Motorola Solutions 89FT3799 Hand Held Transmitter User Manual 89C80 A Book

Motorola Solutions, Inc. Hand Held Transmitter 89C80 A Book

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Instruction Manual

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1. Instruction Manual Cover Page
2. Instruction Manual

Instruction Manual

1 ™ Digital XTS 3500 ™ Portable Radios Basic Service Manual

2 Foreword This manual covers all models of the ASTRO™ Digital XTS 3500 ® 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 VHF and UHF frequency bands; a general description of ASTRO Digital XTS 3500 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 3500 Radio, please read the “Safety Information” section in the front of this manual. 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.

i Table of Contents Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside front cover List Of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiList of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiRelated Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiPortable Radio Model Numbering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivSpecifications for VHF Radios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vSpecifications for UHF Radios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viGlossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiSafety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Notations Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Radio Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2FLASHport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 - Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 - Recommended Test Equipment and Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Service Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Field Programming Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 - Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Non-Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5 - Radio Alignment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Transmit Power Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Transmit Deviation Balance (Compensation) Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Transmit Deviation Limit Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Front End Filter Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A , Motorola, ASTRO, and Private-Line are registered trademarks of Motorola, Inc.XTS 3500, FLASHport, and Digital Private-Line are trademarks of Motorola, Inc. © 1999, 2000 by Motorola Inc.8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322Printed in U.S.A. 3/00 Basic Service Manual68P81089C80-A Commercial, Government and Industrial Solutions Sector

ii 6 - Basic Removal/Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Frequency Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Volume Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 7 -Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Analog Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29ASTRO Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30RF Board Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30VOCON Board Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8 - Radio-Level Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Power-Up Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Operational Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Replacement Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside back cover List Of Figures Figure 1. Radio Alignment Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Figure 2. RSS Service Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Figure 3. Softpot Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Figure 4. Reference Oscillator Alignment Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Figure 5. Transmit Power Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Figure 6. Transmit Deviation Balance (Compensation) Alignment Screen . . . . . . . . . . . . . . . . . 19Figure 7. Transmit Deviation Limit Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Figure 8. Front End Filter (VHF and UHF Only) Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . 21Figure 9. Partial Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 List of Tables Table 1. ASTRO XTS 3500 Basic Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Table 2. Recommended Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Table 3. Service Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Table 4. Initial Equipment Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Table 5. Front-Panel Access Test-Mode Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Table 6. Test Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Table 7. Test Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Table 8. Receiver Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Table 9. Transmitter Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Table 10. Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Table 11. Transmit Power Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Table 12. Transmit Deviation Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Table 13. Partial Exploded View Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Table 14. Local Oscillator and First IF Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Table 15. Power-Up Error Code Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Table 16. Operational Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Table 17. Receiver Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Table 18. Transmitter Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Table 19. Encryption Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

iii Related Publications ASTRO Digital XTS 3500 Model I User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C77ASTRO Digital XTS 3500 Model II User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C78ASTRO Digital XTS 3500 Model III User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C79ASTRO Digital XTS 3500 Detailed Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C81 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.

v SPECIFICATIONS FOR VHF RADIOS All speciﬁcations are per Telecommunications Industries Association TIA-603 unless otherwise noted GENERAL RECEIVER TRANSMITTER FCC Designation: AZ489FT3799 Temperature Range:Operating: –30°C to +60°C Storage: –40°C to +85°C Power Supply: Nickel-Cadmium Battery (NiCd) or Nickel-Metal-Hydride Battery (NiMH) or Lithium-Ion Battery (Li-Ion) Battery Voltage:Nominal: 7.5 Volts Range: 6 to 9 Volts Transmit Current Drain (Typical): 2100mA Receive Current Drain (Rated Audio): 240mA Standby Current Drain: 80mA Recommended Battery: Ultra-HIgh-Capacity NiCd: NTN8294_ or Extended-Capacity NiMH: NTN8293_ or Li-Ion: NTN8610_ or Ultra–High-Capacity NiCd FM: NTN8295_* or Ultra–High-Capacity NiMH FM: NTN8299_* Optional FM (Factory Mutual) Battery: * FM Intrinsically Safe: Class I, II, III, Division 1, Groups C, D,E, F, and G. FM Non-incendive:Class 1, Division 2, Groups A, B, C, and D. Dimensions (H x W x D) Note: 2.44" = width at PTT; 2.34" = width at bottom; 1.83" = depth at speaker; 0.97" = depth at keypad Less Battery: 6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"(167.13mm x 61.90mm x 46.42mm/167.13mm x 59.49mm x 24.56mm) With Battery: 6.58" x 2.44" x 1.83"/6.58" x 2.34" x 1.65"(167.13mm x 61.90mm x 46.42mm/167.13mm x 59.49mm x 41.97mm) Weight: (w/Helical Antenna)Less Battery: 14.10oz. (383gm) With Ultra-High Cap. NiCd: 25.19oz. (693gm) With Li-Ion: 20.41oz. (583gm) With Ultra-High Cap. NiMH: 23.45oz. (644gm) With Extended- Cap. NiMH: 24.04oz. (682gm) Frequency Range: 136-174MHz Bandwidth: 38MHz Quieting Sensitivity (20dBQ): 0.35µV (typical) Usable Sensitivity(12dB SINAD): 0.20µV (typical) Intermodulation: –78dB (typical) Selectivity (typical)(25/30kHz Channel): –80dB (12.5kHz Channel): –67dB Spurious Rejection: –78dB Frequency Stability(–30+60°C; 25°C reference): ±.0002% Rated Audio: 500mW FM Hum and Noise (typical): 25kHz –50dB12.5kHz –44dB Distortion (At Rated Audio): 1.5% Typical Channel Spacing: 12.5/25 kHz RF Power: 136-174MHz: 1 to 6 Watts Frequency Range: 136-174MHz Frequency Stability (typical)(–30 to +60°C; 25°C ref.): ±.0002% Emission (Conducted and Radiated): –75dBc FM Hum and Noise (typical)(Companion Receiver): 25kHz –50dB12.5kHz –44dB Distortion: 2% Typical Modulation Limiting: 25kHz chnls ±5.0kHz12.5kHz chnls ±2.5kHz Adjacent Channel Power Ratio: 25kHz –73dBc12.5kHz –63dBc Emissions Designators: 20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1E Specifications subject to change without notice

vi SPECIFICATIONS FOR UHF RADIOS All speciﬁcations are per Telecommunications Industries Association TIA-603 unless otherwise noted GENERAL RECEIVER TRANSMITTER FCC Designation: AZ489FT4828 Temperature Range:Operating: –30°C to +60°C Storage: –40°C to +85°C Power Supply: Nickel-Cadmium Battery (NiCd) or Nickel-Metal-Hydride Battery (NiMH) or Lithium-Ion Battery (Li-Ion) Battery Voltage:Nominal: 7.5 Volts Range: 6 to 9 Volts Transmit Current Drain (Typical): 2000mA Receive Current Drain (Rated Audio): 240mA Standby Current Drain: 80mA Recommended Battery: Ultra-HIgh-Capacity NiCd: NTN8294_ or Extended-Capacity NiMH: NTN8293_ or Li-Ion: NTN8610_ or Ultra–High-Capacity NiCd FM: NTN8295_* or Ultra–High-Capacity NiMH FM: NTN8299_* Optional FM (Factory Mutual) Battery: * FM Intrinsically Safe: Class I, II, III, Division 1, Groups C, D,E, F, and G. FM Non-incendive:Class 1, Division 2, Groups A, B, C, and D. Dimensions (H x W x D) Note: 2.44" = width at PTT; 2.34" = width at bottom; 1.83" = depth at speaker; 0.97" = depth at keypad Less Battery: 6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"(167.13mm x 61.90mm x 46.42mm/167.13mm x 59.49mm x 24.56mm) With Battery: 6.58" x 2.44" x 1.83"/6.58" x 2.34" x 1.65"(167.13mm x 61.90mm x 46.42mm/167.13mm x 59.49mm x 41.97mm) Weight: (w/Helical Antenna)Less Battery: 14.10oz. (383gm) With Ultra-High Cap. NiCd: 25.19oz. (693gm) With Li-Ion: 20.41oz. (583gm) With Ultra-High Cap. NiMH: 23.45oz. (644gm) With Extended- Cap. NiMH: 24.04oz. (682gm) Frequency Range: 450-520MHz Bandwidth: 70MHz Quieting Sensitivity (20dBQ): 0.35µV (typical) Usable Sensitivity(12dB SINAD): 0.20µV (typical) Intermodulation: –78dB (typical) Selectivity (typical)(25/30kHz Channel): –78dB (12.5kHz Channel): –70dB Spurious Rejection: –80dB Frequency Stability(–30+60°C; 25°C reference): ±.0002% Rated Audio: 500mW FM Hum and Noise (typical): 25kHz –48dB12.5kHz –43dB Distortion (At Rated Audio): 1.5% TypicalChannel Spacing: 12.5/25 kHzRF Power: 450-520MHz: 1 Watt/5 WattsFrequency Range: 450-520MHzFrequency Stability (typical)(–30 to +60°C; 25°C ref.): ±.0002%Emission (Conducted and Radiated): –75dBcFM Hum and Noise (typical)(Companion Receiver): 25kHz –48dB12.5kHz –42dBDistortion: 2% TypicalModulation Limiting: 25kHz chnls ±5.0kHz12.5kHz chnls ±2.5kHzEmissions Designators:20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1ESpecifications subject to change without notice

