radio off, turn the antenna clockwise to attach it. Figure 15. Attaching the Antenna Remove the Antenna With the radio off, turn the antenna counter-clockwise to remove it. Figure 16. Removing the Antenna 37 Disassembly/Assembly Battery Attach the Battery 1. With the radio off, fit the three extensions at the bottom of the battery into the bottom slots on the radio. Figure 17. Step 1, Attaching the Battery 2. Press the top of the battery against the radio until both latches click into place. Figure 18. Step 2, Attaching the Battery Remove the Battery 1. With the radio off, slide down the latches on the sides of the battery. Figure 19. Step 1, Removing the Battery 2. Pull the top of the battery away from the radio. Figure 20. Step 2, Removing the Battery 38 Disassembly/Assembly Belt Clip Attach the Belt Clip 1. Align the grooves of the belt clip with those of the battery. Figure 21. Attaching the Belt Clip Remove the Belt Clip 2. Press the belt clip downward until you clear a “click.” 1. Use a flat-bladed object to press the belt clip tab away from the battery. Figure 22. Removing the Belt Clip 2. Slide the belt clip upward to remove it. 39 Disassembly/Assembly Universal Connector Cover The universal connector cover is located on the antenna side of the radio. It is used to cover the connector when not in use. NOTE: Remove the Universal Connector Cover 1. To prevent damage to the connector, shield it with the connector cover when not in use. Insert a flat-blade screwdriver into the area between the bottom of the cover and the slot below the connector. Figure 23. Removing the Universal Connector Cover Attach the Universal Connector Cover 2. Hold the top of the cover with your thumb while you pry the bottom of the cover away from the radio with the screwdriver. 1. Insert the, hooked end of the cover into the top of the connector. Top Top Slot Hooked End Tab Bottom Hooked End Bottom Slot Figure 24. Attaching the Universal Connector Cover 40 2. Press downward on the top of the cover to seat it into the slot. 3. Press the lower tab of the cover below the connector until it snaps in place. Disassembly/Assembly Remote Speaker Microphone Adapter The Remote Speaker Microphone (RSM) adapter is located on the back of the radio, just above the battery. It must be used to connect the RSM to the radio. If the RSM is not used, the adapter must be removed. Remove the Adapter Lift the larger side (below the antenna port) of the adapter away from the radio using your finger. If you cannot easily remove the adapter with your finger, use a small, flat bladed screwdriver to pry the larger end side of the adapter away from the radio. Figure 25. Removing the RSM Adapter Attach the Adapter 1. With the Motorola side of the adapter facing out, snap the smaller end of the adapter into place in the shroud indent, below the On/Off Volume Control Knob. Figure 26. Step 1, Attaching the RSM Adapter 2. Snap the larger end of the adapter into place in the shroud indent, below the antenna port. Figure 27. Step 2, Attaching the RSM Adapter 41 Disassembly/Assembly Radio Disassembly— Detailed Required Tools Front Cover from Chassis Disassembly When disassembling and reassembling the radio, pay particular attention to the snaps and tabs and how parts align with each other. The following steps describe how to disassemble the radio. This includes the following major components: • Front Cover • Chassis • Backup Battery • Keypad • Keypad/option board • Display • Speaker, microphone, universal flex connector • PTT • Small, flat-bladed screwdriver • TORX™ T7-IP screwdriver • Chassis Opener/Knob removal tool (Motorola part number 6685666D01) For this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. Table 16. Front Cover from Chassis Disassembly Exploded View Item Number 42 Motorola Part Number Description 1 1585746D03 Cover, Front Assembly Kit 3 8485939D01 Assembly Speaker/Microphone/Universal Connector Flex 21 2785787C01 Chassis Cover, Rear 24 3680529Z01 Knob, Volume 25 3685779C01 Knob, Frequency (16-Position Select) 27 4585782C01 Lever, Concentric Switch 30 Typical Antenna 32 8485268D01 Board, Jumper Flex 37 Typical Battery 39 0485667D01 Washer, Teflon 1. Turn off the radio. 2. Remove the battery completely from the radio (see Figure 19 and Figure 20 on page 38). 3. Remove the antenna (see Figure 16 on page 37). Disassembly/Assembly 4. Pull the 16-Position Select and the On/Off/Volume Control knobs off their shafts using the Chassis Opener tool. Figure 28. Knob Removal 5. After you remove the On/Off/Volume Control knob, remove the Teflon® washer and set it aside. 