Motorola Solutions 89FT4828 Hand-held Portable Device. User Manual 89C80 O p i iv TOC

Motorola Solutions, Inc. Hand-held Portable Device. 89C80 O p i iv TOC

Instruction Manual

i Table of Contents Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside front cover List Of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Portable Radio Model Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Specifications for VHF Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv Specifications for UHF Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Specifications for 800 MHz Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii 1 - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 - Radio Alignment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Transmit Power Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Transmit Deviation Balance (Compensation) Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Transmit Deviation Limit Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 A , Motorola, ASTRO, XTS 3500, Private-Line, and Digital Private-Line are trademarks of Motorola, Inc. ® by Motorola Inc., Radio Products Group8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322Printed in U.S.A. 9/98 Basic Service Manual68P81089C80-O
ii 6 - Basic Removal/Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Frequency Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Volume Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 7 - Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Analog Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27ASTRO Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28RF Board Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28VOCON Board Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8 - Radio-Level Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Power-Up Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Operational Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Replacement Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside back cover List Of Figures Figure 1. Radio Alignment Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Figure 2. RSS Service Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Figure 3. Softpot Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Figure 4. Reference Oscillator Alignment Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Figure 5. Transmit Power Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Figure 6. Transmit Deviation Balance (Compensation) Alignment Screen . . . . . . . . . . . . . . . . . 17Figure 7. Transmit Deviation Limit Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Figure 8. Partial Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 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. Test Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Table 6. Test Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Table 7. Receiver Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Table 8. Transmitter Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Table 9. Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Table 10. Transmit Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Table 11. Transmit Deviation Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Table 12. Partial Exploded View Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Table 13. Local Oscillator and First IF Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Table 14. Power-Up Error Code Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Table 15. Operational Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Table 16. Receiver Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Table 17. Transmitter Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Table 18. Encryption Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 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
iii 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.
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vi SPECIFICATIONS FOR VHF RADIOS All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted GENERAL RECEIVER TRANSMITTER FCC Designation: AZ489FT3790 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): 2300mA Receive Current Drain (Rated Audio): 290mA Standby Current Drain: 90mA Recommended Battery: Ultra-HIgh-Capacity NiCd: NTN8294A or Ultra–High-Capacity NiCd FM: NTN8295* or Ultra–High-Capacity NiMH FM: NTN8299A* 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" x1.65"(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 Ultra-High Cap. NiMH: 23.45oz. (644gm) Frequency Range: 136-178MHz Bandwidth: 42MHz Quieting Sensitivity (20dBQ): 0.35 m V (typical) Usable Sensitivity(12dB SINAD): 0.25 m V (typical) Intermodulation: –78dB (typical) Selectivity (typical)(25/30kHz Channel): –78dB Spurious Rejection: –70dB Frequency Stability(–30+60 ° C; 25 ° C reference): ± .0002% Rated Audio: 500mW Distortion (At Rated Audio): 2% Typical Channel Spacing: 12.5/20/25/30kHz RF Power: 136-174MHz: 1 Watt/5 Watts 174-178MHz: 1 Watt/4 Watts Frequency Range: 136-178MHz Frequency Stability (typical)(–30 to +60 ° C; 25 ° C ref.): ± .0002% Emission (Conducted and Radiated): –70dBc FM Hum and Noise (typical)(Companion Receiver): 25/30kHz –48dB12.5kHz –42dB Distortion: 2% Typical Modulation Limiting: 25/30kHz chnls ± 5.0kHz20kHz chnls ± 4.0kHz12.5kHz chnls ± 2.5kHz Emissions Designators: 20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1E Specifications subject to change without notice