viiGLOSSARYA/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.ADDAG Analog-to-Digital/Digital-to-Analog Glue ICAPCO Association of Public Safety Communication OfﬁcersCODEC 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-FrequencyDPL Digital Private-Line™DSP Digital Signal Processor; microcontroller speciﬁcally tailored for signal processing computations. In this case refers speciﬁcally to Motorola DSP56603.DSPS IC Digital Signal Processor Support IC. Generates processor clocks and provides peripheral functions for the DSP.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 UnitFLASHport™ 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 CircuitIMBE Improved Multi-Band Excitation: a sub-band, voice encoding algorithm used in ASTRO digital voice.MCU MicroControl UnitMDC Motorola Digital Communications

viiiMISO 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.OMPAC Over-Molded Pad-Array Carrier; a Motorola custom IC package, distinguished by the presence of solder balls on the bottom pads.Open Architecture A controller conﬁguration that utilizes a microprocessor with extended ROM and RAM.PC Board Printed Circuit boardPCIC Power Control ICPL 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.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 AmpliﬁerRSS Radio Service SoftwareRPT/TA RePeaTer/Talk-AroundRX 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 lineSoftpot 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.

ixSquelch Muting of audio circuits when received signal levels fall below a pre-determined value.SRAM Static-RAM chip used for volatile, program/data memory.SSI Synchronous Serial Interface on the DSP56603 to the CODEC, DSPS IC, and ADDAG.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 PackageUART 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.VCOB IC Voltage-Controlled Oscillator Buffer ICVocoder VOice enCODER; the DSP-based system for digitally processing the analog signals, includes the capabilities of performing voice compression algorithms or voice encoding.VOCON VOcoder/CONtroller boardVSWR Voltage Standing Wave Ratio

xSafety InformationSafe And Efﬁcient Operation Of Motorola Two-Way RadiosFor information regarding radio use in hazardous areas, please refer to the Factory Mutual (FM) approval manual supplement that is included with radio models that offer this capability.Exposure To Radio Frequency EnergyNational and International Standards and GuidelinesYour Motorola Two-Way Radio, which generates and radiates radio frequency (RF) electromagnetic energy (EME), is designed to comply with the following National and International Standards and Guidelines regarding exposure of human beings to radio frequency electromagnetic energy:• Federal Communications Commission Report and Order No. FCC 96-326 (August 1996)• American National Standards Institute (C95.1 - 1992)• National Council on Radiation Protection and Measurements (NCRP - 1986)• International Commission on Non-Ionizing Radiation Protection (ICNRP - 1986)• European Committee for Electrotechnical Standardisation (CENELEC):To assure optimal radio performance and that human exposure to radio frequency electromagnetic energy is within the guidelines set forth in the above standards, always adhere to the following procedures:Portable Radio Operation and EME Exposure• When transmitting with a portable radio, hold the radio in a vertical position with its microphone 1 to 2 inches (2.5 to 5 centimeters) away from your mouth. Keep the antenna at least 1 inch (2.5 centimeters) from your head and body. • If you wear a portable two-way radio on your body, ensure that the antenna is at least 1 inch (2.5 centimeters) from your body when transmitting.Electromagnetic Interference/CompatibilityNearly every electronic device is susceptible to electromagnetic interference (EMI) if inadequately shielded, designed, or otherwise conﬁgured for electromagnetic compatibility.• To avoid electromagnetic interference and/or compatibility conﬂicts, turn off your radio in any facility where posted notices instruct you to do so. Hospitals or health care facilities may be using equipment that is sensitive to external RF energy.• When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in accordance with airline regulations or crew instructions.• ENV. 50166-1 1995 E Human Exposure to Electromagnetic Fields Low Frequency (0Hz to 10kHz) • ENV. 50166-2 1995 E Human Exposure to Electromagnetic Fields High Frequency (10kHz to 300GHz)• Proceedings of SC211/8 1996 Safety Considerations for Human Exposure to E.M.F.s from Mobile Telecommunications Equipment (M.T.E.) in the Frequency Range 30MHz - 6 GHz (E.M.F. - Electromagnetic Fields)MAN WITH RNote

xiOperational WarningsVehicles With an Air BagDo not place a portable radio in the area over an air bag or in the air bag deployment area. Air bags inﬂate with great force. If a portable radio is placed in the air bag deployment area and the air bag inﬂates, the radio may be propelled with great force and cause serious injury to occupants of the vehicle.Potentially Explosive AtmospheresTurn off your two-way radio when you are in any area with a potentially explosive atmosphere, unless it is a radio type especially qualiﬁed for use in such areas (for example, Factory Mutual or CENELEC approved). Sparks in a potentially explosive atmosphere can cause an explosion or ﬁre resulting in bodily injury or even death.BatteriesDo not replace or recharge batteries in a potentially explosive atmosphere. Battery contact sparking may occur while installing or removing batteries and may cause an explosion.Blasting Caps and Blasting AreasTo avoid possible interference with blasting operations, turn off your radio when you are near electrical blasting caps, in a blasting area, or in areas posted: “Turn off two-way radio.” Obey all signs and instructions.The areas with potentially explosive atmospheres referred to above include fueling areas such as: below decks on boats; fuel or chemical transfer or storage facilities; areas where the air contains chemicals or particles, such as grain, dust, or metal powders; and any other area where you would normally be advised to turn off a vehicle engine. Areas with potentially explosive atmospheres are often but not always posted.Operational CautionsAntennas• Do not use any portable two-way radio that has a damaged antenna. If a damaged antenna comes into contact with your skin, a minor burn can result.• Make sure you have the correct antenna installed for your radio’s frequency band. Ask your dealer for details.BatteriesAll batteries can cause property damage and/or bodily injury such as burns if a conductive material such as jewelry, keys, or beaded chains touch exposed terminals. The conductive material may complete an electrical circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, particularly when placing it inside a pocket, purse, or other container with metal objects.Battery InformationCharging BatteriesThis product is powered by a nickel-cadmium (Ni-Cd), nickel-metal-hydride (NiMH), or lithium-ion rechargeable battery. Charge the battery before use to ensure optimum capacity and performance. The battery was designed speciﬁcally to be used with a Motorola charger. Charging in non-Motorola equipment may lead to battery damage and void the battery warranty.When charging a battery attached to a radio, turn the radio off to ensure a full charge.The battery should be at about 77°F (25°C) (room temperature), whenever possible. Charging a cold battery (below 50° F [10°C]) may result in leakage of electrolyte and ultimately in failure of the battery. Charging a hot battery (above 104°F [40°C]) results in reduced discharge capacity, affecting the performance of the radio. Motorola rapid-rate battery chargers contain a temperature-sensing circuit to ensure that batteries are charged within the temperature limits stated above.!W A R N I N G!Note!C a u t i o nNote