6. Separate the chassis from the front cover by inserting the chassis opener between the thin, plastic retaining wall and the metal chassis at the bottom of the radio. OB SO PEN ER WARNING KN ! Be careful not to mar the O-ring sealing area on the housing. Marring the front cover O-ring sealing areas will prevent the radio from sealing properly. ER N PE S SI O AS H C Figure 29. Chassis Removal 43 Disassembly/Assembly 7. Slowly pry the bottom of the chassis away from the front cover by pushing the chassis opener tool down. Rotate the handle of the tool over and behind the base of the radio. This prying action forces the thin inner plastic wall toward the base of the radio, releasing the two chassis tabs. 8. Remove the chassis assembly by holding the chassis in one hand while slowly, with a firm side-to-side motion, removing the chassis. ! Caution The chassis assembly has switches that can be damaged if the chassis is removed too quickly. Be careful not to damage the switches at the top of the board. Figure 30. Chassis Separation 9. Lay the chassis down. Rotate the front cover backward and slightly away from the chassis. ! Caution Flexible ribbon circuits (flexes) connecting the front cover assembly and the chassis prevent you from completely separating the two units. Display radios and radios with option boards have two flexes. Figure 31. Unlatching the Flex Connectors 44 Disassembly/Assembly 10. Carefully lift the latches on the main circuit board to release the flexible circuits from their connectors. NOTE: For proper reassembly, note how the flex circuits are folded. 11. Remove the concentric lever from the front cover assembly. Chassis Disassembly For this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. Table 17. Chassis Disassembly Exploded View Item Number Motorola Part Number Description 19 0385563D01 Screw (5 required) 21 2785787C01 Chassis Cover, Rear 22 3285270D01 Seal, Main O-ring 34 2685785C01 Main Shield 35 Typical Main Board 1. If disassembly of the chassis or the main board is required, then use a TORX™ screwdriver with a T7-IP head to remove the five screws holding the main board and shield to the chassis. ! Caution Refer to the Handling Precautions on page 4 before removing the main board. Be sure to use ESD protection when handing circuit boards. 2. Remove the O-ring from around the bushing at the antenna connector 3. Lift the main board from the chassis as shown in Figure 32. 45 Disassembly/Assembly Figure 32. Removing the Main Board from the Chassis Backup Battery Disassembly 4. Most repairs to the main board can be performed without further disassembly of the chassis. If it is necessary to replace the O-ring, remove the small O-ring retainers from their slots in the chassis. Note the alignment of the retainers for reassembly. 5. Remove the O-ring. For this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. Table 18. Backup Battery Disassembly Exploded View Item Number 46 Motorola Part Number Description 23 4285633D01 Retaining Clip 26 6003710K08 Battery, Backup 1. The backup battery can be removed without disassembling the board or the chassis. 2. Remove the backup battery retaining clip by sliding it away from the main circuit board, as shown in Figure 33. 3. Insert a small, flat head screwdriver between the battery and the battery holder. Gently pry the battery out of the battery holder. Disassembly/Assembly Figure 33. Remove the Backup Battery Keypad and Keypad/Option Board Disassembly For this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. (For the Model II keypad, please refer to the exploded view and parts list on page 34.) Table 19. Keypad and Keypad/Option Board Exploded View Item Number Motorola Part Number Description 2 0185948D01 Keypad Board, Model III 3 8485939D01 Assembly Speaker/Microphone/Universal Connector Flex 6 7285726C01 Display Module 7 7585776C01 Keypad, Full (for Model III only) 9 4285214D01 Retainer, Keypad 22 3285270D01 Seal, Main O-ring 1. The keypad and keypad board can be disassembled without the disassembly of the display or speaker/microphone flex assembly. 2. If the disassembly of the keypad or the keypad printed circuit board is required, lift the microphone flex circuit up to move it out of the way. 3. Disconnect the display connector, and move the tail of flex circuit out of the way. 4. To remove the keypad retainer shield, insert the tip of a “penknife size,” flat-bladed screwdriver in the opening at the end of the keypad retainer arm tab. Pry the tab away from the side of the front cover until it moves past the ledges on the side wall. Repeat this procedure for the four remaining retainer arm tabs. ! WARNING Be careful not to mar the O-ring sealing area on the housing. Marring the front cover O-ring sealing areas will prevent the radio from sealing properly. 47 Disassembly/Assembly Figure 34. Retainer Removal 5. Lift the keypad retainer out of the front cover. 