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TM8100 mobiles
TM8200 mobiles
Service Manual
MMA-00005-04
Issue 4
June 2006
2TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Contact Information
Tait Radio Communications
Corporate Head Office
Tait Electronics Limited
P.O. Box 1645
Christchurch
New Zealand
For the address and telephone number of regional
offices, refer to the TaitWorld website:
We b s i t e : http://www.taitworld.com
Technical Support
For assistance with specific technical issues, contact
Technical Support:
E-mail: support@taitworld.com
We b s i t e : http://support.taitworld.com
Copyright and Trademarks
All information contained in this manual is the property
of Tait Electronics Limited. All rights reserved.
This manual may not, in whole or in part, be copied,
photocopied, reproduced, translated, stored, or reduced
to any electronic medium or machine-readable form,
without prior written permission from Tait Electronics
Limited.
The word TAIT and the TAIT logo are trademarks of
Tait Electronics Limited.
All trade names referenced are the service mark,
trademark or registered trademark of the respective
manufacturers.
Disclaimer
There are no warranties extended or granted by this
manual. Tait Electronics Limited accepts no
responsibility for damage arising from use of the
information contained in the manual or of the
equipment and software it describes. It is the
responsibility of the user to ensure that use of such
information, equipment and software complies with the
laws, rules and regulations of the applicable
jurisdictions.
Enquiries and Comments
If you have any enquiries regarding this manual, or any
comments, suggestions and notifications of errors,
please contact Technical Support.
Updates of Manual and Equipment
In the interests of improving the performance, reliability
or servicing of the equipment, Tait Electronics Limited
reserves the right to update the equipment or this
manual or both without prior notice.
Intellectual Property Rights
This product may be protected by one or more patents
of Tait Electronics Limited together with their
international equivalents, pending patent applications
and registered trade marks: NZ338097, NZ508054,
NZ508340, NZ508806, NZ508807, NZ509242,
NZ509640, NZ509959, NZ510496, NZ511155,
NZ511421, NZ516280/519742, NZ519118,
NZ519344, NZ520650/537902, NZ521450,
NZ524509, NZ524537, NZ524630, NZ530819,
NZ534475, NZ534692, NZ535471, NZ536945,
NZ537434, NZ534369, NZ522236, NZ524378,
AU2003281447, AU2002235062, AU2004216984,
CA2439018, EU03784706.8, EU02701829.0,
EU04714053.8, GB23865476, GB2386010,
GB0516094.0, GB0516092.4, US09/847322, US60/
613748, US60/539617, US10/520827, US10/468740,
US5,745,840, US10/520827.
To Our European Customers
Tait Electronics Limited is an
environmentally responsible company
which supports waste minimization and
material recovery. The European Union’s
Waste Electrical and Electronic Equipment
Directive requires that this product be disposed of
separately from the general waste stream when its
service life is over. Please be environmentally
responsible and dispose through the original supplier,
your local municipal waste “separate collection” service,
or contact Tait Electronics Limited.
TM8100/TM8200 Service Manual 3
© Tait Electronics Limited June 2006
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hardware and Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Associated Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Publication Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alert Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1 Description of the Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 2 Servicing the Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5 Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6 Servicing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7 Power Supply Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8 Interface Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
9 Frequency Synthesizer Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . 179
10 Receiver Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
11 Transmitter Fault Finding (40W/50W) . . . . . . . . . . . . . . . . . . . . . 259
12 Transmitter Fault Finding (25W) . . . . . . . . . . . . . . . . . . . . . . . . . . 323
13 CODEC and Audio Fault Finding. . . . . . . . . . . . . . . . . . . . . . . . . . 381
14 Fault Finding of Control Head with Graphical Display . . . . . . . . . . . 405
15 Fault Finding of Control Head with 1- 2- or 3-Digit Display . . . . . . 429
16 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Chapter 3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447
17 TMAA01-01 Line-Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . 451
18 TMAA01-02 RS-232 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
19 TMAA01-05 Options-Extender Board . . . . . . . . . . . . . . . . . . . . . . 479
20 TMAA02-02 DTMF Microphone . . . . . . . . . . . . . . . . . . . . . . . . . 489
21 TMAA02-06 Support Kit for Concealed & Dynamic Microphones. . 493
22 TMAA02-07 Concealed Microphone . . . . . . . . . . . . . . . . . . . . . . . 501
23 TMAA02-08 Keypad Microphone . . . . . . . . . . . . . . . . . . . . . . . . . 503
24 TMAA03-02 Security Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
25 Installing a Remote Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
26 Installing an Enhanced Remote Kit . . . . . . . . . . . . . . . . . . . . . . . . . 527
27 TMAA04-04 Crossband Linking Cable . . . . . . . . . . . . . . . . . . . . . . 543
4TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
28 TMAA04-05 Ignition Sense Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
29 TMAA10-01 Desktop Microphone . . . . . . . . . . . . . . . . . . . . . . . . 551
30 TMAA10-02 Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
31 TMAA10-03 and TMAA10-06 High-Power Remote Speakers . . . . 559
32 TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit . . 561
33 TMAA10-07 Desktop Microphone . . . . . . . . . . . . . . . . . . . . . . . . 569
34 TOPA-SV-024 Test Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
TM8100/TM8200 Service Manual 5
© Tait Electronics Limited June 2006
Preface
Scope of Manual
This manual contains information to service technicians for carrying out
level-1 and level-2 repairs of TM8100 and TM8200 radios and accessories.
Level-1 repairs entail the replacement of faulty parts and circuit boards;
level-2 repairs entail the repair of circuit boards, with the exception of
certain special items on the boards. The manual does not cover level-3
repairs, which entail the repair of the special items.
Hardware and Software Versions
This manual describes the following hardware and software versions.
The IPNs (internal part numbers) of the boards are listed below; the last two
digits in the IPN represent the issue of the board. The board information in
this manual covers all production-issue boards up to the issue listed below.
■Main board (A4 band) 25W : 220-02074-04
■Main board (B1 band) 25W : 220-01700-11
■Main board (B1 band) 50W : 220-01723-02
■Main board (C0 band) 25W : 220-01742-04
■Main board (D1 band) 25W : 220-01717-02
■Main board (H5 and H6 bands) 25W : 220-01697-11
■Main board (H5 and H7 bands) 40W : 220-01722-02
■Control-head board (1-digit display) : 220-02070-01
■Control-head board (2-digit display) : 220-01699-03
■Control-head board (3-digit display) : 220-02151-02
■Control-head board (graphical display) : 220-01718-01
■Control-head board (RJ45) : 220-01720-05
■Programming application (TM8100) : version 2.92
■Programming application (TM8200) : version 2.1
■Calibration application : version 2.71
6TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Associated Documentation
The following associated documentation is available for this product:
Manuals ■MMA-00002-xx TM8100 User’s Guide
■MMA-00003-xx TM8200 User’s Guide
■MMA-00051-xx TM8235 User’s Guide
■MMA-00028-xx TM8100/TM8200 Installation Guide
■MMA-00006-xx TM8100 Operator’s Guide
■MMA-00004-xx TM8200 Operator’s Guide
PCB Information ■MMA-00016-xx TM8100/TM8200 Main Board (A4) 25W
■
MMAB12-B1-00-814
TM8100/TM8200 Main Board (B1) 25W
(board IPN 220-01700-05)
■MMA-00031-xx TM8100/TM8200 Main Board (B1) 25W
(boards after IPN 220-01700-05)
■MMA-00032-xx TM8100/TM8200 Main Board (D1) 25W
■
MMAB12-H5-00-814
TM8100/TM8200 Main Board (H5/H6) 25W
(board IPN 220-01697-05)
■MMA-00033-xx TM8100/TM8200 Main Board (H5/H6) 25W
(boards after IPN 220-01697-05)
■MMA-00020-xx TM8100/TM8200 Main Board (B1) 50W
■MMA-00021-xx TM8100/TM8200 Main Board (H5/H7) 40W
■MMA-00035-xx TM8100 Control-Head Board (2-Digit Display)
■MMA-00036-xx TM8100 Control-Head Board (1-Digit Display)
■MMA-00015-xx TM8200 Control-head Board (Graphical Display)
■MMA-00058-xx TM8200 Control-Head Board (3-Digit Display)
■MMA-00034-xx TM8200 Control-Head Board (RJ45)
■MMA-00037-xx TM8100/TM8200 PCB Information
(printed, pre-punched and shrink wrapped;
comprises MMA-00015-xx, MMA-00016-xx,
MMA-00020-xx, MMA-00021-xx, MMA-00031-
xx, MMA-00032-xx, MMA-00033-xx, MMA-
00034-xx, MMA-00035-xx, MMA-00050-xx and
MMA-00058-xx).
The characters xx represent the issue number of the documentation.
All available documentation is provided on the
TM8100/TM8200 Service CD, product code TMAA20-01.
Updates may also be published on the Tait support website.
3DK Manuals The following manuals are mainly of concern to third-party developers.
The manuals are supplied on the 3DK (third-party developer’s kit)
resource CD.
■MMA-00011-xx TM8100/TM8200 3DK Hardware Developer’s
Kit Application Manual
TM8100/TM8200 Service Manual 7
© Tait Electronics Limited June 2006
■MMA-00014-xx TMAA30-02 TM8000 3DK Application Board
Software Programmer’s Manual
■MMA-00013-xx TMAA30-02 TM8000 3DK Application Board
Service Manual
■MMA-00038-xx TM8100/TM8200 Computer-controlled Data
Interface Protocol Definition
Publication Record
Alert Notices
Within this manual, four types of alerts are given to the reader: warning,
caution, important and note. The following paragraphs illustrate each type
of alert and its associated symbol.
Warning!! This alert is used when there is a potential risk
of death or serious injury.
Caution This alert is used when there is the risk of minor or
moderate injury to people.
Important This alert is used to warn about the risk of equipment dam-
age or malfunction.
Note This alert is used to highlight information that is required to
ensure that procedures are performed correctly.
Issue Publication Date Description
01 March 2005 first release
02 May 2005 update for 40W/50W radios
03 August 2005 update to board issue 10 (B1, H5 and H6 bands)
of 25W radios, incorporation of accessories
manual
04 June 2006 include TM8200 3-digit-display control head, A4
and C0 bands, and information on issue -05 main
board for B1, H5 and H6 bands
8TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Abbreviations
Abbreviation Description
ACP Adjacent Channel Power
ADC Analog-to-Digital Converter
AGC Automatic Gain Control
ALC Automatic Level Control
ASC Accredited Service Centre
C4FM Compatible Four-level Frequency Modulation
CCTM Computer-Controlled Test Mode
CODEC Coder-Decoder
CSO Customer Service Organisation
CTCSS Continuous-Tone-Controlled Subaudible Signaling
DAC Digital-to-Analog Converter
DC Direct Current
DSP Digital Signal Processor
DTMF Dual-Tone Multi-Frequency
EPTT External PTT (Press-To-Talk)
ESD Electrostatic Discharge
FCL Frequency Control Loop
FE Front-End
FEC Forward Error Correction
FPGA Field-Programmable Gate Array
GPIO General Purpose Input/Output
GPS Global Positioning System
GUI Graphical User Interface
IC Integrated Circuit
IPN Internal Part Number
IF Intermediate Frequency
IQ In-Phase and Quadrature
ISC International Service Centre
LCD Liquid-Crystal Display
TM8100/TM8200 Service Manual 9
© Tait Electronics Limited June 2006
LED Light-Emitting Diode
LNA Low-Noise Amplifier
LO Local Oscillator
LPF Low-Pass Filter
NPN Negative-Positive-Negative
PA Power Amplifier
PCB Printed Circuit Board
PLL Phase-Locked Loop
PNP Positive-Negative-Positive
PSU Power Supply Unit
PTT Press-To-Talk
RISC Reduced Instruction Set Computing
RSSI Received Signal Strength Indication
SFE Software Feature Enabler
SMA Sub Miniature Version A
SMD Surface-Mount Device
SMT Surface-Mount Technology
SMPS Switch-Mode Power Supply
SPI Serial Peripheral Interface
TCXO Temperature-Compensated Crystal Oscillator
TEL Tait Electronics Limited
UHF Ultra High Frequency
VCO Voltage-Controlled Oscillator
VCXO Voltage-Controlled Crystal Oscillator
VHF Very High Frequency
Abbreviation Description
10 TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
TM8100/TM8200 Service Manual 11
© Tait Electronics Limited June 2006
TM8100 mobiles
TM8200 mobiles
Chapter 1
Description of the Radio
12 TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Chapter 1 – Description of the Radio
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Frequency Bands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 RF Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5 Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Mechanical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 User Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Hardware and Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.5 Operation in Receive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.6 Operation in Transmit Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Transmitter Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2 Receiver Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Frequency Synthesizer Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4 Frequency Control Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.5 CODEC and Audio Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.6 Power Supply Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.7 Interface Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.8 Digital Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.9 Control-Head Board with Graphical Display . . . . . . . . . . . . . . . . . . . . . 92
3.10 Control-Head Board with 1-, 2- or 3-Digit Display . . . . . . . . . . . . . . . . 95
3.11 RJ45 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
TM8100/TM8200 Service Manual Introduction 13
© Tait Electronics Limited June 2006
1 Introduction
The TM8100 and TM8200 series is a range of high-performance
microprocessor-controlled radios for analog voice and data communication.
The radios are designed for installation in vehicles but can also be used in
desktop, remote-monitoring and similar applications.
This manual includes the information required for servicing the radio and
its accessories.
This section describes the different options available for:
■frequency bands
■RF output power
■accessories
■product codes.
This section also gives an overview of the labels on the product and the
specifications.
Figure 1.1 TM8200 mobile radios
TM8235 radio with 3-digit-display control head
TM8250 or TM8255 radio with graphical-display control head
TM8252 radio with RJ45 control head
14 Introduction TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 1.2 TM8100 mobile radios
rear view (25W radio)
TM8115 radio with 2-digit-display control head
TM8110 radio with 1-digit-display control head
TM8105 radio with blank control head
TM8100/TM8200 Service Manual Introduction 15
© Tait Electronics Limited June 2006
1.1 Frequency Bands
The radios are available in the following frequency bands:
■66 to 88MHz (A4)
■136 to 174MHz (B1)
■174 to 225MHz (C0)
■216 to 266MHz (D1)
■400 to 470MHz (H5)
■450 to 530MHz (H6)
■450 to 520MHz (H7)
The frequency bands are implemented by different main boards in the radio
body. The control heads are identical for all frequency bands.
1.2 RF Output Power
The radio bodies are available with 40W/50W and 25W RF output power.
The two RF output power options are implemented by different main
boards in the radio body, mechanically different radio bodies, and different
power connectors. The control heads are identical for all RF output
power options.
The 40W/50W radio is available in the following frequency bands:
■B1 (50W)
■H5 (40W)
■H7 (40W)
The 25W radio is available in the following frequency bands:
■A4
■B1
■C0
■D1
■H5
■H6
16 Introduction TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
1.3 Accessories
Tait offers a large variety of audio accessories, installation kits, internal
options boards and other accessories such as a desktop power supply.
For more information on these accessories refer to “Chapter 3 Accessories”
on page 447.
Audio Accessories The radios allow for the connection of a comprehensive range of audio
accessories:
■rugged microphone (standard)
■DTMF microphone
■keypad microphone
■handset
■concealed microphone (TM8200) and concealed microphone kit
(TM8100)
■high-power remote speaker
■remote PTT kit and hands-free kit.
Installation Kits The radio is delivered with a vehicle installation kit, including a U-bracket.
Installation of the radio is described in the user’s guide or the installation
guide.
Optional installation kits are:
■remote control-head kit for remote installation of the control head
■security bracket for secure and quick-release installation
■ignition-sense kit.
Internal Options
Boards The radio provides space for an internal options board inside the radio body
connecting to an internal options connector. An aperture for an external
options connector is also provided.
Tait offers the following internal options boards:
■line-interface board
■RS-232 board
■options-extender board.
Control-Head
Options Boards The radio provides space for a control-head options board inside the blank
control head of the TM8105 and TM8252 radios.
Desktop Power
Supply A desktop power supply including the parts for mounting the radio is
available for desktop installations.
TM8100/TM8200 Service Manual Introduction 17
© Tait Electronics Limited June 2006
1.4 Product Codes
This section describes the product codes used to identify products of the
TM8100 and TM8200 mobile radio product lines.
General The product codes of the TM8100 and TM8200 mobile radio product lines
have the format:
TMAabc–ddee
where:
■a identifies the product category:
A=accessory, B=radio body, C=control head, S=software feature
■b, c, dd and ee identify specific product features.
Radio Bodies The product codes of the radio bodies have the format:
TMABbc–ddee
where:
■b identifies the architecture of the digital board:
1=conventional analog
2=conventional analog (dual-mode capability)
3 identifies the digital boards of the digital TM9100 product line.
■c identifies the RF output power:
2=25W, 3=25W (trigger-base), 4=30 to 59W,
5=30 to 59W (trigger-base).
■dd identifies the frequency band:
A4=66 to 88MHz, B1=136 to 174MHz, C0=174 to 225MHz,
D1=216 to 266MHz, H5=400 to 470MHz, H6=450 to 530MHz,
H7=450 to 520MHz.
■ee identifies any radio options:
00=BNC RF connector, 01=mini-UHF RF connector
Control Heads The product code of the control heads has the format:
TMACbc–dd
where:
■b identifies the control-head type:
1=blank control head, 2=2-digit-display control head,
3=RJ45 control head, 4=graphical-display control head,
5=1-digit-display control head, 6=3-digit-display control head.
■c identifies the control-head configuration:
0=no options, 4=RS-485 option
1 identifies the control-head configuration of the digital TM9100
product line.
■dd identifies label and branding options:
0T=Tait, 0U=unbranded.
18 Introduction TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
1.5 Labels
Four external labels are attached to the bottom of the radio body:
■compliance information
■serial number and product code
■hot surface safety warning
■RF exposure safety warning.
1.6 Specifications
For up-to-date specifications, refer to the area on the TaitWorld website
reserved for TM8100 and TM8200 products.
Figure 1.3 Labels of the TM8100 and TM8200 product lines
Contains intellectual property licenced
by Digital Voice Systems Inc, Motorola
Inc and Tait Electronics Ltd.
Details in user documentation.
N46
IC: 737A-TMAH6C
FCC ID: CASTMAH6C
TAIT
Made in
New Zealand
TMAH6C
S/N 19061964
TMAB22-H600
450-530 MHz
Tait Electronics Ltd, NZ
TM8100/TM8200 Service Manual Description 19
© Tait Electronics Limited June 2006
2 Description
This section describes the mechanical design and architecture of the radio,
explains the operation of the transceiver and the control head, and gives
pinouts of the radio connectors.
2.1 Mechanical Design
Overview The radio consists of the following main components:
■control head B
■radio body C.
The control head B clips firmly to the front face of the radio body C,
where a seal E provides IP54 class protection. A control-head loom D
connects the control head to the radio body. Two dot-dash-dot marks at the
bottom of the radio body indicate the positions where a screwdriver is
applied to separate the control head from the radio body.
Figure 2.1 Components of the radio
C
D
B
E
3068z_01
20 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.1.1 Radio Body
Overview The radio body consists of the following main components (see Figure 2.2
on page 21):
■cover B
■lid D
■internal options board (optional)
■chassis G
■main-board assembly F.
Cover The black plastic cover B wraps over the top and sides of the radio body.
Apertures in the sides of the cover allow access to the four external screw
bosses of the radio body used for mounting the radio to the U-bracket.
Lid The aluminium lid D is attached to the chassis G with four M4x16 Torx-
head screws C. A seal fitted inside a groove at the underside of the lid
provides for IP54 class protection. The rear of the lid has an aperture for an
external options connector, which may be fitted if an internal options board
is used. If no external options connector is used, the aperture is sealed with
a bung for IP54 class protection. The lid contains two of the four screw
bosses to attach the radio to the U-bracket of the installation kit.
Internal Options
Board (Optional) On the inside of the lid, nine screw points are provided for mounting an
internal options board, which can be sized and shaped as required.
The internal options board connects to the internal options connector of
the main board. Tait offers a range of internal options board, which are
described in the accessories section of this manual. For more information on
how to create your own internal options board, contact Tait Electronics
Limited.
Chassis The aluminium chassis g is different for the 40W/50W radio and the 25W
radio.
The chassis G houses the main-board assembly F, which is attached with
five screws E to screw bosses inside the chassis and with two screws I
through the rear of the chassis to the heat-transfer block.
The rear of the chassis has apertures for the RF, power and auxiliary
connectors of the main board. If the auxiliary connector is not used, the
aperture is sealed with a rubber bung J for IP54 class protection.
The RF connector has a rubber seal H which is fitted inside the aperture
for the RF connector.
TM8100/TM8200 Service Manual Description 21
© Tait Electronics Limited June 2006
Figure 2.2 Components of the radio body
Bcover Gchassis
Cscrew M4x16 (x4) Hauxiliary connector bung
Dlid assembly Iscrews M4x16 (x2)
Escrew M3x10 (x5) Jseal
Fmain-board assembly 1) gap pad (50W/40W radio only)
B
Cx4
D
Ex5
F
G
Ix2
H
J
3630z_01
1)
thermal
paste
22 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
The front of the chassis has an aperture for the control-head connector.
The control-head seal is fitted inside a groove around the flange at the front
face of the chassis and provides for IP54 class protection when the control
head is fitted. Two dot-dash-dot marks at the underside side of the chassis
indicate the leverage points for removing the control head from the
radio body.
The sides of the chassis contain two of the four screw bosses to attach the
radio to the U-bracket of the installation kit.
For heat dissipation, the chassis has heat fins at the rear, grooves at the
bottom, and holes in the front.
The heat fins at the rear of the 40W/50W radio are longer than those of the
25W radio. The grooves at the bottom of the 40W/50W radio are deeper
than those of the 25W radio.
For additional heat dissipation, the 40W/50W radio has an additional
L-shaped gap pad 1) between the chassis and the main board.
TM8100/TM8200 Service Manual Description 23
© Tait Electronics Limited June 2006
Main-Board
Assembly The main-board assembly consists of the following components
(see Figure 2.3):
■main board 1^ with SMT components, digital board D, shielding cans,
and connectors
■heat-transfer block H
■mounting and sealing elements for the connectors at the rear of the
radio body.
Figure 2.3 Components of the main-board assembly
BM3x10 screw (x3) JD-range screwlock fastener (x2)
C50W/40W radios:
M2.2x10 PT screw (x2)
25W radios:
K30x8 PT screw (x2)
1) power connector seal
1! power connector
1@ gap pad (50W/40W radio only)
Ddigital board 1# hexagonal nut
Einternal options connector 1$ lock washer
Fauxiliary connector 1% RF connector
Ginner foam D-range seal 1^ main board
Hheat-transfer block 1& control-head connector
Iouter foam seal
J
B
1^
G
I
H
1)
1&
1#
1%
1$
F
E
1!
thermal
paste
x3
3631z_01
1@
Cx2
D
24 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
The main board 1^ is attached to the heat-transfer block H with three
M3x10 Torx-head screws B and the fastening elements J, 1# and 1$ of the
auxiliary and RF connectors.
The inner foam D-range seal G seals the auxiliary connector against the
heat-transfer block. The power connector seal 1) seals the power connector
against the heat-transfer block.
The power connector seal 1) of the 40W/50W radio (blue) is different to
the seal of the 25W radio (black).
Main Board The main board 1^ is a printed circuit board in SMT design with
components on the top and bottom sides. A digital board D is reflow-
soldered to the main board. Most components are shielded by metal cans.
There are different main boards for each frequency band and each RF
output power configuration.
The internal options connector E for connecting an internal options board
and the factory connector (not illustrated) for factory use are soldered to the
top side of the main board. The control-head connector 1& (facing the front
of the radio) and the auxiliary F, power 1! and RF 1% connectors (facing
the rear of the radio) are located on the bottom side of the main board.
The 40W/50W radio has a black power connector 1! and the 25W radio
has a white power connector.
For more information on the connectors, refer to “Connectors” on
page 36.
For heat dissipation, one of the screw bosses inside the chassis is in contact
with the underside of the main board. A larger copper plate at the underside
of the main board connects to the body of the heat-transfer block.
The 40W/50W radio has an additional gap pad between the heat-transfer
block and the main board 1^ which connects to an additional copper plate
at the bottom side of the main board.
Heat-Transfer Block The aluminium heat-transfer block H dissipates heat from the main board
to the heat fins of the chassis. The heat-transfer block has a contact surface
to the larger copper plate at the underside of the main board 1^, and a
contact surface to the rear of the chassis. All contact surfaces are coated with
thermal paste.
Two self-adhesive foam seals G and I around the aperture of the auxiliary
connector on either side of the heat-transfer block and the power connector
seal 1) inside the aperture of the power connector are fitted to the heat-
transfer block.
TM8100/TM8200 Service Manual Description 25
© Tait Electronics Limited June 2006
2.1.2 Control Head with Graphical Display
Overview The control head can be divided into the following main areas:
■front panel with control elements, indicators, LCD, speaker, and
concealed microphone (optional)
■space-frame and seals
■control-head board with SMT components, shielding cans, connectors,
and volume potentiometer
■control-head loom with female-female adapter
■adapter flange.
The circled numbers in this section refer to the items in Figure 2.4 on
page 27.
Front Panel
Assembly The front panel assembly 1^ consists of an injection-moulded plastic part
with an integrated transparent light pipe element for the radio STATUS LEDs,
a transparent lens which cannot be replaced, a cloth membrane which is
fixed to the speaker grille, and a foam seal inside a rectangular LCD recess
behind the lens. A label 1* with the radio model number is attached to the
front panel assembly with self-adhesive coating and can be replaced for
rebranding purposes.
Three clips on the rear side of the front panel assembly snap onto the space-
frame to hold the keypads 1# and 1#, the LCD assembly 1@ and the speaker
1! in place. The rear side of the front panel assembly also has four screw
bosses to fasten the control-head board F.
Knob for
Volume-Control
Potentiometer
The knob for the volume-control potentiometer 1& is fitted to the shaft of
the volume-control potentiometer, which is soldered to the control-head
board F.
Keypads The main keypad 1# (for the function, selection, and scroll keys) and the
power keypad 1$ protrude through apertures in the front panel assembly 1^.
The rear sides of these keypads connect directly to the relevant contacts on
the control-head board F.
LCD Assembly The graphical-display LCD assembly 1@ sits on a foam seal inside a
rectangular recess of the front panel assembly 1^. Another foam seal is
attached to the rear of the LCD with self-adhesive coating. The LCD
assembly has a loom, which runs through a slot in the space-frame J and
connects to a connector on the rear side of the control-head board F.
26 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Speaker The speaker 1! sits inside a round recess of the front panel assembly, where
a cloth membrane is fixed to the speaker grille. The speaker clamp 1) holds
the speaker in position. The speaker cable plugs into the speaker connector
on the rear side of the control-head board F.
Note In some configurations the speaker may be disconnected.
Concealed
Microphone
(Optional)
A concealed microphone 1% consisting of the microphone capsule and a
rubber seal can be fitted in a round recess inside the front panel assembly 1^.
The microphone leads are soldered to two pads on the top side of the
control-head board. Before the microphone is fitted, a small hole is drilled
in the recess to provide an acoustic path to the microphone. The hole is
covered by the rubber seal to ensure that the control head remains sealed to
IP54 standards. For more information refer to “TMAA02-07 Concealed
Microphone” on page 501.
Space-Frame The aluminium space-frame J snaps into the three clips of the front panel
assembly 1^. The front side of the space-frame holds the keypads, the LCD
assembly, and the speaker in place and at the same time allows access to their
electrical contacts. The rear side of the space-frame has four through-holes
for the screws E of the control-head board F and two screw bosses to fit
the adapter flange C. Two light pipes H and I are fitted in recesses in the
space-frame and direct light from LEDs on the control-head board to the
front panel. A slot at the top edge of the space-frame allows the loom of the
LCD assembly 1@ to run to the control-head board.
Seals Two identical ring seals G fitted to grooves around the perimeter of the
space-frame provide for IP54 class protection.
TM8100/TM8200 Service Manual Description 27
© Tait Electronics Limited June 2006
Figure 2.4 Components of the control head with graphical display
BM4 x 12 Taptite screw (x2)
Cadapter flange
Dcontrol-head loom assembly with
female-female adapter
E3 x 10 PT screw (x4)
Fcontrol-head board
Gspace-frame seal (x2)
Hshort light pipe
Ilong light pipe
Jspace-frame
1) speaker clamp
1! speaker
1@ LCD assembly
1# main keypad
1$ power keypad
1% concealed microphone (optional)
1^ front panel assembly
1& knob for volume-control potentiometer
C
E
F
G
G
1)
H
I
J
1!
1^
1@
1#
1$
1&
x2
x4
D
3451z_02
1%
B
28 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Control-Head Board The control-head board F is a printed circuit board in SMT design with
components on the top and bottom sides. Some SMT components are
shielded by metal cans.
The control-head board is fitted to the front panel assembly 1^ through the
space-frame J with four 3x10 PT screws E.
The side facing the radio body has the connectors for the connection of the
control-head loom, the LCD loom, the speaker, an optional control-head
options board, and pads for the leads of the optional concealed microphone.
The side facing the front panel has the volume-control potentiometer, the
microphone connector, the indicator and backlight LEDS, and the contacts
for the keypads.
Control-Head Loom The control-head loom D connects the connector on the control-head
board to the control-head connector of the radio body. For more
information refer to “Control-Head Connectors” on page 42.
Adapter Flange The adapter flange C is an injection-moulded plastic part, which is fitted to
the space-frame with two M4x12 Taptite screws B.
Figure 2.5 Connectors of the control-head board
connector for control-head
options board
connector for
loom of LCD assembly
pads for leads of
concealed microphone
connector for
control-head loom
connector for speaker
TM8100/TM8200 Service Manual Description 29
© Tait Electronics Limited June 2006
2.1.3 Control Heads with 1-, 2- or 3-Digit Display
Overview The control heads with 1-, 2- or 3-digit display can be divided into the
following main areas:
■front panel with control elements, indicators, speaker, and optional
concealed microphone
■space-frame
■control-head board with SMT components, shielding cans, connectors,
and volume potentiometer
■control-head loom with female-female adapter.
The circled numbers in this section refer to the items in Figure 2.6 on
page 31.
Front Panel
Assembly The front panel assembly H consists of an injection-moulded plastic part
with an integrated transparent light pipe element for the radio STATUS LEDs,
a transparent lens which cannot be replaced, and a cloth membrane which
is fixed to the speaker grille. Depending on the type of control head, the
aperture on the lens is sized to display either one, two or three characters.
A label with the radio model number is attached to the front panel assembly
with self-adhesive coating and can be replaced for rebranding purposes.
Six clips on the space-frame G snap into corresponding locations on the
inside of the front panel assembly to hold the keypad 1@, the LCD 1!, and
the speaker J in place.
Knob for
Volume-Control
Potentiometer
The knob for the volume-control potentiometer I is fitted to the shaft of
the volume-control potentiometer, which is soldered to the control-head
board F.
Keypad The keypad 1@ protrudes through apertures in the front panel assembly H.
The rear side of each key connects directly to the relevant contact on the
control-head board E. Four light pipes 1# and 1$ are fitted in the
appropriate recesses in the keypad and direct light from LEDs on the
control-head board to the front panel.
LCD The LCD 1! sits inside a rectangular recess of the front panel assembly H
and is held in place by the space-frame G. Electrical contact between the
LCD and the control-head board is ensured by two elastomeric strips F
held in place by the space-frame.
Speaker The speaker J sits inside a round recess of the front panel assembly, where
a cloth membrane is fixed to the speaker grille. The space-frame G holds
the speaker in position. The speaker cable plugs into the speaker connector
on the rear side of the control-head board E.
Note In some configurations the speaker may be disconnected.
30 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Concealed
Microphone
(Optional)
A concealed microphone 1) consisting of the microphone capsule and a
rubber seal can be fitted in a round recess inside the front panel assembly H.
The microphone leads are soldered to two pads on the top side of the
control-head board E. Before the microphone is fitted a small hole is drilled
in the recess to provide an acoustic path to the microphone. The hole is
covered by the rubber seal to ensure that the control head remains sealed to
IP54 standards. For more information refer to “TMAA02-06 Support Kit
for Concealed & Dynamic Microphones” on page 493.
Space-Frame The plastic space-frame G clips into the six recesses inside the front panel
assembly H. The front side of the space-frame holds the keypad (with the
four light pipes), the LCD, and the speaker in place and at the same time
allows access to their electrical contacts. The rear side of the space-frame has
three holes for the screws D of the control-head board E.
Control-Head Board The control-head board E is a printed circuit board in SMT design with
components on the top and bottom sides. There are different boards for the
control heads with 1-, 2- and 3-digit display.s
The control-head board is clipped and then fitted to the space-frame G with
three 3x8 PT screws D.
The side facing the radio body has the connectors for the connection of the
control-head loom B, the speaker, an optional control-head options board
C, and pads for the leads of the optional concealed microphone 1).
The side facing the front panel has the volume-control potentiometer, the
microphone connector, the indicator and backlight LEDs, the contacts for
the keypads, and the LCD.
Control-Head Loom The control-head loom B with the female-female adapter connects the
connector on the control-head board E to the control-head connector of
the radio body. For more information refer to “Control-Head Connectors”
on page 42.
TM8100/TM8200 Service Manual Description 31
© Tait Electronics Limited June 2006
Figure 2.6 Components of the control head (1-, 2- or 3-digit display)
Bcontrol-head loom with female-female adapter Iknob for volume-control potentiometer
Ccontrol-head options board (optional) Jspeaker
D3 x 8 PT screw (x3) 1) concealed microphone (optional)
Econtrol-head board 1! LCD
Felastomeric strip (x2) 1@ keypad
Gspace-frame 1# short light pipe
Hfront panel assembly 1$ long light pipe
J
B
1^
G
I
H
1)
1&
1#
1%
1$
F
E
1!
3828z_01
Dx3
B
C
E
F
x2
G
H
1)
J
1@
1#
1$
1!
I
32 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.1.4 RJ45 Control Head
The RJ45 control head consists of the following parts:
■front panel
■control-head loom with female-female adaptor
■control-head board
■PCB bracket.
The circled numbers in this section refer to the items in Figure 2.7 on
page 33.
Front Panel The front panel F is an injection-moulded plastic part with two apertures
for the fitted programming connector and a second optional RJ45
connector. When not in use, the apertures are sealed with two RJ45 bungs
F to ensure that the control head is sealed to IP54 standards. There is also a
hole for the POWER ON/OFF LED which illuminates through the label.
A label with the model number is attached to the front panel with self-
adhesive coating and can be replaced for rebranding purposes.
The rear side of the front panel has four screw bosses to fasten the PCB
bracket E.
Control-Head Loom The control-head loom C with the female-female adapter connects the
connector on the control-head board B to the control-head connector of
the radio body. For more information refer to “Control-Head Connectors”
on page 42.
Control-Head Board The control-head board B is a printed circuit board in SMT design with
some hand-soldered parts.
All components are placed on the top side, including the programming
connector, the connector for the control-head loom C, and the
POWER ON/OFF LED.
The control-head board slides into a slot in the front panel and slots in the
PCB bracket E, and is held in place by two clips of the PCB bracket E.
PCB Bracket The PCB bracket E is an injection-moulded plastic part which is fitted to
the front panel F with four 3x8 PT screws D.
TM8100/TM8200 Service Manual Description 33
© Tait Electronics Limited June 2006
Figure 2.7 Components of the RJ45 control head
Bcontrol-head board EPCB bracket
Ccontrol-head loom with female-female adapter Ffront panel
D3 x 8 PT screw (x4) GRJ45 bung (x2)
B
D
E
F
G
x4
C
x2
34 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.1.5 Blank Control Head
The blank control head consists of the following parts:
■front panel
■control-head loom with programming connector
■seals.
The circled numbers in this section refer to the items in Figure 2.8 on
page 34.