xiiRecycling of Nickel-Cadmium BatteriesNickel-cadmium (Ni-Cd) rechargeable batteries can be recycled. However, recycling facilities may not be available in all areas. Under various U.S. state laws and the laws of several other countries, Ni-Cd batteries must be recycled or disposed of properly and cannot be disposed of in landﬁlls or incinerators. Contact your local waste management agency for speciﬁc requirements and information in your area. Motorola fully endorses and encourages the recycling of Ni-Cd batteries. In the U.S. and Canada, Motorola participates in the nationwide Rechargeable Battery Recycling Corporation (RBRC) program for Ni-Cd battery collection and recycling. Many retailers and dealers participate in this program. For the location of the drop-off facility closest to you, access RBRC's Internet website at www.rbrc.com or call 1-800-8-BATTERY. This internet site and telephone number also provide other useful information concerning recycling options for consumers, businesses, and governmental agencies.Intrinsically Safe Radio InformationFMRC Approved EquipmentAnyone intending to use a radio in a location where hazardous concentrations of ﬂammable materials exist (hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500 (hazardous [classiﬁed] locations).An Approval Guide, issued by Factory Mutual Research Corporation (FMRC), lists manufacturers and the products approved by FMRC for use in such locations. FMRC has also issued a voluntary approval standard for repair service (“Class Number 3605”).FMRC Approval labels are attached to the radio to identify the unit as being FM Approved for speciﬁed hazardous atmospheres. This label speciﬁes the hazardous Class/Division/Group along with the part number of the battery that must be used. Depending on the design of the portable unit, this FM label can be found on the back or the bottom of the radio housing. The FM Approval mark is shown below:WARNINGS• Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualiﬁed (for example, FMRC Approved) for such use. An explosion or ﬁre may result.• Do not operate an FMRC Approved Product in a hazardous atmosphere if it has been physically damaged (for example, cracked housing). An explosion or ﬁre may result.• Do not replace or charge batteries in a hazardous atmosphere. Contact sparking may occur while installing or removing batteries and cause an explosion or ﬁre.• Do not replace or change accessories in a hazardous atmosphere. Contact sparking may occur while installing or removing accessories and cause an explosion or ﬁre.• Do not operate an FMRC Approved Product unit in a hazardous location with the accessory contacts exposed. Keep the connector cover in place when accessories are not used.• Turn a radio off before removing or installing a battery or accessory.• Do not disassemble an FMRC Approved Product unit in any way that exposes the internal electrical circuits of the unit.Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and FM Approval labeling. Radios will not be “upgraded” to this capability and labeled in the ﬁeld.A modiﬁcation changes the unit’s hardware from its original design conﬁguration. Modiﬁcations can only be made by the original product manufacturer at one of its FMRC-audited manufacturing facilities.FMAPPROVED!W A R N I N G!

xiiiWARNINGS• Failure to use an FMRC Approved Product unit with an FMRC Approved battery or FMRC Approved accessories speciﬁcally approved for that product may result in the dangerously unsafe condition of an unapproved radio combination being used in a hazardous location.• Unauthorized or incorrect modiﬁcation of an FMRC Approved Product unit will negate the Approval rating of the product.Repair of FMRC Approved ProductsREPAIRS FOR MOTOROLA PRODUCTS WITH FMRC APPROVAL ARE THE RESPONSIBILITY OF THE USER.You should not repair or relabel any Motorola- manufactured communication equipment bearing the FMRC Approval label (“FMRC Approved Product”) unless you are familiar with the current FMRC Approval standard for repairs and service (“Class Number 3605”).You may want to consider using a repair facility that operates under 3605 repair service approval.WARNINGS• Incorrect repair or relabeling of any FMRC Approved Product unit could adversely affect the Approval rating of the unit.• Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in serious injury or death.FMRC’s Approval Standard Class Number 3605 is subject to change at any time without notice to you, so you may want to obtain a current copy of 3605 from FMRC. Per the December 1994 publication of 3605, some key deﬁnitions and service requirements are as follows:RepairA repair constitutes something done internally to the unit that would bring it back to its original condition—Approved by FMRC. A repair should be done in an FMRC Approved facility.Items not considered as repairs are those in which an action is performed on a unit which does not require the outer casing of the unit to be opened in a manner which exposes the internal electrical circuits of the unit. You do not have to be an FMRC Approved Repair Facility to perform these actions.RelabelingThe repair facility shall have a method by which the replacement of FMRC Approval labels are controlled to ensure that any relabeling is limited to units that were originally shipped from the Manufacturer with an FM Approval label in place. FMRC Approval labels shall not be stocked by the repair facility. An FMRC Approval label shall be ordered from the original manufacturer, as needed, to repair a speciﬁc unit. Replacement labels may be obtained and applied by the repair facility, provided there is satisfactory evidence that the unit being relabeled was originally an FMRC Approved unit. Veriﬁcation may include, but is not limited to: a unit with a damaged Approval label, a unit with a defective housing displaying an Approval label, or a customer invoice indicating the serial number of the unit and purchase of an FMRC Approved model.Do Not Substitute Options or AccessoriesThe Motorola communications equipment certiﬁed by Factory Mutual is tested as a system and consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or options, or both. This FM Approved portable and battery combination must be strictly observed. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit. Approved conﬁgurations are listed in the FM Approval Guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped from the manufacturer with the FM Approved radio and battery combination. The Approval Guide, or the Approval Standard Class Number 3605 document for repairs and service, can be ordered directly from Factory Mutual Research Corporation located in Norwood, Massachusetts.!W A R N I N G!!W A R N I N G!

xivNotes

1Introduction 1General This manual covers information needed for level one troubleshooting. Level one troubleshooting consists of radio programming, radio alignment, knobs replacement, and installation and removal of antenna, belt clip, battery, and universal connector cover.Included in this manual are radio speciﬁcations for the VHF and UHF frequency bands, a general description of XTS 3500 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. !C a u t i o nWARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury. !W A R N I N G!DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury.D A N G E R!

2Radio Description The ASTRO Digital XTS 3500 radios are among the most sophisticated two-way radios available. The radios are available in the VHF and UHF R2 bands.One of the newest in a long line of quality Motorola products, the ASTRO Digital XTS 3500 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 3500 radios are available in three basic models. Table 1 describes their basic features.FLASHport The ASTRO Digital XTS 3500 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, similar to how a computer can be loaded with different software, the radio’s features and capabilities can be upgraded with FLASHport software.Table 1 ASTRO XTS 3500 Basic FeaturesFeature Model I Model II Model IIIDisplay None LCD4 lines/12 characters per line LCD4 lines/12 characters per line Keypad None 3 x 2 button 3 x 6 buttonChannel Capability 48 255 255Dialing from Prestored List No Yes YesProgrammable Softkeys No Yes Yes

3Basic Maintenance 2Introduction 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 The ASTRO Digital XTS 3500 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.Cleaning External Plastic Surfaces The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio. A soft, absorbent, lintless cloth or tissue should be used to remove the solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices.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.!C a u t i o n

4Handling Precautions Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices, are used in this family of radios. While the attributes of these devices are many, their characteristics make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair. Handling precautions are mandatory for this radio, and are especially important in low-humidity conditions.