6. The keypad/option board and the keypad can be removed without the use of tools. Figure 35. Keypad Retainer and Boards Removal 48 Disassembly/Assembly Display Disassembly For this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. (For the Model II display, please refer to the exploded view and parts list on page 34.) Table 20. Display Disassembly Exploded View Item Number Motorola Part Number Description 1 1585746D03 Cover, Front Assembly Kit (Model III) 2 0185948D01 Keypad Board, Model III 6 7285726C01 Display Module 9 4285214D01 Retainer, Keypad 1. The display assembly can be removed without the disassembly of the keypad board or the speaker-microphone flex assembly. If the disassembly involves the removal of the display module, disconnect the display flex from the keypad option board connector. ! Caution Take care not to damage the display. Do not cut, bend, or pinch the heat seal. Display modules contain CMOS devices. Be sure to use ESD protection. Figure 36. Display Disassembly 2. The display module snaps into the front cover assembly. Insert two flat-bladed screwdrivers between the flexible beam at the top of the display module (one on each side). Deflect the beam down until it moves past the hooks on the front cover. The display module is hooked to the front cover at the base of the display. Lift the top of the display module past the hooks and remove it from the front cover. 49 Disassembly/Assembly Speaker, Microphone, and Universal Connector Flex Disassembly For this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. Table 21. Speaker, Microphone, and Universal connector Flex Disassembly Exploded View Item Number 50 Motorola Part Number Description 1 1585746D03 Cover, Front Assembly Kit 3 8485939D01 Assembly Speaker/Microphone/Universal Connector Flex 10 4285446D01 Retainer, Speaker 11 4285632D01 Retainer, Microphone Boot 12 4385717D01 Spacer, Plastic 14 1485218D01 Boot, Microphone 1. The speaker-microphone assembly can be removed without the disassembly of the display or the keypad assemblies. If disassembly of the speaker-microphone assembly is necessary, removal of the universal connector dust cover is optional (see Figure 23 on page 40). 2. Remove the plastic spacer at the bottom of the speaker. The spacer can be removed by pulling upward with a slight, side-to-side motion until it clears the retaining ribs in the front cover. Take special care to prevent damage to the tail of the speaker flex circuit while the flex is still in place. 3. Using a screwdriver, push down on the portion of the speaker retainer bracket that is pointing toward the bottom of the radio. Then, remove the retainer by slightly pushing it toward the top of the radio until you slide it past the front cover slot. 4. Remove the microphone boot retainer by inserting a penknife-sized screwdriver in the notch between the retainer and the housing. Pry the retainer away from the housing and remove the clip. 5. Remove the microphone rubber boot by sliding it out of the pocket in the front cover. Take care not to pull on the flex cable while pulling on the microphone boot. Unless you are replacing the microphone, leave it in the boot. At this point, the speaker and microphone are disconnected, but the assembly is still attached to the universal connector by 13 pins in the printed circuit backer board. 6. To remove the speaker-microphone flex circuit from the universal connector, carefully grasp the flex circuit at a point directly across from the universal connector pins. Applying firm pressure, gradually pull the flex away from the pins. Disassembly/Assembly NOTE: There are notches on the ends of the 13-pin printed circuit backer board. If necessary, you can insert a small screwdriver in one of the notches to pry the backer board away from the front cover. After the universal connector portion of the speaker-microphone flex circuit is detached, the assembly can be completely removed. If it is necessary to replace the speaker or the microphone, or both, do it while the flex circuit is removed from the front cover. Figure 37. Speaker-Microphone Removal PTT Disassembly For this section, please refer to the Model III exploded view and parts list on page 35 for part numbers and more information on the location of parts in the radio. Table 22. PTT Disassembly Exploded View Item Number Motorola Part Number Description 1 1585746D03 Cover, Front Assembly Kit 4 1385149D01 Bezel, PTT 5 7585959C01 Keypad, PTT/Side Controls 1. If required, the PTT bezel and the PTT seal assembly can be disassembled using a small screwdriver. 2. Remove the PTT bezel by pushing the snaps out at the top and pulling the bezel up toward the top of the front cover so that the T-tab slides up and out. 3. The PTT seal can be easily lifted from the bezel without the use of tools. 51 Disassembly/Assembly Figure 38. PTT Removal Radio Reassembly— Detailed PTT Reassembly The following steps describe how to reassemble the radio. This includes the following major components: • PTT • Keypad/option board • Display • Speaker, microphone, universal connector flex • Chassis • Backup Battery • Chassis and front cover 1. Put the PTT seal in the PTT bezel. 2. Align the PTT bezel and seal to the front cover housing so that the bottom tabs will engage with the opening in the front cover. 3. Slide the PTT bezel down so that the T-tab engages into the front cover opening. 4. Snap the top snaps. NOTE: 52 Look inside the front cover to be sure the T-tab and snaps are fully engaged with the front cover. Disassembly/Assembly Keypad and Keypad Option Board Reassembly 1. Insert the keypad into the front cover. Align the keypad to the pins in the front cover. 