Front Panel The front panel E is an injection-moulded plastic part with an aperture for
fitting the programming connector, which is part of the control-head loom
G. A label with the model number is attached to the front panel with self-
adhesive coating and can be replaced for rebranding purposes.
Control-Head Loom The programming connector at one end of the control-head loom and a
foam seal F are screwed to the front panel with a pair of lock-nuts D.
When the programming connector is not in use, the seal C is fitted with
two screws B to ensure that the control head is sealed to IP54 standards.
The control-head loom with the female-female adapter connects to the
control-head connector of the radio body. For more information refer to
“Control-Head Connectors” on page 42.
There is provision in the blank control head for the fitting of a custom circuit
board.
Figure 2.8 Components of the blank control head
BUNX 4-40 x 3/16-inch pan Pozi screw (x2) Efront panel
Ccover seal Ffoam seal
Dlock-nut (pair) Gcontrol-head loom with female-female adapter
F
3829z_01
x2 B
E
x2 D
CG
3/16 inch (5mm)
4lb·in (0.45N·m)
TM8100/TM8200 Service Manual Description 35
© Tait Electronics Limited June 2006
2.2 User Interfaces
Figure 2.9 shows the controls and indicators of the user interfaces. For more
information refer to the following user’s guides:
■TM8100 (1-digit and 2-digit-display control head)
■TM8250/TM8255 (graphical-display control head)
■TM8235 (3-digit-display control head).
Some keys have functions assigned to both short and long key presses.
A short key press is less than one second, and a long key press is more than
one second.
Figure 2.9 User interfaces
scroll keys
on/off key
volume
control
microphone
socket
press-to-talk
(PTT) key
red
display speaker
green
amber
microphone radio status LEDs
function keys
1 to 4 left
selection key
right
selection key
1- and 2-digit-display
control head:
function keys 1to 4
microphone
socket
on/off key
volume
control
display red speaker
green
amber
radio status LEDs
scroll keys
function key 1 clear key shift key function key 2
3-digit-display
control head:
36 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.3 Connectors
Overview This section describes the specifications and pinouts of the connectors of the
radio body and the control head.
Figure 2.10 provides an overview of the connectors:
Figure 2.11 shows the connectors of the radio body.
Figure 2.12 shows the connectors of the control head.
For information on the factory connector of the main board and the internal
connectors of the control head, refer to the PCB information of the main
boards and the control-head board.
Figure 2.10 Connectors (radio with graphical-display control head)
Speaker
Control-Head
Board
Speaker
Leads
Speaker
Connector
Microphone
Connector
Control-Head
Options Connector
Control-Head
Options Board
Main Board
Internal
Options
Loom
Control-Head
Connector
Power
Connector
RF Connector
Auxiliary
Connector
Factory
Connector
(Factory Only)
Pads for
Concealed
Microphone
External
Options
Connector
Internal
Options
Board
Internal
Options
Connector
Control-Head
Loom
Volume
Control
Keys
LEDs
LCD
TM8100/TM8200 Service Manual Description 37
© Tait Electronics Limited June 2006
Figure 2.11 Connectors of the radio body (25W radio)
control-head
connector
provision for
external options
connector
provision for
additional
connector
power
connector
auxiliary
connector
RF
connector
internal options
connector
rear view
front view
top view
38 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 2.12 Connectors of the control head with graphical display
Figure 2.13 Connectors of the control head with 1-, 2- or 3-digit display
front view
rear view without adapter flange
microphone
connector control-head
connector
front view
microphone
connector control-head
connector
rear view
connectors for
optional circuit board
pads for leads of
concealed microphone
connector for speaker
TM8100/TM8200 Service Manual Description 39
© Tait Electronics Limited June 2006
2.3.1 RF Connector
The RF connector is the primary RF interface to the antenna. The RF
connector is a BNC connector or a mini-UHF connector with an
impedance of 50Ω.
Important The maximum RF input level is +27dBm. Higher levels
may damage the radio.
2.3.2 Power Connector
The power connector is the interface for the primary 13.8V power source
and the external speaker. The primary power source can be the vehicle
battery or a mains-fed DC power supply. There are different power
connectors for the 40W/50W and 25W radios.
Important The speaker load configuration is balanced; the speaker
output lines must not be connected to ground. Connecting
a speaker output line to ground will cause audio power
amplifier shutdown
Table 2.1 RF connector - pins and signals
Pinout Pin Signal Name Signal Type
1 RF RF analog
2 GND RF ground
BC
rear view
Table 2.2 Power connector (radio) – pins and signals
Pinout Pin Signal name Description Signal type
1 AGND Earth return for radio body power
source.
Ground
2 SPK– External speaker output. Balanced load
configuration.
Analog
3 SPK+ External speaker output. Balanced load
configuration.
Analog
4 13V8_BATT DC power input for radio body and
control head.
Power
rear view
50W/40W radio
1 2 3 4
rear view
25W radio
40 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.3.3 Auxiliary Connector
The auxiliary connector is the standard interface for external devices that are
typically connected to a radio. The auxiliary connector is a 15-way
standard-density D-range socket. The auxiliary connector provides a serial
port, three programmable input lines, four programmable digital I/O lines
and audio I/O.
The I/O lines can be programmed for a variety of functions, logic levels,
and in some cases, direction. Audio lines can also be programmed to tap
into, or out of, different points in the audio processing chain. For more
information refer to the online help of the programming application.
Table 2.3 Auxiliary connector – pins and signals
Pinout Pin Signal name Description Signal type
12 AUX_GPI1 General purpose digital input.
Programmable function.
Digital, 3V3 CMOS
5 AUX_GPI2 General purpose digital input.
Programmable function.
With LK3 fitted, GPI2 is an
emergency power sense input.a
Digital, 3V3 CMOS
4 AUX_GPI3 General purpose digital input.
Programmable function.
With LK2 fitted, GPI3 is a power
sense input.a
Digital, 3V3 CMOS
10 AUX_GPIO4 Programmable function and
direction.
Pads available to fit a higher power
driver transistor on GPIO4 line
Digital, 3V3 CMOS
input; open collector
output with pullup
2 AUX_GPIO5
9 AUX_GPIO6
1 AUX_GPIO7
11 AUX_TXD Asynchronous serial port -
Transmit data
Digital, 3V3 CMOS
3 AUX_RXD Asynchronous serial port -
Receive data
Digital, 3V3 CMOS
7 AUD_TAP_IN Programmable tap point into the Rx
or Tx audio chain. DC-coupled.
Analog
13 AUD_TAP_OUT Programmable tap point out of the
Rx or Tx audio chain. DC-coupled.
Analog
14 AUX_MIC_AUD Auxiliary microphone input.
Electret microphone biasing
provided. Dynamic microphones are
not supported.
Analog
6 RSSI Analog RSSI output. Analog
8 +13V8_SWbSwitched 13.8V supply. Supply is
switched off when radio body is
switched off.
Power
15 AGND Analog ground Ground
a. For more information on hardware links refer to “Power-Sense Options” on page 83.
b. Can be switched or unswitched. For more information refer to “Connector Power Supply Options” on page 86.
J
B
C
D
E
F
G
H
I
1)
1!
1@
1#
1$
1%
rear view
TM8100/TM8200 Service Manual Description 41
© Tait Electronics Limited June 2006
2.3.4 Internal Options Connector
When installing an internal options board, the internal options connector is
the electrical interface to the main board of the radio body.
The internal options connector provides similar I/O to the auxiliary
connector. The internal options connector is an 18-pin 0.1 inch pitch
Micro-MaTch connector.
Important The digital I/O signals are intended to interface directly
with compatible logic signals only. Do not connect these
signals to external devices without appropriate signal con-
ditioning and ESD protection.
2.3.5 Provision for External Options Connector
The radio has a mechanical interface for the external connector of an
internal options board. This external options connector can be a 9-way
standard-density or 15-way high-density D-range connector. If no internal
options board is installed (standard configuration), the hole for the external
options connector is sealed by a bung.
Table 2.4 Internal options connector – pins and signals
Pinout Pin Signal Description Signal type
1 13V8_SWaSwitched 13V8 supply. Supply is switched
off when the Radio Body is switched off.
Power
2 AUD_TAP_OUT Programmable tap point out of the Rx or
Tx audio chain. DC-coupled.
Analog
3 AGND Analog ground. Ground
4 AUX_MIC_AUD Auxiliary microphone input.
Electret microphone biasing provided.
Dynamic microphones are not supported.
Analog
5 RX_BEEP_IN Receive sidetone input. AC-coupled. Analog
6 AUD_TAP_IN Programmable tap point into the Rx or Tx
audio chain. DC-coupled.
Analog
7 RX_AUD Receive audio output. Post volume
control. AC-coupled.
Analog
8 RSSI Analog RSSI output. Analog
9…15 IOP_GPIO1…7 General-purpose port for input and
output of data. Programmable function
and direction. With LK4 fitted, GPIO7 is a
power sense inputb.
Digital.
3V3 CMOS
16 DGND Digital ground. Ground
17 IOP_RXD Asynchronous serial port - Receive data. Digital.
3V3 CMOS
18 IOP_TXD Asynchronous serial port - Transmit data. Digital.
3V3 CMOS
a. Can be switched or unswitched. For more information refer to “Connector Power Supply Options” on page 86.
b. For more information on hardware links refer to“Power-Sense Options” on page 83.
B
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F
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top view
42 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.3.6 Control-Head Connectors
The control-head loom connects the connector on the front of the radio
body to the connector on the rear of the control head.
The connector on the front of the radio body is an 18-way two-row right-
angled IDC (insulation displacement connector) SMD header socket.
The connector on the rear of the control head is an 18-way 0.1 inch pitch
Micro-MaTch SMD socket.
Table 2.5 Control-head connectors – pins and signals
Pinout Pin Signal Description Signal type
1 RX_AUD Receive audio output. Post volume
control. AC-coupled.
Analog
2+13V8
aPower supply output from radio body
power source.
Power
3 CH_TXD Asynchronous serial port -
Transmit data.
Digital. 3V3 CMOS.
4 CH_PTT PTT input from microphone.
Also carries the hookswitch signal.
Digital
5 CH_MIC_AUD Fist microphone audio input. Analog
6 AGND Analog ground. Ground
7 CH_RXD Asynchronous serial port - Receive data. Digital. 3V3 CMOS.
8 DGND Digital ground. Ground
9 CH_ON_OFF Hardware power on/software-
controlled power off input. Active low.
Digital
10 VOL_WIP_DC DC signal from volume pot wiper
(grounded for graphical display).
Analog
11 CH_SPI_DO Data output signal to control head. Digital. 3V3 CMOS.
12 CH_LE Latch enable output to control head. Digital. 3V3 CMOS.
13 CH_GPIO1 General purpose digital input/output. Digital. 3V3 CMOS
input.
Open collector
output with pullup.
14 +3V3 Power supply to control head digital
circuits.
Power
15 CH_SPI_DI Data input from control head. Digital. 3V3 CMOS.
16 CH_SPI_CLK Clock output to control head. Digital. 3V3 CMOS.
17 SPK– Speaker audio output for non-remote
control head. Balanced load
configuration.
Analog
18 SPK+ Speaker audio output for non-remote
control head. Balanced load
configuration.
Analog
a. Can be switched or unswitched. For more information refer to “Connector Power Supply Options” on page 86.
CEGI1)1@1$1^1*
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front view
of radio body
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top view of
control-head
board
TM8100/TM8200 Service Manual Description 43
© Tait Electronics Limited June 2006
2.3.7 Microphone Connector
The microphone connector of the control head is an RJ45 socket.
When the control head is connected to the control-head connector of the
radio body using the loom provided, the microphone connector uses the
following eight control-head connector signals:
2.3.8 Programming Connector (RJ45 Control Head)
The programming connector of the RJ45 control head is an RJ45 socket.
When the RJ45 control head is connected to the radio body, the
programming connector uses the following signals.
Table 2.6 Microphone connector – pins and signals
Pinout Pin Signal name Description Signal type
1 MIC_RX_AUD Receive audio output. Analog
2+13V8
aPower supply output. Switched off
when radio body is switched off.
Power
3 MIC_TXD Asynchronous serial port -
Transmit data.
3.3V CMOS
4 MIC_PTT PTT input from microphone. Also carries
hookswitch signal.
Digital
5 MIC_AUD Fist microphone audio input. Analog
6 AGND Analog ground. Analog ground
7 MIC_RXD Asynchronous serial port - Receive data. 3.3V CMOS
8 MIC_GPIO1 General purpose digital input/output. Open collector out
3.3V CMOS in
a. Can be switched or unswitched. For more information refer to “Connector Power Supply Options” on page 86.
B
I
front view
Table 2.7 Programming connector – pins and signals
Pinout Pin Signal name Description Signal type
1 PRG_RX_AUD Receive audio output. Analog
2 +13V8aPower supply output. Switched off
when radio body is switched off.
Power
3 PRG_TXD Asynchronous serial port -
Transmit data.
3.3V CMOS
4 PRG_PTT PTT input from microphone.
Also carries hookswitch signal.
Digital
5 PRG_MIC_AUD Fist microphone audio input. Analog
6 AGND Analog ground Ground
7 PRG_RXD Asynchronous serial port -
Receive data.
3.3V CMOS
8 PRG_ON_OFF Hardware power on/software-power
off input. Active low.
Digital
a. Can be switched or unswitched. For more information refer to “Connector Power Supply Options” on page 86.
B
I
front view
44 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.3.9 Programming Connector (Blank Control Head)
The programming connector of the blank control head is a 9-way standard-
density D-range plug.
When the blank control head is connected to the radio body, the
programming connector uses the following signals.
Table 2.8 Programming connector – pins and signals
Pinout Pin Signal name Description Signal type
1 PRG_RX_AUD Receive audio output. Analog
2 PRG_TXD Asynchronous serial port -
Transmit data.
3.3V CMOS
3 PRG_MIC_AUD Fist microphone audio input. Analog
4 PRG_RXD Asynchronous serial port -
Receive data.
3.3V CMOS
5 PRG_ON_OFF Hardware power on/software-power
off input. Active low.
Digital
6+13V8
aPower supply output. Switched off
when radio body is switched off.
Power
7 PRG_PTT PTT input from microphone.
Also carries hookswitch signal.
Digital
8 AGND Analog ground Ground
9 DGND Digital ground Ground
a. Can be switched or unswitched. For more information refer to “Connector Power Supply Options” on page 86.
front view
TM8100/TM8200 Service Manual Description 45
© Tait Electronics Limited June 2006
2.4 Hardware and Software Architecture
Overview This section describes the hardware and software modules of the radio and
their interaction in the functioning of the radio.
2.4.1 Hardware Architecture
The electrical hardware of the radio is implemented on a main board inside
the radio body and a control-head board inside the control head.
For a detailed description and block diagrams of individual circuits, refer to
“Circuit Descriptions” on page 19.
Main Board The main board inside the radio body includes the following circuitry:
■transmitter
■receiver
■frequency synthesizer
■digital board with a RISC processor and custom logic (implemented on
an FPGA), memory, and a DSP
■CODEC and audio
■interface
■power supply.
The main board has an internal options connector which allows internal
options boards to access a variety of discrete and programmable signals.
For more information refer to “Internal Options Connector” on page 41.
For a basic block diagram of the main board, refer to Figure 2.14 on
page 46.
For a more detailed block diagram of the transceiver, refer to Figure 2.16 on
page 51.
Control-Head Board The control-head board of the control head with graphical display includes:
■the circuitry needed for the controls and indicators on the front panel
■with a RISC processor and custom logic (implemented on an FPGA),
and memory.
For a block diagram of this control-head board, refer to Figure 3.14 on
page 93.
The control head with graphical display may have a concealed microphone
inside the control head and also has provision for a separate circuit board that
may be designed to perform a variety of tasks including—but not limited
to—Bluetooth connectivity. No separate circuit board is required for a
dynamic microphone.
46 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 2.14 Hardware architecture of the main board
Power Supply
Receiver
Transmitter
Frequency
Synthesizer
DSP
CODEC
and Audio Interface
Digital Board
RF Connector
Power
Connector
Control-Head
Connector
LPF
1)
PIN
Switch
1)
Auxiliary
Connector
Internal Options
Connector
Main Board
FPGA
RISC
Proc.
Serial
Flash
SRAM
Flash
Memory
part of transmitter circuitry
analog-to-digital converter 2)
digital-to-analog converter 2)
part of CODEC and audio circuitry2)
1)
digital
RF
analog
asynchronous serial data
synchronous serial data
Custom
Logic
TM8100/TM8200 Service Manual Description 47
© Tait Electronics Limited June 2006
2.4.2 Software Architecture
Overview Software plays an important role in the functioning of the radio. Some radio
functions such as the graphical user interface, processing of the analog and
digital signals, and the implementation of radio applications are completely
implemented by software.
For a block diagram of the software architecture, refer to Figure 2.15 on
page 48.
Software Modules The following software modules are stored on the digital board of the main
board:
■FPGA image, which includes the software-implemented RISC processor
and the custom logic (the custom logic executes additional digital signal
processing)
■boot code
■radio application code
■digital signal processing
■radio application database and radio calibration database.
The following software modules are stored on the control-head board with
graphical display:
■FPGA image, which includes the software-implemented RISC processor
■boot code
■control-head application code
■control-head application database.
Hardware and interface drivers are part of the boot code, the RISC code,
and—in the case of the main board—the DSP code.
48 Description TM8100/TM8200 Service Manual
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Software Start-Up When the radio is turned on, the following processes are carried out on the
main board:
Note This process describes the software start-up into normal radio
operation mode.
1. The FPGA image, which includes the RISC processor and the cus-
tom logic, is loaded from the serial flash to the FPGA.
2. The RISC processor executes the boot code, which carries out an
initialization and auto-calibration, and—in the case of a fault—
generates an error code for display on the control head.
3. Normal radio operation starts with:
■the RISC processor executing the radio application code,
including application software
■the DSP executing the DSP code for processing of digital signals
■the custom logic executing additional digital signal processing.
Figure 2.15 Software architecture (radio with graphical-display control head shown)
FPGA
SRAM
Dynamic
Memory
FPGA Image
RISC Proc.
Control-Head Application Code
FPGA Image
Boot Code
Serial
Flash
Database
Boot Code
Flash
Memory
Application Code
FPGA
Radio Application
Code
Serial Flash
Radio Application Code
Custom Logic
Additional Digital
Signal Processing
FPGA Image
FPGA Image
RISC Processor
Boot Code
DSP
DSP Code
Flash Memory
Boot Code
Database
DSP Code
SRAM
Dynamic Memory
TM8100/TM8200 Service Manual Description 49
© Tait Electronics Limited June 2006
When the radio is turned on, the following processes are carried out on the
control-head board of the control head with graphical display:
1. The FPGA image, which includes the RISC processor, is loaded from
the serial flash to the FPGA.
2. The RISC processor executes the boot code, which carries out an
initialization, and—in the case of a fault—generates an error code for
display on the control head.
3. Normal radio operation starts with the RISC processor executing
■the graphical user interface
■the I/O processing
■the user interface processing.
During normal radio operation the radio body and control head
communicate via interface software, which is part of the radio and control-
head application software.
Software Shutdown On shutdown, the programming and calibration data is stored in the
database, and power is removed from the radio.
Important On power loss, any changes made to the programming or
calibration data may be lost.
Programming and
Calibration Files One of the servicing tasks is the downloading and uploading of
programming and calibration files to the database. For more information,
refer to “Servicing Procedures” on page 149 and the online help of the
programming and calibration applications.
Software Upgrades During servicing it may become necessary to upload software to a
replacement main board, control head, or control head board using the
Tools>Options> Download command of the programming application.
For more information, refer to the online help of the programming
application and to the technical notes accompanying the software files.
50 Description TM8100/TM8200 Service Manual
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2.5 Operation in Receive Mode
Overview This section describes the functioning of the transceiver in receive mode.
The operation of the transceiver is illustrated in Figure 2.16 on page 51.
These block diagrams show the hardware modules integrated with the
software modules:
■hardware (transmitter, receiver, CODEC and audio)
■RISC processor (on FPGA of digital board)
■custom logic (on FPGA of digital board)
■DSP (on digital board).
The receive path consists of three major functional parts:
■RF hardware
■digital baseband processing
■audio processing and signalling.
TM8100/TM8200 Service Manual Description 51
© Tait Electronics Limited June 2006
Figure 2.16 Transceiver operation
Digital
Down-
converter
Squelch
Front
End
1st
IF
Channel
LPF
RSSI
Second LO
UHF: 90.328 MHz
VHF: 42.928 MHz
FM
Demod
Quad
Demod
RX
AGC
Audio
Filtering
De-
emphasis
Optional
Processing
Data and Signaling
Decoders
Side
Tones
Audio
PA
Phase
locked to
TCXO
LPF
Control
Head
Power
Mag.
PLL
Frequency
Control
Triple-point
Equalization
Audio
Filtering
Pre-
emphasis
Optional
Processing
Data and Signaling
Encoders
ALC
Dir.
Coup. Fin Drv
/Ex
Pwr
Ctrl
Ramp
Control
TCXO:
13.000 MHz
VCO*
Control
Head
VCXO
Bias
Custom
Logic
Hardware
Hardware
DSP
Auxiliary
Mic
FGA
Loop
Filter
Primary
Volume
Control
Secondary
Volume
Control
Mic
PGA
Channel
LPF
Loop
Filter
Antenna
IF:
UHF: 45.1 MHz
VHF: 21.4 MHz
2nd IF:
64 kHz
Rx
Interface
RISC Processor
RISC Processor
Analog-to-digital conversion
Digital-to-analog conversion
System interface
Key Notes
(1) Noise blanker not shown
(2) VHF configuration shown*
For UHF there are separate VCOs for RX and TX
Tx
Interface
52 Description TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2.5.1 RF Hardware
PIN Switch The RF PIN switch circuitry selects the RF path to and from the antenna
to either the Tx or Rx circuitry of the radio. In addition to the switching
functionality, the PIN switch is used to provide attenuation to the Rx front
end in high signal-strength locations.
Front End and
First IF The front-end hardware amplifies and image-filters the received RF
spectrum, then down-converts the desired channel frequency to a first
intermediate frequency (IF1) of 21.4MHz (VHF) or 45.1MHz (UHF)
where coarse channel filtering is performed. The first LO signal is obtained
from the frequency synthesizer and is injected on the low side of the desired
channel frequency for all bands. In receive mode, the modulation to the
frequency synthesizer is muted. See “Frequency Synthesizer” on page 57 for
a description of the frequency synthesizer. The output of the first IF is then
down-converted using an image-reject mixer to a low IF of 64kHz.
Quadrature
Demodulator The LO for the image-reject mixer (quadrature demodulator) is synthesized
and uses the TCXO as a reference. This ensures good centring of the IF
filters and more consistent group-delay performance. The quadrature
demodulator device has an internal frequency division of 2 so the second
LO operates at 2 x (IF1+64kHz). The quadrature output from this mixer is
fed to a pair of ADCs with high dynamic range where it is oversampled at
256kHz and fed to the custom logic device.
Automatic Gain
Control The AGC is used to limit the maximum signal level applied to the image-
reject mixer and ADCs in order to meet the requirements for
intermodulation and selectivity performance. Hardware gain control is
performed by a variable gain amplifier within the quadrature demodulator
device driven by a 10-bit DAC. Information about the signal level is
obtained from the IQ data output stream from the ADCs. The control loop
is completed within the custom logic. The AGC will begin to reduce gain
when the combined signal power of the wanted signal and first adjacent
channels is greater than about -70dBm. In the presence of a strong adjacent-
channel signal it is therefore possible that the AGC may start acting when
the wanted signal is well below -70dBm.
Noise Blanking
(A4, B1 bands only) With frequency bands between 66 and 174MHz, a noise blanker can be
selected to remove common sources of electrical interference such as vehicle
ignition noise. The noise blanker functions by sampling the RF input to the
receiver for impulse noise and momentarily disconnecting the first LO for
the duration of the impulse. The response time of the noise blanker is very
fast (tens of nanoseconds) and is quicker than the time taken for the RF
signal to pass through the front-end hardware, so that the LO is disabled
before the impulse reaches the IF stage where it could cause crystal
filter ring.
TM8100/TM8200 Service Manual Description 53
© Tait Electronics Limited June 2006
2.5.2 Digital Baseband Processing
Custom Logic The remainder of the receiver processing up to demodulation is performed
by custom logic. The digitized quadrature signal from the RF hardware is
digitally down-converted to a zero IF and channel filtering is performed at
baseband. Different filter shapes are possible to accommodate the various
channel spacings and data requirements. These filters provide the bulk of
adjacent channel selectivity for narrow-band operation. The filters have
linear phase response so that good group-delay performance for data is
achieved. The filters also decimate the sample rate down to 48kHz.
Custom logic also performs demodulation, which is multiplexed along with
AGC and amplitude data and fed via a single synchronous serial port to the
DSP. The stream is demultiplexed and the demodulation data used as an
input for further audio processing.
Noise Squelch The noise squelch process resides in the DSP. The noise content above and
adjacent to the voice band is measured and compared with a preset
threshold. When a wanted signal is present, out-of-band noise content is
reduced and, if below the preset threshold, is indicated as a valid wanted
signal.
RSSI Receive signal strength is measured by a process resident in the DSP.
This process obtains its input from the demodulator (RF signal magnitude
value) and from the AGC (present gain value). With these two inputs and a
calibration factor, the RF signal strength at the antenna can be accurately
calculated.
Calibration The following items within the receiver path are factory-calibrated:
■front-end tuning
■AGC
■noise squelch
■RSSI.
Information on the calibration of these items is given in the on-line help
facility of the calibration application.
54 Description TM8100/TM8200 Service Manual
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2.5.3 Audio Processing and Signalling
Audio Processing Raw demodulated data from the receiver is processed within the DSP.
The sample rate at this point is 48kHz with signal bandwidth limited only
by the IF filtering. Scaling (dependent on the bandwidth of the RF channel)
is then applied to normalize the signal level for the remaining audio
processing. The sample rate is decimated to 8kHz and 0.3 to 3kHz bandpass
audio filtering is applied. De-emphasis is then applied to cancel out the
receive signals pre-emphasized response and improve signal to noise
performance. Optional processing such as decryption or companding is then
applied if applicable.
Data and Signalling
Decoders The data and signalling decoders obtain their signals from various points
within the audio processing chain. The point used depends on the decoders’
bandwidth and whether de-emphasis is required. Several decoders may be
active simultaneously.
Side Tones Side tones are summed in at the end of the audio processing chain. These are
tones that provide some form of alert or give the user confidence an action
has been performed. The confidence tones may be generated in receive or
transmit mode. The sidetone level is a fixed proportion (in the order of
-10dB) relative to full scale in the receive path.
CODEC The combined audio and side-tone signal is converted to analog form by a
16-bit DAC with integral anti-alias filtering. This is followed by a
programmable-gain amplifier with 45dB range in 1.5dB steps, that performs
primary volume control and muting. The DAC and primary volume control
are part of the same CODEC device (AD6521).
Output to Speakers The output of the CODEC is fed to an audio power amplifier via a
secondary volume control (not TM8100 radios) and to the control head via
a buffer amplifier. The output configuration of the audio power amplifier is
balanced and drives an internal speaker in non-remote control-head
configuration and, optionally, an external speaker. The speaker loads are
connected in parallel rather than being switched. The power delivered to
each speaker is limited by its impedance. The internal speaker has 16Ω
impedance whereas the external speaker can be as low as 4Ω.
Volume Control
Configurations There are two volume controls in the TM8200 radio but only one is active
at any time when audio is being output to the speaker(s). The inactive
volume control is set to maximum. For non-remote control-head
configuration, the primary volume control is active. For remote control-
head configuration, the secondary volume control is active. This enables
fixed level audio feed to the remote control head, and independent volume
control of the external speaker and the speaker of the remote control head.
TM8100/TM8200 Service Manual Description 55
© Tait Electronics Limited June 2006
2.6 Operation in Transmit Mode
Overview This section describes the functioning of the transceiver in transmit mode.
The operation of the transceiver is illustrated in Figure 2.16 on page 51.
These block diagrams show the hardware modules integrated with the
software modules:
■hardware (transmitter, receiver, CODEC and audio)
■RISC processor (on FPGA of digital board)
■custom logic (on FPGA of digital board)
■DSP block (on digital board).
The transmit path consists of three major functional parts:
■audio processing and signalling
■frequency synthesizer
■RF transmitter.
56 Description TM8100/TM8200 Service Manual
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2.6.1 Audio Processing and Signalling
Microphone Input The input to the transmitter path begins at the microphone input. There are
two microphone sources: a fist microphone connected to the control head
and an auxiliary microphone connected via the auxiliary or external options
connector. Only electret-type microphones are supported. Support for
optional dynamic fist microphones is facilitated by a hardware amplifier and
filter in the control head, and must be activated in the programming
software.
Analog Processing
of the Microphone
Input
The CODEC (AD6521) performs microphone selection and amplification.
The microphone amplifier consists of a fixed gain amplifier of 16dB
followed by a programmable-gain amplifier with 0 to 22dB gain.
The amplified microphone signal is converted to a digital stream by a 16-bit
ADC with integral anti-alias filtering (0.1 to 3.2kHz). The digital stream is
transported to the DSP for further audio processing.
Automatic Level
Control The ALC follows and is used to effectively increase dynamic range by
boosting the gain of the microphone pre-amplifier under quiet conditions
and reducing the gain under noisy acoustic conditions. The ALC function
resides in the DSP and controls the microphone-programmable gain
amplifier in the CODEC. The ALC has a fast-attack (about 10ms) and
slow-decay (up to 2s) gain characteristic. This characteristic ensures that the
peak signal level is regulated near full scale to maximize dynamic range.
DSP Audio
Processing The output of the automatic level control provides the input to the DSP
audio processing chain at a sample rate of 8kHz. Optional processing such
as encryption or companding is done first if applicable. Pre-emphasis, if
required, is then applied. The pre-emphasized signal is hard limited to
prevent overdeviation and filtered to remove high frequency components.
The sample rate is then interpolated up to 48kHz and scaled to be suitable
for the frequency synthesizer.
Data and Signalling
Encoders The data and signalling encoders inject their signals into various points
within the audio processing chain. The injection point depends on the
encoders bandwidth and whether pre-emphasis is required.
TM8100/TM8200 Service Manual Description 57
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2.6.2 Frequency Synthesizer
Introduction As shown in Figure 2.16, the frequency synthesizer consists of two main
parts:
■FCL (frequency control loop)
■RF PLL, comprising RF PLL device, loop filter, VCO, and VCO output
switch.
Frequency Control
Loop The FCL consists of the following:
■TCXO
■mixer
■loop filter
■VCXO
■frequency control block.
The FCL provides the reference frequency for the RF PLL. The FCL
generates a high-stability reference frequency that can be both modulated
and offset in fine resolution steps.
RF PLL ■The RF PLL consists of the following:
■RF PLL device
■loop filter
■VCO
■VCO output switch.
The RF PLL has fast-locking capability but coarse frequency resolution.
This combination of control loops creates improved frequency generation
and acquisition capabilities.
Note that patents are pending for several aspects of the synthesizer design.
Operation of
Control Loop The RF PLL is a conventional integer-N-type design with frequency
resolution of 25kHz. In transmit mode, the loop locks to the transmit
frequency, whereas in receive mode, it locks to the receive frequency minus
the first IF frequency.
Initially, the VCO generates an unregulated frequency in the required range.
This is fed to the PLL device (ADF4111) and divided down by a
programmed ratio to approximately 25kHz. The reference frequency input
from the FCL is also divided down to approximately 25kHz. The phase of
the two signals is compared and the error translated into a DC voltage by a
programmable charge pump and dual-bandwidth loop filter. This DC signal
is used to control the VCO frequency and reduce the initial error. The loop
eventually settles to a point that minimizes the phase error between divided
down reference and VCO frequencies. The net result is that the loop
“locks” to a programmed multiple of the reference frequency.
58 Description TM8100/TM8200 Service Manual
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The FCL generates an output of 13.012MHz±4kHz. Initially, a VCXO
(voltage controlled crystal oscillator) produces a quasi-regulated frequency in
the required range. The VCXO output is fed to a mixer where it is mixed
with the 13.000MHz TCXO frequency. The mixer, after low-pass filtering
to remove unwanted products, produces a frequency of 12kHz nominally.
This is converted to digital form and transported to the frequency control
block in the custom logic.
The frequency control block compares the mixer output frequency to a
reference generated by the digital clock and creates a DC error signal.
A programmed offset is also added. This error signal is converted to analog
form and used to control the VCXO frequency and reduce the initial error.
Once settled, the loop “locks” to the TCXO frequency with a programmed
offset frequency. The FCL output therefore acquires the TCXO's
frequency stability.
Modulation The full bandwidth modulation signal is obtained from the DSP in digital
form at a sample rate of 48kHz. In traditional dual-point modulation
systems the modulation is applied, in analog form, to both the frequency
reference and the VCO in the RF PLL, combining to produce a flat
modulation response down to DC. Reference modulation is usually applied
directly to the TCXO.
In the system employed in the radio, the frequency reference is generated by
the FCL, which itself requires dual-point modulation injection to allow
modulation down to DC. With another modulation point required in the
RF PLL, this system therefore requires triple-point modulation.
The modulation signals applied to the FCL are in digital form while for the
RF PLL (VCO) the modulation signal is applied in analog form.
The modulation cross-over points occur at approximately 30 and 300Hz as
determined by the closed loop bandwidths of the FCL and RF PLL
respectively.
Frequency
Generation The RF PLL has a frequency resolution of 25kHz. Higher resolution
cannot be achieved owing to acquisition-time requirements and so for any
given frequency the error could be as high as ±12.5kHz. This error is
corrected by altering the reference frequency to the RF PLL. The FCL
supplies the reference frequency and is able to adjust it up to ±300 ppm with
better than 0.1ppm resolution (equivalent to better than 50Hz resolution at
the RF frequency). The FCL offset will usually be different for receive and
transmit modes.
Fast Frequency
Settling Both the FCL and RF PLL employ frequency-acquisition speed-up
techniques to achieve fast frequency settling. The frequency-acquisition
process of the FCL and RF PLL is able to occur concurrently with minimal
loop interaction owing to the very large difference in frequency step size
between the loops.
TM8100/TM8200 Service Manual Description 59
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Frequency
Acquisition of
RF PLL
In the RF PLL the loop bandwidth is initially set to high by increasing the
charge-pump current and reducing time constants in the loop filter.
As a result, settling to within 1kHz of the final value occurs in under 4ms.
In order to meet noise performance requirements the loop parameters are
then switched to reduce the loop bandwidth. There is a small frequency kick
as the loop bandwidth is reduced. Total settling time is under 4.5ms.
Frequency
Acquisition of FCL The FCL utilizes self-calibration techniques that enable it to rapidly settle
close to the final value while the loop is open. The loop is then closed and
settling to the final value occurs with an associated reduction in noise.
The total settling time is typically less than 4ms.
Calibration The following items are calibrated in the frequency synthesizer:
■nominal frequency
■KVCO
■KVCXO
■VCO deviation.
Calibration of the nominal frequency is achieved by adding a fixed offset to
the FCL nominal frequency; the TCXO frequency itself is not adjusted.
The items KVCO and KVCXO are the control sensitivities of the RF VCO
(in MHz/V) and VCXO (in kHz/V) respectively. The latter has
temperature compensation.
2.6.3 RF Transmitter
RF Power Amplifier
and Switching
(50W/40W Radio)
The RF power amplifier and exciter of the 40W/50W radio is a five-stage
line-up with approximately 40dB of power gain. The output of the
frequency synthesizer is first buffered to reduce kick during power ramping.
The buffer output goes to a discrete exciter that produces approximately 300
to 400mW output. This is followed by an LDMOS driver producing up to
8W output that is power-controlled. The final stage consists of two parallel
LDMOS devices producing enough power to provide 40 to 50W at
the antenna.