5Recommended Test Equipment and Service Aids 3RecommendedTest EquipmentThe list of equipment contained in Table 2 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.Service Aids Refer to Table 3, “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 2 Recommended Test EquipmentMotorolaModel Number Description Characteristics ApplicationR2600 Series Communications System Analyzer This monitor will substitute for items with an asterisk (*). Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment.Fluke 8012 Digital Multimeter Recommended for ac/dc voltage and current measurementsR1150_* Code Synthesizer Injection of audio and digital signalling codesR1377_* AC Voltmeter 1mV to 300V, 10-Megohm input impedance Audio voltage measurementsR1094_ Dual-Trace Oscilloscope 20MHz bandwidth 5mV to 5V/division Waveform measurementsS1350_*ST1213_ (VHF)*ST1223_ (UHF)*WattmeterPlug-In ElementRF Dummy Load50-ohm, ±5% accuracy10 watts, maximum0-1000MHz, 300WTransmitter power output measurementsR1065_ Load Resistor 10-watt Broadband For use with wattmeterS1339_ RF Millivolt Meter 100µV to 3V RF RF-level measurementsR1013_* SINAD Meter Receiver sensitivity measurementsS1347_ or S1348_ (programmable) DC Power Supply 0-20Vdc, 0-5 Amps current limited Bench supply for 7.5Vdc

6Field Programming EquipmentThis family of radios can be aligned and programmed in the ﬁeld. This requires speciﬁc equipment and special instructions. Refer to the applicable “Radio Service Software User's Guide” for complete ﬁeld programming information.Table 3 Service AidsMotorola Part Number Description ApplicationRKN-4035_ RIB/Radio/Test Set Cable Connects radio to RTX-4005B Test Box and RIB.REX-4424_ Battery Eliminator Interconnects radio to power supply.RLN-4460_, orRTX-4005_, or both RTX-4005_ and RPX-4665_Portable Test Set Enables connection to the universal connector.Allows switching for radio testing.Field Modiﬁcation Kit RLN-1015_ orRLN-4008_Radio Interface Box Enables communications between the radio and the computer's serial communications adapter.01-80357A57 Wall-Mounted Power Supply Used to supply power to the RIB (120 Vac).01-80358A56 Wall-Mounted Power Supply Used to supply power to the RIB (220 Vac).30-80369B71 or 30-80369B72 Computer Interface Cables for RIB RLN4008_ Use B72 for 9-pin serial ports. All other models use B71 (25 pins). Connects the computer's serial communications adaptor to the RIB.30-80390B48 or 30-80390B49 Computer Interface Cables for Smart RIB RLN1015_ Use B49 for 9-pin serial ports. All other models use B48 (25 pins). Connects the computer's serial communications adaptor to the RIB.RVN-4170_ Radio Service Software Software on 3-1/2 in. ﬂoppy disks.58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test equipment.

7Performance Checks 4Introduction to This Section This section covers performance checks used to verify 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 (page 15, Figure 1).Initial equipment control settings should be as indicated in the following table, and should hold for all alignment procedures except as noted in Table 4.Display Radio Test ModeEntering Display Radio Test Mode 1. Turn the radio on.2. Within 10 seconds after “SSSSeeeellllffff TTTTeeeesssstttt” 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 5 on page 8.Table 4 Initial Equipment Control SettingsSystem Analyzer Test Set Power SupplyMonitor Mode: Pwr Mon Spkr Set: A Voltage: 7.5VdcRF Attn: –70dB Spkr/Load: Speaker DC On/Standby: StandbyAM, CW, FM: FM PTT: OFF (center) Volt Range: 10VdcO'scope Source: ModO'scope Horiz: 10mSec/DivO'scope Vert: 2.5kHz/DivO'scope Trig: AutoMonitor Image: HiMonitor BW: NarMonitor Squelch: Mid CWMonitor Vol: 1/4 CWCurrent: 2.5Amps

8Note: All displays are temporary and will expire 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, “RRRRFFFF TTTTEEEESSSSTTTT” will be displayed.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 “CCCCHHHH TTTTEEEESSSSTTTT” will be displayed. Go to the “Control Top and Keypad Test Mode (Display Radio)” section.NOTE: Each press of Side Button 1 will toggle between “CCCCHHHH TTTTEEEESSSSTTTT”and “RRRRFFFF TTTTEEEESSSSTTTT.”OR4b. Press the Top Programmable Button (Emergency button) to stop the displays and put the radio into the RF test mode (display radio). The test mode menu “1111 CCCCSSSSQQQQ.” will be displayed, indicating test frequency 1, Carrier SQuelch mode. Go to the “RF Test Mode (Display Radio)” section.RF Test Mode (Display Radio) When the ASTRO Digital XTS 3500 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 6.)2. Pressing Side Button 2 will scroll through and access test environments as shown in Table 7.NOTE: Transmit into a load when keying a radio under test.Table 5 Front-Panel Access Test-Mode DisplaysName of Display Description Appears“SSSSEEEERRRRVVVVIIIICCCCEEEE” The literal string indicates the radio has entered test mode. Always.Host Software Version The version of host ﬁrmware is displayed. Always.DSP Software Version The version of DSP ﬁrmware is displayed. Always.EMC Secure Version Version of the encryption hardware. When the radio is secure equipped.Encryption Type 1 Type of encryption being used. When the radio is secure equipped.Encryption Type 2 Type of encryption being used. When the radio is secure equipped.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.

9 ** All deviation values are based on deviation tuning of this mode *** On radios equipped with secure optionControl 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; “3333////0000” appears, which indicates that the Top Programmable Button is in the open condition.3. Press the Top Programmable Button again; “3333////1111” appears, which indicates that the Top Programmable Button is in the closed condition.4. Rotate the Mode/Zone Selector Switch; “4444////0000” through “4444////11115555” appears, which indicates that the selector switch is in mode/zone position 1 through 16.Table 6 Test FrequenciesTest Channel VHF UHF Band 2TX #1 136.025 450.025RX #1 136.075 450.075TX #2 142.125 465.225RX #2 142.075 465.275TX #3 154.225 475.125RX #3 154.275 475.275TX #4 160.125 484.975RX #4 160.175 485.025TX #5 168.075 500.275RX #5 168.125 500.225TX #6 173.975 511.975RX #6 173.925 511.925TX #7 177.975 519.975RX #7 177.925 519.925Table 7 Test EnvironmentsNo. of Beeps Display Description Function1 CSQ Carrier Squelch RX: unsquelch if carrier detectedTX: mic audio3 TPL Tone Private-Line RX: unsquelch if carrier and tone (192.8 Hz) detectedTX: mic audio + tone (192.8 Hz)9 SEC Secure*** RX: auto-coded clearTX: with key present—encrypted audio with key absent—constant unsquelch11 AST ASTRO RX: noneTX: 1200Hz tone **12 USQ CarrierUnsquelch RX: unsquelch alwaysTX: mic audio

105. Rotate the Two-Position Concentric Switch; “66665555////0000” and “66665555////1111” appear.6. Cycle through the Three-Position Programmable Switch; “66667777////0000,” “66667777////1111,” and “66667777////2222” appear.7. Rotate the Volume Control; “2222////0000” through “2222////222255555555” appear.8. Press Side Button 1; “99996666////1111” appears; release, “99996666////0000” appears.9. Press Side Button 2; “99997777////1111”appears; release, “99997777////0000” appears.10. Press Side Button 3; “99998888////1111”appears; release, “99998888////0000” appears.11. Press the PTT Switch; “1111////1111” appears; release, “1111////0000” appears.12. Keypad Checks:Model III Only—-Press 0, “44448888////1111” appears; release, “44448888////0000” appears.-Press 1, “44449999////1111” appears; release, “44449999////0000” appears.-Press 2, “55550000////1111” appears; release, “55550000////0000” appears.-Press 3, “55551111////1111” appears; release, “55551111////0000” appears.-Press 4, “55552222////1111” appears; release, “55552222////0000” appears.-Press 5, “55553333////1111” appears; release, “55553333////0000” appears.-Press 6, “55554444////1111” appears; release, “55554444////0000” appears.-Press 7, “55555555////1111” appears; release, “55555555////0000” appears.-Press 8, “55556666////1111” appears; release, “55556666////0000” appears.-Press 9, “55557777////1111” appears; release, “55557777////0000” appears.-Press *, “55558888////1111” appears; release, “55558888////0000” appears.-Press #, “55559999////1111” appears; release, “55559999////0000” appears.All Display Models—-Press <, “111122228888////1111” appears; release, “111122228888////0000” appears.-Press O, “111122229999////1111” appears; release, “111122229999////0000” appears.-Press >, “111133330000////1111” appears; release, “111133330000////0000” appears.-Press the left-hand M key on the top row of keys, “111133331111////1111” appears; release, “111133331111////0000” appears.-Press the center N key, “111133332222////1111” appears; release, “111133332222////0000” appears.-Press the right-hand M key, “111133333333////1111” appears; release, “111133333333////0000” appears.Non-Display Radio Test ModeEntering Non-Display Radio Test Mode1. Turn the radio on.2. Within 10 seconds after the top green LED turns off, press Side button 3 ﬁve times in succession.