2. Replace the board on the locator pins. 3. Replace the keypad retainer legs on the PTT side first. Then, press the retainer down and snap the other two legs into place on the universal connector side; make sure that all four legs snap into place. If necessary, use a small, flat-bladed screwdriver to put pressure on the corner bend of each retainer leg. Figure 39. Lock Retainer Catches to Radio Body Display Reassembly Speaker, Microphone, and Universal Connector Flex Reassembly 1. Slide the two bottom tabs of the display module, with the LCD facing the front housing lens, into the grooves located above the keypad assembly area in the front cover housing. Gently press on the upper portion of the display until it snaps into place past the two small hooks in the housing. 2. Connect the display flex to the keypad option board connector. 1. Insert the microphone boot into the pocket in the front cover housing. 2. Insert the microphone boot plastic retainer. Make sure the retainer is securely hooked to the front cover. 3. Center the speaker in the speaker recess. Make certain the speaker is correctly nested inside the front cover. 4. Before you replace the speaker retainer, be sure the retainer is placed between the speaker-microphone flex circuit and the speaker. Insert the flat end of the speaker retainer into the opening in the front cover. Press the other end of the retainer against the speaker. Hold the retainer in place with your thumb while pushing down on the retainer with a flat-bladed screwdriver. Use the screwdriver to push down on the portion of the speaker retainer that is pointing toward the bottom of the radio. Move the retainer by pushing it toward the bottom of the radio. Slide it into the front cover slot above the display. 5. Connect the universal flex to the pins and press into place. 53 Disassembly/Assembly Chassis Assembly Reassembly Before you assemble the main board to the chassis, make sure that the following steps are done to the chassis. 1. Replace the O-ring. The tabs on the O-ring should reach into the chassis and point down. 2. Stretch the O-ring to place it into the retaining pocket at the bottom end of the chassis. NOTE: 3. Replace the battery contact seal (if necessary) surrounding the battery contact. NOTE: Backup Battery Reassembly When properly assembled, the retainers on the O-ring should align with the slots on the chassis. If this is not the case, remove and replace the O-ring until it is aligned with the chassis and completely seated in place around the perimeter. Be sure the battery contact seal protrudes through the chassis and is not pinched under the chassis. 4. Make sure the thermal pad is placed on top of the RF Power Amplifier on the main board. 5. Use the notch in the bottom of the main board and the protrusion at the bottom of the casting to align the board to the casting. Place the board against the casting. Make sure that the five screw holes are aligned. 6. Place the main shield assembly on the main board. Again, make sure that the five screw holes are aligned. 7. Use the TORX T7-IP screwdriver to fasten the screws holding the main board and shield to the chassis. Do not over torque. Torque limit is 4 inch-lbs. 8. Place the O-ring at the antenna connector over the antenna connector bushing. 1. Insert the backup battery (positive side up) into the battery holder, as shown in Figure 40. 2. Replace the retaining clip by sliding it into its recess on the board. Figure 40. Reassemble the Backup Battery Chassis and Front Cover Reassembly 54 1. Align the chassis assembly end-to-end with the front cover assembly. 2. Insert the tails of the flex circuits into their respective connectors at the bottom of the Disassembly/Assembly chassis assembly. 3. Push down the latches on the connectors to hold the flex circuits to the main board. NOTE: 4. Align the volume knob shaft and the frequency switch shaft with their respective holes in the front cover. Slowly reassemble the chassis and front cover assemblies. Slowly slide the volume knob and frequency switch shafts into their respective holes in the front cover. NOTE: 5. Make sure the flex circuits are correctly folded in place. Take special care to prevent pinching or excess binding of these flexes. Push the chassis assembly completely into the top of the front cover until it settles in place. NOTE: 6. Be sure the concentric lever is not in place on the frequency knob shaft when reassembling the chassis with the front cover assembly. Be sure the O-ring is properly seated. Press down at the bottom of the chassis until the chassis snaps into place in the front cover. Figure 41. Fastening the Chassis 7. Reassemble the concentric lever to the frequency knob shaft by aligning the protrusions in the lever with the openings in the shaft. The triangular-shaped side of the lever should point toward the back of the radio. 