RF Power Amplifier
and Switching
(25W Radio)
The RF power amplifier of the 25W radio is a four-stage line-up with
approximately 37dB of power gain. The output of the frequency synthesizer
is first buffered to reduce kick during power ramping. The buffer output
goes to a broad-band exciter IC that produces approximately 200mW
output. This is followed by an LDMOS driver producing up to 2W output
that is power-controlled. The final stage consists of two parallel LDMOS
devices producing enough power to provide 25W at the antenna.
Output of RF Power
Amplifier The output of the RF power amplifier passes through a dual-directional
coupler, used for power control and monitoring, to the PIN switch.
The PIN switch toggles the antenna path between the receiver and
transmitter in receive and transmit modes respectively. Finally, the output is
low-pass-filtered to bring harmonic levels within specification.
60 Description TM8100/TM8200 Service Manual
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Power Control The steady-state power output of the transmitter is regulated using a
hardware control loop. With the 40W/50W radio, the sum of the forward
power output from the RF power amplifier and reverse power reflected from
the load is sensed by the directional coupler and fed back to the power
control loop. With the 25W radio, the forward power output from the RF
power amplifier is sensed by the directional coupler and fed back to the
power control loop. The PA output power is controlled by varying driver
gate bias voltage that has a calibrated maximum limit to prevent overdrive.
The power control signal is supplied by a 13-bit DAC driven by
custom logic.
Ramping Power ramp-up consists of two stages:
■bias
■power ramping.
The timing between these two stages is critical to achieving the correct
overall wave shape in order to meet the specification for transient ACP
(adjacent channel power). A typical ramping waveform is shown in
Figure 2.17.
Bias Ramp-Up The steady-state final-stage bias level is supplied by an 8-bit DAC
programmed prior to ramp-up but held to zero by a switch on the DAC
output under the control of a TX INHIBIT signal. Bias ramp-up begins upon
release by the TX INHIBIT signal with the ramping shape being determined by
a low-pass filter. Owing to power leakage through the PA chain, ramping
the bias takes the PA output power from less than –20dBm for the
40W/50W or –10dBm for the 25W radio to approximately 25dB below
steady-state power.
Power Ramp-Up The power ramp signal is supplied by a 13-bit DAC that is controlled by
custom logic. The ramp is generated using a look-up table in custom logic
memory that is played back at the correct rate to the DAC to produce the
desired waveform. The ramp-up and ramp-down waveforms are produced
by playing back the look-up table in forward and reverse order respectively.
For a given power level the look-up table values are scaled by a steady-state
Figure 2.17 Typical ramping waveforms
Power
ramp
High power
powerLow
Power
Time
Bias
ramp
Bias
ramp
Power
ramp
TM8100/TM8200 Service Manual Description 61
© Tait Electronics Limited June 2006
power constant so that the ramp waveform shape remains the same for all
power levels.
PIN Switch The RF PIN switch circuitry selects the RF path to and from the antenna
to either the Tx or Rx circuitry of the radio. In addition to the switching
functionality, the PIN switch is used to provide attenuation to the Rx front
end in high signal-strength locations.
62 Description TM8100/TM8200 Service Manual
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TM8100/TM8200 Service Manual Circuit Descriptions 63
© Tait Electronics Limited June 2006
3 Circuit Descriptions
Introduction This section describes and illustrates the circuitry of the main board and the
control-head boards.
The main board is divided into the following circuitry modules:
■transmitter
■receiver
■frequency synthesizer (including FCL)
■CODEC and audio
■power supply
■interface
■digital board.
Figure 3.1 gives an overview of the of the circuitry modules of the main
board and shows how they are interconnected.
Sample Schematics For up-to-date schematics refer to the relevant PCB information (refer to
“Associated Documentation” on page 6).
64 Circuit Descriptions TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 3.1 Main board hardware architecture
Power Supply
Receiver
Transmitter
Frequency
Synthesizer
DSP
CODEC
and Audio Interface
Digital Board
RF Connector
Power
Connector
Control-Head
Connector
LPF
1)
PIN
Switch
1)
Auxiliary
Connector
Internal Options
Connector
Main Board
FPGA
RISC
Proc.
Serial
Flash
SRAM
Flash
Memory
part of transmitter circuitry
analog-to-digital converter 2)
digital-to-analog converter 2)
part of CODEC and audio circuitry2)
1)
digital
RF
analog
asynchronous serial data
synchronous serial data
Custom
Logic
TM8100/TM8200 Service Manual Circuit Descriptions 65
© Tait Electronics Limited June 2006
3.1 Transmitter Circuitry
Introduction For a block diagram of the transmitter circuitry, refer to Figure 3.2.
The transmitter circuitry is different for the 40W/50W radios and the 25W
radios, and the different bands.
Exciter With the 40W/50W radio, the discrete-component exciter is designed for
specific bands (UHF or VHF). It is made up of Q3501, Q3502, and Q3505,
which amplify the signal provided by the frequency synthesizer from its level
of 7 to 10dBm up to 24dBm for the frequency bands 136 to 174MHz and
400 to 520MHz.
With the 25W radio, the broadband exciter is a common element in all the
bands, as it operates across all frequencies from 66 to 530MHz. It is made
up of Q300 and Q303, which amplify the signal provided by the frequency
synthesizer from its level of 7 to 10dBm up to 24.5dBm for the frequency
band from 66 to 530MHz.
The exciter operates in full saturation, thereby maintaining a constant
output power independent of the varying input power level supplied by the
synthesizer.
Power Amplifier The power amplifier comprises the driver amplifier Q306 and two paralleled
final devices Q309 and Q310.
With the 40W/50W radio, the signal from the exciter is amplified by Q306
to a power level of approximately 2W (VHF) using a PD55003 and about
3W (UHF) using a PD55008. The resulting signal is then amplified by
Q309 and Q310 to produce a typical output power of 90W at 155MHz and
65W across the UHF band, when measured after the series capacitors
(C348, C349, C350) at the start of the directional coupler.
With the 25W radio, the 24.5dBm signal from the exciter is reduced by a
band-dependent pi-attenuator and is amplified by Q306. The resulting
signal is then amplified a second time by Q309 and Q310 to produce a
typical output power of 40W when measured after the series capacitors
(C348, C349, C350) at the start of the directional coupler.
The high-level RF signal passes via the directional coupler, the transmit-
receive PIN switch, and the LPF, through to the antenna. The LPF is used
to attenuate unwanted harmonic frequencies.
Power Control Loop Calibration is used to adjust the power control loop, thus setting the output
of the transmitter to one of four preferred power levels:
■10, 15, 25, and 50 watts (VHF), and
10, 15, 20, and 40 watts (UHF) for 40W/50W radios
■1, 5, 12 and 25 watts (all bands) for 25W radios.
66 Circuit Descriptions TM8100/TM8200 Service Manual
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Figure 3.2 Block diagram of the transmitter circuitry
RF
Connector
Receiver
LPF Directional
Coupler PA
Forward Power
Buffer Amplifier
Power
Control
PIN
Switch
Driver Exciter
Bias
Limiter
Shaper
and Level
Shifter
Shaper
and Level
Shifter
Crowbar
Shaping
Filter
Tempera-
ture
Sensor
Buffer Amplifier
TX RX RF
Thermal
Coupling
OR Gate
Switch
TX INH
+9V0 TX
+13V8 BATT
DIG TX INH
DIG SYN EN
SYN LOCK
SYN TX LO
Power
Supply
Digital
Board
Frequency
Synthesizer
CDC TX DRV BIAS
CDC TX FIN BIAS1
CDC TX FIN BIAS2
CDC TX PWR CTL
TX TEMP
TX FWD PWR
TX REV PWR
CODEC
and
Audio
Interface
AGND
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
Transmitter
Reverse Power
Buffer Amplifier
(40W/50W only)
TM8100/TM8200 Service Manual Circuit Descriptions 67
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The loop maintains these power settings under changing environmental
conditions. The control mechanism for this loop is via the DAC IC204 and
one of the operational amplifiers making up IC301. The power control loop
will be inhibited if for any reason an out-of-lock signal is detected from the
synthesizer. This ensures that no erroneous signals are transmitted at
any time.
With the 40W/50W radio, the power control loop processes the voltages
from the forward and reverse power sensors in the directional coupler.
This signal is fed to the buffer and a band-limited operational amplifier back
to the gate of Q306. In this way, the transmitter is protected against bad
mismatches.
With the 25W radio, the power control loop senses the forward power by
means of the diode D304. This signal is fed to the buffer and a band-limited
operational amplifier back to the gate of Q306.
A voltage clamp (one of the operational amplifiers of IC301) for Q306 limits
the maximum control-loop voltage applied to its gate.
Directional
Coupler With the 40W/50W radio, the directional coupler actively senses the
forward power and the reverse power, and feeds them back to the power-
control circuit.
With the 25W radio, the directional coupler actively senses the forward
power and feeds it back to the power-control circuit. If the directional
coupler detects too much reverse power, indicating a badly matched
antenna, the transmitter will be reduced to the lowest power setting.
Temperature Sensor For added protection, a temperature sensor ensures that the transmitter
power is reduced to very low levels should a temperature threshold be
exceeded. If the temperature does not decrease, the transmitter is
switched off.
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3.2 Receiver Circuitry
Introduction For a block diagram of the receiver circuitry, refer to Figure 3.3 (B1, H5,
H6 bands, 05 issue PCBs) and Figure 3.4 (other bands and later issue PCBs).
The receiver is of the triple-conversion superheterodyne type. The first two
IF stages are implemented in hardware; the third stage is implemented in the
FPGA (Field-Programmable Gate Array) of the digital board. The FPGA
also carries out the demodulation of the received signals.
Front-End Circuitry The front-end circuitry is a standard varicap-tuned singlet (band-pass filter),
followed by an LNA (low-noise amplifier), and then a varicap-tuned
doublet (image filter). The varicap tuning voltage CDC RX FE TUNE is provided
by a DAC, with voltages calculated from a calibration table stored in non-
volatile memory. The two varicap-tuned filters need to be calibrated to
ensure that maximum sensitivity is achieved.
First Mixer The first mixer is a standard diode-ring mixer with SMD (surface-mount
device) baluns and a quadruple SMD diode. For the bands between 66 and
174MHz, the receiver includes a circuit for suppressing ignition noise.
This circuit momentarily removes the LO signal from the mixer when an
ignition noise pulse is detected. The ignition-noise suppressor is selectable
on a per-channel basis when the radio is programmed.
First IF Stage and
Second Mixer The first IF stage consists of a crystal channel filter (BPF1), followed by an
IF amplifier, and then another crystal filter (BPF2). The second mixer is an
IC quadrature mixer with an internal AGC amplifier. This IC has a divide-
by-two function on the LO input in order to provide the quadrature LO
frequencies required internally. The second LO frequency is synthesized by
an integer PLL (IC403), which uses the TCXO frequency SYN RX OSC
(13.0000 MHz) as its reference.
Frequencies
of IF Stages The frequency of the first IF stage depends as follows on the frequency band
of the radio:
■VHF bands: 21.400029MHz
■UHF bands: 45.100134MHz.
The above are nominal values; the actual frequency will differ by a small
amount depending on the exact initial frequency of the TCXO.
The frequency of the second IF stage will always be precisely 64.000kHz
once the TCXO calibration has been completed. (The TCXO calibration
does not adjust the TCXO frequency, but instead adjusts the VCXO
frequency, which in turn adjusts the VCO or first LO frequency as well as
the frequency of the first IF stage. The second LO frequency remains fixed.)
The third IF stage is completely within the FPGA and is not accessible.
Demodulation Demodulation takes place within the FPGA. Demodulated audio is passed
to the DSP of the digital board for processing of the receiver audio signal.
Raw demodulated audio can be tapped out from the DSP for use with an
external modem. The modem may be connected to the auxiliary connector
or to the external options connector when an internal options board
is fitted.
TM8100/TM8200 Service Manual Circuit Descriptions 69
© Tait Electronics Limited June 2006
Figure 3.3 Block diagram of the receiver circuitry (05 issue boards, B1, H5, H6 bands)
(NOT USED)
BPF LNA IMAGE FILTER FIRST IF STAGE
BPF 1 IF AMPLIFIER FIRST IF STAGE
BPF 2 QUADRATURE
DEMODULATOR
BIAS NETWORK
POWER SUPPLY
CODEC
AND AUDIO
CIRCUITRY
DIGITAL BOARD
PLL
TRANSMITTER FREQUENCY SYNTHESIZER
MIXER
RF
SIGNAL TYPES
ANALOGUE
CLOCK
DIGITAL
ASYNCHRONOUS
SERIAL DATA
SYNCHRONOUS
SERIAL DATA
RECEIVER
VCO
CDC RX FE TUNE
CDC RX AGC
RX CDC QN
RX CDC QP
RX CDC IN
RX CDC IP
+3V0 RX
+3V0 AN
CDC RX VREF
DIG RX EN
DIG RX LE
RX DIG LD
DIG SYN SPI DO
DIG SYN SPI CLK
DIG RX NB EN
SYN RX OSC
SYN RX LO1
TX RX RF
LOOP FILTER AGND INTERFACE
CIRCUITRY
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Figure 3.4 Block diagram of the receiver circuitry (B1, H5, H6 bands after PCB issue 05 & other bands)
Image Filter LNA Image Filter First IF
BPF 1 IF Amplifier First IF
BPF 2 Quadrature
Demodulator
Bias
Network
Power
Supply
CODEC
and
Audio
Digital
Board
PLL
Noise
Blanker
(66-174 MHz only)
Switch
(66-225 MHz
only)
Transmitter Frequency
Synthesizer
Mixer
Receiver
VCO
CDC RX PIN AGC
CDC RX AGC
RX CDC QN
RX CDC QP
RX CDC IN
RX CDC IP
+3V0 RX
+3V0 AN
CDC RX VREF
DIG RX EN
DIG RX LE
RX DIG LD
DIG SYN SPI DO
DIG SYN SPI CLK
DIG RX NB EN
SYN RX OSC
SYN RX LO1
TX RX RF
Loop Filter AGND Interface
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
Attenuator
CDC RX FE TUNE
TM8100/TM8200 Service Manual Circuit Descriptions 71
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Automatic Gain
Control The receiver has an AGC circuit to enable it to cover a large signal range.
Most of the circuit functions are implemented in the FPGA. The FPGA
passes the AGC signal to the CODEC IC204 for output from pin 14
(IDACOUT) and then via IC201 as the signal CDC RX AGC to pin 23 of the
quadrature mixer IC400. As the antenna signal increases, the AGC voltage
decreases.
Channel Filtering The channel filtering is split between the first and third IF stages.
The channel filtering circuit in the first IF stage comprises a pair of two-pole
crystal filters. The first filter has a 3dB bandwidth of 12kHz, and the second
a 3dB bandwidth of 15kHz. Most of the channel filtering, however, is
implemented in the FPGA. When the radio is programmed, the different
filters are selected as assigned by the channel programming. The selectable
filters plus the fixed crystal filters result in the following total IF 3dB
bandwidths:
■wide channel spacing : 12.6kHz
■medium channel spacing: 12.0kHz
■narrow channel spacing : 7.8kHz.
(The FPGA runs from the DIG SYS CLK signal, which has a frequency of
12.288MHz.) The receiver requires the TCXO calibration to be completed
to ensure that the channel filtering is centred, thereby minimizing
distortion.
Received Signal
Strength Indication The RSSI is calculated in the FPGA and DSP, and can be passed as an analog
voltage to the internal options interface and the external auxiliary interface.
To obtain an accurate estimate of the RSSI (over the signal level and
frequency), it is necessary to calibrate the AGC characteristic of the receiver
and the front-end gain versus the receive frequency.
Front-End AGC
Control The receiver has a front-end AGC circuit to enable it to handle large
receiver signals with minimal receiver distortion. This is very important for
the correct operation of the THSD modem (Tait High-Speed Data). It
enables THSD to maintain residual BER of < 10-4. The front-end AGC is
controlled by an algorithm which monitors the RSSI and configures the
DAC to turn on the front-end attenuation via the receive pin diode of the
PIN switch.
Noise Blanker (A4,
B1 bands only) If the frequency band is between 66 and 174MHz, a noise blanker can be
selected to remove common sources of electrical interference such as vehicle
ignition noise. The noise blanker functions by sampling the RF input to the
receiver for impulse noise and momentarily disconnecting the first LO for
the duration of the impulse. The response time of the noise blanker is very
fast (tens of nanoseconds) and is quicker than the time taken for the RF
signal to pass through the front-end hardware, so that the LO is disabled
before the impulse reaches the IF stage where it could cause crystal
filter ring.
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3.3 Frequency Synthesizer Circuitry
Introduction For a block diagram of the frequency synthesizer circuitry, refer to
Figure 3.5 and Figure 3.6 (FCL for the A4 band).
The frequency synthesizer includes an active loop filter, one or two VCOs
and buffer amplifiers, and a PLL IC. The last-named uses conventional
integer-N frequency division and includes a built-in charge pump. Speed-
up techniques ensure a transmit-receive settling time of less than 4.5ms
while retaining low noise characteristics in static operation.
Power Supplies Several power supplies are used by the frequency synthesizer owing to a
combination of performance requirements and the availability of suitable
components. The PLL IC includes analog and digital circuitry and uses
separate power supplies for each section. The digital section is run on 3V,
while the analog section is run on approximately 5V. The VCOs and buffer
amplifiers run off a supply of about 5.3V. The active loop filter requires a
supply of 14 to 15V, and a reference voltage of approximately 2.5V.
Performance
Requirements Low noise and good regulation of the power supply are essential to the
performance of the synthesizer. A 6V regulator IC provides good line
regulation of the 9V supply and good load regulation. Good regulation of
the power-supply line and load is essential for meeting the transient ACP
requirements. The regulator output voltage is electrically noisy, however,
and filtering is essential. Filtering of the power supply is achieved with two
capacitance multipliers (Q508 and C585 for the VCO supply, and Q512 and
C579 for the PLL and loop-filter supply). The VCO (or VCOs) use a
separate capacitance multiplier because these multipliers have poor load
regulation and the VCOs impart sufficient load transients to warrant a
separate supply.
Effect of Tuning
Range For reasons of noise performance, the VCOs are designed to be tuned
within a range of 2 to 12V. Active tuning circuitry is required. An active
loop filter incorporating an IC operational amplifier achieves this range with
a suitable power supply voltage. Normal synthesizer switching behaviour
involves overshoot, which dictates that the tuning voltage range must extend
above and below the range of 2 to 12V. The 14V limit is a result of limits
on the working supply voltage of the IC operational amplifier.
Switch-mode Power
Supply The power supply VCL SUPPLY for the active loop filter is provided by a
SMPS, which is in turn powered by 9V. The SMPS consists of an oscillator
(switching circuit) and a detector. The output voltage is monitored by a
feedback circuit that controls the DC bias of the switching circuit to
maintain a constant output voltage.
Synthesizer
Circuitry The essential function of the PLL frequency synthesizer is to multiply a
25kHz reference frequency (30kHz for A4 band) to give any desired
frequency that is an integer multiple of 25 kHz (30 kHz for A4 band). There
are some constraints imposed by the capabilities of the synthesizer hardware,
especially the tuning range of the VCOs.
TM8100/TM8200 Service Manual Circuit Descriptions 73
© Tait Electronics Limited June 2006
Figure 3.5 Block diagram of the frequency synthesizer circuitry
Coupler
PLL
MOD
5 V SWITCH
SYN TX LO
SYN RX LO1
TR SWITCH
VCO (VHF only)
DIG SYN TR SW
PLL
Summer
5V
VP SUPPLY
Loop
Filter
VCO
Supply
Filter
+5 V DEC VCL SUPPLY
+5 V
VP
Frequency Synthesizer
LPF
Mixer
VCXO
TCXO
Modulator
Buffer Amplifier
PLL
MOD
VCO 2
VCO 1
Buffer
Amplifiers
and
Coupler
5 V SwitchTR Switch
VCO (UHF only)
+6V0
AGND
+3V0 AN
Power
Supply
CDC VCXO MOD
SYN CDC FCL
SYN CDC LFV
CDC VCO MOD
CODEC
and
Audio
SYN TX LO
SYN RX LO1
Trans-
mitter
SYN RX OSC
Receiver
Digital
Board
DIG SYN SPI DO
DIG SYN SPI CLK
DIG SYN TR SW
DIG SYN EN
DIG SYN FAST
DIG SYN LATCH
SYN LOCK
SYN DIG FREF
14 V
SMPS
Buffer Amplifier
Interface
Inverter
+9V0
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
LPF
Mixer
VCXO
TCXO
Modulator
Buffer Amplifier
Buffer Amplifier
Frequency Control Loop
(FCL)
74 Circuit Descriptions TM8100/TM8200 Service Manual
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Reference
Frequency The approximately 25kHz (30kHz for A4) reference is obtained by dividing
the approximately 13MHz (2.612kHz for A4) output of the FCL. Any error
in the FCL output frequency will be multiplied by the synthesizer.
Therefore, if the synthesizer is locked but not the FCL, then the synthesizer
output frequency will be wrong. The FCL frequency division is performed
by a digital counter inside the PLL IC. The divider setting is constant.
VCO Frequency and
Output Power The output frequency from the synthesizer is generated by a VCO.
The VCO frequency is tuned across the frequency range of the radio by
means of a DC control voltage, typically between 2V and 12V. The VCO
output power is amplified by a buffer amplifier. The power is low and varies
from band to band. The buffer output power depends on which mode—
receive or transmit—is used. In receive mode the output power should be
about 7dBm, whereas in transmit mode it should be about 9dBm.
Dual VCOs Some variants of the synthesizer use two VCOs: one for receive and one for
transmit. Synthesizers with two VCOs share the same tuning signal.
Only one VCO is switched on at a time, and so the PLL IC will see only
one output frequency to tune. A portion of the RF output from the VCOs
is fed to the RF input of the PLL IC. The RF signal is divided by an integer
that gives 25kHz (30kHz for A4) if the output frequency is correct.
Phase-locked Loop The PLL IC compares the 25kHz reference (30kHz for A4) and the divided
VCO signal, and the error is used to control the internal charge pump.
The charge pump is a current source that can sink or source current in
proportion to the frequency or phase error. The output is a series of 25kHz
pulses (30kHz for A4) with a width that is dependent on the phase error.
When the output frequency of the synthesizer is correct, there is no error
and the charge pump output will become open circuit.
Figure 3.6 Block diagram of the frequency control loop circuitry—A4 band
÷4
÷4
Buffer
Amplifier
FCL
÷4
÷4
Buffer
Amplifier
FCL
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© Tait Electronics Limited June 2006
Active Loop Filter The loop filter continuously integrates the current pulses from the charge
pump and produces a steady DC output voltage that tunes the VCO
(or VCOs). When the VCO frequency is correct, there is no frequency
error and therefore no charge-pump output, and so the loop filter’s output
voltage remains constant. If the frequency is too high or too low, the error
will result in the output of charge-pump current pulses (negative or positive
depending on the sign of the error). The loop filter’s output voltage will
change accordingly, causing the VCO frequency to change in proportion.
The synthesizer design is such that normally the VCO frequency will be
automatically corrected.
Re-tuning of VCO
Frequency When the radio changes channels or switches between receive and transmit,
the VCO frequency must be changed. The rate at which the VCO is re-
tuned is dependent on many factors, of which the loop filter is the main
factor. The loop filter is an integrator built around an operational amplifier.
The resistors and capacitors of the filter affect both the switching time and
the stability of the synthesizer; the values of these components have been
carefully selected to give optimum control characteristics.
Speed-up
Techni q u es To reduce the change-over time between transmit and receive, part-time
speed-up techniques have been implemented. Speed-up involves changing
some resistor values while simultaneously changing the PLL IC settings.
This process is implemented in hardware under software control in
conjunction with use of the synthesized reference input. The result is a
transmit-receive settling time of less than 4.5ms. (The switching time is
measured for a frequency change equal to the first IF plus 10MHz or 1MHz,
depending on the repeater offsets used for the band. This implies a
synthesizer transmit-receive change-over plus an offset of 1MHz or 10MHz
in less than 4.5ms. The ramp-up and ramp-down of the transmitter, which
totals 1ms, extends this change-over time to 5.5ms.)
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3.4 Frequency Control Loop
Introduction The FCL is included in the block diagram of the frequency synthesizer
(see Figure 3.5 and Figure 3.6).
The FCL forms part of the frequency-synthesizer module. The basis of the
FCL is a VCXO, which generates the reference frequency required by the
main PLL of the synthesizer.
Elements of
FCL Circuitry The FCL is a simple frequency-locked loop. The circuitry consists of the
following elements:
■VCXO (XL501, Q501, Q503)
■TCXO (XL500)
■buffer amplifier (IC500)
■mixer (IC501)
■low-pass filter (IC502, pins 5 to 7)
■modulator buffer amplifier (IC502, pins 1 to 3).
The A4 band has additional circuitry:
■2.612MHz mixer (IC506)
■amplifiers (Q504, IC509)
■TCXO divide by 4 (IC508)
The TCXO supplies a reference frequency of 13.0000MHz (10.4MHz for
the A4 band), which is extremely stable, regardless of the temperature.
The VCXO runs at a nominal frequency of 13.0120MHz, and is frequency-
locked to the TCXO reference frequency.
Circuit Operation The VCXO is mixed with the TCXO output to create a nominal difference
(or offset) frequency of 12kHz SYN CDC FCL. In A4 band radios, there is
additional circuitry and the VCXO is mixed with the TCXO to produce
2.612MHz. This is then mixed with 2.6MHz (TCXO divided by 4) to
produce the 12kHz SYN CDC FCL.
The signal SYN CDC FCL is fed via the CODEC IC502 in the CODEC
circuitry to the FPGA on the digital board. The FPGA detects the offset
frequency, compares it with the programmed offset frequency, and outputs
a corresponding feedback signal CDC VCXO MOD via IC205. The feedback
signal is amplified and inverted by the modulator buffer amplifier and output
as the loop voltage for the VCXO. With this design the VCXO frequency
can be adjusted by very small precise amounts, and because the loop is
locked, the VCXO inherits the temperature stability of the TCXO.
Modulation The FCL modulation is implemented within the FPGA and appears at the
output of IC205, and therefore on the VCXO loop voltage. Consequently,
the VCXO is frequency modulated directly by the relevant modulation
information. The latter may be the microphone audio, an audio tap-in
signal, internal modem signals, or any combination of these.
TM8100/TM8200 Service Manual Circuit Descriptions 77
© Tait Electronics Limited June 2006
3.5 CODEC and Audio Circuitry
Introduction For a block diagram of the CODEC and audio circuitry, refer to Figure 3.7.
A/D and D/A
Conversion The analog-to-digital conversion and digital-to-analog conversion is
performed by the devices IC203, IC204 and IC205.
Device IC203 IC203 is an eight-channel DAC that provides control of transmitter biasing,
front-end AGC, front-end tuning, and the output of analog RSSI signals.
The digital input data are fed to IC203 in synchronous serial form. Three of
the DAC channels are not used.
Device IC205 IC205 contains two CODECs. One is used by the FCL. The second is used
for auxiliary audio (input) and VCO modulation (output). The digital
section communicates with this device via a four-wire synchronous serial
interface.
Device IC204 IC204 contains base-band, voice-band and auxiliary CODECs and some
analog signal conditioning. The reference voltage (nominally 1.2V) for
these CODECs is provided internally by IC204 but is decoupled externally
by C228.
Base-band CODEC The base-band CODEC handles the I and Q outputs (IRXP, IRXN, QRXP and
QRXN balls) of the receiver’s second IF stage. The analog signals are
differential and biased at 1.2V nominally. The digital section communicates
with this CODEC via a two-wire synchronous serial interface (BSDO and
BSOFS balls). The digital-to-analog conversion section of the base-band
CODEC is not used.
Voice-band CODEC The voice-band CODEC handles the microphone and speaker signals.
The digital section communicates with this CODEC via a three-wire
synchronous serial interface (VSFS, VSDO and VSDI balls). IC204 also contains
voice-band filtering, pre-amplification and volume control.
Auxiliary CODEC The auxiliary CODEC handles transmitter power control, receiver gain
control, auxiliary audio output and general analog monitoring functions.
The digital section communicates with this CODEC via a three-wire
synchronous serial interface (ASFS, ASDI and ASDO balls). The DAC used for
receiver gain control (IDACOUT ball) is a current output type. Current-to-
voltage conversion is performed by R238. The full-scale output of 1.2V is
amplified by IC201 to approximately 3V as required by the receiver.
Audio Circuitry The audio circuitry performs four functions:
■output of audio signal for speaker
■input of microphone audio signal
■input of auxiliary audio signal
■output of auxiliary audio signal.
78 Circuit Descriptions TM8100/TM8200 Service Manual
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Figure 3.7 Block diagram of the CODEC and audio circuitry
DAC CODEC 1
CODEC 2
Level
Shifter
2V3
Supply
Voltage
Divider
Buffer
Amplifier
Summer
Audio PA
Bias
Network
LPF
Buffer
Amplifier
CODEC and Audio
CDC RX VREF
RX CDC IP
RX CDC IN
RX CDC QP
RX CDC QN
DIG RX EN
CDC RX AGC
CDC RX FE TUNE
CDC TX FIN BIAS1
CDC TX FIN BIAS2
CDC TX DRV BIAS
CDC TX PWR CTL
TX TEMP
TX FWD PWR
TX REV PWR
SYN CDC LFV
CDC VCO MOD
CDC VCXO MOD
SYN CDC FCL
Digital Board
AGND
+13V8 BATT
+2V5 CDC
+9V0
+3V3
+3V0 AN
CDC RX AUD
AUD ITF SPK+
AUD ITF SPK–
ITF RX BEEP IN
ITF CH MIC AUD
ITF AUX MIC AUD
ITF VOL WIP DC
CDC AUD TAP OUT
CDC RSSI
ITF AUD TAP IN
CDC2 DIG SDTO
DIG RX EN
DIG CDC2 SDTI
DIG CDC2 SCLK
DIG CDC2 LRCK
DIG SYS CLK
DIG DAC LATCH
DIG DAC SPI DO
DIG DAC SPI CLK
+1V8
DIG CDC ARSM
CDC DIG VSFS
CDC DIG VSDO
DIG CDC VSDI
CDC DIG BSDO
CDC DIG BSOFS
DIG CDC ASFS
DIG CDC ASDI
CDC DIG ASDO
PSU SYS RST
PSU SYS RST
DIG RX EN
+2V3 FIL
Interface
Power
Supply
Receiver
Trans-
mitter
Frequency
Synthesizer
Volume
Control
DIG AUD CS
DIG AUD UD
DIG AUD PA EN1
DIG AUD PA EN2
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
CDC RX PIN AGC
TM8100/TM8200 Service Manual Circuit Descriptions 79
© Tait Electronics Limited June 2006
The sections of the circuitry concerned with these functions are described
below.
Audio Signal
for Speaker The audio signal for the speaker is generated by IC204 (VOUTAUXP ball).
This signal is post-volume-control and has a pre-emphasized frequency
response. The signal is then processed by R218, R217 and C231 (C205) to
restore a flat frequency response and reduce the signal level to that required
by the audio power amplifier.
Summing Circuit The top of C231 (C205) is where side tones are summed in and the CDC RX
AUD signal is obtained. C201 and R211 pre-emphasize and attenuate the
side-tone signal to give a flat side-tone frequency response and reduce the
input to an appropriate level.
Buffer Amplifier IC201 (pins 8 to 10) amplifies the signal at the top of C231 (C205) by 19dB
and drives the CDC RX AUD system interface line via C212 and R225.
The capacitor C212 provides AC output coupling and R225 ensures
stability. The DC bias for this amplifier is derived from IC204.
Audio Power
Amplifier The signal at the top of C231 (C205) is fed via C204 to the audio power
amplifier IC202. IC202 has 46dB of gain and a differential output
configuration. C209, C211, R252 and R253 ensure stability of the amplifier
at high frequencies. When operational, the output bias voltage for IC202 is
approximately half the radio supply voltage. When not operational, the
output becomes high impedance.
Control of Audio
Power Amplifier Power up, power down, and muting of IC202 is controlled by two signals
from the digital section, DIG AUD PA EN1 and DIG AUD PA EN2. The network
consisting of Q200, Q201, R200 to R206, R210 and R250 converts the
two digital signals to the single three-level analog signal required by IC202.
Microphone Signals There are two microphone source signals:
■ITF AUX MIC AUD from auxiliary or internal options connector
■ITF CH MIC AUD from control head.
The biasing for electret microphones is provided by a filtered 3.0V supply
via R226 and R227. The components R209 and C202 provide the supply
filtering. The microphone inputs to IC204 (VINAUXP, VINAUXN, VINNORP, and
VINNORN balls) are differential. The negative inputs are decoupled to the
filtered 3.0V supply by C215 and C216. The positive inputs are biased to
approximately 1.5 V by R229, R232, R230 and R233. AC coupling and
DC input protection is provided by C213 and C214.
Auxiliary Audio
Input The auxiliary audio input signal ITF AUD TAP IN is DC-coupled to the ADC
input of IC205. R241 combined with internal clamping diodes in IC205
provide DC protection for the ADC input. IC205 provides the input biasing
of approximately 1.5V.
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Auxiliary Audio
Output The source for the auxiliary audio output signal CDC AUD TAP OUT is provided
by IC204 (RAMPDAC ball). The DAC output of IC204 is low-pass filtered to
remove high-frequency artefacts. The low-pass filter, formed by IC201
(pins 1 to 3), R219, R220, R221, R224, C206, C208 and C210, is a third-
order Butterworth type with a cut frequency of approximately 12kHz.
The output of the low-pass filter is amplified by 6dB by a buffer amplifier,
IC201 (pins 5 to 7), and fed via R207 and R208 to drive the CDC AUD TAP
OUT interface line. The DC bias for this signal path is provided by IC204 and
is approximately 1.2V when operational. The offset at CDC AUD TAP OUT is
approximately 2.4V owing to the gain of the buffer amplifier.
TM8100/TM8200 Service Manual Circuit Descriptions 81
© Tait Electronics Limited June 2006
3.6 Power Supply Circuitry
Introduction For a block diagram of the power supply circuitry, refer to Figure 3.8.
The power-supply circuitry consists of the following main sections:
■supply protection
■supervisory circuit
■internal power supplies
■control of internal power supplies
■control of external power supply.
Supply Protection Electrical protection to the radio is provided by the clamping diode D600
and by 20A fuses (for the 40W/50W radios) and 10A fuses (for the 25W
radios) in the positive and negative leads of the power cable. This provides
protection from reverse voltages, positive transients greater than 30V, and all
negative transients. An ADC monitors the supply and is responsible for the
protection of internal devices, which have an operating voltage of less than
30V. The ADC also ensures protection if the radio operates outside its
specified voltage range of 10.8V to 16V.
Supervisory Circuit The supervisory circuit comprises a reset and watchdog timer. The circuit
provides the reset signal PSU SYS RST to the digital section, which in turn
provides the watchdog signal DIG WD KICK required by the supervisory circuit.
Internal Power
Supplies There are eight internal power supplies:
■one SMPS (+3V3)
■four linear regulators (+9V0, +6V0, +3V0 AN, +2V5 CDC)
■three switched supplies (+9V0 TX, +3V0 RX, +13V8 SW).
The SMPS is used to regulate to 3.3V from the external supply +13V8BATT.
The four lower voltages required are then further stepped down with linear
regulators. These all take advantage of the efficiency gain of the SMPS.
The 9V regulator and the 13.8V switched supply are connected to +13V8
BATT. The two remaining switched supplies (9V and 3V) use P-channel
MOSFETs.
Control of Internal
Power Supplies The radio can be switched on using the ON/OFF key on the control head or
by means of external signals. For the latter case hardware links are required
and there are several power-sense options; these are discussed below. Some
internal power supplies can be controlled by means of digital lines
depending on the mode in which the radio is operating.