vii SPECIFICATIONS FOR UHF RADIOS All specifications are per Electronic Industries Association (EIA) 316B 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): 1700mA Receive Current Drain (Rated Audio): 290mA Standby Current Drain: 90mA Recommended Battery: Ultra-HIgh-Capacity NiCd: NTN8294A or Ultra–High-Capacity NiCd FM: NTN8295* or Ultra–High-Capacity NiMH FM: NTN8299A* 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" x1.65"(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 Ultra-High Cap. NiMH: 23.45oz. (644gm) Frequency Range: 403-520MHz Bandwidth: 70MHz Quieting Sensitivity (20dBQ): 0.316 m V (typical) Usable Sensitivity(12dB SINAD): 0.25 m V (typical) Intermodulation: –78dB (typical) Selectivity (typical)(25/30kHz Channel): –78dB (12.5kHz Channel): –68dB Spurious Rejection: –75dB Frequency Stability(–30+60 ° C; 25 ° C reference): ± .0002% Rated Audio: 500mW Distortion (At Rated Audio): 1.5% Typical Channel Spacing: 12.5/20/25/30kHz RF Power: 403-470MHz: 1 Watt/5 Watts 450-520MHz: 1 Watt/5 Watts Frequency Range: 403-520MHz Frequency Stability (typical)(–30 to +60 ° C; 25 ° C ref.): ± .0002% Emission (Conducted and Radiated): –70dBc FM Hum and Noise (typical)(Companion Receiver): 25/30kHz –48dB12.5kHz –42dB Distortion: 1.5% Typical Modulation Limiting: 25/30kHz chnls ± 5.0kHz20kHz chnls ± 4.0kHz12.5kHz chnls ± 2.5kHz Emissions Designators:20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1ESpecifications subject to change without notice
viiiSPECIFICATIONS FOR 800 MHz RADIOSAll specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.GENERAL RECEIVER TRANSMITTERFCC Designation: AZ489FT5774Temperature Range:Operating: –30°C to +60°CStorage: –40°C to +85°CPower Supply: Nickel-Cadmium Battery (NiCd)or Nickel-Metal-Hydride Battery (NiMH)or Lithium-Ion Battery (Li-Ion)Battery Voltage:Nominal: 7.5 VoltsRange: 6 to 9 VoltsTransmit Current Drain (Typical): 1700mAReceive Current Drain (Rated Audio): 280mAStandby Current Drain: 90mARecommended Battery:Ultra-HIgh Capacity NiMH: H335ACor Ultra–High Capacity NiCd FM: H223AX*or NiMH FM IS: Q393ABOptional FM (Factory Mutual) Battery:* FM Intrinsically Safe: Class I, II, III, Division 1, Groups D, F, and GDimensions (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 keypadLess 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 Ultra-High Capacity NiMH Battery:6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"(167.13mm x 61.90mm x 46.42mm/167.13mm x 59.49mm x 41.97mm)With Ultra-High Capacity NiCd Battery:6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"(167.13mm x 61.90mm x 46.42mm/167.13mm x 59.49mm x 41.97mm)With NiMH FM IS Battery:6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"(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. NiMH:23.45oz. (644gm)With Ultra-High Cap. NiCd: 25.19oz. (693gm)With NiMH FM IS: 23.45oz. (644gm)Frequency Range: 851–870MHzBandwidth: 19MHzQuieting Sensitivity (20dBQ): 0.5mV Max.Usable Sensitivity(12dB SINAD): 0.35mV Max.Intermodulation: –70dB Selectivity(25kHz Adjacent Channel): –70dB Spurious Rejection: –70dB Frequency Stability(–30+60°C; 25°C reference): ±.00015%Rated Audio: 500mWDistortion (At Rated Audio): 3% TypicalChannel Spacing: 25kHzRF Power: 3 WattsFrequency Range: 806–825MHz851–870MHzFrequency Stability(–30 to +60°C; 25°C ref.): ± .00015%Emission (Conducted and Radiated): –46dBwFM Hum and Noise(Companion Receiver): –40dBDistortion: 3% TypicalModulation Limiting: ±5kHz(821-824MHz): ±4kHzEmissions Designators:20K0F1E, 16K0F3E, 15K0F2D, 15K0F1D, and 8K10F1ESpecifications subject to change without notice
1 Introduction 1 General 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. This will be the only level of service allowed for the service centers, self-maintained customers, and distributors for the first six months of the life of this product.Included in this manual are radio specifications for the VHF, UHF, and 800MHz 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!
2 Radio Description The ASTRO Digital XTS 3500 radios are among the most sophisticated two-way radios available. The radio is presently available in the UHF R2 band; radios in the UHF R1, VHF, and 800MHz bands will be available by the end of 1999.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 two basic models. Table 1 provides a description of 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 Features Feature Model I Model II Model III Display 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
3 Basic Maintenance 2 Introduction to This Section This section of the manual describes preventive maintenance and handling precautions. Each of these topics provides information vital to the successful operation and maintenance of your radio. Preventive Maintenance 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
4 Handling 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. At this time, troubleshooting and repair of the radio will not be supported by the field or self-maintained customer. DO NOT attempt to disassemble the radio.