8. Reassemble the Teflon washer to the volume knob shaft. Reassemble the knobs, dust cover, antenna, and battery. 55 Disassembly/Assembly Notes 56 Radio-Level Troubleshooting Introduction to This Section 9 This section of the manual contains troubleshooting charts and error codes that will help you to isolate problems. Level one troubleshooting will support only radio alignment, programming, battery replacement, and knob replacement. If the radio needs further troubleshooting, it must be sent to the depot. Board-level, component-level, and service information can be found in the ASTRO Digital XTS 2500 Portable Radios Detailed Service Manual, Motorola publication number 68P81094C10. Power-Up Error Codes When the radio is turned on (power-up), the radio performs cursory tests to determine if its basic electronics and software are in working order. Problems detected during these tests are presented as error codes on the radio’s display. For non-display radios, the problem is indicated at power-up by a single, low-frequency tone. If cycling power and code plug reprogramming do not fix the error, the radio should be sent to the depot for repair. The presence of an error should prompt the user that a problem exists and that a service technician should be contacted. Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit user operation; non-fatal errors will not. Table 23. lists their descriptions and suggested corrective action. 57 Radio-Level Troubleshooting Table 23. Power-Up Error Code Displays Error Code Description Corrective Action 01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug. 01/12 Security partition Checksum Non-Fatal Error Send Radio to Depot. 01/22 Tuning Codeplug Checksum Non-Fatal Error Send Radio to Depot. 01/81 Host ROM Checksum Fatal Error Send Radio to Depot. 01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug. 01/88 External RAM FATAL Error -- Note: not a checksum failure Send radio to depot. 01/90 General Hardware Failure Fatal Error Turn the radio off, then on. 01/92 Security Partition Checksum Fatal Error Send radio to depot. 01/93 Flashport AUTHENTIFICATION CODE failure Send radio to depot. 01/98 Internal RAM Fail Fatal Error Send radio to depot. 01/A0 ABACUS Tune failure Fatal Error Turn the radio off, then on. 01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot. 02/10 DSP Support IC Checksum Non-Fatal Error Turn the radio off, then on. 02/81 DSP ROM Checksum Fatal Error Send radio to depot. 02/88 DSP RAM Fatal Error -- Note: not a checksum failure Turn the radio off, then on. 02/90 General DSP Hardware Failure (DSP startup message not received correctly) Turn the radio off, then on. NOTE: If the corrective action does not fix the failure, send the radio to the depot. Operational Error Codes During radio operation, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as error codes on the radio’s display. Ann error code indicates that a problem exists and that a service technician should be contacted. Operational error codes are listed in Table 24.. Table 24. Operational Error Code Displays Error Code FAIL 001 Description Synthesizer Out-of-Lock Corrective Action a. Reprogram external codeplug b. Send radio to depot FAIL 002 58 Selected Mode/Zone Codeplug Checksum Error Reprogram external codeplug Radio-Level Troubleshooting Table 25. Receiver Troubleshooting Chart Symptom Radio dead; Display does not light up Correction or Test (Measurements Taken at Room Temperature) Possible Cause 1. Dead Battery Replace with charged battery. 2. Blown Fuse Send radio to depot. 3. On/Off Switch 4. Regulators Radio dead; display lights up 1. VOCON No receiver audio or receiver does not unmeet Programming Send radio to depot. 2. RF a. Does the transmitted signal match the receiver configuration (PL, DPL, etc.)? b. With the monitor function enabled, can the radio be unmuted? Audio distorted or not loud enough Synthesizer Not On Frequency Check synthesizer frequency by measuring the transmitter frequency; if off by more than ±1000Hz, realign. RF sensitivity poor 1. Synthesizer Not On Frequency Check synthesizer frequency by measuring the transmitter frequency; if off by more than ≤ ±1000Hz, realign. 2. Antenna Switch Send radio to depot. 3. Receiver FrontEnd Tuning Check RF front-end tuning for optimum sensitivity using the CPS. VOCON Send radio to depot. Radio will not turn off Table 26. Transmitter Troubleshooting Chart Symptom No RF power out Possible Cause Correction or Test (Measurements Taken at Room Temperature) 1. TX Power Level or Frequency Check TX power level and frequency programming (from CPS). 2. No PTT From Control Top Send radio to depot. 3. No Injection To Power Amplifier No modulation; Distorted modulation 1. Programming Check deviation and compensation settings using the CPS. 2. VOCON Send radio to depot. 1. Check Deviation and Compensation Realign if necessary. 2. Microphone Send radio to depot. No/Low signalling (PL, DPL, MDC) 1. Programming Check programming. 