82 Circuit Descriptions TM8100/TM8200 Service Manual
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Figure 3.8 Block diagram of the power supply circuitry
Power Supply
Trans-
mitter
Frequency
Synthesizer
CODEC
and
Audio
Receiver
Digital
Board
Debug
Connector
Interface
SMPS 3V
Regulator
9V
Regulator
9 V Tx Switch
+3V3
2V5
Regulator
3 V Rx
Switch
PSU
Super-
visor
13V8 Switch
Reverse
Polarity
Protection
+13V8 BATT
+9V0 TX
+9V0
+3V0 AN
+13V8 BATT
+9V0
+3V0 AN
+3V3
+2V5 CDC
+3V0 AN
+3V0 RX
DIG RX EN
DIG TX EN
DIG SLP EN
+3V3
DIG PSU LATCH
DIG WD KICK
PSU SYS RST
+3V3
AGND
CH ON OFF
AUX GPI3
AUX GPI2
ITF IOP GPIO7
+3V3
+13V8 SW
+13V8 BATT
OR Gate
Hardware
Links
IOP PWR SENSE
IGNITION SENSE
EMERGENCY
+9V0
6V0
Regulator
+6V0
13V8 PWR
SENSE
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
TM8100/TM8200 Service Manual Circuit Descriptions 83
© Tait Electronics Limited June 2006
Power-Sense
Options The radio allows the configuration of different power-sense options to
control how the radio is powered up and down:
■battery power sense
■auxiliary power sense (ignition sense)
■internal-options power sense
■no power sense
■emergency power sense.
The emergency power-sense option can be used in conjunction with any of
the other four options.
The different power-sense options have to be facilitated by hardware means,
as the software cannot act before it is powered up. The radio provides four
hardware links (LK1 to LK4) on the top-side of the main board which can
be configured to attain the power-sense option desired.
Figure 3.9 shows a block diagram of the hardware links LK1 to LK4.
The radio can be programmed to be either on, or to return to its previous
state when the power sense signal is removed. For information on
programming the power-on mode refer to the online help of the
programming software.
The ON/OFF key can be used with any of the of the power-sense options to
turn the radio on and off.
Figure 3.9 Block diagram of hardware links LK1 to LK4
IOP GPIO7
13V8 BATT
LK2
Auxiliary Power Sense
AUX GPI3
13.8V Battery
13V8 BATT Power-up
Circuit
(Ignition Sense)
AUX GPI2 LK3
Emergency
Sense
LK4
Internal Options
Power Sense
ON/OFF Key
LK1
Power Sense
84 Circuit Descriptions TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Table 3.1 shows the configuration of the hardware links LK1, LK2 and LK4
for the individual power-sense options. It also lists the dependence of the
power-sense options with respect to the GPI lines, which can or cannot be
used.
Table 3.2 shows the configuration of ‘emergency power sense’. ‘Emergency
power sense’ can be configured with any of the above power sense options.
Table 3.1 Configuration of hardware links and GPI lines for power-sense options
Power-sense option Links
required
Configuration of remaining links and
use of AUX GPI3 and IOP GPIO7
Voltages
required
13.8V battery power
sense
LK1 in LK2 in:
AUX GPI3 must be left floating.
10.8V≤ supply≤16V
LK2 out:
AUX GPI3 can be used as GPIa.
LK4 out IOP GPIO7 can be used as GPIO.
auxiliary power sense
(ignition sense)
LK2 in LK1 in:
Input line must sink >1mA from
AUX GPI3 (which is pulled to 13.8V by a
33kΩ resistor). The impedance between
the vehicle ignition signal and ground
must be ≤1kΩ.
AUX GPI3≤0.7V off
AUX GPI3≥2.6V high (active)
ignition-sense tolerant to
3.3V, 5V and 12V
LK1 out:
Input line must be active highb.
LK4 out IOP GPIO7 can be used as GPIO.
internal power sense LK1 out IOP GPIO7≤0.7V off
IOP GPIO7≥2.6V high
(active)
ignition-sense tolerant to
3.3V and 5V only
LK2 out AUX GPI3 can be used as GPI.
LK4 in With LK4 in, the input line must be active
highc.
no power sense LK1 out 10.8V≤ supply≤16V
LK2 out AUX GPI3 can be used as GPI.
LK4 out IOP GPIO7 can be used as GPIO.
a. If LK2 is out and AUX GPIO is not used, R775 (33k) should be placed to ensure that AUX GPI3 does not float
(R775 is not placed by factory default).
b. If LK1 is out and R775 is placed, AUX GPI3 should be driven low as well.
c. If LK 4 is in and R723 is placed, IOP GPIO7 should be driven low as well. (R723 is placed by factory default.)
Table 3.2 Configuration of hardware link LK3 and AUX GPI2 for ‘emergency power sense’
External push-button
or toggle switch
required to enter
emergency mode
Links
required Implications on AUX GPI2 Voltages required
Yes LK3 in AUX GPI2 must be connected to an
external (hidden) push-button or toggle
switch, which connects it to ground.
≤0.7V active,
floating inactive
No LK3 in AUX GPI2 must be left floating
LK3 out AUX GPI2 can be used as GPI.
TM8100/TM8200 Service Manual Circuit Descriptions 85
© Tait Electronics Limited June 2006
Battery Power
Sense With this option, link LK1 connects +13V8BATT of the power connector to
the power-up circuitry. With this option, when a 13.8V supply is connected
to the radio, the radio enters the programmed power-on mode. The ON/OFF
key can then be used to switch the radio on and off. This option has the
disadvantage that the radio still draws about 50mA after being switched off
using the ON/OFF key. The reason is that the radio enters the stand-by mode
and does not shut down completely.
Auxiliary Power
Sense
(Ignition Sense)
This option uses the digital input line AUX GPI3 of the auxiliary connector to
power the radio up and down. Link LK2 is required to connect the line to
the power-up circuitry. The line is active high; it is on when the level
exceeds 2.6V and off when the level falls below 0.7V; the line tolerates
maximum inputs equal to the radio supply voltage. When the line becomes
active, the radio enters the programmed power-on mode. The ON/OFF key
can then be used to switch the radio on and off. With the radio off and the
line active, the radio draws about 50mA. When the line becomes inactive,
the radio is shut down completely regardless of whether it was on or in
stand-by mode. With the line inactive the radio draws less than 1mA.
In a vehicle installation this avoids flattening the battery when the ignition
key is off.
Internal-Options
Power Sense This option is similar to the auxiliary power-sense option, except that the
IOP GPIO7 line of the internal options connector is used. Link LK4 is required
to connect the line to the power-up circuitry. This line is active high; it is
on when the level exceeds 2.6V and off when the level falls below 0.7V;
the line tolerates maximum inputs of 5V. The behaviour of the ON/OFF key
is the same as with the auxiliary power-sense option.
No Power Sense If no power-sense option is selected, the radio can only be powered up and
powered down by means of the ON/OFF key. For this option, the links LK1,
LK2 and LK4 must be removed. The advantage of this option over the
battery power-sense option is that the radio draws less than 1mA when it is
switched off.
Emergency
Power Sense This option uses the AUX GPI2 line of the auxiliary connector. Externally, this
line is typically connected to a hidden switch. Internally, link LK3 is
required to connect the line to the power-up circuitry. The line is active low
and has an internal pull-up resistor to the external supply voltage. The line
is on when the level falls below 0.7V. When the line becomes active (when
the hidden switch is pressed for two seconds) the radio enters the emergency
mode. This mode can also be activated by making an emergency call or by
pressing a key that has been programmed appropriately. The concealed
microphone is typically fitted when the emergency power-sense option is
selected.
86 Circuit Descriptions TM8100/TM8200 Service Manual
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Operation in
Emergency Mode If the radio is off when the emergency mode is activated, the radio is
powered up but the display on the control head is not switched on. If the
radio is on when the mode is activated, the display is frozen. In the latter
case, if the ON/OFF key is pressed, the display is switched off but the radio
remains in the emergency mode. While in this mode the radio cycles
between transmit and receive. To exit the emergency mode, the ON/OFF key
needs to be pressed again.
Connector Power
Supply Options Power from the radio’s primary power source is fed to the auxiliary, internal
options, control head and microphone connectors. Whether power to these
connectors is unswitched, switched or not supplied is determined by
hardware links LK5 to LK8 on the top side of the main board, as shown in
Figure 3.10 and Table 3.3.
Unswitched power means that power will always be supplied to the
connector while the primary power source is connected to the radio and is
alive. The supply to the connector is not affected by the state of the radio.
Switched power means that when the radio is off or in standby mode, the
power to the connector is switched off. The power will also be switched off
if the primary power source voltage is outside the radio’s operating range.
The combined switched current drawn by the internal options connector,
the auxiliary connector and the control-head connector must not exceed
1A.
Note The switched output is protected. Short-circuiting the switched
power on any connector will not damage the radio. In the event
of a short circuit, the current folds back to protect the switch
device and connectors.
Note The links LK7 and LK8 have the alternative designations R787
and R786 respectively. The factory-default setting is with LK5
and LK7 inserted and LK6 and LK8 omitted.
Figure 3.10 Connector power supply options
Power
Connector
LK8
(R786)
LK7
(R787)
LK5
LK6
+13V8
+13V8 BATT
Primary
Power
Source 2
Microphone
Connector
2
Auxiliary
Connector
Internal
Options
Connector
8
1
Control-
Head
Connector
TM8100/TM8200 Service Manual Circuit Descriptions 87
© Tait Electronics Limited June 2006
3.7 Interface Circuitry
Introduction For a block diagram of the interfaces circuitry, refer to Figure 3.11.
For more on the connector pinouts, refer to “Connectors” on page 36.
Bi-directional Lines Bi-directional lines are provided on four pins of the auxiliary connector,
(AUX GPIO4 to AUX GPIO7) one on the control-head connector (CH GPIO1), and
seven on the internal options connector (IOP GPIO1 to IOP GPIO7). Those on
the auxiliary and control-head connectors are formed by combining two
uni-directional lines. For example, the line AUX GPIO4 at pin 10 of the
auxiliary connector is formed from ITF AUX GPI4 and DIG AUX GPO4.
The circuitry is the same in all five cases and is explained below for the case
of AUX GPIO4.
Output Signals
(e.g. AUX GPIO4)An output on the line AUX GPIO4 originates as the 3.3V signal DIG AUX GPO4
from the digital section. The signal is first inverted by Q703 (pins 3 to 5) and
the output divided down to 1.6V by R748 and R753 to drive the base of
Q703 (pins 1, 2 and 6). When the latter’s collector current is low, the base
current is a maximum and creates a small voltage drop across R761, causing
the collector emitter to saturate. As the collector current increases, the base
current decreases proportionally until the voltage across R761 reaches 1V.
At this point the base-emitter begins to turn off and the base current
diminishes rapidly. The net effect is a current-limiting action. The current
limit value is approximately 18mA (the inverse of the value of R761).
The output configuration is open-collector with a pull-up to 3.3V by
default. Pull-up options to 5V and 13.8V are also available. On AUX GPIO4
only, the optional MOSFET Q707, which has a high current drive, may be
fitted. If Q707 is fitted, R768 must be removed.
5-Volt Regulator The 5V supply mentioned above is provided by a simple buffered zener
regulator formed by Q702, D721, R721 and R722. The resistor R722
limits the current to about 25mA under short-circuit conditions.
Table 3.3 Connector power supply options
Link state Connector power state
LK5 LK6 LK7
(R787)
LK8
(R786) Auxiliary Internal
options Control head Microphone
out out out out switched no power no power no power
in out in out switched switched switched switched
out in in out switched switched unswitched unswitched
in out out in switched unswitched switched switched
out in out in switched unswitched unswitched unswitched
in in/out in in unswitched unswitched unswitched unswitched
88 Circuit Descriptions TM8100/TM8200 Service Manual
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Figure 3.11 Block diagram of the interface circuitry
+13V8 BATT
AGND
+3V3
+13V8 SW
AUX GPI2
AUX GPI3
CH ON OFF
ITF IOP GPIO7
AUD ITF SPK+
AUD ITF SPK-
ITF VOL WIP DC
AGND
ITF CH MIC AUD
CDC RX AUD
ITF RX BEEP IN
CDCAUDTAP OUT
ITF AUD TAP IN
ITF AUX MIC AUD
CDC RSSI
ITF ON OFF
ITF CH RXD
DIG CH TXD
ITF CH HOOK
ITF CH PTT
ITF CH GPI1
DIG CH GPO1
ITF CH SPI DI
DIG CH SPI DO
DIG CH SPI CLK
DIG CH LE
ITF IOP GPIO1-6
ITF IOP GPIO7
ITF IOP RXD
DIG IOP TXD
ITF AUX RXD
DIG AUX TXD
ITF AUX GPI1
ITF AUX GPI2
ITF AUX GPI3
DGND
ITF AUX GPI4-7
DIG AUX GPO4-7
AGND
AGND
AGND
+13V8 BATT
AGND
SPK+
SPK–
+13V8 BATT
+3V3
AGND
DGND
SPK+
SPK–
VOL WIP DC
CH MIC AUD
RX AUD
CH ON OFF
CH RXD
CH TXD
CH PTT
CH GPIO1
CH SPI DI
CH SPI DO
CH SPI CLK
CH LE
RX AUD
RX BEEP IN
AUD TAP OUT
AUD TAP IN
AUX MIC AUD
RSSI
+13V8 SW
IOP GPIO1-6
IOP GPIO7
IOP RXD
IOP TXD
AGND
DGND
AUX RXD
AUX TXD
AUX GPI1
AUX GPI2
AUX GPI3
AGND
+13V8 SW
AUX GPIO4-7
AUD TAP OUT
AUD TAP IN
AUX MIC AUD
RSSI
Interface
+3V3 CL
+5V
5V
Regulator
I/O
Combine
and
Pull-up
Resistors
Debug
Connector
Frequency
Synthesizer
Receiver
and
Transmitter
Power
Supply
CODEC
and
Audio
Digital
Board
EMC
Filters
Power
Connector
Control-
Head
Connector
EMC
Filters
ESD and
EMC
Filters
ESD and
EMC
Filters
EMC
Filters
I/O
Combine
PTT and
Hookswitch
Decode
Clamps
and
Pull-up
Resistors
Internal
Options
Connector
Clamps,
ESD
Filters,
and
EMC
Filters Auxiliary
Connector
+3V3
Clamp
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
TM8100/TM8200 Service Manual Circuit Descriptions 89
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Input Signals
(e.g. AUX GPIO4)An input signal applied to AUX GPIO4 is coupled via R757 to ITF AUX GPI4 and
fed to the digital section. As the input signal may exceed the maximum
allowed by the digital section, it is clamped by D711 and a shunt regulator.
The shunt regulator consists of Q708, R719 and R720 and begins to turn
on at approximately 2.7V. In combination with D711, the input to
ITF AUX GPI4 is therefore clamped to 3.3V nominally. The value of R757 is
made large to minimize the loading effect on the output pull-up resistors.
Input Signals
(AUX GPI1 to AUX GPI3)Dedicated inputs are provided on three pins of the auxiliary connector
(AUX GPI1 to AUX GPI3). AUX GPI1 is a general-purpose input with strong
protection of the same type used for AUX GPIO4. AUX GPI2 is normally a
dedicated emergency input but can be made a general-purpose input like
AUX GPI1 by removing the link LK3 in the power supply area. AUX GPI3 is
normally a dedicated ignition-sense input but can be made a general-
purpose input like AUX GPI1 by removing the link LK2 in the power supply
area and fitting the 33kΩ resistor R775.
ESD Protection On exposed inputs of the auxiliary and control-head connectors ESD
(electrostatic discharge) protection is provided by a 470pF capacitor and by
clamping diodes to ground and to 13.8V. For example, on AUX GPIO4 this
consists of D713 and C725. The lines IOP GPIO1 to IOP GPIO7 are intended for
connection to internal digital devices and so these have relatively light
protection.
Hookswitch
Detection Hookswitch detection is performed by Q700, R709, R706 and R712.
When the resistance to ground on the PTT line is less than 13.2kΩ, Q700
will turn on and drive the ITF CH HOOK line high; this indicates either that the
microphone is on hook or that the PTT (press-to-talk) switch is pressed.
3.8 Digital Board
Introduction Different digital boards are used for the TM8200 and TM8100 radios.
For a block diagram of the digital board of the TM8200 radios, refer to
Figure 3.12. For a block diagram of the digital board of the TM8100 radios,
refer to Figure 3.13.
The digital board is not serviceable at level-2 and is not described in this
manual.
90 Circuit Descriptions TM8100/TM8200 Service Manual
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Figure 3.12 Block diagram of the digital board (TM8200 radios)
+1V8+3V3
Trans-
mitter
DIG TX INH
DIG SYN EN
SYN LOCK
DIG SYN TR SW
DIG SYN FAST
DIG SYN LATCH
SYN DIG FREF
Frequency
Synthesizer
DIG SYN SPI DO
DIG SYN SPI CLK
DIG RX LE
RX DIG LD
DIG RX NB EN
Receiver
DIG RX EN
CDC2 DIG SDTO
DIG CDC2 SDTI
DIG CDC2 CLK
DIG CDC2 LRCK
DIG DAC SPI DO
DIG DAC SPI CLK
DIG DAC LATCH
DIG CDC ARSM
CDC DIG VSFS
CDC DIG VSDO
DIG CDC VSDI
CDC DIG BSOFS
CDC DIG BSDO
DIG CDC ASFS
DIG CDC ASDI
CDC DIG ASDO
DIG AUD PA EN1
DIG AUD PA EN2
+1V8
CODEC
and
Audio
Serial
Flash
DGND
AGND
DIG CH SPI CLK
DIG CH SPI DO
ITF CH SPI DI
DIG CH LE
ITF CH GPI1
DIG CH GPO1
ITF CH PTT
ITF CH HOOK
ITF ON OFF
ITF IOP GPIO1-7
DIG IOP TXD
ITF IOP RXD
ITF AUX GPI1-7
DIG AUX GPO4-7
DIG AUX TXD
ITF AUX RXD
DIG CH TXD
ITF CH RXD
DIG PSU LATCH
DIG WD KICK
DIG TX EN
+3V3
PSU SYS RST
DIG RX EN
Interface
Power
Supply
FPGA
DSP
McBSP0
McBSP1
1V8
Regulator
+1V8
AGND
+3V3
Factory Connector
DSP JTAG Signals:
FPGA JTAG Signals:
JTAG TCKFPGA
JTAG TMSFPGA
FPGA JTAG TDO
JTAG FPGA TDI
JTAG TCKDSP
JTAG TMSDSP
DSP JTAG TDO
JTAG DSP TDI
JTAG TRSTDSP
DSP JTAG EMU0
DSP JTAG EMU1
DSP JTAG (x7)
FPGA JTAG (x4)
Digital Board
DIG SLP EN
+1V8+3V3
1V5
Regulator
+1V5
+1V5
SRAM
CONTROL
ADDRESS
DATA
Flash
Memory
IO
RESET
4
4
PSU SYS RST
BIRDIE
FPGA CLOCK
System
Clock
DIG SYS CLK
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
DIG CDC RST
TM8100/TM8200 Service Manual Circuit Descriptions 91
© Tait Electronics Limited June 2006
Figure 3.13 Block diagram of the digital board (TM8100 radios)
Trans-
mitter
DIG TX INH
DIG SYN EN
SYN LOCK
DIG SYN TR SW
DIG SYN FAST
DIG SYN LATCH
SYN DIG FREF
Fre-
quency
Synthe-
sizer
DIG SYN SPI DO
DIG SYN SPI CLK
DIG RX LE
RX DIG LD
DIG RX NB EN
Receiver
DIG RX EN
CDC2 DIG SDTO
DIG CDC2 SDTI
DIG CDC2 SCLK
DIG CDC2 LRCK
DIG DAC SPI DO
DIG DAC SPI CLK
DIG DAC LATCH
DIG CDC ARSM
CDC DIG VSFS
CDC DIG VSDO
DIG CDC VSDI
CDC DIG BSOFS
CDC DIG BSDO
DIG CDC ASFS
DIG CDC ASDI
CDC DIG ASDO
DIG AUD PA EN1
DIG AUD PA EN2
DIG SYS CLK
+1V8
CODEC
and
Audio
PSU SYS RST
DIG EE CS
EE DIG SPI DI Serial
EEPROM
DGND
AGND
DIG CH SPI CLK
DIG CH SPI DO
ITF CH SPI DI
DIG CH LE
ITF CH GPI1
DIG CH GPO1
ITF CH PTT
ITF CH HOOK
ITF ON OFF
ITF IOP GPIO1-7
DIG IOP TXD
ITF IOP RXD
ITF AUX GPI1-7
DIG AUX GPO4-7
DIG AUX TXD
ITF AUX RXD
DIG CH TXD
ITF CH RXD
DIG PSU LATCH
DIG WD KICK
DIG TX EN
+3V3
DIG RX EN
PSU SYS RST
Interface
Power
Supply
FPGA
RAM
CONTROL
ADDRESS
DATA
Flash
Memory
ITF CH RXD
DIG CH TXD
PSU SYS RST
DSP and
Address
Decoder
McBSP0 (x4)
McBSP1 (x4)
BIRDIE
FPGA CLK
System
Clock
1V8
Regulator
1V5
Regulator
+1V8
+1V5
AGND
+3V3
Factory Connector
FPGA JTAG Signals: DSP JTAG Signals:
FPGA JTAG TCK
FPGA JTAG TMS
FPGA JTAG TDO
JTAG FPGA TDI
DSP JTAG TCK
DSP JTAG TMS
DSP JTAG TDO
JTAG DSP TDI
DSP JTAG TRST
DSP JTAG EMU0
DSP JTAG EMU1
DSP JTAG (x7)
FPGA JTAG (x4)
Digital Board
DIG SLP ENDIG CDC RST
Signal Types:
RF
analog
clock
digital
asynchronous serial data
synchronous serial data
92 Circuit Descriptions TM8100/TM8200 Service Manual
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3.9 Control-Head Board with Graphical Display
Introduction This section describes the control-head board for the control head with
graphical display.
For a block diagram of the digital circuitry, refer to Figure 3.14.
Most signals (except power on/off, speaker and microphone) to and from
the radio body are processed by a RISC processor, which is implemented on
an FPGA on the control-head board. For more information on the RISC
processor and the FPGA, refer to “Software Architecture” on page 47.
User Interface The control-head board includes the circuitry for the following control
elements:
■ON/OFF key
■volume potentiometer
■main keypad (with four functions keys, two scroll keys and
two selection keys)
■LCD module (with backlighting and optional heating element)
■three status LEDs
■two function key LEDs (for function keys F1 and F4)
■keypad backlighting LEDs
■speaker.
Connectors The control-head board includes the circuitry for the following connectors:
■microphone connector (RJ45 socket)
■control-head connector (18-way MicroMaTch socket)
■LCD connector (for internal connection of LCD module)
■speaker connector (2 leads)
■soldering pads (2 leads) for an optional concealed microphone
■control-head options connector (for optional circuit board).
Protection circuitry is provided for the microphone connector. For pinouts
of the control-head connector and the microphone connector, refer to
“Connectors” on page 36. For more information on the control-head
options connector, please contact Tait Electronics Limited.
ON/OFF Key When battery power (13.8V) is applied to the radio, a press of the ON/OFF key
will create an active low signal (CH ON OFF) back to the radio body to initiate
the power-on or power-off sequence. This key-press will also be detected
by the FPGA of the control head through Q611 as an active high signal.
For more information on the start-up process, refer to “Software
Architecture” on page 47.
TM8100/TM8200 Service Manual Circuit Descriptions 93
© Tait Electronics Limited June 2006
Figure 3.14 Block diagram of the control-head board with graphical display
On/Off
Keypad
Volume
Potentio-
meter
LCD LCD Loom LCD
Connector
Function
Key and
Status LEDs
Keypad
Backlighting
LEDs
Main
Keypad
LED
Lenses
On/Off Key
Function/
Scroll/
Selection
Keys
Contact made
when key
pressed
Light Pipes
Control-
Head
Options
Connector
Microphone
Connector
+13.8 V
MIC RXD
MIC TXD
MIC GPIO1
MIC PTT
MIC RX AUD
MIC AUD IN
Protection
Circuitry
+3V3 +13V8
COL
ROW
BRIGHT
BRIGHT
HEATER
BACKLIGHT
+3V3
Analog/
Digital
Converter
Speaker
Connector
ASYNC UART
JTAG
+3V3
Soldering
Pads
AGND
DGND
Concealed
Microphone
Speaker
MIC–
MIC+
AGND
Power
Supply
+3V3+1V5 +1V5
+3V3
+13V8
CH RXD
CH TXD
CH GPIO1
CH PTT
CH ON OFF
+13V8
SPK+
SPK–
SPK–
SPK+
Speaker Leads
Microphone
Leads
DGND
AGND
CH SPI DO
+3V3 SENSE
+13V8
CH ON OFF
VOL WIP DC
RESET
AGND
AGND
Power
Switches
TEMP SENSOR
CH RX AUD
CH MIC AUD
Boot
Flash
BIRDIE
FPGA CLOCK
System
Clock
SRAM
CONTROL
ADDRESS
DATA
Flash
Memory
Control-
Head
Connector
Control-Head Board
DEBUG
FPGA JTAG Signals:
FPGA JTAG TCK
FPGA JTAG TMS
FPGA JTAG TDO
JTAG FPGA TDI
RESET
CONTROL
DISPLAY CONTROL
Constant-
Current
Drivers
WATCHDOG TRIGGER
POWER ON/OFF SENSE
BRIGHT
BRIGHT
ENABLE
HEATER
BACKLIGHT
Contact made
when key
pressed
Signal Types:
analog
clock
digital
asynchronous
serial data
synchronous
serial data
FPGA
Microphone
Pre-amplifier
and Audio
Switching
94 Circuit Descriptions TM8100/TM8200 Service Manual
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Power Supply A 3.3V regulator (U1) converts the switched 13.8V supply from the radio
body to 3.3V. A 1.5V regulator (U203) converts the 3.3V to 1.5V.
A power-sense module (U202) verifies the outputs of the voltage regulators
and—in the case of a fault—creates a power reset signal which is processed
by the FPGA.
Volume Control The voltage level of the volume control potentiometer is converted to a
digital signal by an analog/digital converter (U601), processed by the FPGA
and transmitted to the radio body.
Main Keypad The eight keys of the main keypad (function, scroll and selection keys) are
connected to the FPGA by an array of 3 columns and 3 rows. During idle
operation, the KEY ROW signals are driven low by the FPGA and the KEY COL
signals (pulled high by an external resistor) are monitored for activity by the
FPGA. A key-press will generate a high-to-low transition on the associated
column KEY COL signal. This, in turn, will initiate a sequence of high output
levels on the KEY ROW signals to identify which key was pressed.
LCD Module The LCD module is connected to the control-head board via the LCD
connector. The LCD module display is controlled by a serial data link to the
FPGA. The backlighting and the optional heating element incorporated in
the LCD module are controlled by a data line each from the FPGA, which
switch two transistors on MOSFET Q102. A temperature signal from the
LCD module is converted to a digital signal by an analog/digital converter
(U601) and processed by the FPGA.
Function Key LEDs
and Status LEDs The function key LEDs (F1 and F4) and the red, green and amber status
LEDs each are controlled by an FPGA signal and a transistor (Q604 to
Q608). The brightness level is controlled by two FPGA signals, resulting in
four intensity levels (off, low, medium and high).
Keypad
Backlighting The keypad backlighting LEDs are controlled by two FPGA signals and two
transistors (Q2), resulting in four intensity levels (off, low, medium and
high). The keypad backlighting LEDs are arranged in two groups for the
main keypad and one group for the power button keypad, each group
consisting of three LEDs.
Speaker The two speaker lines (SPK+ and SPK–) are connected to the speaker
connector (J104) which is joined to the control-head connector (J103)
through two ferrite beads (L105 and L106).
Microphone and
Concealed
Microphone
(Optional)
The audio signals from the microphone connector or the soldering pads of
the optional concealed microphone are routed to a switching and pre-
amplifier circuit. If a dynamic microphone is required, the pre-amplifier is
engaged. The switching logic is used to select either the standard
microphone input or the concealed microphone signal. The dynamic
microphone must be activated in the programming software.
PTT The PTT signal from the microphone connector is connected to the FPGA
via a resistor (R25) and relayed to the radio as a digital command.
TM8100/TM8200 Service Manual Circuit Descriptions 95
© Tait Electronics Limited June 2006
3.10 Control-Head Board with 1-, 2- or 3-Digit Display
Introduction This section describes the circuitry of the control-head boards for the
control heads with 1-, 2- or 3-digit display. The boards differ in their layouts
but the components are virtually identical. The circuit description given
below is sufficiently general to be applicable to all boards.
User Interface The control-head board includes the circuitry for the following control
elements:
■ON/OFF key
■volume potentiometer
■keypad (with four functions keys and two scroll keys)
■LCD
■three status LEDs
■four function key LEDs (for function keys F1 to F4)
■keypad backlighting LEDs
■speaker.
Connectors The control-head board includes the circuitry for the following connectors:
■microphone connector (RJ45 socket)
■control-head connector (18-way MicroMaTch socket)
■speaker connector (2 leads)
■soldering pads (2 leads) for an optional concealed microphone
■two control-head options connectors (for optional circuit board).
Protection circuitry is provided for the microphone connector. For pinouts
of the control-head connector and the microphone connector, refer to
“Connectors” on page 36. For more information on the control-head
options connector, please contact Tait Electronics Limited.
The optional circuit board is installed when a dynamic microphone is used
or a concealed microphone is fitted.
Basic Circuitry The LCD driver is based on IC2, IC5 and IC7. Electrical contact between
the control head and the LCD itself is via two elastomeric strips as described
in “Control Heads with 1-, 2- or 3-Digit Display” on page 29. There are
pads on the board for the seven keys—four function keys, two channel-
selection keys, and the ON/OFF key. The device IC4 reads the status of the
function and channel-selection keys. Of the 18 LEDs, there are red, orange
and green STATUS LEDs, and four green LEDs for the function keys, as well
as 11 green LEDs for back-lighting—one for each key and four for the LCD.
The four dual switching transistors Q1 to Q4 control the switching of the
LEDs; the transistors are driven by IC3.
96 Circuit Descriptions TM8100/TM8200 Service Manual
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Figure 3.15 Block diagram of the control-head board with 1-, 2- or 3-digit display
R52
C50
R53
(not implemented)
LINK
Control-
Head
Options
Connector
Control-
Head
Options
Board
(optional)
Microphone
Connector Protection
Circuitry
Control-
Head
Connector
LCD LCD Driver
LED Lenses LEDs LED Drivers
On/Off Key
Volume
Control
Switch Pads
Key Drivers
Switch Pads
Switch Pads
Function
Keys
Channel-
Selection
Keys
Speaker
Connector
Speaker
+13V8 SW
CH ON OFF
SPK+
SPK–
DGND
CH SPI DI
CH LE
CH SPI CLK
+3V3
+13V8 SW
CH ON OFF
CH SPI DI
CH LE
CH SPI CLK
+3V3
AGND
DGND
Contact made
when key
pressed
Contact made
when key
pressed
Speaker Leads SPK+
SPK–
+13V8 SW
MIC AUD IN P1
MIC AUD OUT
DGND
AGND
VOL WIP DC
+3V3
AGND
VOL WIP DC
Control-head
options board
attached via
connector
Concealed
Microphone
(optional)
Control-Head
Board
RST
OE
CH LE
CH SPI CLK
+3V3
+13V8 SW
DGND
Q7
D2 D3
RST
OE
CH LE
CH SPI CLK
+3V3
Light Pipes
CH SPI DO
R11
CH RXD
CH TXD
CH GPIO1
CH PTT
MIC AUD OUT
RX AUD
CH SPI DO
+3V3
CH SPI CLK
CH LE
OE
RST
DGND
D1 D2
RXD
TXD
CH GPIO1
PTT
RX AUD
MIC AUD IN
+13V8 SW
GND GND
Elastomeric Strips
MIC+
L1
C1
R50
R51
DGND
(not implemented)
Signal Types:
analog
clock
digital
asynchronous
serial data
synchronous
serial data
Contact made
when key
pressed
Soldering
Pads
MIC+
AGND
TM8100/TM8200 Service Manual Circuit Descriptions 97
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Serial Peripheral
Interface The control-head board uses an SPI (serial peripheral interface) to control
the display on the LCD, turn back-lighting on and off, control the STATUS
LEDs, and read the status of the keys. The interface consists of the following
four lines at the control-head connector:
■pin 11: data out CH SPI DO
■pin 12: latch line CH LE
■pin 15: data in CH SPI DI
■pin 16: clock CH SPI CLK.
Data Input and
Output Data that are input to the control head are clocked through the LCD driver
and daisy-chained to a shift register. Once all the data have been clocked in,
the latch line is driven low. On this falling edge all the outputs (LEDs and
LCD segments) are driven to their new state. When the latch line is driven
high, the state of each key is latched into another shift register. The data are
then clocked out back to the radio body so that the radio can respond
accordingly.
LCD Driver An oscillator is used to run the LCD. It oscillates at about 60Hz and employs
a Schmitt trigger and D flip-flop to ensure a 50% duty cycle to the LCD.
A reset circuit is required because the reset from the main board is not routed
to the control head. The reset circuit also employs a Schmitt trigger.
Volume Control The volume-control potentiometer is linear and passes the DC voltage signal
VOL WIP DC to the radio body. The signal is read by an ADC on the main
board, and the volume is adjusted accordingly.
98 Circuit Descriptions TM8100/TM8200 Service Manual
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3.11 RJ45 Control Head
Introduction This section describes the circuitry of the control-head board for the RJ45
control head.
User Interface The control-head board includes a POWER ON/OFF LED which indicates
whether the radio is switched on or off1.
Connectors The control-head board includes the circuitry for the following connectors:
■programming connector (RJ45 socket)
■control-head connector (18-way MicroMaTch socket).
For pinouts of the connectors, refer to “Connectors” on page 36.
Basic Circuitry The signals of the control-head connector are directly connected to the
telemetry connector. The POWER ON/OFF LED is supplied by the +13V8
voltage.
1. The signal supplying the LED can be switched or unswitched. For more information refer to
“Connector Power Supply Options” on page 86.