11ppypmode (non-display radio). Go to the “Control Top and Keypad Test Mode (Non-Display Radio)” section.NOTE: Each press of Side Button 1 will toggle between ControlTop and Keypad test mode (non-display radio) and RF testmode (non-display radio).OR3b. Press the Top Programmable Button (Emergency button) to stop the displays and put the radio into the RF test mode (non-display radio). Go to the “RF Test Mode (Non-Display Radio)” section.RF Test Mode (Non-Display Radio)When the ASTRO Digital XTS 3500 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 6.) The channel number is represented by the number of beeps 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 7. 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 (Non-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; 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 Two-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 Three-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.

12Table 8 Receiver Performance ChecksTest Name System Analyzer Radio Test Set CommentsReference Frequency Mode: PWR MON 4th channel test frequency❖Monitor: Frequency error. Input at RF In/OutTEST MODE, 4 CSQ output at antennaPTT to continuous (during the performance check)Frequency error to be ≤ ±1.0kHzRated Audio Mode: GEN Output level: 1.0mV RF 4th channel test frequency❖Mod: 1kHz tone at 3kHz deviationMonitor: DVM: ac VoltsTEST MODE, 4 CSQ PTT to OFF (center); meter selector to Audio PASet volume control to 3.74VrmsDistortion As above, except to distortion As above As above Distortion < 3.0%Sensitivity (SINAD) As above, except SINAD; lower the RF level for 12dB SINADAs above PTT to OFF (center) RF input to be < 0.35µVNoise 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 speakerSet volume control to 3.74VrmsAs above, except change frequency to a conventional system. Raise RF level from zero until radio unsquelches.Out of TEST MODE; select a conventional systemAs above Unsquelch to occur at < 0.25µV. Preferred SINAD = 5-8dB❖ See Table 7

13Table 9 Transmitter Performance ChecksTest Name System Analyzer Radio Test Set CommentsReference Frequency Mode: PWR MON 4th channel test frequency❖Monitor: Frequency error. Input at RF In/OutTEST MODE, 4 CSQ PTT to continuous (during the performance check).Frequency error to be ≤ ±1.0kHz.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. Monitor: DVM, ac Volts. Set 1kHz Mod Out level for 0.025Vrms at test set, 80mVrms at ac/dc test set jackAs above, 4 CSQ As above, meter selector to mic Deviation: ≥ 4.1kHz but ≤ 5.0kHzVoice Modulation (internal)Mode: PWR MON 4th channel test frequency❖ atten to –70, input to RF In/OutTEST MODE, 4 CSQ, output at antennaRemove modulation input Press PTT switch on radio. Say “four” loudly into the radio mic. Measure deviation: ≥ 4.1kHz but ≤ 5.0kHzPL Modu-lation (radios with conven-tional, clear mode, coded squelch oper-ation only)Change frequency to a conventional transmit frequencyConventionalcoded squelch personality (clear mode operation) 4 TPLAs above Deviation: ≥ 500Hz but ≤ 1000HzTalkaround Modulation (radios with conventional, clear mode, talk-around operation only)Change frequency to conventional talk-around frequency. Mode: PWR MON deviation, attenuation to –70, input to RF In/Out. Monitor: DVM, ac volts Set 1kHz Mod Out level for 25mVrms at test set.Conventional talkaround personality (clear mode operation) 1 CSQAs above Deviation: ≥ 4.1kHz but ≤ 5.0kHzTalkaround Modulation (radios with conventional, secure mode, talkaround operation only)Change frequency to conventional talk-around frequency. Mode: PWR MON deviation, attenuation to –70, input to RF In/Out.Monitor: DVM, ac voltsMod: 1kHz out level for25mVrms at test set.Conventional talkaround personality (secure mode operation) 1 SEC. Load key into radio.As above Deviation: ≥ 3.7kHz but ≤ 4.3kHz❖See Table 7

14Notes

15Radio Alignment Procedures 5Introduction to This Section This section describes both receiver and transmitter radio alignment procedures.General A personal computer (PC) and radio service software (RSS) are required to align the radio. Refer to the applicable RSS manual for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the PC, radio interface box (RIB), and a universal test set as shown in Figure 1.Figure 1 Radio Alignment Test SetupAll service and tuning procedures are performed from the SERVICE menu, which is selected by pressing B from the MAIN MENU. Figure 2 illustrates how the RSS alignment SERVICE screens are organized.BNCRIBRLN-4008BRIB POWER SUPPLY01-80357A57 (120V)COMPUTER INTERFACECABLE30-80369B7130-80369B72 (IBM "AT" ONLY)DATABUSYGND COMPUTERAUDIO GENERATORSINAD METERAC VOLTMETERTXRX30 dB PAD30 dB PADRF GENERATORSYSTEM ANALYZEROR COUNTERWATTMETERBATTERYELIMINATORRTL-4224ATRANSMITRECEIVETEST SETRTX-4005BRADIOPROGRAM/TEST CABLERKN-4046AAUDIO INSET TO APPROX. 450mV FOR TxMEASURE 80mV FOR TxSMA-BNC58-80348B33REX-4424RKN-4035_ RIBRLN-4008_RLN-1015_ orTEST SETRLN-4460_ orRTX-4005_30-80369B71 (25 pins)30-80369B72 (7 pins)

16Figure 2 RSS Service Menu LayoutAll SERVICE screens read and program the radio codeplug directly; you do NOT have to use the RSS GET/SAVE functions to use the SERVICE menus.The SERVICE screens introduce the concept of the “softpot,” an analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls.Each SERVICE screen provides the capability to increase or decrease the ‘softpot’ value with the keyboard UP/DOWN arrow keys respectively. A graphical scale is displayed indicating the minimum, maximum, and proposed value of the softpot, as shown in Figure 3.Figure 3 Softpot ConceptREFERENCE OSCILLATOR ALIGNMENTTRANSMIT POWER ALIGNMENTTRANSMITTER ALIGNMENT MENUTRANSMIT DEVIATION BALANCE (COMPENSATION) ALIGNMENTTRANSMIT DEVIATION LIMIT ALIGNMENTF2 -F2 -F3 -F4 -F5 -RECEIVER ALIGNMENT MENUF3 -FRONT END BANDPASS FILTER ALIGNMENTF2 -SERVICEHELPF1 -EXIT, RETURN TO SERVICE MENUF10 -BABCDECBJDo NOT switch radios in the middle of any SERVICE procedure. Always use the EXIT key to return to the MAIN menu screen before disconnecting the radio. Improper exits from the SERVICE screens may leave the radio in an improperly conﬁgured state and result in seriously degraded radio or system performance.!C a u t i o nMin.Value Max.Value015

17Adjusting the softpot value sends information to the radio to increase (or decrease) a dc voltage in the corresponding circuit. For example, pressing the UP arrow key at 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-to-analog (D/A) generated voltage in the radio.Perform the following procedures in the sequence indicated.NOTE: Some of the following screens may varydepending upon the radio under test and theversion of radio service software you are using.Refer to your radio service software user’s guide.Reference Oscillator AlignmentAdjustment 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. The frequency counter used for this procedure must have a stability of 0.1 ppm (or better).1. From the SERVICE MENU, press B to select the TRANSMITTER ALIGNMENT MENU.2. Press B again to select the REFERENCE OSCILLATOR alignment screen. See Figure 4.Figure 4 Reference Oscillator Alignment Screen3. Press F to key the radio. The screen will indicate that the radio is transmitting.4. Measure the transmit frequency on your service monitor.5. Use the É/Ç arrow keys to adjust the reference oscillator softpot value. See Table 10.MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDC9PW5AN MAIN:SERVICE:TX ALIGN:REF OSC REFERENCE OSCILLATOR -------------------- Frequency Current Value --------- ------------- 519.975 150 New Softpot Value.....150 Transmitter..On 0 215 MIN |----+----+----+----+----+----+----+----+----+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE

186. Press F again to dekey the radio.7. Press H to program the new softpot value.8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU.Transmit Power AlignmentNOTES:•All power measurements are to be made at the antenna port.•The transmitter power setting keeps the radiated power at or below the level speciﬁed in the exclusionary clause for low power devices of IEEE Standard C95.1-1991.1. From the SERVICE MENU, press B to select the TRANSMITTER ALIGNMENT MENU.2. Press C to select the TRANSMIT POWER alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 5.Figure 5 Transmit Power Alignment Screen3. Press P (or Z or [RETURN]) to select a frequency ﬁeld (starting with the highest frequency shown). Then, press F to key the radio. The screen will indicate that the radio is transmitting.4. Use the É/Ç arrow keys to adjust the transmit power per the values shown in Table 11.Table 10 Reference Oscillator AlignmentBand TargetVHF or UHF ±100 HzMOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDH9PW7AN MAIN:SERVICE:TX ALIGN:TX POWER TRANSMIT POWER -------------- Current Value New Softpot Value Frequency High Pwr Mid Pwr Low Pwr High Pwr Mid Pwr Low Pwr --------- -------- -------- ------- -------- -------- ------- 450.0250 65 25 25 65 25 25 465.2250 67 26 26 67 26 26 475.1250 68 27 27 68 27 27 484.9750 69 28 28 69 28 28 500.2750 72 29 29 72 29 29 511.9750 75 30 30 75 30 30 519.9750 59 31 31 59 31 31 Transmitter..Off 0 127 MIN |----+----+----+----+----+----X----+----+----+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE

195. Press F to dekey the radio.6. Press H to program the value.7. Repeat steps 3-6 for the remaining frequencies.8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU.Transmit Deviation Balance (Compensation) AlignmentCompensation alignment balances the modulation sensitivity of the VCO and reference modulation (synthesizer low-frequency port) lines. The compensation algorithm 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. 1. From the SERVICE MENU, press B to select the TRANSMITTER ALIGNMENT MENU.2. Press D to select the TRANSMIT DEVIATION BALANCE (COMPENSATION) alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 6.Figure 6 Transmit Deviation Balance (Compensation) Alignment Screen3. Press P (or Z or [RETURN]) to select a frequency ﬁeld (starting with the lowest frequency shown).4. Press D. This will cause the radio to key and the radio’s DSP IC to inject an 80Hz tone into the RF board.5. Measure the deviation and record this value.Table 11 Transmit Power SettingsPower Level Test Frequencies136-174MHz 450-512MHz 512-520MHz1 Watt 1.2W - 1.4W 1.2W - 1.4W 1.2W - 1.4W5 Watts ———— 5.2W - 5.4W 3.2W - 3.4W6 Watts 6.2W - 6.5W ———— ————MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDC9PW5AN MAIN:SERVICE:TX ALIGN:BAL ATTN TRANSMIT DEVIATION BALANCE (COMPENSATION) ----------------------------------------- Current Frequency Value New Softpot Value --------- ------- ----------------- 450.025 30 30 465.225 30 30 475.125 30 30 484.975 45 45 500.275 45 45 511.975 45 45 519.975 45 Transmitter..Off 45 0 63 MIN |---+---+---+---+---+---+---+---+---+---+---+---+---+---+---+---| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE LOW TOGGLE HIGH PROGRAM EXIT TONE PTT TONE PTT VALUE

206. Press D to dekey the radio.7. Press F. This will cause the radio’s DSP IC to change the injection tone to 3kHz, 100mVrms. Use the É/Ç arrow keys to adjust the deviation to within ±2% of the value recorded in step 5.8. Repeat steps 4-7 until the 3kHz tone deviation is within ±2% of the 80Hz tone deviation.9. Press F again to dekey the radio.10. Press H to program the new softpot value.11. Repeat steps 3-10 for the remaining frequencies.12. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU.Transmit Deviation Limit Alignment1. From the SERVICE MENU, press B to select the TRANSMITTER ALIGNMENT MENU.2. Press E to select the TRANSMIT DEVIATION LIMIT alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 7.Figure 7 Transmit Deviation Limit Alignment Screen3. Press P (or Z or [RETURN]) to select a frequency ﬁeld (starting with the lowest frequency shown).4. Press F to key the radio. Then use the É/Ç arrow keys to adjust for a deviation per the values shown in Table 12.5. Press F again to dekey the radio.6. Press H to program the softpot value.7. Repeat steps 3-6 for the remaining frequencies.Table 12 Transmit Deviation LimitBand Deviation (Hz)VHF or UHF 2785 - 2885MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDC9PW5AN MAIN:SERVICE:TX ALIGN:DEV.LIMIT TRANSMIT DEVIATION LIMIT ------------------------ Current Frequency Value New Softpot Value --------- ------- ----------------- 450.025 24500 24500 465.225 24500 24500 475.125 24500 24500 484.975 24500 24500 500.275 24500 24500 511.975 24500 24500 519.975 24500 Transmitter..Off 24500 0 32767 MIN |----+----+----+----+----+----+----+----+X---+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE

218. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU.Front End Filter Alignment1. From the SERVICE MENU, press C to select the RECEIVER ALIGNMENT MENU.2. Press B to select the FRONT END FILTER (VHF AND UHF ONLY) screen. The screen will indicate the receive frequencies at which the ﬁlter is to be aligned. See Figure 8.Figure 8 Front End Filter (VHF and UHF Only) Alignment Screen3. Press P (or Z or [RETURN]) to select a frequency ﬁeld.4. Set the RF test generator to the ﬁrst receive frequency +150Hz. Set the RF level at the radio standard antenna port to 4.0µV with no modulation.5. Adjust the É/Ç arrow keys to obtain a peak value in the RSSI (receive signal strength indicator) ﬁeld. NOTE: D must be pressed to obtain each RSSI reading after adjustment.6. Press H to program the new softpot value. 7. Repeat steps 3-6 for the remaining frequencies.8. Press J once to return to the RECEIVER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU.MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. ASTRO Model: H09KDH9PW7AN MAIN:SERVICE:RX ALIGN:FE FL FRONT END FILTER (VHF AND UHF ONLY) ----------------------------------- Current Frequency Value New Softpot Value RSSI....0 --------- ------- ----------------- 450.075 0 0 465.275 0 0 475.275 0 0 485.025 0 0 500.225 0 0 511.925 0 0 519.925 0 0 0 255 MIN |---+---+---+---+---+---+---+---+---+---+---+---+---+---+---+---| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP READ PROGRAM EXIT RSSI VALUE

22 Notes

23Basic Removal/Installation Procedures 6Introduction to This Section This section gives basic procedures for removing and installing the XTS 3500 radio’s:•Antenna,•Battery,•Belt Clip,•Universal Connector Cover,•Volume Knob, and•Frequency Knob.AntennaInstalling the Antenna Screw the threaded end of the antenna into the antenna receptacle on the top of the radio. Rotate the antenna clockwise until it seats ﬁrmly against the bushing. Removing the Antenna Rotate the antenna counterclockwise until its threaded end unscrews from the radio’s antenna receptacle.Battery NOTE: The battery is shipped uncharged, and must becharged for at least 16 hours before use. To avoid a possible explosion:• DO NOT replace the battery in an area labeled “hazardous atmosphere.”• DO NOT discard batteries in a ﬁre.!W A R N I N G!If your radio is programmed with volatile-key retention (consult your service technician), encryption keys will be retained for approximately 30 seconds after battery removal.!C a u t i o n