5 Recommended Test Equipment and 3 Service Aids RecommendedTest Equipment The 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 Equipment MotorolaModel Number Description Characteristics Application R2670 or R2600 System Analyzer This monitor will substitute for items with an asterisk (*). Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment.R1049A* Digital Multimeter Recommended for ac/dc voltage and current measurementsR1150C* Code Synthesizer Injection of audio and digital signalling codesS1053D*SKN6008A*SKN6001A*AC VoltmeterPower Cable for MeterTest Leads for Meter1mV to 300V, 10-Megohm input impedance Audio voltage measurementsR1094A Dual-Trace Oscillo-scope 20MHz bandwidth 5mV to 5V/division Waveform measurementsS1350C*ST1213B (VHF)*ST1223B (UHF)*WattmeterPlug-In ElementRF Dummy Load50-ohm, ± 5% accuracy10 watts, maximum0-1000MHz, 300WTransmitter power output measurementsR1065 Load Resistor 10-watt Broadband For use with wattmeterS1339A RF Millivolt Meter 100 m V to 3V RF RF-level measurementsR1013A* SINAD Meter Receiver sensitivity measurementsS1347D or S1348D (programmable) DC Power Supply 0-20Vdc, 0-5 Amps current limited Bench supply for 7.5Vdc
6 Field Programming Equipment This 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 Aids Motorola Part Number Description Application RKN-4035D RIB/Radio/Test Set Cable Connects radio to RTX-4005B Test Box and RIB.REX-4424 Battery Eliminator Interconnects radio to power supply.RLN-4460A, orRTX-4005B, or both RTX-4005A and RPX-4665APortable Test Set Enables connection to the universal connector.Allows switching for radio testing.Field Modification Kit RLN-1015A orRLN-4008BRadio 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 Cable Use B72 for the IBM PC AT. All other IBM models use B71. Connects the computer's serial communications adaptor to the RIB.RVN-4100F Radio Service Software Software on 3-1/2 in. and 5-1/4 in. floppy disks.58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test equipment.
7 Performance Checks 4 Introduction 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. 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 13, 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. Test Mode RF Test Mode 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. However, when the unit is on the bench for testing, alignment, or repair, it is removed from its normal environment. It cannot receive commands from its system and, therefore, the internal microcomputer will not key the transmitter nor unmute the receiver. This prevents the use of normal tune-up procedures. To solve this problem a special routine, called TEST MODE or “air test,” has been incorporated in the radio. Table 4 Initial Equipment Control Settings System Analyzer Test Set Power Supply Monitor Mode: Pwr Mon Spkr Set: A Voltage: 7.5Vdc RF Attn: –70dB Spkr/Load: Speaker DC On/Standby: Standby AM, CW, FM: FM PTT: OFF (center) Volt Range: 10Vdc O'scope Source: Mod O'scope Horiz: 10mSec/Div O'scope Vert: 2.5kHz/Div O'scope Trig: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: Mid CW Monitor Vol: 1/4 CW Current: 2.5Amps
8 To enter the test mode:1. Turn the radio on and adjust the volume for a comfortable listening level. The volume level remains constant once in the test mode.2. Within 10 seconds after the “ SSSSeeeellllffff TTTTeeeesssstttt ” is complete, press Side Button 3 five times in succession.3. After “ RRRRFFFF TTTTEEEESSSSTTTT ” appears, press the Top Programmable Button (normally programmed as the emergency button) once. “ 1111 CCCCSSSSQQQQ ” appears, indicating: test frequency 1, carrier squelch mode.4. Each additional press of Side Button 3 will advance to the next test channel. (Refer to Table 5.)5. Pressing Side Button 2 will scroll through and access test environments as shown in Table 6. NOTE: Transmit into a load when keying a radiounder test. * All deviation values are based on deviation tuning of this mode. Table 5 Test Frequencies Test Channel UHF Band 2 TX #1 450.025RX #1 450.075TX #2 465.225RX #2 465.275TX #3 475.125RX #3 475.275TX #4 484.975RX #4 485.025TX #5 500.275RX #5 500.225TX #6 511.975RX #6 511.925TX #7 519.975RX #7 519.925 Table 6 Test Environments Display Description Function CSQ Carrier Squelch RX: unsquelch if carrier detected TX: mic audioTPL Tone Private-Line RX: unsquelch if carrier and tone (192.8 Hz) detected TX: mic audio + tone (192.8 Hz)AST ASTRO RX: none TX: 1200Hz tone *