Figure 3.16 Block diagram of the control-head board of the RJ45 control-head
Control-Head
Connector
Control-Head Board of
RJ45 Control Head
PRG ON OFF
+13V8
CH RXD
CH MIC AUD
AGND
CH PTT
CH RX AUD
CH TXD
CH ON OFF
+13V8
PRG RXD
PRG MIC AUD
AGND
PRG PTT
PRG RX AUD
PRG TXD
Programming
Connector
Power On/Off
LED
Signal types:
analog
digital
asynchronous
serial data
+13V8
TM8100/TM8200 Service Manual 99
© Tait Electronics Limited June 2006
TM8100 mobiles
TM8200 mobiles
Chapter 2
Servicing the Radio
100 TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Chapter 2 – Servicing the Radio
4 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
4.1 Repair Levels and Website Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2 Tools, Equipment and Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.3 Servicing Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.4 Test Equipment Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.5 Replacing Board Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.6 Shielding Cans and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.7 SMT Repair Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.8 Computer-Controlled Test Mode (CCTM) . . . . . . . . . . . . . . . . . . . . . 118
4.9 Defining Frequency Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.10 Visual and Audible Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5 Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
5.1 Removing and Mounting the Control Head . . . . . . . . . . . . . . . . . . . . 130
5.2 Disassembling the Radio Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 Reassembling the Radio Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.4 Disassembling and Reassembling the Control Head . . . . . . . . . . . . . . . 141
6 Servicing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
6.1 Initial Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.2 Final Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7 Power Supply Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
8 Interface Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
9 Frequency Synthesizer Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . .179
9.1 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
9.2 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.3 Phase-locked Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
9.4 Loop Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.5 Receive VCO and Related Circuitry (UHF Radios) . . . . . . . . . . . . . . 203
9.6 Transmit VCO and Related Circuitry (UHF Radios) . . . . . . . . . . . . . . 212
9.7 VCO and Related Circuitry (VHF Radios) . . . . . . . . . . . . . . . . . . . . . 217
9.8 Power Supply for FCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
9.9 VCXO and TCXO Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
9.10 Signals at TP501 and TP502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
9.11 VCXO and CODEC Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
TM8100/TM8200 Service Manual 101
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10 Receiver Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
10.1 Faulty Receiver Sensitivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
10.2 Excessive Loss of Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
10.3 Moderate or Slight Loss of Sensitivity. . . . . . . . . . . . . . . . . . . . . . . . . . 246
10.4 Incorrect RSSI Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
10.5 Faulty Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.6 High Receiver Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
11 Transmitter Fault Finding (40W/50W) . . . . . . . . . . . . . . . . . . . . . . . .259
11.1 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
11.2 Transmitter RF Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
11.3 Biasing of PA Driver and PAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
11.4 RF Signal Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
12 Transmitter Fault Finding (25W) . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
12.1 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
12.2 Transmitter RF Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
12.3 Biasing of PA Driver and PAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
12.4 RF Signal Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
13 CODEC and Audio Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . .381
13.1 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
13.2 Faulty Speaker Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
13.3 No Speaker Audio at Auxiliary Connector . . . . . . . . . . . . . . . . . . . . . . 391
13.4 Faulty Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
13.5 Faulty Modulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
13.6 Faulty Modulation Using Auxiliary Connector . . . . . . . . . . . . . . . . . . . 402
14 Fault Finding of Control Head with Graphical Display . . . . . . . . . . . . .405
14.1 CCTM Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
14.2 Power Supply Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
14.3 LCD Display Faulty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
14.4 LCD Backlighting Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
14.5 LCD Heating Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
14.6 Function Key LEDs or Status LEDs Faulty . . . . . . . . . . . . . . . . . . . . . . 414
14.7 Keypad Backlighting Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
14.8 On/Off Key Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
14.9 Function, Scroll, or Selection Keys Faulty. . . . . . . . . . . . . . . . . . . . . . . 420
14.10 Speaker Faulty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
14.11 Volume Control Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
14.12 PTT Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
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15 Fault Finding of Control Head with 1- 2- or 3-Digit Display . . . . . . . . .429
15.1 Display Faulty but not LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
15.2 Some LEDs Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
15.3 All LEDs Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
15.4 Display and All LEDs Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
15.5 Some but not All Keys Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
15.6 All Keys Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
15.7 Speaker Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
15.8 Volume Control Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
16 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437
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4 General Information
Scope of Section This section discusses the two repair levels covered by the service manual,
details concerning website access, the tools, equipment and spares required,
and the setting up of the necessary test equipment. General servicing
precautions are also given, as well as details of certain non-standard SMT
techniques required for level-2 repairs.
4.1 Repair Levels and Website Access
Repair Levels This manual covers level-1 and level-2 repairs of the radios. Level-1 repairs
comprise the replacement of control-head boards, main-board assemblies,
and other parts of the radio; level-2 repairs comprise repairs of control-
head boards and, except for special items, main-board assemblies.
The special items are:
■digital board
■RF PAs (Q309 and Q310)
■CODEC 1 (IC204)
■copper plate.
Replacements of the connectors and volume-control potentiometer on the
control-head board are level-1 repairs. Replacements of the connectors on
the main-board assembly, however, are level-2 repairs because these repairs
entail the disassembly of the main-board assembly.
Important The circuit boards in the radio are complex. They should
be serviced only by accredited service centres (ASC).
Repairs attempted without the necessary equipment and
tools or by untrained personnel might result in permanent
damage to the radio and void the warranty.
Accreditation of
Service Centres Service centres that wish to achieve ASC status should contact Technical
Support. They will need to provide evidence that they meet the criteria
required for accreditation; Technical Support will supply details of these
criteria. These centres must then make available suitable staff for training by
TEL personnel, allow their service facilities to be assessed, and provide
adequate documentation of their processes. They will be accorded ASC
status and endorsed for repairs of the radios after their staff have been trained
and their facilities confirmed as suitable. Existing ASCs need to apply for and
be granted an endorsement for repairs of the radios. All ASCs with the
necessary endorsements may carry out level-1 and level-2 repairs of these
radios, whether under warranty or not.
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Skills and Resources
for Level-1 Repairs For level-1 repairs basic electronic repair skills are sufficient. Apart from the
standard tools and equipment of any service centre, certain torque drivers
are required as well as a service kit and, for diagnostic purposes, a spare
control head.
Skills and Resources
for Level-2 Repairs For level-2 repairs expertise is required in SMT repairs of circuit boards with
a very high complexity and extreme component density. Apart from the
tools and equipment needed for level-1 repairs, the standard SMT repair
tools are required. A can-removal tool is strongly recommended but not
mandatory.
Website Access To carry out level-1 and level-2 repairs, service centres need access to the
secured portion of the Technical Support website. There are different access
levels; those required for level-1 and level-2 repairs are:
■level-1 repairs: associate access
■level-2 repairs: ASC and Tait-only access.
Log-in passwords are needed for associate and Tait-only access; Technical
Support supplies service centres with the necessary log-in information.
(The unsecured portion of the Technical Support website is accessible to the
general public. This type of access is called public access, and no log-in
password is required.)
Items Available
on Website The information available at the different access levels is summarized in
Table 4.1. The technical notes mentioned are of different types. Associate
technical notes relate to the repair of the radio but not the downloading of
firmware; Tait-only technical notes relate to the firmware. The PCB
information is discussed in more detail below.
Table 4.1 Items relating to the radios that are available on the Technical Support website
Item Public
access
Associate
access
ASC
access
Tait-on l y
access
User’s guide
Installation guide
Public technical notes
•
•
•
•
•
•
•
•
•
•
•
•
Product release notes
Specifications
Calibration software
Programming software
Programming user manuals
Fitting instructions
Service manual
Associate technical notes
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Software release information
Firmware
Tait-only technical notes
PCB information
•
•
•
•
•
•
•
TM8100/TM8200 Service Manual General Information 105
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PCB Information PCB information for a particular circuit board consists of the relevant parts
lists, grid reference indexes, PCB layouts, and circuit diagrams. (The grid
reference indexes give the locations of components on the PCB layouts and
circuit diagrams.) PCB information is compiled whenever there is a major
change in the layout of the board. All PCB information is published on the
Technical Support website.
Tait FOCUS
Database An additional source of information to service centres is the Tait FOCUS
call-logging database. (This is accessible on the Technical Support website
also.) All Customer-related technical issues regarding the radios are recorded
on this database. These issues may be raised by both Customers and service
centres. Technical Support resolves the issues and informs the Customer or
service centre concerned of the outcome. All issues and their solutions are
available for review by all service centres.
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4.2 Tools, Equipment and Spares
Torq u e -driv e r s For level-1 and level-2 repairs, excluding SMT repairs of the circuit boards,
the following torque-drivers are required.
■For level-1 repairs Torx T6, Torx T10, and Torx T20 driver bits are
necessary.
■For level-1 repairs, 3/16 inch and 14mm long-reach sockets are
required.
Refer to the illustrations in “Reassembling the Radio Body” on page 137
for the corresponding torque values.
Tools for SMT
Repairs In general only the standard tools for SMT work are required for level-2
repairs of the circuit boards. In addition, a can-removal tool is recommended
but if none is available, a hot-air tool may be used instead. However, it
should be noted that a hot-air tool affords little control. Even in skilled
hands, use of a hot-air tool to remove cans will result in rapid uncontrolled
rises in the temperature of components under the can being removed as well
as under any adjacent cans. The circuit board might suffer damage as a result.
Test Equipment The following test equipment is required for servicing the radio:
■test PC (with programming and calibration applications loaded)
■RF communications test set (audio bandwidth of at least 10kHz)
■oscilloscope
■digital current meter (capable of measuring up to 20A)
■multimeter.
■DC power supply (capable of 13.8V and 20A for the 40W/50W radios,
and 10A for the 25W radios)
■spare control head
■service kit.
Separate instruments may be used in place of the RF communications test
set. These are an RF signal generator, audio signal generator, audio analyser,
RF power meter, and modulation meter.
TM8100/TM8200 Service Manual General Information 107
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Service Kit The service kit contains all the items needed for connecting the radio to the
test equipment. The setting up of the equipment is described in “Test
Equipment Setup” on page 111. The service kit also includes a product
support CD and a folder with the necessary service documentation,
including this manual. The CD contains the programming application,
calibration application, and soft-copies of the service and related
documentation. The contents of the service kit are listed in Table 4.2. Note
that the TMAA20-04 cable listed is required only if the test PC is to be
connected directly to the radio for programming purposes.
Note The characters xx below stand for the issue number of the manual.
Only the latest issue of each manual will normally be available for
ordering.
Table 4.2 Contents of service kit (TMAA21-00)
Product code Item
TMAA20-02 Cable (RJ45 socket to DB9 socket)
TMAA20-03 Cable (25W power connector to banana plugs plus speaker connector)
TMAA20-04 Cable (RJ12 socket to RJ45 plug)
TMAA21-01 Cable (DB15 socket to RJ45 plug plus speaker connector)
TMAA23-02 Cable (50W/40W power connector to banana plugs plus speaker connector)
T2000-A19 Cable (DB9 socket to RJ12 plug)
TOPA-SV-024 Test unit
MMA-00005-xx Service manual
MMA-00037-xx PCB information
TMAA20-01 Product support CD
406-00046-xx Programming CD
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4.3 Servicing Precautions
Introduction This section discusses the precautions that need to be taken when servicing
the radios. These precautions fall into the following categories:
■mechanical issues
■compliance issues
■anti-static precautions
■transmitter issues.
Service technicians should familiarize themselves with these precautions
before attempting repairs of the radios.
Use of Torque-
drivers Apply the correct torque when using a torque-driver to tighten a screw or
nut in the radio. Under-torquing can cause problems with microphonics and
heat transfer. Over-torquing can damage the radio. The illustrations in
“Disassembly and Reassembly” on page 129 show the correct torque values
for the different screws and nuts.
Non-scratch Bench
Tops Use workbenches with non-scratch bench tops so that the mechanical parts
of the radio are not damaged during disassembly and re-assembly.
(The workbench must also satisfy the anti-static requirements specified
below.) In addition, use a clear area of the bench when disassembling and re-
assembling the radio.
Compliance
Issues Note The radio is designed to satisfy the applicable compliance regula-
tions. Do not make modifications or changes to the radio not
expressly approved by TEL. Failure to do so could invalidate com-
pliance requirements and void the Customer’s authority to operate
the radio.
Sealing of Radio To maintain the sealing of the radio to IP54 standards, ensure that all bungs
and seals are fitted after servicing the radio. These are for the auxiliary, RF,
external options, and programming connectors:
■bung for auxiliary connector
■rubber seal for RF connector
■bung for aperture for options connector (connector not fitted)
■cover seal for options connector (connector fitted).
In addition, ensure that the grommet sealing the aperture to the microphone
connector of the control head is properly fitted.
ESD Precautions Important This equipment contains devices which are susceptible to
damage from static discharges. You must handle these
devices carefully and according to the procedures described
in the manufacturers’ data books.
Purchase an antistatic bench kit from a reputable manufacturer and install
and test it according to the manufacturer’s instructions. Figure 4.1 shows a
typical antistatic bench set-up.
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You can obtain further information on antistatic precautions and the dangers
of electrostatic discharge (ESD) from standards such as ESD S4.1-1997
(revised) or EN 100015-4 1994. The Electrostatic Discharge Association
website is http://www.esda.org/.
Storage and
Transport
of Items
Always observe anti-static precautions when storing, shipping or carrying
the circuit boards and their components. Use anti-static bags for circuit
boards and anti-static bags or tubes for components that are to be stored or
shipped. Use anti-static bags or trays for carrying circuit boards, and foil or
anti-static bags, trays, or tubes for carrying components.
Anti-static
Workbenches Use an anti-static workbench installed and tested according to the
manufacturer’s instructions. A typical installation is shown in Figure 4.1.
These benches have a dissipative rubber bench top, a conductive wrist strap,
and a connection to the building earth. The material of the bench top must
satisfy not only anti-static requirements but also the non-scratch
requirements mentioned above.
Transmitter Issues The following issues relate to the operation of the transmitter:
■RF and thermal burns
■antenna loading
■test transmissions
■accidental transmissions
■distress beacons.
The precautions required in each case are given below.
Caution Avoid thermal burns. Do not touch the cooling fins
or underside of the radio body when the transmitter
is or has been operating. Avoid RF burns. Do not
touch the antenna while the transmitter is operating.
Important The radio has been designed to operate with a 50Ω
termination impedance. Do not operate the transmitter
Figure 4.1 Typical antistatic bench set-up
to building ground or
mains ground via
1MΩ series resistor
conductive wrist strap dissipative rubber
bench mat
110 General Information TM8100/TM8200 Service Manual
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without a suitable load. Failure to do so might result in
damage to the power output stage of the transmitter.
Important While servicing the main board, avoid overheating the
radio during test transmissions. The following is good
practice: Secure the main-board assembly in the chassis
with the two external screws and one of the internal screws.
The heat-transfer block must be secured to the main board.
The lid of the radio body may be left off. After completing
any measurement or test requiring activation of the
transmitter, immediately return the radio to the receive
mode.
Important Under certain circumstances the microprocessor can key on
the transmitter. Ensure that all instruments are protected at
all times from such accidental transmissions.
Note The frequency ranges 156.8MHz±375kHz, 243MHz±5kHz,
and 406.0 to 406.1MHz are reserved worldwide for use as mari-
time emergency frequencies or by distress beacons. Do not pro-
gram transmitters to operate in any of these frequency bands.
TM8100/TM8200 Service Manual General Information 111
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4.4 Test Equipment Setup
Introduction This section covers the setting up of the test equipment for servicing the
radios, as well as related aspects:
■setting up of test equipment, including test unit
■basic programming and calibration tasks
■invoking CCTM (computer-controlled test mode)
■summary tables of CCTM commands and error codes
■visual and audible indications provided by radio
The last-named aspect applies to control heads with UI, and concerns the
STATUS LEDs and LCD screen, and the various alerts and confidence tones
emitted from the speaker.
Connect Equipment Connect the test equipment to the radio as shown in Figure 4.2. Use the test
unit, cables and adaptor of the service kit. Refer to “Tools, Equipment and
Spares” on page 106 for details of the test equipment and service kit.
The test unit is described in “TOPA-SV-024 Test Unit” on page 571.
For testing receive and transmit functions respectively, the switches of the
test unit must be set as described below. (When programming or calibrating
radios the switches have no effect, although it is good practice to set the
MODE switch to “RX”.)
Settings for
Receive Tests For receive tests set the switches on the test unit as follows:
■HOOK switch : “OFF HOOK”
■MODE switch : “RX”
■AUDIO IN switch : “OFF”
■AUDIO OUT switch: “SPEAKER” or “LOAD”.
In the last-named case, with the switch in the “SPEAKER” position, the
received audio is output from the test unit’s speaker. In the “LOAD” position a
16Ω load is switched into the circuit in place of the test unit’s speaker.
Note, however, that the AUDIO OUT switch has no effect on the radio’s speaker.
Settings for
Transmit Tests For transmit tests set the switches on the test unit as follows:
■HOOK switch : “OFF HOOK”
■MODE switch : “RX” initially
■AUDIO IN switch : “MIC AUDIO”
■AUDIO OUT switch: (immaterial).
When ready to transmit, set the MODE switch to the “TX/PTT” position.
This switch functions in the same way as the PTT switch on the
microphone.
Product Support CD Install the programming and calibration applications on the test PC.
These applications are included on the product support CD supplied with
the service kit.
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Figure 4.2 Test setup
radio connector
(DB15)
RF connector
(mini UHF or
BNC)
auxiliary
connector
(DB15)
microphone
connector (RJ45)
receive audio /
SINAD connector
(BNC)
transmit audio
connector (BNC)
computer
connector
(RJ12)
serial port
(DB9)
speaker
connector
banana plugs
AC input
(BNC)
audio
monitor
out (BNC)
AUDIO
IN HI
(BNC)
AUDIO
OUT
(BNC)
RF in/out
(N-type)
power
connector
TMAA23-02 cable
(50W/40W radios)
TMAA20-03 cable
(25W radios)
TMAA21-01 cable
TOPA-SV-024
TPA-SV-006
cable
TM9100 radio
T950-001
USB1.1 to serial
DB9 adapter
(optional)
RF comms set
Test PC
Oscilloscope
DC power supply
TM8100/TM8200 Service Manual General Information 113
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4.5 Replacing Board Components
This section describes the procedure for obtaining the correct replacement
for any faulty component on the boards.
■identify version of PCB information applicable to board
■identify replacement component in the parts list of the PCB information
■consult technical notes
■obtain replacement component
The technical notes will indicate whether there have been any changes
affecting the component in question.
Identify
PCB Information Identify the IPN of the PCB and compare the issue number with that in the
PCB information supplied with the service documentation.
Note The IPN is the ten-digit number printed at one corner of the
board. The last two digits in the IPN represent the issue number
of the PCB.
If the issue numbers match, consult the parts list, as described below. If the
issue number indicates that the board is either an earlier or a later version,
obtain the PCB information for the board under repair from the Technical
Support website (support.taitworld.com).
Tip Print and store a copy of every PCB information published on the
Technical Support website.
Identify
Replacement
Component
After locating the correct PCB information for the board, consult the parts
list for the board. Identify the component in question in the parts list.
Note, however, that a new PCB information is published only whenever
there is a major change in the design of the board. A major change normally
involves a change in the layout of the PCB, which requires that the issue
number in the IPN be incremented. Any minor changes following a major
change (and preceding the next major change) normally involve only
changes in the components on the board. Such minor changes might affect
the component in question. To determine if this is the case, consult any
technical notes that might apply to the board as described below.
Consult Technical
Notes A technical note about each major change is published on the Technical
Support website (support.taitworld.com). Technical notes giving details of
any intervening minor but important changes are also published. It is
advisable to print and store a copy of every technical note published.
Obtain
Replacement
Component
Determine if the required replacement component is included in one of the
spares kits. (Check with TEL regarding the availability of the kit.)
If the required component is not included in a kit, order the component
from a CSO or, in the case of a CSO, from TEL. Always ensure that the
replacement component has the identical specification to that given in the
parts list. It is particularly important for the tolerances to be the same.
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4.6 Shielding Cans and Connectors
The shielding cans on the top- and bottom-side of the main-board assembly
are identified in Figure 4.3 and Figure 4.4. The figures also show the
locations of the connectors on the board.
Figure 4.3 Shielding cans and connectors (top side of main-board assembly)
Digital Board
SK102
Internal-Options Connector
PL101
Factory
Connector
PIN TOP LPF TOP
DIRC TOP
FE TOP
VCO TOP
(UHF only)
PAF TOP
IF TOP
SYN TOP
CDC TOP
FCL TOP
PAD TOP
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Can Removal
and Installation Cans are best removed and installed using a can-removal tool. If this tool is
available, technicians should refer to the documentation supplied with the
tool for the correct procedures. If the tool is not available, a hot-air tool may
be used instead. However, technicians require training in the best techniques
to employ in the absence of a can-removal tool. Such training is part of the
accreditation process for service centres.
Figure 4.4 Shielding cans and connectors (bottom side of main-board assembly)
116 General Information TM8100/TM8200 Service Manual
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Spare Cans It is good practice to discard any can that has been removed and replace it
with a spare can. If this is not done, special precautions are needed when re-
installing the original can. These precautions are discussed as part of the
training for accreditation.
4.7 SMT Repair Techniques
Standard
Procedures Service centres carrying out level-2 repairs are expected to be familiar with
the standard techniques for the replacement of SMT components. However,
certain components on the main board require non-standard techniques and
these are discussed below. Another issue of concern is the procedure for
removing and installing cans. A discussion of the issue concludes this section.
Non-standard
Procedures Do not use the standard SMT repair techniques when replacing the
capacitors C548 and C565 and the inductors L601 and L602. The standard
techniques tend to produce excessive heat, which will damage these
components. Do not use a hot-air tool or heat gun. Instead use solder paste
and a standard soldering iron with an iron tip with a specified temperature
of 600°F (315°C). The capacitors are part of the frequency-synthesizer
circuitry under the SYN TOP can. The inductors are part of the SMPS of the
power-supply circuitry on the bottom-side of the board. Figure 4.5 on
page 117 shows the locations of the components.
TM8100/TM8200 Service Manual General Information 117
© Tait Electronics Limited June 2006
Figure 4.5 Locations of the capacitors C548 and C565 and the inductors L601 and L602
top side
(VHF board. UHF board similar)
Note that other components may be
fitted for C548 (such as C5085 and
C5086 for UHF radios)
bottom side
(UHF board. VHF board similar)
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4.8 Computer-Controlled Test Mode (CCTM)
The servicing procedures require a radio to be placed in the computer-
controlled test mode. In this mode CCTM commands can be entered at the
test PC. These commands are then relayed via the test unit to the radio.
Certain CCTM commands cause the radio to carry out particular functions;
others read par ticular settings and parameter values in the radio. The CCTM
commands of use in servicing radios are listed in Table 4.3 to Table 4.7,
grouped according to category.
Terminal Program
for CCTM Use the calibration application to place the radio in CCTM. To do this, run
the calibration application, select To o l s > C C T M , and click the CCTM Mode
button. For more information, refer to the online help of the calibration
application.
You can also use the HyperTerminal utility which is supplied with Microsoft
Windows. As a preliminary, first select the settings for the communications
port as follows:
1. Open the terminal program. (In the case of HyperTerminal, click
Start > Programs > Accessories > Communications > HyperTerminal.)
2. In the terminal program first select the COM port to which the radio
is connected. Then select the following settings for the port:
■bits per second : 19 200
■data bits : 8
■parity : none
■stop bits : 1
■flow control : none.
3. Click the OK button (or equivalent).
4. Save the file with the port settings under a suitable name.
For subsequent sessions requiring the terminal program, open
this file.
Invoking CCTM Using the terminal program, place the radio in CCTM as follows:
1. Enter the character ^ to reset the radio.
2. As soon as the radio is reset, the letter v is displayed. (If an uppercase
letter V appears, this implies a fault.)
3. Immediately the letter v is displayed, enter the character%.
(The character% must be entered within half a second of the letter v
appearing.)
4. If the character% is accepted, the character – is displayed in response,
and the message Te s t M o d e appears on the radio display. This implies
that the radio has entered CCTM. If the attempt fails, repeat
Steps 1 to 3.
TM8100/TM8200 Service Manual General Information 119
© Tait Electronics Limited June 2006
Table 4.3 CCTM commands in the audio category
Command
Usage
Entry at keyboard Response on screen
Audio category
20 – Mute received audio
Forces muting of the received
audio signal
20 None
21 – Unmute received audio
Forces unmuting of the received
audio signal
21 None
22 – Mute microphone
Mutes transmit modulation
(effectively mutes microphone
audio)
22 None
23 – Unmute microphone
Unmutes transmit modulation
(effectively unmutes microphone
audio)
23 None
74 – Audio PA
Controls the state of the audio PA
(and hence enables or disables the
speaker)
74 x
where x is the required state
(0=stand-by, 1=on, 2=mute)
None
110 – Audio volume
Sets the level of the audio volume
110 x
where x defines the required level
(any integer from 0 to 255)
None
138 – Select microphone
Selects the microphone required
138 x
where x is the required microphone
(0=control-head microphone;
1=auxiliary microphone)
None
323 – Audio tap in
Generates the audio tone AUD TAP IN
at the specified tap point
323 x y
where x specifies the tap point
(r2, r5, t1 or t5) and y the tap type
(A=bypass in, B=combine, E=splice)
(the default is A when y is omitted)
None
324 – Audio tap out
Outputs the audio signal at the
specified tap point to AUD TAP OUT
324 x y
where x specifies the tap point
(r1, r2, r3, r4, r5, t1, t2, t3 or t7)
and y the tap type
(C=bypass out, D=split, E=splice)
(the default is D when y is omitted)
None
120 General Information TM8100/TM8200 Service Manual
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Table 4.4 CCTM commands in the radio-information, radio-control and system categories
Command
Usage
Entry at keyboard Response on screen
Radio-information category
94 – Radio serial number
Reads the serial number of the
radio
94 x
where x is the serial number
(an eight-digit number)
96 – Firmware version
Reads the version number of the
radio firmware
96 QMA1F_x_y
where x is a three-character
identifier and y is an eight-digit
version number
97 – Boot-code version
Reads the version number of the
boot code
97 QMA1B_x_y
where x is a three-character
identifier and y is an eight-digit
version number
98 – FPGA version
Reads the version number of the
FPGA
98 QMA1G_x_y
where x is a three-character
identifier and y is an eight-digit
version number
133 – Hardware version
Reads the product code of the
radio body and the hardware
version number
133 x
y
where x is the product code
and y is the version number
(a four-digit number)
134 – FLASH serial number
Reads the serial number of the
FLASH memory
134 x
where x is the serial number
(a 16-digit hexadecimal number)
Radio-control category
400 – Select channel
Changes the current channel to
that specified
400 x (alternatively *x)
where x is a valid channel number
None
System category
46 – Supply voltage
Reads the supply voltage
46 x
where x is the supply voltage in
millivolts
203 – Clear system error
Clears the last recorded system
error
203 None
204 – Read system error
Reads the last recorded system
error and the associated data
204 SysErr: x
y
where x is the error number and
y represents the associated data
205 – Erase persistent data
Effectively resets the calibration
parameters to their default values
205 None
TM8100/TM8200 Service Manual General Information 121
© Tait Electronics Limited June 2006
Table 4.5 CCTM commands in the frequency-synthesizer and receiver categories
Command
Usage
Entry at keyboard Response on screen
Frequency-synthesizer category
72 – Lock status
Reads the lock status of the RF PLL,
FCL and LO2 respectively
72 x y z
where x is the RF PLL, y the FCL,
and z the LO2 lock status
(0=not in lock, 1=in lock)
101 – Radio frequencies
Sets the transmit and receive
frequencies to specified values
101 x y 0
where x is the transmit and y the
receive frequency in hertz
(any integer from 50 000 000 to
1000 000 000)
None
301 – Calibrate VCXO
Calibrates the VCXO of the FCL
301 0 10 Four KVCXO control sensitivity
values, followed by message with
results of calibration attempt
302 – Calibrate VCO(s)
Calibrates the VCO(s) of the
frequency synthesizer
302 0 10 Eight KVCO control sensitivity
values, followed by message with
results of calibration attempt
334 – Synthesizer power
Switches the frequency synthesizer
on or off via the DIG SYN EN line
334 x
where x is the required state
(0=off, 1=on)
None
335 – Synthesizer switch
Switches the transmit-receive
switch of the frequency synthesizer
on or off via the DIG SYN TR SW line
335 x
where x is the required state
(0=off, 1=on)
None
389 – Synthesizer mode
Sets the mode of the frequency
synthesizer to fast or slow
389 x
where x is the required mode
(0=slow, 1=fast)
None
Receiver category
32 – Receive mode
Sets the radio in the receive mode
32 None
63 – RSSI level
Reads the averaged RSSI level
63 x
where x is the averaged level in
multiples of 0.1 dBm
376 – Front-end tuning
Sets or reads the tuning voltage for
the front-end circuitry of the
receiver
376 (to read voltage) x
where x is the front-end tuning
voltage in millivolts
376 x(to set voltage)
where x is the front-end tuning
voltage in millivolts
(any integer from 0 to 3000)
None
378 – Receiver output level
Reads the signal power at the
output of the channel filter
(the square of the amplitude)
378 x
where x is the signal power
122 General Information TM8100/TM8200 Service Manual
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Table 4.6 CCTM commands in the transmitter category (part 1)
Command
Usage
Entry at keyboard Response on screen
Transmitter category
33 – Transmit mode
Sets the radio in the transmit mode
33 None
47 – Temperature
Reads the temperature in the
vicinity of the PAs
47 x
y
where x is the temperature in
degrees celsius, and y is the
corresponding voltage in millivolts
(a value from 0 to 1200 mV)
114 – Transmitter power
Sets or reads the transmitter power
setting (compare command 326)
114 (to read value) x
where x is the current power
setting (an integer from 0 to 1023)
114 x(to set value)
where x is the required power
setting (an integer from 0 to 1023)
None
304 – Driver bias
Sets or reads the clamp current at
the gate of the PA driver
304 (to read value) x
where x is the DAC value of the
clamp current (an integer from 0 to
255)
304 x (to set value)
where x is the required DAC value
of the clamp current
(an integer from 0 to 255)
None
318 – Forward power
Reads the forward-power level
318 x
where x is the voltage in millivolts
corresponding to the power level
(a value from 0 to 1100 mV)
319 – Reverse power
Reads the reverse-power level
319 x
where x is the voltage in millivolts
corresponding to the power level
(a value from 0 to 1100 mV)
326 – Transmitter power
Sets the power level of the
transmitter
326 x
where x specifies the level
(0=off, 1=very low, 2=low,
3=medium, 4=high, 5=maximum)
None
TM8100/TM8200 Service Manual General Information 123
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Table 4.7 CCTM commands in the transmitter category (part 2)
Command
Usage
Entry at keyboard Response on screen
Transmitter category
331 – Final bias 1
Sets or reads the bias voltage for
the first PA
331 (to read value) x
where x is the DAC value of the
bias voltage (an integer from 0 to
255)
331 x (to set value)
where x is the DAC value of the
required bias voltage
(any integer from 0 to 255)
None
332 – Final bias 2
Sets or reads the bias voltage for
the second PA
332 (to read value) x
where x is the DAC value of the
bias voltage (an integer from 0 to
255)
332 x (to set value)
where x is the DAC value of the
required bias voltage
(any integer from 0 to 255)
None
124 General Information TM8100/TM8200 Service Manual
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Table 4.8 CCTM commands for the control head (graphical display)
Command
Usage
Entry at keyboard Response on screen
1000 – Switch all LEDs
Switches all the function-key and
STATUS LEDs on or off
1000 x
where x is the required state
(0=off, 1=on)
None
1001 – Switch selected LED
Switches a selected function-key or
STATUS LED on or off
1001 x y
where x identifies the LED
(0=F1, 1=F4, 2=yellow, 3=green,
4=red) and y is the state
(0=off, 1=on)
None
1002 – LED intensity
Sets the LED intensity
1002 x
where x is the intensity level
(0=off, 1=low, 2=medium, 3=high)
None
1003 – Keypad back-lighting
Activates the keypad back-lighting
at a specified intensity
1003 x
where x is the intensity level
(0=off, 1=low, 2=medium, 3=high)
None
1004 – LCD back-lighting
Activates the LCD back-lighting at
a specified intensity
1004 x
where x is the intensity level
(0=off, 1=low, 2=medium, 3=high)
None
1005 – Display contrast
Sets the contrast of the display to a
specified level
1005 x
where x is the contrast level
(any integer from 0 to 15)
None
1006 – Display elements
Switches all the elements of the
display on or off
1006 x
where x is the required state
(0=off, 1=on)
None
1007 – LCD temperature sensor
Reads the output of the LCD
temperature sensor
1007 x
where x corresponds to the
temperature reading
(an integer between 00 and FF)
1008 – LCD heating
Switches the LCD heating on or off
1008 x
where x is the required state
(0=off, 1=on)
None
1009 – Key press
Switches on or off the facility for
detecting if any key is pressed or
released
1009 x
where x is the required state
(0=off, 1=on)
x
where x is the serial output from
the detection facility
1010 – Volume control
Reads the setting of the volume-
control potentiometer
1010 x
where x is the potentiometer
setting
(an integer between 00 and FF)
1011 – Microphone source
Selects the microphone input
source
1011 x
where x is the required source
(0=microphone connector,
1=concealed microphone)
None
Table 4.9 CCTM commands of the remote control-head kit
CCTM command Entry at keyboard Response on screen
1012 – Remote kit
turns the audio amplifier on and off
1012 0 = off
1012 1 = on
none
1013 – Mute audio amplifier
mutes and unmutes the audio amplifier
1012 0 = mute
1012 1 =unmute
none
1014 – Digital potentiometer
reads the digital potentiometer
1014 value between 0 and
255
1017 – Audio amplifier gain
sets the audio amplifier gain (4 levels)
1017 x
where x is the gain (0 to 3)
none
TM8100/TM8200 Service Manual General Information 125
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CCTM Error Codes Once the radio is in CCTM, the CCTM commands may be entered as
shown in Table 4.3 to Table 4.7. Depending on the command, a response
might or might not be displayed. If an error occurs, an error code will be
displayed. Possible error codes are listed in Table 4.10.
Table 4.10 CCTM error codes
Error code Description
C01 An invalid CCTM command has been received. Enter a valid CCTM command.
C02 A valid CCTM command with invalid parameters has been received. Re-enter the CCTM
command with valid parameters.
C03 A valid CCTM command has been received but cannot be processed at this time. Enter the
CCTM command again. If the error persists, power the radio down and up again, and re-enter
the CCTM command.
C04 An error occurred on entry into CCTM. Power the radio down and up again, and place the
radio in CCTM again.
C05 The radio has not responded within the specified time. Re-enter the CCTM command.
X04 The DSP is not responding. Check the DSP pin connections. If the error persists, replace the
DSP.
X05 The version of the DSP is incompatible with the version of the radio firmware. Replace the DSP
with a later version.
X06 The internal configuration of the MCU is incorrect. Adjust the configuration.
X31 There is an error in the checksum for the model configuration.
X32 There is an error in the checksum for the radio’s database.
X35 The radio temperature is above the T1 threshold and a reduction in the transmit power is
impending. To avoid damaging the radio, stop transmitting until the radio has cooled down
sufficiently.
X36 The radio temperature is above the T2 threshold and the inhibiting of transmissions is
imminent.
X37 The supply voltage is less than the V1 threshold.
X38 The supply voltage is less than the V2 threshold and the radio has powered itself down.
The radio will not respond to the reset command character ^.
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4.9 Defining Frequency Bands
Where test procedures or figures differ according to the frequency band of
the radio, the frequency band is given in brackets. The frequency band may
be referred to as either ‘VHF’ (very high frequency) or ‘UHF’ (ultra-high
frequency) or identified by the frequency sub-band, such as ‘B1’ or ‘H7’.
For example:
The frequency bands for TM8100/TM8200 radios are listed in Table 4.11.
The relevant frequencies for the different bands are listed in this table.
RF output power: > 60W (VHF), > 52W (UHF)
current: < 15A (VHF), < 12A (UHF)
Table 4.11 Defining frequency bands
Frequency identification Frequency sub-band
VHF A band
B band
C band
D band
A4 = 66MHz to 88MHz
B1 = 136MHz to 174MHz
C0 = 174MHz to 225MHz
D1 = 216MHz to 266MHz
UHF H band H5 = 400MHz to 470MHz
H6 = 450MHz to 530MHz
H7 = 450MHz to 520MHz
TM8100/TM8200 Service Manual General Information 127
© Tait Electronics Limited June 2006
4.10 Visual and Audible Indications
Visual and audible indicators give information about the state of the radio.
Visual indications are provided by the STATUS LEDs, function-key LEDs, and
LCD display. The information conveyed by the STATUS LEDs is listed in
Table 4.12. The behaviour of the function-key LEDs depends on the way
the function keys are programmed. The LCD display normally displays
channel and user information, or error messages. For more information on
the LCD display during normal operation, refer to the user’s guide.
The error messages are listed in Table 6.1 on page 154. Audible indications
are provided in the form of different tones emitted from the speaker.
The information conveyed by the tones is given in Table 4.13 on page 128.