24Installing the Battery 1. Turn off the radio and hold it with the back of the radio facing upward2. Insert the top edge of the battery into the area at the top of the radio between the radio’s case and chassis. Make sure the three tabs on the radio chassis align with the three slots under the top edge of the battery.3. Rotate the battery toward the radio, and squeeze the battery and radio together until the battery “clicks” in place.Removing the Battery 1. Turn off the radio and hold it so that the release button on the bottom of the battery is facing upward.2. Press downward on the release button so the battery disengages from the radio.3. Remove the battery completely away from the radioBelt Clip NOTE: The battery must be removed from the radio before the belt clip can be installed or removed.Installing the Belt Clip 1. Hold the battery in one hand so that the top of the battery faces upward, and the back of the battery faces you.2. Holding the belt clip in the other hand with its top facing upward, align the slide assembly on the front of the belt clip with the slots on the back of the battery.3. Slide the belt clip downward toward the bottom of the battery until the belt clip “clicks” in place.Removing the Belt Clip 1. Hold the battery (with belt clip installed) in one hand so that the top of the battery faces upward, and the front (radio side) of the battery faces you.2. At the top of the battery, press down on the belt clip’s metal tab and slide the belt clip upward until it disengages from the battery.3. Continue to slide the belt clip upward until it is free from the battery.Slide AssemblySlotsBelt ClipBatteryMetalTabPressDownRadio ChassisReleaseButton

25Universal Connector CoverInstalling the Universal Connector Cover1. Looking at the antenna side of the radio, insert the top (ﬂat) hooked end of the cover into the slot on the top of the radio, above the universal connector. Press downward on the cover’s top to seat it in the slot.2. While holding the cover seated in the top slot, insert the cover’s bottom (rounded) hooked end into the slot below the universal connector. Press ﬁrmly inward on the cover’s bottom until it snaps in place. Removing the Universal Connector Cover1. Looking at the antenna side of the radio, insert a ﬂat-bladed screwdriver into the area between the lower end of the universal connector cover and the slot below the universal connector.2. While holding the cover’s top (ﬂat) end in place with your thumb, pry upward on the cover’s lower end until it disengages from the radio.Frequency Knob NOTES:•Refer to Figure 9, the Partial Exploded View, and Table 13, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 9 and Table 13.•The battery (7) should be removed from the radio before installing or removing the frequency knob (1).•In cases where the frequency insert (3) and escutcheon (2) must be removed, a new frequency insert and new escutcheon must be used for reassembly.Removing the Frequency Knob 1. Hold the radio in one hand so that the top of the radio faces upward, and the front of the radio faces you.2. With the other hand, grasp the frequency knob (1) and pull it upward, while rocking the knob back and forth, until it is free from the frequency insert (3) or the insert is free from the shaft.3. If necessary, while pressing the insert’s (3) two snap tabs away from the frequency control shaft so that the insert disengages from the shaft, use needle-nosed pliers to lift the insert up and off of the frequency control shaft. Discard the removed frequency insert.4. Remove the secure lever (4) and the lightpipe (5).When the universal connector is not in use, keep it covered with the universal connector cover.!C a u t i o nTopSlotBottomSlotTopHooked EndBottomHooked End

26Installing the Frequency Knob 1. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.2. Align the lightpipe (5) so that its straight tab is over the slot for the illuminated pointer. Push the tab down into the slot so that it is securely seated.3. Place the secure lever (4) on the frequency control shaft, aligning it so that its pointer is at the front of the radio and its two inner slots line up with the two keys on the shaft. Slide the secure lever down to the bottom of the shaft.4. If you are replacing the escutcheon (2): a. Remove the backing paper from the escutcheon.b. Align the number “1” on the escutcheon with the alignment notch on the insert (3).c. Slide the escutcheon down over the insert until the alignment tabs on the escutcheon ﬁt inside the tab recesses on the insert.d. Adhere the escutcheon to the insert.5. Place a new frequency insert (3) and new escutcheon (2) on the frequency control shaft, aligning the insert’s D-shaped hole with the D-shaped shaft. Press downward ﬁrmly on the insert until it “snaps” in place on the shaft.6. Place the frequency knob (1) on the frequency insert (3), aligning it’s pointer with the number “1” on the escutcheon (2). Press ﬁrmly downward on the knob until it seats securely in place.Volume Knob NOTES:•Refer to Figure 9, the Partial Exploded View, and Table 13, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 9 and Table 13.•The battery (7) should be removed from the radio before installing or removing the volume knob (8).•In cases where the volume insert (9) must be removed, a new volume insert must be used for reassembly.Removing the Volume Knob 1. Hold the radio in one hand so that the top of the radio faces upward, and the front of the radio faces you.2. With the other hand, grasp the volume knob (8) and pull it upward, while pushing it toward the back of the radio, until it is free from the volume insert (9).3. While pressing the volume insert’s (9) two snap tabs away from the volume control shaft so that the insert disengages from the shaft, use needle-nosed pliers to pull the insert up and off of the volume control shaft. Discard the removed volume insert.4. Using needle-nosed pliers or some other pointed instrument, remove the o-ring (21).

27Installing the Volume Knob 1. Place the o-ring (21) inside a new volume insert (9), and press it downward until it seats securely at the bottom of the insert.2. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.3. Place a new volume insert (9) on the volume control shaft, aligning the insert’s D-shaped hole with the D-shaped shaft. Press downward ﬁrmly on the insert until it “snaps” in place on the shaft.4. Place the volume knob (8) on the volume insert (9), aligning the two lugs on the inside of the knob with the insert’s two snap tabs. Press ﬁrmly downward on the knob until it seats securely in place.Figure 9 Partial Exploded View1234567809ABCDEFGHIJKLMNOPRSTUVWXYHOMEXTS 3500123451718201615891011211413127619ABCTab RecessesAlignment TabsAlignment NotchMAEPF-26563-B

28Table 13 Partial Exploded View Parts ListITEM NO. MOTOROLA PART NO. DESCRIPTION1 3605370Z01 KNOB, Frequency2 1305374Z01 ESCUTCHEON, Frequency3 4305373Z01 INSERT RETAINER, Frequency Knob4 4305375Z01 LEVER, Secure Frequency5 6105376Z01 LIGHTPIPE INDICATOR/STOP, Frequency6 NTN8266_ CLIP, Belt7 NTN8923_or NTN8294_or NTN8295_or NTN8299_or NTN8610_Battery, NiMH Extended LifeBattery, NiCdBattery, NiCd FMBattery, NiMH FMBattery, Li-Ion8 3605371Z01 KNOB, Volume9 4305372Z01 INSERT RETAINER, Volume Knob10 3305574Z03 LABEL, Motorola, Back11 - - - - - - - - - - LABEL, Flashport12 - - - - - - - - - - LABEL, Radio Serial Number13 - - - - - - - - - - LABEL, Approval Agency14 3305630Z02or 3305630Z01 LABEL, BottomLABEL, Bottom, FM15 NAD6563_or NAD6566_or NAD6567_or NAD6568_or NAE6547_or NAE6548_or NAE6549_ANTENNA, Wideband Helical (136-174 MHz)ANTENNA, Helical (136-151 MHz)ANTENNA, Helical (151-162 MHz)ANTENNA, Helical (162-174 MHz)ANTENNA, Helical (430-470 MHz)ANTENNA, Helical (470-512 MHz)ANTENNA, Wideband Whip (403-512 MHz)16 - - - - - - - - - - ESCUTCHEON, Concentric Switch (optional)17 - - - - - - - - - - ESCUTCHEON, Toggle (optional)18 1505579Z01 COVER, Dust, Universal Connector19 3386139A01 LABEL, Motorola, Front20 3505586Z01 Gortex21 3205379W01 O-Ring

29Basic Theory of Operation 7General Overview The ASTRO Digital XTS 3500 radio is a wideband, synthesized, ﬁxed-tuned radio available in the VHF and UHF bands. All ASTRO Digital XTS 3500 radios are capable of both analog operation (12.5kHz or 25kHz bandwidths) and ASTRO mode (digital) operation (12.5kHz only).The ASTRO Digital XTS 3500 radio includes the following major assemblies:•VOCON 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.•RF Board - contains all transmit, receive, and frequency generation circuitry including the digital receiver back-end IC and the reference oscillator.•Controls/Universal Flex - contains volume/on/off switch, frequency selector switch, push-to-talk (PTT) switch, monitor button, several function-selectable switches, universal connector, speaker, and microphone.•Display (Models II and III Only) — a four-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.Analog Mode of Operation When the radio is receiving, the signal comes from the antenna connector to the RF board, passes through the RX/TX switch and the receiver front end. The signal is then ﬁltered, ampliﬁed, and mixed with the ﬁrst local-oscillator signal generated by the voltage-controlled oscillator (VCO). The resulting intermediate frequency (IF) signal is fed to the IF circuitry, where it is again ﬁltered and ampliﬁed. This ampliﬁed signal is passed to the digital back-end IC, where it is mixed with the second local oscillator to create the second IF at 450kHz. 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 board through a current-driven differential output. On the VOCON board, the digital-signal processor (DSP) support IC digitally ﬁlters and discriminates the signal, and passes it to the digital-signal processor (DSP). The DSP decodes the information in the signal and identiﬁes the appropriate destination for it. For a voice signal, the DSP will route the digital voice data to the CODEC for conversion to an analog signal. The CODEC will then present the signal to the audio power ampliﬁer, which drives the speaker.