9 Control Top and Keypad Test Mode To check the display, buttons, and switches, perform the following tests:1. Turn the radio on and adjust the volume for a comfortable listening level. The volume level remains constant once in the test mode.2. Within 10 seconds after the “ SSSSeeeellllffff TTTTeeeesssstttt ” is complete, press Side Button 3 five times in succession.3. After “ RRRRFFFF TTTTEEEESSSSTTTT ” appears on the display, press Side Button 1 once, “CCCCHHHH TTTTEEEESSSSTTTT” appears on the display.4. Next, 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.5. Release the Top Programmable Button; “3333////0000” appears, which indicates that the Top Programmable Button is in the open condition.6. Press the Top Programmable Button again; “3333////1111” appears, which indicates that the Top Programmable Button is in the closed condition.7. 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 15.8. Rotate the Two-Position (A/B) Switch; “66665555////0000” and “66665555////1111” appear.9. Cycle through the Three-Position Programmable Switch; “66667777////0000,” “66667777////1111,” and “66667777////2222” appear.10.Rotate the Volume Control; “2222////0000” through “2222////222255555555” appear.11.Press Side Button 1; “99996666////1111” appears; release, “99996666////0000” appears.12.Press Side Button 2; “99997777////1111”appears; release, “99997777////0000” appears.13.Press Side Button 3; “99998888////1111”appears; release, “99998888////0000” appears.14.Press the PTT Switch; “1111////1111” appears; release, “1111////0000” appears.15.Keypad Checks:-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.-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.
10-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.Table 7 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 £ ±1.2kHzRated 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 < 0.35mVNoise 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 < 0.25mV. Preferred SINAD = 8-10dB❖ See Table 6
11Table 8 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 £ ±1.2kHz.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: UHF: ³ 3.6kHz 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: UHF: ³ 3.8kHz but £ 5.0kHzPL Modu-lation (radios with conven-tional, clear mode, coded squelch oper-ation only)Change frequency to a conventional transmit frequency; BW to narrowConventionalcoded squelch personality (clear mode operation) 4 TPLAs above Deviation: UHF: ³ 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.Conventionaltalkaround personality (clear mode operation) 1 CSQAs above Deviation: UHF: ³ 3.8kHz 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.Conventionaltalkaround personality (secure mode operation). Load key into radio 1 sec.As above Deviation: UHF: ³ 3.6kHz but £ 4.4kHz** The secure mode, talkaround modulation test is only required for trac mode radios which do not have clear modetalkaround capability.❖See Table 6
13Radio 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-4035D RIBRLN-4008BRLN-1015A orTEST SETRLN-4460A orRTX-4005B
14Figure 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
15Adjusting 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 mayvary depending upon the radio undertest and the version of radio servicesoftware you are using. Refer to yourradio 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 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.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 0 255 MIN |----+----+----+----+----+----+----+----+----+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE
164. Measure the transmit frequency on your service monitor.5. Use the É/Ç arrow keys to adjust the reference oscillator softpot value. See Table 9.6. 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 10.Table 9 Reference Oscillator AlignmentBand TargetUHF ±100 HzMOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDC9PW5AN MAIN:SERVICE:TX ALIGN:TX POWER TRANSMIT POWER -------------- Current Value New Softpot Value Frequency High Pwr Low Pwr High Pwr Low Pwr --------- -------- ------- -------- ------- 450.025 10 23 10 23 465.225 11 28 11 28 475.125 20 33 20 33 484.975 33 40 33 40 500.275 43 45 43 45 511.975 58 58 58 58 519.975 58 58 Transmitter..On 58 58 0 127 MIN |---+---+---+---+---+---+---+---+---+---+---+---+---+---+---+---| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE
175. 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.6. Press D to dekey the radio.Table 10 Transmit Power SettingsUHF Power Level Test Frequencies450-512MHz 512-520MHz1 Watt 1.2W - 1.4W 1.2W - 1.4W5 Watts 5.2W - 5.4W 3.2W - 3.4WMOTOROLA 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