Table 4.12 Visual indications provided by the STATUS LEDs
LED color LED name Indications Meanings
Red Transmit LED is on The radio is transmitting
LED flashes (1) The transmit timer is about to expire
(2) The radio has been stunned
Green Receive and
monitor
LED is on There is activity on the current channel, although it might
not be audible
LED flashes (1) The radio has received a call with valid special signaling
(2) The monitor has been activated
(3) The squelch override has been activated
Amber Scanning LED is on The radio is scanning a group of channels for activity
LED flashes The radio has detected activity on a certain channel and
scanning has halted on this channel
128 General Information TM8100/TM8200 Service Manual
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Table 4.13 Audible indications
Type of tone Meanings
One short beep (1) After power-up — Radio is locked; PIN is required
(2) On power-down — Radio is off
(3) On pressing key — Key-press is valid
(4) On pressing function key — Function has been initiated
One short low-pitched beep On pressing function key again — Function has been terminated
One short high-pitched beep While powered up — Radio has been stunned
One long low-pitched beep (1) On pressing key — Key-press is invalid
(2) On entry of PIN — PIN is invalid
(3) On pressing PTT switch — Transmission is inhibited
Two short beeps (1) On power-up — Radio is ready to use
(2) On entry of PIN — PIN has been accepted and radio is ready to use
(3) After radio has been stunned — Radio has been revived and is ready to use
Two low-pitched beeps While powered up — Temperature of radio is high
Two high-pitched beeps While powered up — Temperature of radio is very high and all transmissions
will be at low power; if temperature rises further, transmissions will be inhibited
Three short beeps While powered up — Previously busy channel is now free
Three beeps During transmission — Transmit time-out is imminent; transmission will be
terminated in 10 seconds
Warble While powered up — Frequency synthesizer is out of lock on current channel;
LCD will usually display Out of Lock (graphical display), OL (2- or 3-digit display),
or L (1-digit display).
Continuous low-pitched
tone
While powered up — System error has occurred and radio might be inoperable;
LCD usually displays System Error (graphical display), E1 or E2 (2- or 3-digit
display), or E (1-digit display).
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5 Disassembly and Reassembly
This section describes how to:
■remove and mount the control head
■disassemble and reassemble the radio body
■disassemble and reassemble the control heads.
General Important Before disassembling the radio, disconnect the radio from
any test equipment or power supply.
Disassemble only as much as necessary to replace the defective parts.
Inspect all disassembled parts for damage and replace them, if necessary.
Observe the torque settings indicated in the relevant figures.
For information on spare parts, refer to “Spare Parts” on page 437.
130 Disassembly and Reassembly TM8100/TM8200 Service Manual
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5.1 Removing and Mounting the Control Head
Important Before removing the control head, disconnect the radio
from any test equipment or power supply.
Removing the
Control Head 1. Note which way up the control head is attached to the radio body in
order to return the radio to the customer in its original configuration.
2. On the underside of the radio body, two lever points are indicated on
the radio body by a dot-dash-dot pattern ( ).
The lever point is between the control-head seal and the plastic of the
control head.
Important When inserting the flat-bladed screwdriver, take care not to
damage the control-head seal.
3. At either of the lever points, insert a 3/16 inch (5mm) flat-bladed
screwdriver between the control head and the control-head seal.
4. Use the screwdriver to lift the edge of the control head up and off the
clip, then repeat in the other position. The control head can now be
removed.
5. Disconnect the control-head loom.
6. Inspect the control-head seal for damage, and replace if necessary.
Mounting the
Control Head 1. Plug the control-head loom onto the control-head connector.
2. Insert the bottom edge of the control head onto the two clips in the
front of the radio body, then snap into place.
Figure 5.1 Disconnecting the control head from the radio body
lever point
indication of
lever point
control-head
seal
control head
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5.2 Disassembling the Radio Body
Disassemble only as much as necessary to replace the defective parts.
For reassembly instructions, refer to “Reassembling the Radio Body” on
page 137.
Removing the Cover 1. At the upper edge of the lower screw bosses on both sides of the radio
body, insert a 1/8 inch (3mm) flat-bladed screwdriver.
2. Push the screwdriver under the cover towards the upper screw boss to
release the cover from the upper screw boss.
3. Remove the cover.
Figure 5.2 Removing the cover
insertion
point
upper
screw boss
cover
lower
screw boss
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Opening the
Radio Body The circled numbers in this section refer to the items in Figure 5.3 on
page 133.
1. Use a Torx T20 screwdriver to remove the four screws c.
Important If an options board is fitted inside the lid, an options loom
will connect the options board to the internal options con-
nector on the main board. In this case, carefully fold over
the lid and disconnect the loom.
2. Carefully remove the lid assembly d.
3. Inspect the main seal in the lid for damage, and replace if necessary.
Removing the
Main-Board
Assembly
The circled numbers in this section refer to the items in Figure 5.3 on
page 133.
1. Remove the auxiliary connector bung h (if fitted).
2. Remove the RF connector seal j using one of the tabs located at the
bottom of the seal—preferably by hand. If necessary, lift up the tap
using the blade of a small flat-bladed screwdriver. Do not damage the
seal with the screwdriver.
3. Use a Torx T10 screwdriver to remove the screws e connecting the
main board to the chassis.
4. Use a Torx T20 screwdriver to remove the screws i connecting the
heat-transfer block to the rear of the chassis.
Note Make sure not to touch the thermal paste on the chassis, the heat-
transfer block, and the underside of the main board. If the thermal
paste is contaminated, you must re-apply thermal paste as
described in “Fitting the Main-Board Assembly to the Chassis” on
page 139.
5. Holding a hand over the chassis to catch the main-board assembly,
turn the chassis upside down and tap its fins on the edge of the
workbench. This will release the heat-transfer block from the chassis.
6. With the 40W/50W radio, the gap pad 1) on the L-shaped ridge
must be replaced each time the main board is removed.
TM8100/TM8200 Service Manual Disassembly and Reassembly 133
© Tait Electronics Limited June 2006
Figure 5.3 Components of the radio body
Bcover Gchassis
Cscrew M4x16 (x4) Hauxiliary connector bung
Dlid assembly Iscrews M4x16 (x2)
Escrew M3x10 (x5) JRF connector seal
Fmain-board assembly 1) gap pad (50W/40W radio only)
Torx T20
22lb·in (2.5N·m)
Torx T10
15lb·in (1.7N·m)
Torx T20
22lb·in (2.5N·m)
B
Cx4
D
Ex5
F
G
Ix2
H
J
3630z_01
1)
thermal
paste
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Disassembling the
Main-Board
Assembly
The circled numbers in this section refer to the items in Figure 5.4 on
page 135. This figure shows the 40W/50W configuration.
1. Remove the power connector seal I.
2. Use a torque-driver with a 3/16 inch (5mm) socket to remove the
D-range screwlock fasteners H.
3. Use a torque-driver with a 9/16 inch (14mm) long-reach socket to
remove the RF connector nut 1!. Also remove the lock washer 1@.
4. Use a Torx T10 screwdriver to remove the three screws b securing
the main board 1$ to the heat-transfer block F.
Note Make sure not to touch the thermal paste on the heat-transfer
block and the underside side of the main board. If the thermal
paste is contaminated, you must re-apply thermal paste as
described in “Reassembling the Main-Board Assembly” on
page 137.
5. Separate the main board 1$ from the heat-transfer block F.
6. Inspect the inner foam D-range seal E and the outer foam seal G,
and replace if necessary.
7. The gap pad 1) (40W/50W radio only) must be replaced each time
the heat-transfer block is separated from the main board.
8. To replace the power connector J:
■With the 40W/50W radio, use a Torx T6 screwdriver to undo the
two screws C.
■With the 25W radio, use a Torx T10 screwdriver to undo the two
screws C.
TM8100/TM8200 Service Manual Disassembly and Reassembly 135
© Tait Electronics Limited June 2006
Figure 5.4 Components of the main-board assembly
BM3x10 screw (x3) HD-range screwlock fastener (2x)
C50W/40W radios:
M2.2x10 PT screw (x2)
25W radios:
K30x8 PT screw (x2)
Ipower connector seal
Jpower connector
1) gap pad (50W/40W radio only)
Dauxiliary connector 1! RF connector nut
Einner foam D-range seal 1@ RF connector lock washer
Fheat-transfer block 1# RF connector
Gouter foam seal 1$ main board
H
1$
E
G
F
I1#
1@
D
J
thermal
paste
3631z_01
1)
9/16 inch (14mm)
15lb·in (1.7N·m)
3/16 inch (5mm)
8lb·in (0.9N·m)
Torx T6
1lb·in (0.11N·m) Torx T10
15lb·in (1.7N·m)
Cx2
Torx T10
3lb·in (0.34N·m)
1!
B
x3
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© Tait Electronics Limited June 2006
Removing an
Options Board
(Optional)
The radio may be fitted with an options board in the lid assembly, which
may or may not have an external options connector fitted in a provision in
the lid assembly.
The circled numbers in this section refer to the items in Figure 5.5.
1. If an external options connector is fitted:
■Undo the two screws b and remove the protective rubber cap c
(if fitted).
■Undo the two D-range screwlock fasteners d.
2. Undo up to nine screws h and remove the options board G from the
lid assembly E.
3. If an external options connector is fitted, a foam seal for the D-range
connector f is fitted to the inside of the lid. Remove the foam seal
only if it is damaged.
Reassembly is carried out in reverse order of the disassembly.
Figure 5.5 Removing an options board
Bscrew 4-40x3/15 (x2) Ffoam seal for D-range connector
Cprotective rubber cap Goptions board (example)
DD-range screwlock fastener 4-40 (x2) Hscrew M3x10, self-tapping (x9)
Elid assembly
d
3614z_01
Torx T10
17lb·in (1.9N·m)
3/16 inch (5mm)
8lb·in (0.9N·m)
f
g
h
c
b
e
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© Tait Electronics Limited June 2006
5.3 Reassembling the Radio Body
Inspect all disassembled parts for damage and replace them, if necessary.
Reassembling the
Main-Board
Assembly
The circled numbers in this section refer to the items in Figure 5.4 on
page 135. This figure shows the 40W/50W configuration.
1. If the power connector has been replaced:
■With the 40W/50W radio, use a Torx T6 torque-driver to
tighten the two screws C to 1lb·in (0.11N·m).
■With the 25W radio, use a Torx T10 torque-driver to tighten the
two screws C to 3lb·in (0.34N·m).
2. If the outer foam seal E or the inner foam D-range seal G have been
removed, fit new seals to the heat-transfer block F.
3. With the 40W/50W radio, the rectangular gap pad 1) must be
replaced each time the heat-transfer block F is separated from the
main board 1$:
■Remove any residue of the old rectangular gap pad from the
underside of main board and the heat-transfer block.
■Peel off the transparent film on one side of the gap pad and evenly
press the gap pad on the contact surface of main board (refer to
Figure 5.6).
■Peel off the transparent film on other of the gap pad.
Figure 5.6 Contact surfaces on the bottom side of the main board
tin-plated
copper plate
contact surface
of rectangular
gap pad Audio-PA area
contact surface of L-shaped gap pad
138 Disassembly and Reassembly TM8100/TM8200 Service Manual
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4. If the thermal paste on the heat-transfer block F or the tin-plated
cooper plate of the main board 1$ has been contaminated, new
thermal paste must be applied:
■Remove any residue of the old thermal paste from both contact
surfaces.
■Use Dow Corning 340 silicone heat-sink compound
(IPN 937-00000-55).
Important Ensure that no bristles from the brush come loose and
remain embedded in the paste. The paste needs to be
completely free of contaminants.
■Use a stiff brush to apply 0.1cm3 of thermal paste over the
complete contact surface on the tin-plated copper plate (refer to
Figure 5.6 on page 137).
5. Place the main board 1$ in position on the heat-transfer block F, and
push them together to spread the thermal paste.
Important You must observe the following order of assembly to ensure
that the main board and the connectors are not assembled
under stress.
6. Use a torque-driver with a 3/16 inch (5mm) socket to fasten the
D-range screwlock fasteners H to 8lb·in (0.9N·m).
7. Fit the RF connector lock washer 1@. Use a torque-driver with a
9/16 inch (14mm) long-reach socket to fasten the RF connector nut
1! to 15lb·in (1.7N·m).
8. Use a torque-driver with a Torx T10 bit to fasten the three screws b
to 15lb·in (1.7N·m).
9. Loosen both the D-range screwlock fasteners H and the
RF connector nut 1!.
10. Re-tighten both the D-range screwlock fasteners H and the
RF connector nut 1! to the torques indicated in steps 7 and 8.
11. Fit the power connector seal I.
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Fitting the Main-
Board Assembly to
the Chassis
The circled numbers in this section refer to the items in Figure 5.3 on
page 133. This figure shows the 40W/50W configuration.
1. With the 40W/50W radio, the L-shaped gap pad 1) must be replaced
each time the main-board assembly F is removed from the chassis G:
■Remove any residue of the old gap pad from the audio-PA area on
the underside of the main board (refer to Figure 5.6 on page 137)
and the L-shaped ridge of the chassis (refer to Figure 5.3 on
page 133).
■Peel off the transparent film on one side of the gap pad and evenly
press the gap pad on the L-shaped ridge of the chassis.
■Peel off the transparent film on other of the gap pad.
2. If the thermal paste on the heat-transfer block or the underside of the
main board has been contaminated, new thermal paste must be
applied:
■Remove any residue of the old thermal paste from both contact
surfaces.
■Use Dow Corning 340 silicone heat-sink compound
(IPN 937-00000-55).
Important Ensure that no bristles from the brush come loose and
remain embedded in the paste. The paste needs to be
completely free of contaminants.
■Use a stiff brush to apply 0.1cm3 of thermal paste on the heat-
transfer block (refer to Figure 5.3 on page 133).
■Use a stiff brush to apply 0.01cm3 of thermal paste on the
audio-PA heat sink of the chassis (refer to Figure 5.3 on page 133)
3. Place the main-board assembly F in position in the chassis G.
4. Loosely screw in the two screws I through the heat-transfer block by
hand.
140 Disassembly and Reassembly TM8100/TM8200 Service Manual
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5. While pressing down firmly on the diagonal edge of the PAD TOP can
(refer to Figure 5.7), use a Torx T20 torque-driver to tighten the two
screws I to 22lb·in (2.5N·m). This will ensure that the main board
is seated correctly on the bosses for the five internal screws E.
6. Clean off any excess thermal paste on the heat-transfer block.
7. Screw in the five screws E through the main board by hand as far as
possible. Use a Torx T10 torque-driver to tighten the screws to
17lbf·in (1.9N·m).
8. Fit the RF connector seal j. Ensure that the seal is properly seated
around its entire periphery.
9. If an auxiliary connector bung h was fitted, fit the bung.
Closing the
Radio Body The circled number in this section refer to the items in Figure 5.3 on
page 133.
1. If an internal options board is fitted inside the lid, connect the loom
to the internal options connector.
2. Inspect the main seal in the lid for damage, and replace if necessary.
3. Place the lid assembly D on the chassis G.
4. Use a Torx T20 torque-driver to tighten the four screws c to 22lbf·in
(2.5N·m).
5. Slide the cover b over the radio body and snap holes in the side of
the cover over the screw bosses.
6. Inspect the control-head seal for damage, and replace if necessary.
Figure 5.7 PAD TOP can on the top side of the main board
PAD TOP can
TM8100/TM8200 Service Manual Disassembly and Reassembly 141
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5.4 Disassembling and Reassembling the Control Head
5.4.1 Control Head with Graphical Display
Disassemble only as much as necessary to replace the defective parts.
Reassembly is carried out in reverse order of the disassembly.
The circled numbers in this section refer to the items in Figure 5.9 on
page 143.
The connectors of the control-head board and the orientation of the speaker
and speaker clamp are illustrated in Figure 5.8.
1. With your fingers, pull off the volume control knob 1&.
Do not use any tools as this might cause damage.
2. Unscrew the two screws B and remove the adaptor flange C.
3. Disconnect the control-head loom D.
4. If an optional circuit board is fitted, unplug it from the control-head
board F (refer to Figure 5.8).
5. Note whether the speaker is connected or disconnected. If it is
connected, disconnect the speaker cable from the speaker connector
of the control-head board F (refer to Figure 5.8). Note that the radio
must be returned to the customer in its original configuration.
6. Release the lock of the LCD connector and unplug the loom of the
LCD assembly 1@ (refer to Figure 5.8). Note that the loom runs
through a slot in the space-frame J.
Figure 5.8 Speaker orientation and connectors of the control-head board (graphical display)
connectors for
optional circuit board
connector for speaker
connector for
loom of LCD assembly
connector for
control-head loom 3470z_01
pads for leads of
concealed microphone
speaker terminals
legs of the
speaker clamp
142 Disassembly and Reassembly TM8100/TM8200 Service Manual
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7. Unscrew the four screws E and remove the control-head board F.
8. If a concealed microphone is fitted, pull the concealed microphone
1% capsule out of its rubber seal when removing the control head-
board F. If necessary, unsolder the leads from the pads on the control-
head board (refer to Figure 5.8).
9. Remove the light pipes H and I.
10. The space-frame J clips into three clips of the front panel.
Unclip the spaceframe and remove it along with the two seals G.
Check the seals Gand replace them, if necessary.
11. Remove the speaker 1! and speaker clamp 1).
Important When fitting the speaker and the speaker clamp, observe the
orientation of the speaker terminals. Make sure that the
larger of the three legs of the speaker clamp is placed
between the two clips of the front panel assembly as shown
in Figure 5.8 on page 141.
12. Remove the LCD assembly 1@, main keypad 1#, and power
keypad 1$.
Important When replacing the LCD, carefully remove the protective
plastic film from the LCD. Take care not to scratch the soft
polarizer material on the top side of the LCD.
The LCD seal is replaced whenever the LCD is replaced.
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© Tait Electronics Limited June 2006
Figure 5.9 Components of the control head (graphical display)
BM4 x 12 Taptite screw (x2)
Cadaptor flange
Dcontrol-head loom assembly with
female-female adapter
E3 x 10 PT screw (x4)
Fcontrol-head board
Gspace-frame seal (x2)
Hshort light pipe
Ilong light pipe
Jspace-frame
1) speaker clamp
1! speaker
1@ LCD assembly (including LCD seal)
1# main keypad
1$ power keypad
1% concealed microphone (optional)
1^ front panel assembly
1& knob for volume-control potentiometer
C
E
F
G
G
1)
H
I
J
1!
1^
1@
1#
1$
1&
x2
x4
D
3451z_02
Torx T20
18lb·in (2.0N·m)
Torx T10
5.5lb·in (0.62N·m)
1%
B
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5.4.2 Control Head with 1-, 2- or 3-Digit Display
Disassemble only as much as necessary to replace the defective parts.
Reassembly is carried out in reverse order of the disassembly.
The circled numbers in this section refer to the items in Figure 5.11 on
page 145.
1. With your fingers, pull off the volume control knob I.
Do not use any tools as this might cause damage.
2. If an optional circuit board C for a concealed microphone is fitted,
unplug it from the control-head board E (refer to Figure 5.10).
3. If a concealed microphone 1) is fitted, unsolder the microphone leads
from the control-head board. The leads are soldered to pads on the
board as shown in Figure 5.10.
4. Note whether the speaker J is connected or disconnected. If it is
connected, disconnect the speaker cable from the speaker connector
of the control-head board (refer to Figure 5.10). Note that the radio
must be returned to the customer in its original configuration.
5. Use a Torx T10 screwdriver to unscrew the three screws D securing
the control-head board. The screws are labelled screw 1 to screw 3;
these numbers are also inscribed on the PCB. The control-head board
is now held down only by the clips labelled clip 1 to clip 3 in
Figure 5.10.
6. While pressing on the shaft of the volume-control potentiometer,
push clip 2, clip 1 and then clip 3 away from the control-head board.
The board will be freed from the space-frame. Remove the board.
7. While pulling upwards on the space-frame G at the corner where the
microphone connector is situated, release the clips labelled B to G in
Figure 5.11 in the order: Band C, Dand E, and then Fand G.
To release each clip use a 3/16 inch (5mm) flat-bladed screwdriver to
Figure 5.10 Connectors and clips of the control-head board (1-, 2- or 3-digit display)
connector for speaker
connectors for
optional circuit board
3830z_01 pads for leads of
concealed microphone
clip 1 clip 2
clip 3
connector for
control-head loom
TM8100/TM8200 Service Manual Disassembly and Reassembly 145
© Tait Electronics Limited June 2006
lever the clip out of its recess. Pulling on the space-frame helps release
the clips.
Important When fitting the space-frame G, make sure that the clips
labelled B to G fully snap into the front panel assembly.
If necessary, use a flat-bladed screwdriver to push down the
clips until they snap into place.
8. Remove the elastomeric strips F, speaker J, LCD 1!, keypad 1@,
lightpipes 1$ and 1%, and, if fitted, the concealed microphone 1).
Important When replacing the LCD, carefully remove the protective
plastic film from the LCD. Take care not to scratch the soft
polarizer material on the top side of the LCD.
Figure 5.11 Components of the control head (1-, 2- or 3-digit display)
Bcontrol-head loom with female-female adaptor Iknob for volume-control potentiometer
Ccontrol-head options board (optional) Jspeaker
D3 x 8 PT screw (x3) 1) concealed microphone (optional)
Econtrol-head board 1! LCD
Felastomeric strip (x2) 1@ keypad
Gspace-frame 1# short light pipe
Hfront panel assembly 1$ long light pipe
J
B
1^
G
I
H
1)
1&
1#
1%
1$
F
E
1!
3828z_01
Dx3
B
C
E
F
x2
G
H
1)
J
1@
1#
1$
1!
I
B
D
F
G
E
C
Torx T10
5lb·in (0.6N·m)
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5.4.3 RJ45 Control Head
Disassemble only as much as necessary to replace the defective parts.
Reassembly is carried out in reverse order of the disassembly.
The circled numbers in this section refer to the items in Figure 5.12.
1. Release the clip of the PCB bracket E and remove the control-head
board B.
2. Disconnect the control-head loom C from the control-head-board
B.
3. Use a Torx T10 screwdriver to unscrew the four screws D and
remove the PCB bracket E.
Figure 5.12 Components of the RJ45 control head
Bcontrol-head board EPCB bracket
Ccontrol-head loom with female-female adapter Ffront panel
D3 x 8 PT screw (x4) GRJ45 bung (x2)
B
D
E
F
G
x4
C
Torx T10
5lb·in (0.6N·m)
x2
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5.4.4 Blank Control Head
Disassemble only as much as necessary to replace the defective parts.
Reassembly is carried out in reverse order of the disassembly.
The circled numbers in this section refer to the items in Figure 5.13.
1. Note whether the cover seal C is fitted or not. If it is fitted, remove
the two screws B and remove the cover seal. Note that the radio must
be returned to the customer in its original configuration.
2. Note whether an options board (not shown) is fitted inside the
control head. If a an options board is fitted, remove the screws and
remove the options board.
3. Remove the lock-nuts D and remove the foam seal F and the control
head loom G.
Figure 5.13 Components of the blank control head
BUNX 4-40 x 3/16-inch pan Pozi screw (x2) Efront panel
Ccover seal Ffoam seal
Dlock-nut (pair) Gcontrol-head loom with female-female adapter
F
3829z_01
x2 B
E
x2 D
CG
3/16 inch (5mm)
4lb·in (0.45N·m)
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TM8100/TM8200 Service Manual Servicing Procedures 149
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6 Servicing Procedures
Scope of Section This section gives the full sequence of tasks required when servicing a
particular radio. These tasks are:
■initial inspection, visual inspection and fault diagnosis
■repair, final inspection, test and administration.
For disassembly and reassembly instructions, refer to “Disassembly and
Reassembly” on page 129.
6.1 Initial Tasks
List of Tasks The following tasks need to be carried out for all radios:
■initial administration
■visual inspection
■powering up the radio
■reading the programming file
■obtaining the details of the Software Feature Enabler (SFE)
■reading the calibration file
■checking the user interface
■checking any error messages.
The following tasks only need to be carried out if they relate to the fault
reported:
■checking the transmit and transmit-audio functions
■checking the receive and receive-audio functions.
Important Observe the “General Information” on page 103.
Task 1 —
Initial
Administration
When a radio is received for repair, details of the Customer and the fault will
be recorded in a fault database. The fault reported by the Customer might
concern damage to or loss of a mechanical part, or the failure of a function
of the radio, or both.
Task 2 —
Visual Inspection Check the radio for mechanical loss or damage, even if the fault concerns a
function failure only. Inspect the radio as follows:
■knob for volume-control potentiometer
■microphone grommet
■rubber seal for RF connector
■bung for auxiliary connector
■bung for aperture for external options connector.
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The bung for aperture for external options connector should be replaced by
a cover seal if an external options connector is present. All the parts are
illustrated in “Spare Parts” on page 437. Except for the microphone
grommet, if any of these parts is missing or damaged, replace it as described
below. In the case of the microphone grommet, refer to the accessories
section for the repair procedure.
Replace Damaged
or Missing Knob Remove the volume-control knob if it is damaged. Push the replacement
knob onto the shaft of the volume-control potentiometer. Ensure that the
knob turns freely.
Replace Damaged
or Missing Seals
and Bungs
Remove any damaged seal or bung. Obtain a replacement seal for the
RF connector or a replacement bung from Spares kit 2. Order a
replacement cover seal (and screws) from TEL; the IPNs of the parts are
listed in “Spare Parts” on page 437. In fitting a replacement bung, ensure
that it is not upside down and that it is properly seated. To fit the seal for the
RF connector, first fit the upper part of the seal and then press down around
the sides of the seal to the bottom. Ensure that the seal is properly seated
around its entire periphery.
Check for
Additional Damage Also check for damage to exterior parts that can be replaced only by partly
disassembling the radio. These parts are:
■cover assembly for radio body
■keys, lens and LCD of control head
■front panel of control head.
In the case of the front panel, inspect particularly the light pipes for the
STATUS LEDs and the membrane behind the speaker grille. If the radio is
reported to have a functional fault, continue with Task 3. Any additional
mechanical damage will be repaired during the course of rectifying the
functional fault. If the radio has no functional fault, repair any additional
damage as described below; conclude with the tasks of “Final Tasks” on
page 157.
Repair Damaged
Control Head If the control head is damaged, detach it from the radio body as described
in “Removing and Mounting the Control Head” on page 130.
The procedure includes inspecting the interior of the control head for
evidence of other damage. Disassemble the control head and repair all
damage as described in “Disassembling and Reassembling the Control
Head” on page 141. Then re-assemble the control head and re-attach it to
the radio body.
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Task 3 —
Power Up the Radio With the radio connected to the test equipment as described in “Test
Equipment Setup” on page 111, attempt to power up the radio.
1. Apply power to the radio. If the radio is programmed not to start on
power-on, press the ON/OFF switch.
Note If the radio powers up but keeps resetting itself, check the power-
sensing circuitry. If the radio powers up but fails to enter user-
mode, or displays an error, refer to Table 6.1 on page 154.
2. If the radio powers up successfully, go to Ta s k 4 . If it does not, go to
Step 3.
3. Check the fuses, cables, and the power supply.
4. Check whether the control-head loom, the control head or the radio
body is faulty by first connecting a spare control-head loom and then
a spare control head.
5. If the control head is faulty, check the control-head connector
(pin 2: +13V8, pin 14: +3V3, pin 6: AGND), and repair or replace
the control-head board.
6. If the repair succeeded without the need for replacing the main-board
assembly, go to Tas k 4. Otherwise continue with Step 7.
7. If the main-board assembly was replaced or if the repair failed, re-
assemble the radio as described in “Disassembly and Reassembly” on
page 129. Conclude with the tasks of “Final Tasks” on page 157.
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Task 4 —
Read the
Programming File
Given that the radio powers up, the next task is to read the radio’s
programming file or upload a default file.
1. Use the programming application to read the programming file.
2. If the programming file can be read, save a copy on the test PC, and
go to Tas k 5. If not, go to Step 3.
3. If it seems that the file cannot be read, cycle the power to the radio
and again attempt to read the file. First cycling the power is essential
if the radio is programmed to power up in transparent-data mode
(both 1200 baud FFSK and Tait high-speed data) and if the selected
data port is the microphone connector (control head with user
interface) or programming connector (blank control head).
4. If the programming file cannot be read, check whether:
■the radio is connected to the correct serial port of the test PC,
■the Mode switch of the test unit is set to Rx,
■the programming application is set-up correctly. Refer to the
troubleshooting section of the online help.
5. If the programming file can be read now, save a copy on the test PC,
and go to Ta s k 5 . If not, go to Step 6.
6. Check whether the control-head loom, the control head or the radio
body is faulty by first connecting a spare control-head loom and then
a spare control head.
7. If the control head is faulty, check:
■the control-head connector (pin 3: TXD, pin 7: RXD),
■the microphone or programming connector,
■the path between the control-head connector and the microphone
or programming connector,
and repair or replace the control-head board.
8. If the repair succeeded without the need for replacing the main-board
assembly, go to Step 9. Otherwise continue with Step 10.
9. If the programming file can be read now, save a copy on the test PC,
and go to Ta s k 5 . If the file still cannot be read, go to Step 10.
10. Set up a suitable default programming file and attempt to upload it to
the radio
11. If the upload succeeds, go to Ta s k 6 . If the upload fails, continue with
Step 12.
12. If the main-board assembly was replaced or if the repair failed, re-
assemble the radio as described in “Disassembly and Reassembly” on
page 129. Conclude with the tasks of “Final Tasks” on page 157.
TM8100/TM8200 Service Manual Servicing Procedures 153
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Task 5 —
Obtain the Details
of the Software
Feature Enabler
(SFE)
Use the programming application to obtain and record the details of any
software-enabled features (Tools > Optional Features).
For more information refer to the online help of the programming
application.
Task 6 —
Read the
Calibration File
Use the calibration application to read the calibration file and save it on the
test PC. If the calibration file cannot be read, set up a suitable default
calibration file and load it to the radio
Task 7 —
Check the
User Interface
Check the user interface as follows (This task does not apply to the blank
control head):
1. Use the programming application to activate backlighting, deactivate
silent and quiet modes, and view the programmed function keys,
channels and scan groups.
2. Tur n on the radio, make sure that the volume control is not set to low,
and check the start-up sequence:
■the LEDs light up red briefly
■the speaker gives two short beeps
■LCD and keypad backlighting activates
■the LCD displays a power-up message then a channel number, or
an error message.
3. Check the following elements of the user interface:
■volume control: With the graphical display, use CCTM command
1010 to read the volume potentiometer. The returned value
should be between 0 and 255.
■LCD: Check visually or, with the graphical display, use CCTM
command 1006 1 to switch on all LCD elements. Power-cycle the
radio to reset the LCD to its original state.
■PTT key: With the graphical display, while pressing the PTT key,
the transmit symbol or should appear on the radio display
(unless transmit is inhibited on the selected channel).
■scroll and selection keys: Scroll through all settings and observe the
radio display.
■function keys: Check whether the programmed function is
activated.
■keypad: With the graphical display, use CCTM command 1009 1
to turn on keypad notification. Check that each keypress returns
a different number. CCTM command 1009 1 turns keypad
notification off.
■backlighting (if programmed): Any keypress should activate
backlighting.
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4. If there is a fault in the user interface, repair the radio as described in
“Fault Finding of Control Head with Graphical Display” on
page 405 or “Fault Finding of Control Head with 1- 2- or 3-
Digit Display” on page 429.
5. If there is no fault, go to Ta s k 8 .
Task 8 —
Check
Error Messages
The radio may display an error message. Carry out the corrective actions
described in Table 6.1.
Table 6.1 Error messages
Error message Corrective action
Error E0001
Unknown
Turn the radio off and then back on.
Error E0002
Unknown
Continue with servicing tasks to locate the problem.
Error E0003
Corrupt FW
Re-download the radio’s firmware.
Error E0008
System error
0xabcdefgh
Turn the radio off and then back on. If the system error persists, download new
radio firmware.
To capture details of the system error, use CCTM command 204.
Temperature threshold
exceeded
Wait until the radio has cooled down.
Cannot tx Go to Task 9 on page 155.
Out of lock Go to “Frequency Synthesizer Fault Finding” on page 179.
Programming mode,
invalid radio ...
Re-program the radio with a new programming database. If the problem persists,
update or reload the radio’s firmware, and re-program the radio’s calibration
database.
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Task 9 —
Check the Transmit
and Transmit-Audio
Functions
If the radio does not transmit, this can be caused by:
■the synthesizer not being in lock
■no or wrong carrier power
■no modulation.
If the cause is already known, go directly to the relevant fault-finding
section.
Caution Observe the servicing precautions for transmitter
issues listed on page 109.
1. Use CCTM command 101 x y 0 to set the transmit frequency to the
bottom of the band.
2. Use CCTM command 33 to set the radio to transmit mode.
3. Use CCTM command 72 to read the lock status.
4. If the synthesizer is in lock, go to Step 5. If the synthesizer is not in
lock, repair the radio as described in “Frequency Synthesizer Fault
Finding” on page 179.
5. Repeat Step 1 to Step 4 with the transmit frequency set to the top of
the band.
6. Use CCTM command 326 1 to set the power level to very low.
7. Connect a power meter and measure the transmit power.
8. If the carrier power is correct, go to Step 10. If the carrier power is
not correct, try to re-calibrate the radio.
9. If the re-calibration repairs the fault, go to “Final Tasks” on page 157.
If it does not, repair the radio as described in “Transmitter Fault
Finding (40W/50W)” on page 259 and “Transmitter Fault Finding
(25W)” on page 323.
10. Repeat Step 6 to Step 9 with the power level set to high (326 4).
11. Check whether the speaker is the source of the fault, as described in
“Speaker Faulty” on page 422 (graphical display) or “Speaker Faulty”
on page 436 (1-, 2- or 3-digit display).
12. If the radio transmits audio now, the original speaker was faulty.
Reassemble the radio and go to “Final Tasks” on page 157. If the
radio still fails to transmit, reconnect the original speaker and go to
Step 13.
13. After having eliminated the synthesizer, the transmitter circuitry, and
the speaker as cause for the fault, repair the radio as described in
“CODEC and Audio Fault Finding” on page 381.
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14. If the main-board assembly was replaced or if the repair failed, re-
assemble the radio as described in “Disassembly and Reassembly” on
page 129. Conclude with the tasks of “Final Tasks” on page 157.
Task 1 0 —
Check the Receive
and Receive-Audio
Functions
If the radio does not receive, this can be caused by:
■the synthesizer not being in lock
■no carrier detected
■a faulty speaker or volume control
■no modulation.
If the cause is already known, go directly to the relevant fault-finding
section.
1. Use CCTM command 101 x y 0 to set the receive frequency to the
bottom of the band.
2. Use CCTM command 72 to read the lock status.
3. If the synthesizer is in lock, go to Step 5. If the synthesizer is not in
lock, repair the radio as described in “Frequency Synthesizer Fault
Finding” on page 179.
4. Repeat Step 1 to Step 3 with the receive frequency set to the top of
the band
5. Feed a signal without modulation on the receive channel at –47dBm.
Check for maximum RSSI using:
■the indicator on the radio display (graphical display)
■the green status LED
■CCTM command 63 should return the fed signal strength
±1dBm.
6. Repeat the check in Step 5 with –117dBm. The RSSI indicator
should show as empty or close to empty (graphical display).
7. If the carrier is detected correctly, go to Step 9. If the carrier is not
detected correctly, try to re-calibrate the radio.
8. If the re-calibration repairs the fault, go to “Final Tasks” on page 157.
If it does not, repair the radio as described in “Receiver Fault
Finding” on page 239.
9. Check whether the speaker is the source of the fault, as described in
“Speaker Faulty” on page 422 (graphical display) or “Speaker Faulty”
on page 436 (1-, 2- or 3-digit display).