30For signalling information, the DSP will decode the message and pass it to the microcontrol unit.When the radio is transmitting, 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/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. 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 Board Basic Theory of OperationThe 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 digital/analog (D/A) IC. The RF ampliﬁer is a dual-gate, gallium-arsenide-based IC. The mixer is a double-balanced, active mixer, coupled by transformers. Injection is provided by the VCO through an injection ﬁlter. See Table 14 for local oscillator (LO) and ﬁrst IF information.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 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. Most of the synthesizer circuitry is enclosed in rigid metal cans on the RF board to reduce microphonic effects. Table 14 Local Oscillator and First IF FrequenciesVHF UHFLO Frequency Range 180.85-218.85MHz 376.65-446.65MHzFirst IF Frequency 44.85MHz 73.35MHz

31The receiver back end consists of a two-pole crystal ﬁlter, an IF ampliﬁer, a second two-pole crystal ﬁlter, and the digital back-end IC. The two-pole ﬁlters are wide enough to accommodate 4kHz 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 2.4MHz synthesis circuit to provide a clock to the DSP-support IC on the VOCON board. 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 Board Basic Theory of OperationThe vocoder and controller (VOCON) board contains the radio’s microcontrol unit with its memory and support circuits, the digital-signal processor (DSP), its memory devices, and the DSP-support IC, voltage regulators, audio, and power control circuits. Connected to the VOCON board are the display board, RF board, keypad board, controls/universal ﬂex, and (optional) encryption module.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 16.8MHz clock from the RF board. 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 5-volt 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 5-volt 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 8kHz interrupt signal generated by the DSP-support IC is also required for functionality. It is programmed using parallel programming from the microcontrol unit.

32The audio CODEC performs analog-to-digital 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 2.4MHz clock, and receives data and formats it for the DSP.

33Radio-Level Troubleshooting 8Introduction to This Section This section of the manual contains troubleshooting charts and error codes that will help you to isolate a problem. 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- and component-level and service information can be found in the “ASTRO Digital XTS 3500 Portable Radios Detailed Service Manual,” Motorola publication number 68P81089C81.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 will be presented at power-up by a single, low-frequency tone. The radio should be sent to the depot if cycling power and reprogramming the code plug do not solve the problem. 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. Use Table 15 to aid in understanding particular power-up error code displays.Table 15 Power-Up Error Code DisplaysError Code Description Corrective Action01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug.01/12 Internal EEPROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug.01/22 RF Deck Codeplug Checksum Non-Fatal Error Reprogram the codeplug.01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug.01/88 RAM Fatal Error — Note: not a checksum failure Send radio to depot.01/92 Internal EEPROM Codeplug Checksum Fatal Error Reprogram the codeplug.01/A2 RF Deck Codeplug Checksum Fatal Error Reprogram the codeplug.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.09/10 Secure Hardware Error Turn the radio off, then on.09/90 Secure Hardware Fatal Error Send radio to depot.Note: If the corrective action does not fix the failure, send the radio to the depot.

34Operational 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. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Table 16 to aid in understanding particular operational error codes.Table 16 Operational Error Code DisplaysError Code Description Corrective ActionFAIL 001 Synthesizer Out-of-Lock a. Reprogram codeplugb. Send radio to depotFAIL 002 Selected Mode/Zone Codeplug Checksum Error Reprogram codeplugTable 17 Receiver Troubleshooting ChartSymptom Possible Cause Correction or Test (Measurements Taken at Room Temperature)Radio Dead; Display Does Not Light Up 1. Dead Battery Replace with charged battery.2. Blown Fuse Send radio to depot. 3. On/Off Switch4. RegulatorsRadio Dead; Display Lights Up 1. VOCON Board Send radio to depot.2. RF BoardNo Receiver Audio or Receiver Does Not Unmute Programming 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 Front- End Tuning Check RF front-end tuning for optimum sensitivity using the RSS.Radio Will Not Turn Off VOCON Board Send radio to depot.

35Table 18 Transmitter Troubleshooting ChartSymptom Possible Cause Correction or Test (Measurements Taken at Room Temperature)No RF Power Out 1. TX Power Level or Frequency Check TX power level and frequency programming (from RSS).2. No PTT From Control Top Send radio to depot.3. No Injection To Power AmpliﬁerNo Modulation; Distorted Modulation 1. Programming Check deviation and compensation settings using the RSS.2. VOCON Board Send radio to depot. Bad Microphone Sensitivity 1. Check Deviation and Compensation Realign if necessary.2. Microphone Send radio to depot.No/Low Signalling (PL, DPL, MDC) 1. Programming Check Programming2. VOCON Board Send radio to depot.Can’t Set Deviation Balance RF Board Send radio to depot. Table 19 Encryption Troubleshooting ChartSymptom Possible Cause Corrective ActionNo “KKKKEEEEYYYYLLLLOOOOAAAADDDD” on Radio Display When Keyloading Cable is Attached to the Radio Side Connector 1. Defective Keyload Cable Send radio to depot.2. Defective RadioKeyloader Displays “FFFFAAAAIIIILLLL.” 1. Wrong Keyloader Make Sure the Keyloader is a “T----CX” or “T----DX” Keyloader.2. Bad Keyloader Try Another Keyloader3. Defective Radio Send radio to depot.Note: Keyloaders “T----AX” and “T----BX” must be upgraded to “T----CX” and “T----DX” in order to keyload an XTS 3500 radio.

3 REPLACEMENT PARTS ORDERING ORDERING INFORMATIONMAIL ORDERS Send written orders to the following addresses: TELEPHONE ORDERS United States and Canada Aftermarket Products Division: Servicers Training (VHS Video Tapes):Call: 1-800-422-4210 Call: 847-576-28281-800-826-1913 (For Federal Government Orders)1-847-538-8023 (International Orders) FAX ORDERS United States and Canada Aftermarket Products Division: Federal Government Orders:FAX: 847-538-8198 (Domestic) FAX: 410-712-4991847-576-3023 (International) International: 410-712-6200Parts ID: 847-538-8194 PARTS CUSTOMER SERVICE PRODUCT CUSTOMER SERVICE When ordering replacement parts or equipmentinformation, the complete identiﬁcation numbershould be included. This applies to all components,kits, and chassis. If the component part number isnot known, the order should include the number ofthe chassis or kit of which it is a part, and sufﬁcientdescription of the desired component to identify it.Crystal and channel element orders should specifythe crystal or channel element type number, crystaland carrier frequency, and the model number inwhich the part is used.Replacement Parts/Test Equipment/Manuals/Crystal Service Items:Motorola Inc.United States and Canada Aftermarket Products DivisionAttention: Order Processing1313 E. Algonquin RoadSchaumburg, IL 60196Federal Government Orders:Motorola Inc.United States and Canada Aftermarket Products DivisionAttention: Order Processing7230 Parkway DriveLandover, MD 21076International Orders:Motorola Inc.United States and Canada Aftermarket Products DivisionAttention: International Order Processing1313 E. Algonquin RoadSchaumburg, IL 60196United States and Canada Aftermarket Products Division: Call: 1-800-422-4210 Parts Identiﬁcation:Call: 847-538-0021Customer Response Center(Sales and Service Assistance):Call: 1-800-247-2346FAX: 1-800-232-9272 TEPF-9679-U

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