187. 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 AlignmentIMPORTANT NOTE:Put the radio in the RF test mode and scroll tothe ASTRO test environment, indicated by“AST” on the display (refer to the“Performance Checks” section for details). Allother deviation values are derived from theASTRO test environment mode transmitdeviation limit.1. 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 11.MOTOROLA 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 --------- ------- ----------------- 450.025 175 175 465.225 175 175 475.125 180 180 484.975 180 180 500.275 180 180 511.975 180 180 519.975 180 Transmitter..Off 180 0 32767 MIN |----+----+----+----+----+----+----+----+X---+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE
195. Press F again to dekey the radio.6. Press H to program the softpot 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.Table 11 Transmit Deviation LimitBand Deviation (Hz)UHF 2785 - 2885
21Basic 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
22Installing 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 ClipBatteryMetalTabPressDown
23Universal 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. Pry upward on the cover’s lower end until it disengages from the radio.Frequency Knob NOTES:•Refer to Figure 8, the Partial Exploded View, and Table 12, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 8 and Table 12.•The battery (7) should be removed from the radio before installing or removing the frequency knob (1).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 pushing it toward the back of the radio, until it is free from the frequency insert (3).3. 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.4. Remove the secure lever (4) and the lightpipe (5).Installing the Frequency Knob 1. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you.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
242. 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), remove the backing paper from the escutcheon, align its alignment marker with the alignment notch (between numbers 4 and 5) on the insert, and adhere it to the insert.5. Place a new frequency insert (3) and 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 8, the Partial Exploded View, and Table 12, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 8 and Table 12.•The battery (7) should be removed from the radio before installing or removing the volume knob (8).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).Installing 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 the volume insert (9) on the volume control shaft, aligning its 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.
25Figure 8 Partial Exploded View1234567809ABCDEFGHIJKLMNOPRSTUVWXYHOMEXTS 30001234517182016158910112114131276ABCAlignment NotchAlignment Marker
26Table 12 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 NTN8266A CLIP, Belt7 NTN8298A Battery, NiCd8 3605371Z01 KNOB, Volume9 4305372Z01 INSERT RETAINER, Volume Knob10 3305574Z01 LABEL, Motorola, Back11 - - - - - - - - - - LABEL, Flashport12 - - - - - - - - - - LABEL, Radio Serial Number13 - - - - - - - - - - LABEL, Approval Agency14 3305630Z02 LABEL, Bottom15 NAF5037Aor NAF5039Aor NAF5042AANTENNA, 800MHz Whip (806-870 MHz)ANTENNA, 800MHz Dipole (806-870 MHz)ANTENNA, 800MHz Stubby Quarterwave (806-870 MHz)16 - - - - - - - - - - ESCUTCHEON, Concentric Switch (optional)17 - - - - - - - - - - ESCUTCHEON, Toggle (optional)18 1505579Z01 COVER, Dust, Universal Connector19 3305573Z01 LABEL, Motorola, Front20 3505586Z01 Gortex21 3205379W01 O-Ring
27Basic Theory of Operation 7General Overview The ASTRO Digital XTS 3500 radio is a wideband, synthesized, fixed-tuned radio available in the UHF band. All ASTRO Digital XTS 3500 radios are capable of both analog operation and ASTRO mode (digital) operation in 12.5kHz or 25kHz bandwidths.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 (Full-Featured Model Only) - a four-line, 12-character liquid crystal display (LCD).•Keypad (Full-Featured Model Only) - 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. For signalling information, the DSP will decode the message and pass it to the microcontrol unit.
28When 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. 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 13 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. The 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.Table 13 Local Oscillator and First IF FrequenciesUHFLO Frequency Range 376.65-446.65MHzFirst IF Frequency 73.35MHz
29The 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.
30The 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.

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