10. If the radio receives audio now, the original speaker was faulty.
Reassemble the radio and go to “Final Tasks” on page 157. If the
radio still fails to receive, reconnect the original speaker and go to
Step 11.
11. Use CCTM command 804 to read the status of the volume
potentiometer.
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12. If the volume potentiometer is faulty, repair it as described in
“Volume Control Faulty” on page 424 (graphical display) or
“Volume Control Faulty” on page 436 (1-, 2- or 3-digit display).
If it is not faulty, go to Step 13.
13. After having eliminated the synthesizer, the receiver circuitry, the
speaker, and the volume potentiometer as cause for the fault, repair
the radio as described in “CODEC and Audio Fault Finding” on
page 381.
14. If the main-board assembly was replaced or if the repair failed, re-
assemble the radio as described in “Disassembly and Reassembly” on
page 129. Conclude with the tasks of “Final Tasks” on page 157.
6.2 Final Tasks
List of Tasks The following tasks need to be carried out for all radios:
■repair
■enable software features (if applicable)
■final inspection
■final test
■final administration.
Task 1 —
Repair The fault diagnosis will have resulted in the repair or replacement of the
main-board assembly. This section describes the steps after completion of
the fault diagnosis:
1. Use the programming and calibration applications to load the pro-
gramming and calibration files read or set-up in “Initial Tasks”.
Note If the radio had to be reprogrammed with a default programming
file, the following additional actions are required: If the radio is to
be returned direct to a Customer who has no programming facil-
ities, the appropriate programming file needs to be obtained and
uploaded (or the data obtained to create the file). If the radio is to
be returned to a Dealer or direct to a Customer who does have
programming facilities, the Dealer or Customer respectively need
to be informed so that they can program the radio appropriately.
Note If the main-board assembly has been replaced, certain software
features may need to be enabled before the programming file can
be loaded. See Task 2 on page 158.
2. Test the radio as described in “Final Test” on page 159.
It may be necessary to also re-calibrate to make the radio functional,
in particular if the main-board assembly had to be replaced or if a
default calibration file had to be loaded. Refer to the online help of
the calibration application.
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3. If the main-board assembly has been replaced, level-1 service centres
should return the faulty board to the nearest ASC, and level-2 service
centres should return the board or assembly to the ISC, if deemed
necessary. Supply details of the fault and, if applicable, the attempted
repair. Go to step Step 6.
If the main-board assembly has not been replaced, go to Step 4.
4. Replace any cans removed. Refer to “Shielding Cans and
Connectors” on page 114.
5. Re-test the radio as described in “Final Test” on page 159.
6. Reassemble the radio as described in “Disassembly and Reassembly”
on page 129.
7. Reconnect the radio to the test equipment and carry out a final
calibration of the radio. Refer to the online help of the calibration
application.
Task 2 —
Enable Software
Features (SFE)
If the main-board assembly has been replaced, ensure that the correct
software features, if any, are enabled for the Customer. If software features
need to be enabled, a special licence file is required for the replacement
main-board assembly. The file must allow for the enabling of the same
software features as in the original assembly. Proceed as follows:
1. If it was possible to read the software features in “Obtain the Details
of the Software Feature Enabler (SFE)” on page 153, go to Step 2.
If it was not possible, go to Step 3.
2. Reading the software features reveals if any software features are
enabled for the radio under repair. If there are, go to Step 3. If there
are none, go to Tas k 3 .
3. Technicians not at a CSO should contact their CSO regarding the
radio’s software features. Technicians at CSOs should contact
Technical Support at TEL.
4. Supply the serial number of the radio under repair, and the serial
number of the replacement main-board assembly (located on a label
on the main-board assembly).
5. If it is known that the radio had software features enabled, go to
Step 6. Otherwise go to Step 7.
6. Ask the CSO (or TEL) for a licence file for the replacement main-
board assembly. The CSO will supply the required file. Go to Step 8.
7. Ask the CSO (or TEL) if the radio under repair had any software
features enabled, and if so, to send a licence file for the replacement
main-board assembly. The CSO (or TEL) will either indicate that the
radio had no software features enabled or supply the required file. If
the radio had no software features enabled, go to Tas k 3 . If the
required file was supplied, go to Step 8.
TM8100/TM8200 Service Manual Servicing Procedures 159
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8. On receiving the licence file, run the programming application on the
test PC. On the menu bar click To o l s > Optional Features.
The Software Feature Enabler dialog appears.
9. Use the licence file to enable the appropriate software features.
The procedure is given in the on-line help facility under the heading
Enabling a feature. Go to Task 3.
Task 3 —
Final Inspection Make a final inspection of the exterior to check that no mechanical parts
have been damaged during the repair. Repeat the inspection given in
“Visual Inspection” on page 149. Rectify any damage.
Task 4 —
Final Test Test the radio to confirm that it is fully functional again. The recommended
tests are listed in Table 6.2 to Table 6.4. (The calibration application can be
used for many of these tests.) It is good practice to record the test results on
a separate test sheet. A copy of the test sheet can be supplied to the Customer
as confirmation of the repair.
Task 5 —
Final
Administration
The final administration tasks are the standard workshop procedures for
updating the fault database and returning the repaired radio to the Customer
with confirmation of the repair.
If the radio could not be repaired for one of the following reasons:
■fault not located
■repair of fault failed
■required repair is level-3 repair.
Level-1 service centres should return the faulty radio to the nearest ASC,
and level-2 service centres should return the radio to the ISC. Supply details
of the Customer, the fault and, if applicable, the attempted repair.
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Table 6.2 Final tests of transmitter function
Test Limits
Error in transmit frequency +100 Hz to –100 Hz
Transmit power:
•High
• Medium
•Low
• Very low
23.2 W to 29.2 W
11.1 W to 14.0 W
4.6 W to 5.8 W
0.9 W to 1.2 W
Current at high power:
• A4-band radios
• B1-band radios
• C0-band radios
• D1-band radios
• H5-band radios
• H6-band radios
< 5.5 A
< 5.5 A
< 5.5 A
< 5.5 A
< 6.5 A
< 6.5 A
Peak deviation (sweep tone of 300 Hz to 3 kHz):
• Narrow-band
• Medium-band
• Wide-band
< 2.5 kHz
< 4.0 kHz
< 5.0 kHz
Distortion:
• 1 kHz at 1.5 kHz deviation (narrow-band)
• 1 kHz at 3.0 kHz deviation (wide-band)
< 3%
< 3%
CTCSS (continuous-tone-controlled subaudible signaling) deviation:
• Narrow-band
• Medium-band
• Wide-band
250 to 350 Hz
500 to 560 Hz
580 to 680 Hz
Table 6.3 Final tests of receiver functions
Test Limits
Receive sensitivity <118 dBm for 12 dB SINAD
Mute opening:
• Country
•City
• Hard
>6 dB and <10 dB SINAD
>8 dB and <14 dB SINAD
>18 dB and <22 dB SINAD
Audio power (maximum volume at –47 dBm):
•At “RX AUDIO/SINAD” connector on test unit
• At pins 3 (SPK–) and 4 (SPK+) of power connector on radio
>500 mVrmsa
>5.00 Vrms
Distortion (at –47 dBm, 60% rated system deviation at 1kHz,
with volume set to give 3 W into 16 Ω load) <3.00%
a. The RX AUDIO/SINAD output on the test unit has 10dB of attenuation switched in when the test unit PORTABLE/MOBILE switch is
set to MOBILE. Refer to “TOPA-SV-024 Test Unit” on page 571 for details.
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Table 6.4 Final tests of general radio functions
Test Description
PTT switch Check that PTT switch functions.
Microphone Check operation of microphone.
Check operation of hook-switch.
Data communications Test 1200 baud data transmission (standard).
Test Tait high-speed data transmission (if feature is enabled).
Direct-connect GPS
(global positioning system)
Check that GPS poll returns correct position (if feature is enabled).
Selcall Check that radio encodes selcall.
Check that radio decodes selcall.
Audio tap points and digital I/O Check configuration of programmed options and test operation of
these lines to confirm that Customer requirements are satisfied.
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7 Power Supply Fault Finding
Fault-Diagnosis
Tasks Fault diagnosis of the power-supply circuitry is divided into the following
tasks:
■Task 1: check inputs to SMPS
■Task 2: check 3.3V supply
■Task 3: check linear regulators (for 2.5V, 3V, 6V and 9V supplies)
■Task 4: check power-up configuration
■Task 5: check power-up options
■Task 6: check provision of external power.
Types of Fault Which of the above tasks are applicable depends on the nature of the fault:
■Radio fails to power up: The radio fails to power up immediately when
power is applied, or it fails to power up when power is applied and the
ON/OFF key is pressed. Carry out Task 1 to Task 3
■Power-up option has failed: The radio powers up when the ON/OFF key is
pressed, but not for a power-up option for which it is configured.
Carry out Task 4 and Task 5.
■External power at connector has failed: The external power required at
a particular connector is no longer present. Carry out Task 6.
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Task 1 —
Check Inputs to
SMPS
The test equipment and radio should be set up as described in “Test
Equipment Setup” on page 111. If not already done, remove the board.
Connect the control head to the assembly. Then check the SMPS as follows:
1. Use a multimeter to check the supply voltage at pin 7 of IC602
(see Figure 7.1) in the SMPS circuitry; the voltage should be:
If it is, go to Step 5. If it is not, go to Step 2.
2. Disconnect the 13.8V supply at the power connector PL100. Check
for continuity and shorts to ground in the path between the power
connector PL100 and pin 7 of IC602 (see Figure 7.1). Locate and
repair the fault.
3. Reconnect the 13.8V supply. Confirm the removal of the fault by
measuring the voltage at pin 7 of IC602. If the voltage is correct,
continue with Step 4. If it is not, the repair failed; replace the board
and go to “Final Tasks” on page 157.
4. Press the ON/OFF key. If the radio powers up, return to “Initial Tasks”
on page 149. If it does not, go to Step 5.
5. Check the digital power-up signal at pin 5 of IC602
(see Figure 7.1); the signal is active high, namely, when the voltage
exceeds 2.0V DC. Measure the voltage at pin 5.
If it exceeds 2.0V, go to Tas k 2 . If it does not, go to Step 6.
6. Keep the probe of the multimeter on pin 5 of IC602 and press the
ON/OFF key. The voltage should exceed 2.0V DC while the key is
depressed. If it does, go to Tas k 2. If it does not, go to Step 7.
7. Disconnect the 13.8V supply at the power connector PL100. Check
for continuity and shorts to ground in the path from pin 5 of IC602,
via R600 and via Q709 in the interface circuitry (see Figure 8.4), to
pin 9 of the control-head connector SK100 (ITF PSU ON OFF line).
Locate and repair the fault. Go to Step 8.
8. Reconnect the 13.8V supply. Press the ON/OFF key. If the radio powers
up, return to “Initial Tasks” on page 149. If it does not, go to Step 9.
9. With the probe of the multimeter on pin 5 of IC602 (see Figure 7.1),
press the ON/OFF key again. The voltage should exceed 2.0V DC
while the key is depressed. If it does, go to Tas k 2 . If it does not, the
repair failed; replace the board and go to “Final Tasks” on page 157.
pin 7 of IC602: 13.8 V DC
pin 5 of IC602: more than 2.0 V DC
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Figure 7.1 Important components of the power-supply circuitry (bottom side),
including 3.3V regulator IC602
pin 7
pin 5
C603
C618
R199
D604 Q709D601
C718
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Task 2 —
Check 3.3V Supply If the inputs at pin 5 and pin 7 of IC602 in the SMPS circuitry are correct,
but the radio fails to power up, then the 3.3V DC supply needs to be
investigated.
1. First determine as follows if a fault on the digital board is affecting the
supply or preventing the radio from powering up: While keeping the
ON/OFF key depressed, measure the supply at the 3V3test point near
the corner of the digital board (see Figure 7.2). The voltage is 3.3V
when there is no fault.
If the voltage is correct, the digital board is faulty; replace the board
and go to “Final Tasks” on page 157. If the voltage is not correct, go
to Step 2.
Figure 7.2 Important components of the power-supply circuitry (top side),
including 9V regulator IC601
3V3 test point
Q600 LK8 (R786)
LK7 (R787)
3V3 test point: 3.3 ± 0.1 V DC
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2. Disconnect the 13.8V supply at the power connector. Remove R199
(see Figure 7.1). Reconnect the 13.8V supply.
3. With the probe of the multimeter on the 3V3 test point, press the
ON/OFF key. If the voltage is now 3.3 ± 0.1V, the digital board is faulty;
replace the board and go to “Final Tasks” on page 157. If the voltage
is still not correct, go to Step 4.
4. If the digital board is functional, the fault is on the main board.
Replace R199. Disconnect the 13.8V supply. Use the multimeter to
measure the resistance between the 3V3 test point and ground.
If there is a short circuit, continue with Step 5. If there is no short
circuit (but the voltage is wrong), go to Step 7.
5. Search for shorts to ground in the components C603, C612, C613,
C618, D606 of the SMPS circuitry (see Figure 7.1) as well as in the
CODEC and interface circuitry. Repair any fault and repeat the
resistance measurement of Step 4 to confirm the removal of the fault.
If there is no fault, go to Step 6. If the fault remains, the repair failed;
replace the board and go to “Final Tasks” on page 157.
6. Reconnect the 13.8V supply. Press the ON/OFF key. If the radio powers
up, return to “Initial Tasks” on page 149. If the radio fails to power
up, disconnect the 13.8V supply and go to Step 7.
7. Measure the resistance of L601 (see Figure 7.1). The resistance
should be virtually zero. If it is, go to Step 8. If it is not, replace L601.
Reconnect the 13.8V supply and press the ON/OFF key. If the radio
powers up, return to “Initial Tasks” on page 149. If the radio fails to
power up, disconnect the 13.8V supply and go to Step 8.
8. Remove the CDC BOT can. Remove IC603 (3.0V regulator) and
IC604 (2.5V regulator) (see Figure 7.3). Reconnect the 13.8V
supply and press the ON/OFF key. If the 3.3V supply is restored, go to
Task 3 to check each regulator (3.0V and 2.5V) in turn. If the 3.3V
supply is not restored, continue with Step 9.
9. Suspect IC602. Disconnect the 13.8V supply. Replace IC602 with a
spare (see Figure 7.1). Resolder IC603 and IC604 in position
(see Figure 7.3). Reconnect the 13.8V supply and press the ON/OFF
key. If the radio powers up, return to “Initial Tasks” on page 149.
If the radio fails to power up, the repair failed; replace the board and
go to “Final Tasks” on page 157.
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Task 3 —
Check Linear
Regulators
This task describes the general procedure for checking any linear regulator.
There are two possible faults: either the regulator has failed and prevents the
radio from powering up, or the regulator voltage is incorrect. (The regulator
IC might or might not have been removed during earlier checks.)
1. Disconnect the 13.8 V supply. Check for continuity and shorts to
ground (if not already done) on the input, output and control line of
the relevant regulator IC. Repair any fault.
2. If the regulator IC has been removed, resolder it in position.
3. Reconnect the 13.8 V supply and press the ON/OFF key. If the radio
powers up or the correct regulator voltage is restored, return to
“Initial Tasks” on page 149. If the repair failed, go to Step 4.
4. Disconnect the 13.8 V supply. Replace the regulator IC with a spare.
Reconnect the 13.8 V supply and press the ON/OFF key. If the radio
powers up or the correct regulator voltage is restored, go to “Final
Tasks” on page 157. If the repair failed, replace the board and go to
“Final Tasks” on page 157.
Figure 7.3 Power-supply circuitry under the CDC BOT can, including 3V regulator IC603 and 2.5V
regulator IC604
LO2 BOT CAN
CAN FOR
DIGITAL
BOARD
TP601
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Task 4 —
Check Power-up
Configuration
The radio may be configured for one or more of the following power-up
options:
■battery power sense
■auxiliary power sense
■emergency power sense
■internal-options power sense
A particular option is implemented by inserting the link mentioned in
Table 7.1. If there is a fault with a power-up option for which the radio is
configured, first confirm that the configuration is correct:
1. Confirm that the correct link or links have been inserted for the
required power-up options (see Figure 7.2 and Table 7.1). For all
except the battery-power-sense option, also check the radio’s
programming as follows:
2. Open the “Programmable I/O” form.
3. Under the “Digital” tab, scroll to the relevant digital line listed in the
“Pin” field:
■internal-options power sense: IOP GPIO7
■auxiliary power sense: AUX GPI3
■emergency power sense: AUX GPI2
4. For the first two lines, confirm that the “Power Sense (Ignition)” option
has been selected in the “Action” field, and “High” or “Low” in the “Active”
field. For the third line, confirm that “Enter Emergency Mode” has been
selected.
5. If the link and programming settings are correct, go to Task 5. If they
are not, rectify the settings and check if the fault has been removed.
If it has, return to “Initial Tasks” on page 149. If it has not, go to
Task 5.
Table 7.1 Implementation of the power-up options
Power-up
option
Link to
insert
Factory
default Activation mechanism Connector
Battery
power sense
LK1 Link in Connection of 13.8V supply Power connector
Auxiliary
power sense
LK2 Link in AUX GPI3 line goes high
(If LK1 is in, line floats high;
if LK1 is out, line floats low)
Pin 4 of
auxiliary connector
Emergency
power sense
LK3 Link in AUX GPI2 line goes low Pin 5 of
auxiliary connector
Internal-options
power sense
LK4 Link out IOP GPIO7 line goes high Pin 15 of
internal-options connector
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Task 5 —
Check Power-up
Options
The functioning of the power-up options may be checked as described in
Step 1 to Step 4 below. Carry out the procedure in the appropriate step or
steps. In all four cases the procedure involves checking the digital power-up
signal at pin 5 of IC602. For a particular option, the activation mechanism
is the condition that results in the power-up signal becoming active (the
signal is active high).
1. For the battery power-sense option the link LK1 should be inserted
(see Figure 7.2). Check the power-up signal at pin 5 of IC602
(see Figure 7.1) while first disconnecting and then reconnecting the
13.8V DC supply at the power connector.
The power-up signal should go high when the power is reconnected.
If it does, conclude with Step 5. If it does not, check for continuity
and shorts to ground between the link LK1 and the +13V8BATT input
at the power connector PL100. Repair any fault and go to Step 5.
2. For the auxiliary power-sense option the link LK2 should be inserted
(see Figure 7.2). Connect +3.3V DC (more than 2.6V to be
precise) from the power supply to the AUX GPI3 line (pin 4 of the
auxiliary connector SK101). Check that the power-up signal at pin 5
of IC602 (see Figure 7.1) is high.
Remove the +3.3V supply and ground the AUX GPI3 line (to be precise
the voltage on the line should be less than 0.6V). If the power-up
signal is now low, conclude with Step 5. If it is not, check for
continuity and shorts to ground between D601 (see Figure 7.1) and
pin 4 of the auxiliary connector SK101. Repair any fault and go to
Step 5.
3. For the emergency power-sense option the link LK3 should be
inserted (see Figure 7.2). Connect the AUX GPI2 line (pin 5 of the
auxiliary connector SK101) to ground. Check that the power-up
signal at pin 5 of IC602 (see Figure 7.1) is high.
Remove the connection to ground. If the power-up signal is now
low, conclude with Step 5. If it is not, check for continuity and shorts
to ground in the path from D601 (see Figure 7.1), via Q600
(see Figure 7.2), to pin 5 of the auxiliary connector SK101. Repair
any fault and go to Step 5.
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4. For the internal-options power-sense option the link LK4 should be
inserted (see Figure 7.2). Connect +3.3V DC (more than 2.6V to
be precise) from the power supply to the IOP GPIO7 line (pin 15 of the
internal-options connector SK102). Check that the power-up signal
at pin 5 of IC602 (see Figure 7.1) is high.
Remove the +3.3V supply and ground the IOP GPIO7 line (to be
precise the voltage on the line should be less than 0.6V). If the power-
up signal is now low, conclude with Step 5. If it is not, check for
continuity and shorts to ground between D604 (see Figure 7.1) and
pin 15 of the internal-options connector SK102. Repair any fault and
go to Step 5.
5. After checking all the relevant power-up options, and if necessary
repairing any faults, go to “Final Tasks” on page 157. If the fault
could not be found or repairs failed, replace the board and go to
“Final Tasks” on page 157.
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Task 6 —
Check Provision of
External Power
External power is supplied to pin 8 of the auxiliary connector SK101.
The power is normally switched, but will be unswitched if all the links LK5
to LK8 are inserted. (With all the links inserted, the power at the other
connectors is also unswitched.)
External power, either switched or unswitched, is supplied to pin 2 of the
control-head connector SK100. The power is switched or not depending on
the links LK5 and LK6:
■switched power: LK5 in, LK6 out
■unswitched power: LK5 out, LK6 in
External power is also supplied to pin 1 of the internal-options connector
SK102. The power is switched or not depending on the links LK7 and LK8:
■switched power: LK7 in, LK8 out
■unswitched power: LK7 out, LK8 in
Note In some boards, LK7 is R786 and LK8 is R787.
If there is a fault with the supply of external power to any of these
connectors, first confirm the link settings required and then carry out the
following procedure:
1. With the radio powered up, confirm that 13.8V DC is present at pin
3 of IC605 (see Figure 7.1) and more than 3V DC at pin 2.
2. Check that 13.8 V is present at pin 5 of IC605. If there is, go to
Step 3. If there is not, go to Step 4.
3. Check for an open circuit between pin 5 of IC605 and the relevant
pin of the connector in question. Repair any fault, confirm the
removal of the fault, and go to “Final Tasks” on page 157. If the
repair failed or the fault could not be found, replace the board and go
to “Final Tasks” on page 157.
4. Check for continuity between pin 5 of IC605 and the relevant pin of
the connector in question. Check for shorts to ground, check C718
at the auxiliary connector (see Figure 7.1), and check C715 at the
internal-options connector (see Figure 8.2).
5. Repair any fault found in the above checks. If no fault could be
found, replace IC605.
6. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
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8 Interface Fault Finding
Introduction This section covers the diagnosis of faults involving signals output from or
input to the radio’s internal circuitry via the control-head, internal options,
power, or auxiliary connectors. For most inputs and outputs, filtering or
basic processing is applied between the internal circuitry and the connectors.
Internal and
Connector Signals The signals at the internal circuitry and those at the connectors are
distinguished as internal signals and connector signals respectively. On the
circuit diagram for the internal circuitry, dashed lines enclose connector
signals. Internal signals are all named signals outside these enclosures. In
Figure 8.1, which shows part of the internal options connector as an
example, IOP GPIO7 is a connector signal and ITF IOP GPIO7 is an internal signal.
Types of Signals The connector and internal signals can be of three types:
■output lines
■input lines
■bi-directional lines.
For diagnosing faults in these three cases, carry out Task 1, Task 2 or Task 3
respectively. Where components need to be replaced to rectify faults, refer
to Figure 8.2 to Figure 8.4 for the locations of the components. These
figures show the three areas of the main board where the components of the
interface circuitry are situated.
Figure 8.1 Example illustrating the convention for internal and connector signals
+3V3_CL +3V3
D705
BAV70W
2
3 R723
33K R731
1K0
IOP_GPIO7
1B2
6B4
ITF_IOP_GPO7
+3V3_CL +3V3
D706
BAV70W
1
3 R724
33K R732
1K0
IOP_GPIO6
1B2
ITF_IOP_GPO6
+3V3_CL +3V3
D706
BAV70W
2
3 R725
33K R733
1K0
IOP_GPIO5
1B2
ITF_IOP_GPO5
TO
INTERNAL
OPTIONS
CONNECTOR
174 Interface Fault Finding TM8100/TM8200 Service Manual
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Figure 8.2 Components of the interface circuitry (top side near the CDC TOP and IF TOP cans)
Figure 8.3 Components of the interface circuitry (top side at the corner)
CDC TOP CANIF TOP CAN
TM8100/TM8200 Service Manual Interface Fault Finding 175
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Task 1 —
Check Output Lines For an output line suspected or reported to be faulty, compare actual and
expected signals as described below. If necessary, determine what an
expected signal should be by copying the faulty radio’s programming file
into a serviceable radio and measuring the relevant points on the latter.
1. Check the electrical signal at the appropriate pin of a connector
mated to the radio connector in question. If the expected connector
signal is not present, go to Step 3. If it is, go to Step 2.
2. If the expected signal is present, there might be no fault on that line
or there could be an intermittent fault. Subject the radio to mild
mechanical shock or vibration, or to a temperature change. This
might expose any intermittent contact, in which case go to Step 3.
3. If the expected signal is not present, check whether the expected
internal signal is present. If it is, go to Step 5. If it is not, go to Step 4.
4. The fault lies with the radio’s internal circuitry. If the power-supply
circuitry or the CODEC and audio circuitry is suspect, continue with
the fault diagnosis as in “Power Supply Fault Finding” on page 163
and “CODEC and Audio Fault Finding” on page 381 respectively. If
the digital board is suspect, replace the board and go to “Final Tasks”
on page 157.
5. The fault lies in the filtering, basic processing, or connector for the
line under test. Re-solder components or replace damaged or faulty
components as necessary. Confirm the removal of the fault and go to
“Final Tasks” on page 157. If the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
176 Interface Fault Finding TM8100/TM8200 Service Manual
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Figure 8.4 Components of the interface circuitry (bottom side)
TM8100/TM8200 Service Manual Interface Fault Finding 177
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Task 2 —
Check Input Lines For an input line suspected or reported to be faulty, proceed as follows:
1. For a suspect CH ON OFF line, go to Step 4. For all other input lines go
to Step 2.
2. For the suspect line, apply a 3.3V DC test signal to a connector mated
to the radio connector in question.
3. Check the internal signal for the line under test. If 3.3V DC is
present, go to Step 7. If it is not, go to Step 8.
4. For the CH ON OFF line, apply a short to ground on pin 5 of a connector
mated to the control-head connector. Check that there is 3.9V DC
present on the ITF ON OFF line, and that PSU ON OFF is approximately
equal to the radio’s primary supply voltage, nominally 13.8V DC.
5. Remove the short on the connector. Check that, with CH ON OFF
open-circuit, both ITF ON OFF and ITF PSU ON OFF are close to 0.0V.
6. If the voltages given in Step 4 and Step 5 are observed, go to Step 7.
If they are not, go to Step 8.
7. The fault lies with the radio’s internal circuitry. If the power-supply
circuitry or the CODEC and audio circuitry is suspect, continue with
the fault diagnosis as in “Power Supply Fault Finding” on page 163
and “CODEC and Audio Fault Finding” on page 381, respectively.
If the digital board is suspect, replace the board and go to “Final
Tasks” on page 157.
8. The fault lies in the filtering, basic processing, or connector for the
line under test. Re-solder components or replace faulty components
as necessary. Confirm the removal of the fault and go to “Final Tasks”
on page 157. If the fault could not be found, replace the board and
go to “Final Tasks” on page 157.
Task 3 —
Bi-directional Lines For a bi-directional line suspected or reported to be faulty, proceed as
described below. In the procedure the direction of the line will need to be
configured. For information on this topic consult the on-line help facility
on the programming application’s “Programmable I/O” page.
1. Configure the suspect line as an output, and then carry out the
procedure given in Tas k 1 .
2. Configure the suspect line as an input, and then carry out the
procedure given in Tas k 2 .
178 Interface Fault Finding TM8100/TM8200 Service Manual
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TM8100/TM8200 Service Manual Frequency Synthesizer Fault Finding 179
© Tait Electronics Limited June 2006
9 Frequency Synthesizer Fault Finding
Introduction This section covers the diagnosis of faults in the frequency synthesizer.
The sections are divided into the following:
■Initial checks
■Fault diagnosis of RF PLL circuitry
■Fault diagnosis of FCL circuitry.
The initial checks will indicate whether it is the RF PLL or the FCL that is
suspect. Note that the synthesizer is a closed-loop control system. A fault in
one area can cause symptoms to appear elsewhere. Locating the fault can
therefore be difficult.
Measurement
Techni q u es The radio must be in CCTM for all the fault-diagnosis procedures of this
section. The CCTM commands required are listed in Table 9.1. Full details
of the commands are given in “Computer-Controlled Test Mode
(CCTM)” on page 118. Use an oscilloscope with a x10 probe for all voltage
measurements required. The signals should appear stable and clean.
Consider any noise or unidentified oscillations as evidence of a fault
requiring investigation. Use a frequency counter for all measurements of
high frequencies. The RF power output from the frequency synthesizer will
not exceed 10mW. If a probe is used for frequency measurements, use the
x1 setting.
Table 9.1 CCTM commands required for the diagnosis of faults in the frequency synthesizer
Command Description
72 Read lock status of RF PLL, FCL and LO2 — displays xyz (0=not in lock, 1=in lock)
101 x y 0 Set transmit frequency (x in hertz) and receive frequency (y in hertz) to specified values
205 Reset calibration parameters to their default values
301 0 10 Calibrate VCXO of FCL
302 0 10 Calibrate VCO(s) of RF PLL
334 xSet synthesizer on (x=1) or off (x=0) via DIG SYN EN line
335 xSet transmit-receive switch on (x=1) or off (x=0) via DIG SYN TR SW line
389 xSet synthesizer mode to slow (x=0) or fast (x=1)
393 1 xWrite data x to FPGA
180 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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9.1 Initial Checks
Types of checks There are two different types of initial checks, which are covered in the
following tasks:
■Task 1: calibration checks
■Task 2: lock status.
Which, if any, of these tasks needs to be carried out depends on the
symptoms of the fault.
Symptoms of Fault The symptoms of the fault may be divided into three categories:
■radio fails to power up and system error is displayed
■lock error is displayed
■radio is in lock but exhibits transmit or receive fault.
The nature of the display depends on the type of control head as shown in
Table 9.2.
In the first two cases the checks of Task 1 and Task 2 respectively are
required. In the last case there are several symptoms; these are listed below.
Frequency Bands Where test procedures or figures differ according to the frequency band of
the radio, the frequency band is given in brackets. The frequency band may
be referred to as either ‘VHF’ (very high frequency) or ‘UHF’ (ultra high
frequency) or identified by the frequency sub-band, such as ‘B1’ or ‘H7’.
The product-code label on the radio body will identify the frequency band
as described in “Product Codes” on page 17. A definition of frequency
bands is given in “Defining Frequency Bands” on page 126.
Table 9.2 Format of error displays by different control heads
Control head Type of error
Lock error System error
1-digit-display control head LE
2-digit-display control head OL E2
3-digit-display control head OL E2
Graphical-display control head Out of lock System error
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Transmit and
Receive Faults A transmit or receive fault will be implied by one of the following
consequences:
■radio fails to receive or receive performance is degraded
■radio fails to enter transmit mode
■radio exits transmit mode unexpectedly
■radio enters transmit mode but fails to transmit
■radio enters transmit mode but transmit performance is degraded.
With a fault of this kind, neither of the initial tasks is required.
Fault diagnosis should begin with “Power Supplies” on page 183.
Summary To summarize, given the nature of the fault, proceed to the task or section
indicated below:
■Task 1: system error
■Task 2: lock error
■“Power Supplies”: transmit or receive fault.
The checks of Task 1 and Task 2 will indicate the section with which the
fault diagnosis should continue.
Task 1 —
System Error A system error indicates a fault in the calibration of either the FCL or the
frequency synthesizer. To determine which is faulty, calibrate the VCXO
and the transmit VCO as described below. (Always calibrate the former first,
because the latter depends on the former.)
1. Place the radio in CCTM.
2. Enter the CCTM command 301 0 10 to calibrate the VCXO.
The response will be one of the following three messages:
■“passed sanity check. Cal’d values put into effect”
■“failed sanity check. Cal’d values not in effect”
■“Cal failed: lock error”.
The first two messages will be preceded by four calibration values.
3. In the case of the first message (passed), go to Step 4. In the case of
the second and third messages (failed), the FCL is suspect; go to
“Power Supply for FCL” on page 227.
4. Enter the CCTM command 302 0 10 to calibrate the transmit VCO.
The response will be one of the three messages listed in Step 2.
The first two messages will be preceded by eight calibration values.
Reset the radio and re-enter CCTM.
5. If the calibration succeeded but the system error persists, replace the
board and go to “Final Tasks” on page 157. In the case of the second
message (failed sanity check), go to Step 6. In the case of the third
message (calibration failed), go to Step 8 (UHF radios) or “Power
Supplies” on page 183 (VHF radios).
182 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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6. Enter the CCTM command 205 to reset the calibration values to the
default values. Then enter the CCTM command 302 0 10 again to
calibrate the transmit VCO.
7. If the calibration succeeded, confirm the removal of the fault, and go
to “Final Tasks” on page 157. If the calibration failed, go to Step 8
(UHF radios) or “Power Supplies” on page 183 (VHF radios).
8. Program the radio with the maximum frequency in the radio’s
frequency band: Enter the CCTM command 101 x x 0, where x is the
frequency in hertz.
9. Enter the CCTM command 72 to determine the lock status in receive
mode. Note the response.
10. If the lock status is 111 or 110, the synthesizer is functioning in the
receive mode, and the power supplies and PLL are functioning
correctly. Go to “Loop Filter” on page 198 to check the loop filter,
VCOs, and buffer amplifiers. If the lock status is 011 or 010, the
synthesizer is faulty in the receive mode. Go to “Power Supplies” on
page 183.
Task 2 —
Lock Status A lock error indicates that the frequency synthesizer, FCL or second LO is
out of lock. To determine which is faulty, check the lock status as described
below.
1. If not already done, place the radio in CCTM.
2. Program the radio with the receive frequency of a channel that is
known to be out of lock: Enter the CCTM command 101 x x 0,
where x is the frequency in hertz.
3. Enter the CCTM command 72 to determine the lock status in receive
mode. Note the response. The action required depends on the lock
status as described in the following steps.
4. If the lock status is x0x, where x is 0 or 1, the FCL is suspect; go to
“Power Supply for FCL” on page 227.
5. If the lock status is 011, the synthesizer is suspect, although the power
supplies are functioning correctly; go to “Loop Filter” on page 198.
6. If the lock status is 010, the synthesizer and second LO are both out
of lock. First investigate the synthesizer, excluding the power supplies;
go to “Loop Filter” on page 198. If necessary, investigate the receiver
later.
lock status=xyz (x=RF PLL; y=FCL; z=LO2) (0=not in lock; 1=in lock)
lock status=xyz (x=RF PLL; y=FCL; z=LO2) (0=not in lock; 1=in lock)
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7. If the lock status is 110, the second LO is out of lock. Go to
“Receiver Fault Finding” on page 239.
8. If the lock status is 111, this implies normal operation. But if the lock
error persists, replace the board and go to “Final Tasks” on page 157.
9.2 Power Supplies
Introduction First check that a power supply is not the cause of the fault. There are four
power supplies for the frequency synthesizer — two are supplied from the
PSU (power supply unit) module and two are produced in the synthesizer
circuitry itself:
■Task 3: 14 V DC supply from SMPS (VCL SUPPLY)
■Task 4: 6 V DC supply from 6 V regulator in PSU module (+6V0)
■Task 5: 5 V DC supply following filtering of 6 V supply (+5V DEC)
■Task 6: 3 V DC supply from 3 V regulator in PSU module (+3V0 AN).
The measurement points for diagnosing faults in the power supplies are
summarized in Figure 9.1.