2. VOCON Send radio to depot. Cannot set deviation balance RF Send radio to depot. Bad microphone sensitivity 59 Radio-Level Troubleshooting Notes 60 10 Accessories General Motorola provides the following approved accessories to improve the productivity of your XTS 2500 portable two-way radio. Antennas NAF5037 806-870 MHz Whip, Half-wave, 7 inch NAF5042 806-870 MHz Quarter Wave, 3 inch, Stubby NAF5080 764-870 MHz Whip, Half-wave, 6.5 inch BDN6635 Boom Mic Headset with VOX (Adapter BDN6673) BDN6636 Throat Mic Headset with VOX (Adapter BDN6673) BDN6645 Noise-Canceling Boom Mic Headset with PTT on earcup BDN6673 Headset Adapter Cable for use with BDN6645, BDN6635, and BDN6636 NMN6258 Over the Head Headset w/ In Line PTT NMN6259 Medium Weight Dual Headset with NC Mic RMN4049 Temple Transducer Audio Headsets Earpieces BDN6677 Ear mic, standard, noise up to 95dB, black (must order Interface module) BDN6641 Ear mic, high noise level up to 105dB, grey (must order interface module) NMN6193 Remote Speaker Microphone NMN6191 RSM Noise Cancelling Includes: 6.0' coiled cord assembly, 3.5mm earjack, swivel clip, quick disconnect Remote Speaker Microphones 61 Accessories Surveillance BDN6671 PTT and VOX Interface Module for use with BDN6677, BDN6678, and BDN6641 BDN6677 Ear Microphone, Standard 95 dB (Black) BDN6678 Ear Microphone, Standard 95 dB (Beige) BDN6708 PTT Interface Module for use with BDN6677, BDN6678, and BDN6641 NTN9815 NiCd High Capacity NTN9816 NiCd High Capacity, Factory Mutual Intrinsically Safe NTN9857 NiMH Ultra-High Capacity, Factory Mutual Intrinsically Safe NTN9858 NiMH Ultra-High Capacity HLN6853 Belt Clip, 2 1/4 inch NNTN4115 Carrying case, Bonded leather with 3” Swivel Belt Loop and Tstrap NNTN4116 Carrying case, Bonded leather with 2.5” Swivel Belt Loop and Tstrap NNTN4117 Carrying case, Bonded leather with 3” Belt Loop and T-strap Batteries Belt Clips Carrying Cases 62 Accessories Chargers NTN1177 Multi-Unit, Dual Rate, Rapid: 110 V NTN1178 Multi-Unit, Dual Rate, Rapid: 240 V (3-prong UK plug) NTN1179 Multi-Unit, Rapid, 240V (UK 13 MAP Plug) NTN1667 Tri-Chemistry, 110V NTN1668 Tri-Chemistry, 220V Single Unit Charger (2 Prong Euro Plug) NTN1669 Tri-Chemistry, 230V NTN1873 IMPRES™ Rapid, 110V Single Unit Charger NTN1874 IMPRES™ Rapid, 220V Single Unit Charger NTN1875 IMPRES™ Rapid, 240V Single Unit Charger NTN7209 Single-Unit Dual Rate, Rapid w/o Cord WPLN4111_R IMPRES™ Single-Unit Smart Charger, 110V NOTE: Charge only the battery, not the radio with the battery attached, with NTN1177, NTN1178, and NTN1179. Charger Mounting Kits Enhanced and Multi-Unit Line Cords NLN7967 Wall Mount Kit for Multi-unit (6-pocket) Charger NLN7968 Charger, Rack Mount for 6 Unit NTN7373 110 V Interchangeable Line NTN7374 220 V Interchangeable Line (2 prong Euro plug) NTN7375 240 V Interchangeable Line (3 prong Euro plug) 63 Accessories Notes 64 ➠ Glossary A/D Analog-to-Digital converter; converts an instantaneous dc voltage level to a corresponding digital value. ABACUS IC Custom integrated circuit providing a digital receiver IF backend. CPS Customer Programming Software CODEC Coder/Decoder IC for analog-to-digital and digital-to-analog conversion. D/A Digital-to-Analog converter; converts a digital value to a corresponding dc voltage value. DTMF Dual-Tone Multi-Frequency DPL Digital Private-Line™ DSP Digital Signal Processor; microcontroller specifically tailored for signal processing computations. In this case refers specifically to Motorola DSP56603. Firmware Software or a software/hardware combination of computer programs and data, with a fixed logic configuration stored in a read-only memory; information can not be altered or reprogrammed. FGU Frequency Generation Unit FLASHport™ A Motorola term that describes the ability of a radio to change memory. Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to, again and again. Host Motorola HC12A4 microcontrol unit U204 (see MCU). Host Port Parallel memory mapped interface consisting of eight registers in the DSP56603. IC Integrated Circuit IMBE Improved Multi-Band Excitation: a sub-band, voice encoding algorithm used in ASTRO digital voice. MCU MicroControl Unit MDC Motorola Digital Communications MISO Master In Slave Out; used by the slave device to send data to the master device MOSI Master Out Slave In; used by the master device to send data to the slave device. Open Architecture A controller configuration that utilizes a microprocessor with extended ROM and RAM. PC Board Printed Circuit board PCIC Power Control IC PL Private-Line® tone squelch; a continuous sub-audible tone that is transmitted along with the carrier. PLL Phase-Locked Loop; a circuit in which an oscillator is kept in phase with a reference, usually after passing through a frequency divider. 65 Glossary PTT Push-To-Talk; the switch located on the left side of the radio which, when pressed, causes the radio to transmit. Registers Short-term data-storage circuits within the microcontrol unit or programmable logic IC. Repeater Remote transmit/receive facility that re-transmits received signals in order to improve communications coverage. RESET Reset line; an input to the microcontroller that restarts execution. RF PA Radio Frequency Power Amplifier RPT/TA RePeaTer/Talk-Around RX DATA Recovered digital data line. Signal Qualifier Mode An operating mode whereby the radio is muted but still continues to analyze receive data to determine RX signal type. SCI IN Serial Communication Interface INput line Softpot Software potentiometer; a computer-adjustable electronic attenuator. Software Computer programs, procedures, rules, documentation, and data pertaining to the operation of a system. SPI Serial Peripheral Interface; how the microcontroller communicates to modules and ICs through the CLOCK and DATA lines. Squelch Muting of audio circuits when received signal levels fall below a pre-determined value. SRAM Static-RAM chip used for volatile, program/data memory. Standby Mode An operating mode whereby the radio is muted but still continues to monitor data. System Select The act of selecting the desired operating system with the system-select switch (also, the name given to this switch). TOT Time-Out Timer; a timer that limits the length of a transmission. TSOP Thin Small-Outline Package UART Universal Asynchronous Receiver Transmitter. µC Microcontrol unit (see MCU). VCO Voltage-Controlled Oscillator; an oscillator whereby the frequency of oscillation can be varied by changing a control voltage. Vocoder VOice enCODER; the DSP-based system for digitally processing the analog signals, includes the capabilities of performing voice compression algorithms or voice encoding. VSWR Voltage Standing Wave Ratio 66 ➠ Index A M accessories antennas ...................................................................... 61 batteries ....................................................................... 62 belt clips ...................................................................... 62 carry cases .................................................................. 62 chargers ....................................................................... 63 multi-unit line cords ................................................... 63 remote speaker microphones ...................................... 61 analog mode of operation ................................................. 6 antenna attach the antenna ....................................................... 37 remove the antenna ..................................................... 37 ASTRO mode of operation .............................................. 7 model chart, radio .................................................................. xv model chart ASTRO digital XTS 5000 .......................................... xv Model numbering system ...............................................xiii B power-up codes ..............................................................57 preventive maintenance ....................................................3 battery attach the battery ......................................................... 38 remove the battery ...................................................... 38 belt clip attach the belt clip ....................................................... 39 remove the belt clip .................................................... 39 bit error rate .................................................................... 29 C chassis disassembly ........................................................ 45 cleaning external plastic surfaces ..................................... 3 control top and keypad test mode (display radio) .......... 14 control top and keypad test mode (non-display radio) ... 16 D display radio test mode .................................................. 12 E exploded view, Model I ................................................. 33 exploded view, Model II ................................................ 34 exploded view, Model III ............................................... 35 F field programming equipment ........................................ 10 FLASHport ....................................................................... 2 front end filter alignment ............................................... 28 G glossary .......................................................................... 65 H handling precautions ........................................................ 4 N non-display radio test mode ...........................................15 notations used in this manual ...........................................1 O operational error codes ...................................................58 P R radio model chart ................................................................. xv radio alignment front end filter .............................................................28 general ........................................................................19 reference oscillator .....................................................21 transmit deviation balance (compensation) ................25 transmit deviation limit ...............................................27 transmit power ............................................................23 radio alignment test setup ...............................................11 radio description ...............................................................2 radio disassembly backup battery .............................................................46 chassis disassembly ....................................................45 display disassembly ....................................................49 front cover from chassis .............................................42 kepad and keypad option board ..................................47 PTT disassembly .........................................................51 required tools ..............................................................42 speaker, microphone, and universal connector flex ...50 radio information screen ................................................21 radio reassembly backup battery .............................................................54 chassis and front cover ...............................................54 chassis assembly .........................................................54 keypad and keypad option board ..........................53, 54 PTT reassembly ..........................................................52 speaker, microphone, and universal connector flex ...53 recommended test equipment ...........................................9 reference oscillator alignment ........................................21 67 Index remote speaker microphone adapter attach the adapter ........................................................41 remove the adpater ......................................................41 required tools ..................................................................42 RF basic theory of operation ............................................7 RF test mode (display model) ........................................13 RF test mode (non-display radio) ...................................15 S service aids .....................................................................10 Specifications for 700/800 MHz radios ........................ xiv T transmit deviation balance alignment .............................25 transmit deviation limit alignment .................................27 transmit power alignment ...............................................23 transmitter test pattern ....................................................31 U universal connector cover attach the connector cover ..........................................40 remove the connector cover ........................................40 V VOCON basic theory of operation ...................................8 W warranty ........................................................................... ix warranty service ............................................................... x 68 REPLACEMENT PARTS ORDERING ORDERING INFORMATION When ordering replacement parts or equipment information, the complete identification number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufficient description of the desired component to identify it. Crystal and channel element orders should specify the crystal or channel element type number, crystal and carrier frequency, and the model number in which the part is used. MAIL ORDERS Send written orders to the following addresses: International Orders: Replacement Parts/ Test Equipment/Manuals/ Crystal Service Items: Federal Government Orders: Motorola Inc. United States and Canada Accessories and Aftermarket Division Attention: Order Processing 1313 E. Algonquin Road Schaumburg, IL 60196 Motorola Inc. United States and Canada Accessories and Aftermarket Division Attention: Order Processing 7230 Parkway Drive Landover, MD 21076 Motorola Inc. United States and Canada Accessories and Aftermarket Division Attention: International Order Processing 1313 E. Algonquin Road Schaumburg, IL 60196 TELEPHONE ORDERS United States and Canada Accessories and Aftermarket Division: Call: 1-800-422-4210 1-800-826-1913 (For Federal Government Orders) 1-847-538-8023 (International Orders) Servicers Training (VHS Video Tapes): Call: 847-783-2522 847-783-2523 (FAX) FAX ORDERS United States and Canada Accessories and Aftermarket Division: FAX: 847-538-8198 (Domestic) 847-576-3023 (International) Parts ID: Federal Government Orders: FAX: 410-712-4991 International: 410-712-6200 847-538-8194 PARTS CUSTOMER SERVICE United States and Canada Accessories and Aftermarket Division: Call: 1-800-422-4210 Parts Identification: Call: 847-538-0021 PRODUCT CUSTOMER SERVICE Customer Response Center (Sales and Service Assistance): Call: 1-800-247-2346 FAX: 1-800-232-9272 Motorola, Inc. 8000 West Sunrise Boulevard Ft. Lauderdale, Florida 33322 MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners. © Motorola, Inc. 2002, 2003 All rights reserved. Printed in U.S.A. 6881094C09-B
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