Figure 9.1 Measurement points for the frequency synthesizer power supply circuitry
PIN4OF
Q508
PIN 4 OF
Q508
PIN4OF
IC606
PIN 4 OF
IC606
PIN5OF
IC606
PIN 5 OF
IC606
Q500 AND
R533
Q500 AND
R533
PINS 7 AND 15
OF IC503
PINS 7 AND 15
OF IC503
SIGNAL TYPES
RF
ANALOG
CLOCK
DIGITAL
PLL
14 V
SMPS
LOOP
FILTER
AND
SUMMER
FILTERING
OF SUPPLY
FOR PLL
AND LOOP
FILTER
FILTERING
OF SUPPLY
FOR VCO
CIRCUITRY
3V
SUPPLY
VCO
CIRCUITRY
FREQUENCY
SYNTHESIZER
INTERFACE
CIRCUITRY
INVERTER
JUNCTION OF
C531 AND R530
JUNCTION OF
C531 AND R530
+3V0 AN
L506
9V
SUPPLY
6V
SUPPLY
AGND
+9V0
+6V0
VCL SUPPLY+5V DEC
184 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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Figure 9.2 Synthesizer circuitry under the SYN TOP can and the 6 V regulator IC606 (top side)
VHF bands
UHF bands
Measurement
point on L506
(pin not used)Pin 5 (5-pin device)
Q508
Q507
Q506
Q508
Q512
Q512
Q508
Q5004
A4 band differences
SMPS output (C531 and
R530 are on the bottom side
of the PCB)
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Task 3 —
14V Power Supply First check the output VCL SUPPLY from the SMPS, which is itself provided
with a 9V DC supply from a 9V regulator in the PSU module.
1. Remove the board from the chassis.
2. Place the radio in CCTM.
3. Measure the SMPS output VCL SUPPLY at the via between C531 and
R530 (see Figure 9.2).
Note On A4 band radios, C531 and R530 are on the bottom side of the
PCB. Measure the VCL SUPPLY voltage on the via beside C5050.
4. If the SMPS output is correct, go to Tas k 4 . If it is not, go to Step 5.
5. Check the 9 V supply at Q500 and R533 (see Figure 9.3).
6. If the voltage is correct, go to Step 7. If it is not, the 9V regulator
IC601 is suspect; go to Tas k 3 of “Power Supply Fault Finding” on
page 168.
7. Remove the FCL TOP can and check the SMPS circuit based on Q500,
Q502 and L502 (see Figure 9.3).
Note On A4 band radios, these components are not located under the
FCL TOP can (see Figure 9.3).
Remove the SYN BOT can and check IC504 and IC505 for shorts
(see Figure 9.4); replace any suspect IC.
8. If a fault is found, repair the circuit, confirm the removal of the fault,
and go to “Final Tasks” on page 157. If the repair failed or no fault
could be found, replace the board and go to “Final Tasks” on
page 157.
C531: 14.2 V ± 0.3 DC
Q500 and R533: 9.0 V ± 0.3 DC
186 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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Figure 9.3 Synthesizer circuitry under the FCL TOP can (top side)
A4 band
PAD TOP can
(top side PCB)
VCXO BOT can
(bottom side PCB)
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Task 4 —
6V Power Supply If the output of the SMPS is correct, check the 6V DC supply next.
1. Measure the supply +6V0 at pin 4 of IC606 (see Figure 9.2).
2. If the voltage is correct, go to Task 5 . If it is not, measure the 9V
input at pin 5 of IC606 (see Figure 9.2).
3. If the voltage is correct, go to Step 4. If it is not, the 9V regulator
IC601 is suspect; go to Tas k 3 of “Power Supply Fault Finding” on
page 168.
4. If the input to the regulator IC606 is correct but not the output,
check IC606 (see Figure 9.2) and the associated circuitry; if
necessary, replace IC606.
Remove the SYN TOP can and check the C-multipliers Q508 (pins 3,
4, 5) and Q512 for shorts (see Figure 9.2); replace any suspect
transistor.
5. If a fault is found, repair the circuit, confirm the removal of the fault,
and go to “Final Tasks” on page 157. If the repair failed or no fault
could be found, replace the board and go to “Final Tasks” on
page 157.
pin 4 of IC606: 6.0 ± 0.3V DC
pin 5 of IC606: 9.0 ± 0.3V DC
188 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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Figure 9.4 Synthesizer circuitry under the SYN BOT can (bottom side)
IC505
IC504 Q505
Q511
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Task 5 —
5V Power Supply If the SMPS output and 6V DC supply are correct, check the +5V DEC
supply next.
1. Remove the SYN TOP can.
2. Measure the supply +5V DEC at pin 4 of Q508 (see Figure 9.2).
3. If the voltage is correct, go to Task 6 . If it is not, go to Step 4 (UHF
radios) or Step 5 (VHF radios).
4. With a UHF radio check for faults in the C-multiplier Q508 (pins 3,
4, 5) and the 5V and transmit-receive switches based on Q506, Q507
and Q508 (pins 1, 2, 6) (see Figure 9.2). Replace any suspect
transistor. Conclude with Step 6.
5. With a VHF radio, check for faults in the C-multiplier and 5V switch
based on Q508 and Q5004 (see Figure 9.2). Remove the SYN TOP
can (A4 band only) and VCO BOT can, and check the transmit-receive
switch based on Q5002 and Q5003 (see Figure 9.5). Replace any
suspect transistor. Conclude with Step 6.
6. If a fault is found, repair the circuit, confirm the removal of the fault,
and go to “Final Tasks” on page 157. If the repair failed or no fault
could be found, replace the board and go to “Final Tasks” on
page 157.
pin 4 of Q508: 5.3 ± 0.3V DC
190 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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Figure 9.5 Transmit-receive switch components — VHF bands
Q5003
Q5002
Q5003 Q5002
SYN TOP
A4 band
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Task 6 —
3V Power Supply If the SMPS output and the 6V and 5V supplies are correct, the remaining
power supply to check is the 3V DC supply.
1. Measure the supply +3V0 AN at pins 7 and 15 of IC503
(see Figure 9.2).
2. If the voltage is correct, go to “Phase-locked Loop” on page 192.
If it is not, go to Step 3.
3. Check the supply at L506 (see Figure 9.2). The measurement point
is the via shown in the figure.
4. If the voltage is correct, go to Step 5. If it is not, the 3 V regulator
IC603 is suspect; go to Tas k 3 of “Power Supply Fault Finding” on
page 168.
5. Check the components in the path from L506 to IC503. Also check
IC503; if necessary, replace IC503 (see Figure 9.2).
6. If a fault is found, repair the circuit, confirm the removal of the fault,
and go to “Final Tasks” on page 157. If the repair failed or no fault
could be found, replace the board and go to “Final Tasks” on
page 157.
pins 7 and 15 of IC503: 2.9 ± 0.3V DC
L506: 2.9 ± 0.3V DC
192 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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9.3 Phase-locked Loop
Introduction If there is no fault with the power supplies, check the critical output from,
and inputs to, the PLL:
■Task 7: supply for charge pump
■Task 8: reference frequency input
■Task 9: DIG SYN EN line input
■Task 10: SYN LOCK line output.
The measurement points for diagnosing faults concerning the PLL inputs
and output are summarized in Figure 9.6.
Task 7 —
Supply for
Charge Pump
First check the supply for the charge pump of the PLL.
1. Measure the supply for the charge pump at pin 16 of IC503
(see Figure 9.2).
2. If the voltage is correct, go to Task 8. If it is not, go to Step 3.
3. Check the C-multiplier Q512 (see Figure 9.2) and check IC503
itself; if necessary, replace the transistor or IC.
4. If there is a fault, repair the circuit, confirm the removal of the fault,
and go to “Final Tasks” on page 157. If the repair failed or no fault
could be found, replace the board and go to “Final Tasks” on
page 157.
pin 16 of IC503: 5.0 ± 0.3 V DC
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Figure 9.6 Test and measurement points for the synthesizer PLL and loop filter
FEEDBACK
VOLTAGE
PIN 6 OF IC505
FEEDBACK
VOLTAGE
PIN 6 OF IC505
PIN 16 OF
IC503
PIN 16 OF
IC503
PIN5OF
IC505
PIN 5 OF
IC505
PIN8OF
IC503
PIN 8 OF
IC503
PIN 14 OF
IC503
PIN 14 OF
IC503
PIN 10 OF
IC503
PIN 10 OF
IC503
COLLECTOR
OF Q505
COLLECTOR
OF Q505
OUTPUT OF LOOP
FILTER AT C565
OUTPUT OF LOOP
FILTER AT C565
TP503
(JUNCTION OF
R566 AND R570)
TP503
(JUNCTION OF
R566 AND R570)
SIGNAL TYPES
RF
ANALOG
CLOCK
DIGITAL
PLL
LOOP
FILTER
AND
SUMMER
FILTERING
OF SUPPLY
FOR PLL
AND LOOP
FILTER
FCL
VCO
CIRCUITRY
FREQUENCY
SYNTHESIZER
PLL FEEDBACK
CODEC
AND AUDIO
CIRCUITRY
DIGITAL
BOARD
DIG SYN FAST
SYN LOCK
DIG SYN EN
INVERTER
VIA TO CHECK
DIG SYN FAST
VIA TO CHECK
DIG SYN FAST
VIA TO CHECK
DIG SYN EN
VIA TO CHECK
DIG SYN EN
VIA TO CHECK
SYN LOCK
VIA TO CHECK
SYN LOCK
R105
R104
JUNCTION OF
C541 AND R547
JUNCTION OF
C541 AND R547
R549
R544
+3V0 AN
L506
3V
SUPPLY
R568
R542
L102
REFERENCE
FREQUENCY
C536
SYN CDC LFV
CDC VCO MOD
SUPPLY FOR CHARGE PUMP
REFERENCE
VOLTAGE
OUTPUT
PLL
LOOP
VOLTAGE
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Task 8 —
Reference
Frequency
If the supply for the charge pump is correct, check the reference frequency
input from the FCL to the PLL.
1. Measure the reference frequency at pin 8 of IC503 (see Figure 9.2).
2. If the signal is correct, go to Task 9. If it is not, go to Step 3.
3. Check IC503 (see Figure 9.2). Replace IC503 if it is suspect.
4. Determine if the fault has been removed. If it has, go to “Final Tasks”
on page 157. If it has not, the FCL is suspect; go to “Power Supply
for FCL” on page 227.
Figure 9.7 Components between the digital board and the frequency synthesizer
VIAS FOR
MEASUREMENTS
FCL TOP CAN
pin 8 of IC503: 13.012 ± 0.002 MHz and 1.1 ± 0.2 Vpp
A4 band: pin 8 of IC503: 2.612 ± 0.002 MHz and 1.1 ± 0.2 Vpp
TM8100/TM8200 Service Manual Frequency Synthesizer Fault Finding 195
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Task 9 —
DIG SYN EN Line If the supply for the charge pump and the reference frequency are correct,
check the DIG SYN EN line input.
1. Check the DIG SYN EN line at pin 10 of IC503 (see Figure 9.2).
Enter the CCTM command 334 0 to switch off the synthesizer, and
measure the voltage at pin 10.
2. Enter the command 334 1 to switch on the synthesizer, and measure
the voltage again.
3. If the voltages measured in Step 1 and Step 2 are correct, go to
Task 10 . If they are not, go to Step 4.
4. Remove R104 (see Figure 9.7) and repeat the above measurements
as follows:
5. Enter the CCTM command 334 0 to switch off the synthesizer, and
measure the voltage at the via between R104 (see Figure 9.7) and
the digital board.
6. Enter the CCTM command 334 1 to switch on the synthesizer, and
measure the voltage at the via between R104 (see Figure 9.7) and
the digital board.
7. If the voltages measured in Step 5 and Step 6 are still not correct, the
digital board is faulty; replace the board and go to “Final Tasks” on
page 157. If the voltages are correct, go to Step 8.
8. There is a fault between the digital board and IC503. Locate the fault.
Check and resolder R104 in position (see Figure 9.7), and check for
continuity between pin 10 of IC503 (see Figure 9.2) and the digital
board via R104.
9. If there is a fault, repair the circuit, confirm the removal of the fault,
and go to “Final Tasks” on page 157. If the repair failed or no fault
could be found, replace the board and go to “Final Tasks” on
page 157.
pin 10 of IC503: 0 V DC (after entry of CCTM 334 0)
pin 10 of IC503: 2.5 ± 0.3 V DC (after entry of CCTM 334 1)
via at R104: 0 V DC (after entry of CCTM 334 0)
via at R104: 3.3 ± 0.3 V DC (after entry of CCTM 334 1)
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Task 1 0 —
SYN LOCK Line If all the critical inputs to the PLL are correct, check the SYN LOCK line
output.
1. Enter the CCTM command 72 to determine the lock status in receive
mode. Note the status.
2. Check the SYN LOCK line by measuring the voltage at pin 14 of IC503
(see Figure 9.2). The voltage should depend on the lock status as
follows:
3. If the voltage measured in Step 2 is correct, go to “Loop Filter” on
page 198. If it is not, go to Step 4.
4. Check for continuity between pin 14 of IC503 and the digital board
via R568 (see Figure 9.2) and L102 (see Figure 9.7).
5. If there is a fault, go to Step 6. If there is no fault, the digital board is
faulty; replace the board and go to “Final Tasks” on page 157.
6. Repair the fault. Confirm the removal of the fault and go to “Final
Tasks” on page 157. If the repair failed or no fault could be found,
replace the board and go to “Final Tasks” on page 157.
lock status=xyz (x=RF PLL; y=FCL; z=LO2) (0=not in lock; 1=in lock)
lock status 111 or 110: 3.0 ± 0.3 V DC at pin 14 of IC503
lock status 011 or 010: 0 V DC at pin 14 of IC503
TM8100/TM8200 Service Manual Frequency Synthesizer Fault Finding 197
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Figure 9.8 Synthesizer circuitry under the SYN TOP can (top side)
VHF bands
UHF bands
Q512
Q512
Junction of
C541 and R547
Junction of
C541 and R547
TP503
TP503
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9.4 Loop Filter
Introduction If the power supplies for the frequency synthesizer are correct, and the PLL
is functioning properly, check the loop filter next:
■Task 11: check loop voltage
■Task 12: VCO fault
■Task 13: check reference voltage
■Task 14: check feedback voltage
■Task 15: check DIG SYN FAST line
■Task 16: check TP503 test point.
The test and measurement points for diagnosing faults concerning the loop
filter are summarized in Figure 9.6.
Task 1 1 —
Check Loop Voltage Check whether the loop filter is functioning correctly by measuring the
loop voltage at the output of the filter at C565.
1. If not already done, remove the board from the chassis, remove the
SYN TOP can, and place the radio in CCTM.
2. Remove R542 (see Figure 9.8).
3. Using an oscilloscope, proceed as follows to observe the voltage at
C565 before and after grounding the junction between C541 and
R547 (see Figure 9.8):
While holding the oscilloscope probe at C565, use a pair of tweezers
to momentarily ground the junction. The voltage should change to
the following value (if it is not already at this value):
4. If the loop voltage is correct, go to Step 5. If it is not, the loop-filter
circuitry is suspect; go to Ta s k 1 3 .
5. Proceed as follows to observe the voltage at C565 before and after
applying 3 V DC to the junction of C541 and R547; there is a
convenient 3 V level at R544 (see Figure 9.8):
While holding the probe at C565, use the tweezers to momentarily
apply 3 V DC to the junction; do not touch the board with your
hand, and do not allow the tweezers to touch any cans when you
remove them. The voltage should change to:
6. If the loop voltage is correct, go to Task 1 2. If it is not, the loop-filter
circuitry is suspect; go to Ta s k 1 3 .
C565: 13.3 ± 0.3 V DC
C565: < 0.5 V DC
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Task 12 —
VCO Faulty If the loop voltage is correct, the loop filter is functioning properly.
The VCO and related circuitry is therefore suspect. The section to proceed
to depends on the type of the radio and the nature of the fault.
1. With a UHF radio go to Step 2. With a VHF radio go to “VCO and
Related Circuitry (VHF Radios)” on page 217.
2. If a UHF radio exhibits a lock error or a receive fault. the receive
VCO is suspect; go to “Receive VCO and Related Circuitry (UHF
Radios)” on page 203.
If it exhibits a system error or a transmit fault, the transmit VCO is
suspect; go to “Transmit VCO and Related Circuitry (UHF
Radios)” on page 212.
Task 13 —
Check Reference
Voltage
If the loop-filter circuitry is suspect, first check the reference voltage for
the filter.
1. Remove the SYN BOT can.
2. Measure the reference voltage at pin 5 of IC505 (see Figure 9.4).
The result should be:
3. If the voltage is correct, go to Task 1 4 . If it is not, the reference-
voltage circuitry is suspect; go to Step 4.
4. Resolder R542 in position and check the C-multiplier Q512
(see Figure 9.8).
5. If a fault is found, repair the circuit, and confirm that the reference
voltage is now correct. If it is, go to “Final Tasks” on page 157. If it
is not, or if no fault could be found, replace the board and go to “Final
Tasks” on page 157.
IC505 pin 5: 2.8 ± 0.1 V DC
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Task 1 4 —
Check Feedback
Voltage
If the loop filter is suspect but the reference voltage is correct, check the
feedback voltage.
1. Measure the feedback voltage at pin 6 of IC505 (see Figure 9.4).
The result should be:
2. If the voltage is not correct, the loop filter is faulty; go to Step 3.
If the voltage is correct, resolder R542 in position (see Figure 9.8)
and go to Ta s k 1 5 .
3. Check IC504, IC505, Q511 (see Figure 9.4) and associated
components.
4. Check the following components (see Figure 9.8):
Note On early issue boards, C548 is fitted instead of these components.
5. If a fault is found, repair the circuit, repeat the measurement of the
feedback voltage in Step 1, and resolder R542 in position
(see Figure 9.8).
6. If the feedback voltage is now correct, go to “Final Tasks” on
page 157. If it is not, or if no fault could be found, replace the board
and go to “Final Tasks” on page 157.
IC505 pin 6: 2.8 ± 0.1 V DC
A4 band: C5085 to C5089
B1 band: C5085 to C5089
C0 band: C5085 to C5088
D1 band: C5085 to C5088
H5 band: C5085 and C5086
H6 band: C5085 and C5086
TM8100/TM8200 Service Manual Frequency Synthesizer Fault Finding 201
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Task 15 —
Check DIG SYN FAST
Line
If the loop filter is suspect but the reference and feedback voltages are
correct, check the DIG SYN FAST line, which is input to the inverter.
1. Enter the CCTM command 389 1 to set the synthesizer mode to fast.
2. Measure the voltage at the collector of Q505 (see Figure 9.4).
The result should be:
3. Enter the CCTM command 389 0 to set the mode to slow.
4. Measure the voltage at the collector of Q505 (see Figure 9.4).
The result should be:
5. If the voltages measured in Step 2 and Step 4 are correct, go to
Task 16 . If they are not, go to Step 6.
6. Remove R105 (see Figure 9.7).
7. Enter the CCTM command 389 1 to set the mode to fast.
8. Measure the voltage at the via between R105 and the digital board
(see Figure 9.7). The result should be:
9. Enter the CCTM command 389 0 to set the mode to slow.
10. Measure the voltage at the via between R105 and the digital board
(see Figure 9.7). The result should be:
11. If the voltages measured in Step 8 and Step 10 are correct, go to
Step 12. If they are not, the digital board is faulty; replace the board
and go to “Final Tasks” on page 157.
12. Check and resolder R105 in position (see Figure 9.7), and check for
continuity between the collector of Q505 (see Figure 9.4) and the
digital board via R105.
13. If a fault is found, repair the circuit, and confirm that the voltages are
now correct. If they are, go to “Final Tasks” on page 157. If they are
not, or if no fault could be found, replace the board and go to “Final
Tasks” on page 157.
Q505 collector: 14.2 ± 0.3 V DC (after entry of CCTM 389 1)
Q505 collector: 0 V DC (after entry of CCTM 389 0)
via at R105: 0 V DC (after entry of CCTM 389 1)
via at R105: 3.3 ± 0.3 V DC (after entry of CCTM 389 0)
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Task 1 6 —
Check TP503 Test
Point
If the reference voltage, feedback voltage, and DIG SYN FAST line are all
correct, check the voltage at the TP503 test point.
1. Measure the voltage at the TP503 test point (see Figure 9.8).
The oscilloscope should show a DC level less than 3.0V with no sign
of noise or modulation.
2. If the correct result is obtained, go to Step 3. If it is not, go to Step 5.
3. The loop filter is faulty but the above measurements do not provide
more specific information. Check IC504, IC505, Q511
(see Figure 9.4) and associated components.
4. Check the following components (see Figure 9.8), then conclude
with Step 9:
Note On early issue boards, C548 may be fitted instead of these
components.
5. Remove R566 and R570 (see Figure 9.8), which provide a
modulation path to the VCO(s).
6. Repeat the measurement of Step 1.
7. If the correct result is now obtained, go to Step 8. If the correct result
is still not obtained, the CODEC and audio circuitry is suspect;
resolder R566 and R570 in position (see Figure 9.8), and go to
“CODEC and Audio Fault Finding” on page 381.
8. Resolder R566 and R570 in position (see Figure 9.8).
9. Check IC504 (pins 6, 8, 9) (see Figure 9.4) and the associated
components in the loop filter.
10. If a fault is found, repair the circuit, and confirm that the voltages are
now correct. If they are, go to “Final Tasks” on page 157. If they are
not, or if no fault could be found, replace the board and go to “Final
Tasks” on page 157.
TP503 test point: < 3.0 V DC
A4 band: C5085 to C5089
B1 band: C5085 to C5089
C0 band: C5085 to C5088
D1 band: C5085 to C5088
H5 band: C5085 and C5086
H6 band: C5085 and C5086
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9.5 Receive VCO and Related Circuitry (UHF Radios)
Introduction If there is no fault with the power supplies, the PLL inputs and output, and
the loop filter, check the VCO and related circuitry. The procedures in this
section apply only to UHF radios with a lock error or receive fault, and
therefore with suspect receive VCO and related circuitry. (The minimum
and maximum receive frequencies for the different UHF frequency bands
are defined in Table 9.3.) There are six aspects:
■Task 17: check receive VCO
■Task 18: repair PLL feedback
■Task 19: repair receive VCO
■Task 20: check switching to receive mode
■Task 21: repair switching network
■Task 22: check receive buffer amplifier.
The measurement points for diagnosing faults in the VCO and related
circuitry are summarized in Figure 9.9.
Table 9.3 Minimum and maximum receive frequencies for the different UHF frequency bands
Frequency band Receive frequency in MHz
Minimum Maximum
H5 337 ± 5441 ± 5
H6/H7 378 ± 5498 ± 5
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Figure 9.9 Measurement points for the VCO and related circuitry in UHF radios
+5V DEC
PIN6OF
Q5001
PIN 6 OF
Q5001
PIN3OF
Q506
PIN 3 OF
Q506
Q508 AND
R593
Q508 AND
R593
PIN6OF
Q506
PIN 6 OF
Q506
BASE OF
Q5100
BASE OF
Q5100
TX PORT
TX PORT
RX PORT
RX PORT
PIN4OF
IC5100
PIN 4 OF
IC5100
SIGNAL TYPES
RF
ANALOG
CLOCK
DIGITAL
PLL
LOOP
FILTER
AND
SUMMER
FILTERING
OF SUPPLY
FOR VCO
CIRCUITRY
FREQUENCY SYNTHESIZER
PLL FEEDBACK
LOOP VOLTAGE
RECEIVE
VCO
TRANSMIT VCO
TRANSMIT
BUFFER
AMPLIFIER
AND
COUPLER
5 V SWITCH
TR SWITCH
SYN TX LO
SYN RX LO1
TRANS-
MITTER
RECEIVER
DIGITAL
BOARD
DIG SYN TR SW
DIG SYN EN
INVERTER
RECEIVE
BUFFER
AMPLIFIER
AND
COUPLER
VIA TO CHECK
DIG SYN TR SW
VIA TO CHECK
DIG SYN TR SW
R103
JUNCTION OF
C541 AND R547
JUNCTION OF
C541 AND R547
R577
R544
+3V0 AN
L506
3V
SUPPLY
R593
R585
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Task 17 —
Check Receive VCO Check that the correct receive frequency is synthesized. This is the
frequency of the receive VCO output SYN RX LO1 at the RX port shown in
Figure 9.10.
1. Enter the CCTM command 335 0 to set the transmit-receive switch
off (receive mode).
2. Using a frequency counter, proceed as follows to observe the receive
frequency at the RX port before and after grounding the junction
between C541 and R547 (see Figure 9.10):
While holding the probe from the counter on the RX port, use a pair
of tweezers to momentarily ground the junction. The frequency
should change to:
The loop filter will hold its output steady at 13.3 V. This should result
in a frequency equal to the maximum given in Table 9.3.
3. If the receive frequency measured in Step 2 is correct, go to Step 4.
If it is incorrect, go to Tas k 1 9 , but if no frequency is detected, go to
Task 20 .
4. Proceed as follows to observe the receive frequency at the RX port
before and after applying 3 V DC to the junction of C541 and R547;
there is a convenient 3 V level at R544 (see Figure 9.10):
While holding the probe on the RX port, use the tweezers to
momentarily apply 3 V DC to the junction; do not touch the board
with your hand, and do not allow the tweezers to touch any cans
when you remove them. The frequency should change to:
The loop filter will hold its output steady at about 0V. This should
result in a frequency equal to the minimum given in Table 9.3.
5. If the receive frequency measured in Step 4 is correct, go to Tas k 1 8 .
If it is incorrect, go to Tas k 1 9 . If no frequency is detected, go to
Task 20 .
RX port: maximum receive frequency (see Table 9.3)
RX port: minimum receive frequency (see Table 9.3)
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Figure 9.10 Synthesizer circuitry under the SYN TOP and VCO TOP cans (UHF radio, top side)
Tx port
Junction of
C541 and R547
Rx port
Q507 Q506 Q508
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Task 18 —
Repair PLL feedback If both the minimum and maximum receive frequencies are correct, the
PLL feedback is suspect.
1. Resolder R542 in position (see Figure 9.10).
2. Remove the VCO BOT can.
3. Replace the components C567, R574 (see Figure 9.11) and IC503
(see Figure 9.10).
4. Also check the second stage of the receive buffer amplifier based on
IC5100 (see Figure 9.11). Repair any fault.
5. Confirm that the fault in the radio has been removed. If it has, go to
“Final Tasks” on page 157. If it has not, replace the board and go to
“Final Tasks” on page 157.
Figure 9.11 Synthesizer circuitry under the VCO BOT can
(UHF radios, bottom side)
Q5001
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Task 1 9 —
Repair Receive VCO If either or both the minimum and maximum receive frequencies are
incorrect, the receive VCO circuitry is faulty.
1. Remove the VCO TOP can.
2. Check the receive VCO. The circuitry is based on Q504
(see Figure 9.10).
3. If a fault is found, repair it and go to Step 4. If no fault is found, go
to Step 6.
4. Repeat the frequency measurements in Step 2 and Step 4 of Ta s k 1 7 .
5. If the frequencies are now correct, resolder R542 in position
(see Figure 9.10), and go to “Final Tasks” on page 157. If they are
still not correct, go to Step 6.
6. Resolder R542 in position (see Figure 9.10). Replace the board and
go to “Final Tasks” on page 157.
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Task 20 —
Check Switching
to Receive Mode
If no receive frequency is detected in the check of the receive VCO, first
check that the transmit-receive switch is functioning correctly.
1. Resolder R542 in position (see Figure 9.10).
2. Enter the CCTM command 335 0 to switch on the supply to the
receive VCO.
3. Measure the voltage at the first collector (pin 3) of Q506
(see Figure 9.10). The voltage should be:
4. Enter the CCTM command 335 1 to switch off the supply.
5. Again measure the voltage at the first collector of Q506.
6. If the voltages measured in Step 3 and Step 5 are correct, go to
Task 22 . If they are not, the switching network is suspect; go to
Task 21 .
pin 3 of Q506: 5.0 ± 0.3 V DC (after entry of CCTM 335 0)
pin 3 of Q506: 0 V DC (after entry of CCTM 335 1)
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Task 2 1 —
Repair Switching
Network
If the transmit-receive switch is not functioning correctly, first check the DIG
SYN TR SW line to confirm that the digital board is not the cause. If the digital
board is not faulty, the switching network is suspect.
1. Enter the CCTM command 335 0 to set the transmit-receive switch
off (receive mode). Measure the voltage on the DIG SYN TR SW line
between Q508 and R593 (see Figure 9.10).
2. Enter the CCTM command 335 1 to set the transmit-receive switch
on (transmit mode). Again measure the voltage at R593.
3. If the voltages measured in Step 1 and Step 2 are correct, go to
Step 9. If they are not, remove R103 (see Figure 9.7) and go to
Step 4.
4. Enter the CCTM command 335 0 and measure the voltage at the via
between R103 and the digital board (see Figure 9.7).
5. Enter the CCTM command 335 1 and again measure the voltage at
the via between R103 and the digital board.
6. If the voltages measured in Step 4 and Step 5 are correct, go to
Step 7. If they are not, the digital board is faulty; resolder R103 in
position (see Figure 9.7), replace the board and go to “Final Tasks”
on page 157.
7. Check and resolder R103 in position (see Figure 9.7), and check for
continuity between Q508 and the digital board via R593
(see Figure 9.10) and R103.
8. If no fault is found, go to Step 9. If a fault is found, repair the circuit,
confirm that the voltages are now correct, and go to “Final Tasks” on
page 157 If the repair failed, replace the board and go to “Final
Tasks” on page 157.
9. Check the circuitry for the transmit-receive and 5V switches (based
on Q506, Q507 and Q508) (see Figure 9.10).
10. If a fault is found, repair the circuit, confirm that the voltages are now
correct, and go to “Final Tasks” on page 157. If the repair failed or
the fault could not be found, replace the board and go to “Final
Tasks” on page 157.
R593: 0 V DC (after entry of CCTM 335 0)
R593: 2.0 ± 0.5 V DC (after entry of CCTM 335 1)
via at R103: 0 V DC (after entry of CCTM 335 0)
via at R103: 3.3 ± 0.3 V DC (after entry of CCTM 335 1)
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Task 22 —
Check Receive
Buffer Amplifier
If no receive frequency is detected but the switching network is not faulty,
check the receive buffer amplifier. If the amplifier is not faulty, there might
be a fault in the receive VCO that was not detected earlier.
1. Remove the VCO BOT can.
2. Check the receive buffer amplifier in receive mode: Enter the CCTM
command 335 0 to set the transmit-receive switch off.
3. Measure the voltages at the base of Q5100 and at pin 4 of IC5100
(see Figure 9.11).
4. Then check the receive buffer amplifier in transmit mode: Enter the
CCTM command 335 1 to set the transmit-receive switch on.
5. Again measure the voltages of Q5100 and IC5100.
6. If the voltages are correct, the receive VCO is suspect; go to Step 7.
If they are not, the receive buffer amplifier is suspect; go to Step 9.
7. Remove the VCO TOP can.
8. Check the receive VCO circuitry based on Q504 (see Figure 9.10).
Conclude with Step 10.
9. Check the first buffer stage (based on Q5100) and the second stage
(based on IC5100) (see Figure 9.11).
10. If a fault is found, repair the circuit, and confirm that the voltages are
now correct. If they are, go to “Final Tasks” on page 157. If they are
not, or if no fault could be found, replace the board and go to “Final
Tasks” on page 157.
base of Q5100: 0.7 ± 0.1V DC (receive mode)
pin 4 of IC5100: 2.0 ± 0.5V DC (receive mode)
base of Q5100: 0V DC (transmit mode)
pin 4 of IC5100: 0V DC (transmit mode)
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9.6 Transmit VCO and Related Circuitry (UHF Radios)
Introduction If there is no fault with the power supplies, the PLL inputs and output, and
the loop filter, check the VCO and related circuitry. The procedures in this
section apply only to UHF radios with a system error or transmit fault, and
therefore with suspect transmit VCO and related circuitry. (The minimum
and maximum transmit frequencies for the different UHF frequency bands
are defined in Table 9.4.) There are five aspects:
■Task 23: check transmit VCO
■Task 24: repair PLL feedback
■Task 25: repair transmit VCO
■Task 26: check switching to transmit mode
■Task 27: check transmit buffer amplifier.
The measurement points for diagnosing faults in the VCO and related
circuitry are summarized in Figure 9.9.
Table 9.4 Minimum and maximum transmit frequencies for the different UHF frequency bands
Frequency band Transmit frequency in MHz
Minimum Maximum
H5 371 ± 5 492 ± 5
H6/H7 419 ± 5 545 ± 5
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Task 23 —
Check Transmit VCO Check that the correct transmit frequency is synthesized. This is the
frequency of the transmit VCO output SYN TX LO at the TX port shown in
Figure 9.10.
1. Enter the CCTM command 335 1 to set the transmit-receive switch
on (transmit mode).
2. Using a frequency counter, proceed as follows to observe the transmit
frequency at the TX port before and after grounding the junction
between C541 and R547 (see Figure 9.10):
While holding the probe from the counter on the TX port, use a pair
of tweezers to momentarily ground the junction. The frequency
should change to:
The loop filter will hold its output steady at 13.3 V. This should result
in a frequency equal to the maximum given in Table 9.4.
3. If the transmit frequency measured in Step 2 is correct, go to Step 4.
If it is incorrect, go to Tas k 2 5 . If no frequency is detected, go to
Task 26 .
4. Proceed as follows to observe the transmit frequency at the TX port
before and after applying 3 V DC to the junction of C541 and R547;
there is a convenient 3 V level at R544 (see Figure 9.10):
While holding the probe on the TX port, use the tweezers to
momentarily apply 3 V DC to the junction; do not touch the board
with your hand, and do not allow the tweezers to touch any cans
when you remove them. The frequency should change to:
The loop filter will hold its output steady at about 0V. This should
result in a frequency equal to the minimum given in Table 9.4.
5. If the transmit frequency measured in Step 4 is correct, go to Ta s k 2 4 .
If it is incorrect, go to Tas k 2 5 . If no frequency is detected, go to
Task 26 .
TX port: maximum transmit frequency (see Table 9.4)
TX port: minimum transmit frequency (see Table 9.4)
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Task 2 4 —
Repair PLL feedback If both the minimum and maximum transmit frequencies are correct, the
PLL feedback is suspect.
1. Resolder R542 in position (see Figure 9.10).
2. Remove the VCO BOT can.
3. Replace the components C570, R578 (see Figure 9.11) and IC503
(see Figure 9.10).
4. Confirm that the fault in the radio has been removed. If it has, go to
“Final Tasks” on page 157. If it has not, replace the board and go to
“Final Tasks” on page 157.
Task 2 5 —
Repair Transmit
VCO
If either or both the minimum and maximum transmit frequencies are
incorrect, the transmit VCO circuitry is faulty.
1. Remove the VCO TOP can.
2. Check the transmit VCO. The circuitry is based on Q510
(see Figure 9.10).
3. If a fault is found, repair it and go to Step 4. If no fault is found, go
to Step 6.
4. Repeat the frequency measurements in Step 2 and Step 4 of Ta s k 2 3 .
5. If the frequencies are now correct, resolder R542 in position
(see Figure 9.10), and go to “Final Tasks” on page 157. If they are
still not correct, go to Step 6.
6. Resolder R542 in position (see Figure 9.10). Replace the board and
go to “Final Tasks” on page 157.
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Task 26 —
Check Switching
to Transmit Mode
If no transmit frequency is detected in the check of the transmit VCO, first
check that the transmit-receive switch is functioning correctly.
1. Resolder R542 in position (see Figure 9.10).
2. Enter the CCTM command 335 1 to switch on the supply to the
transmit VCO.
3. Measure the voltage at the second collector (pin 6) of Q506
(see Figure 9.10). The voltage should be:
4. Enter the CCTM command 335 0 to switch off the supply.
5. Again measure the voltage at the second collector of Q506.
6. If the voltages measured in Step 2 and Step 4 are correct, go to
Task 27 . If they are not, the switching network is suspect; go to
Task 21 .
pin 6 of Q506: 5.0 ± 0.3 V DC (after entry of CCTM 335 1)
pin 6 of Q506: 0 V DC (after entry of CCTM 335 0)
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Task 2 7 —
Check Transmit
Buffer Amplifier
If no transmit frequency is detected but the switching network is not faulty,
check the transmit buffer amplifier. If the amplifier is not faulty, there might
be a fault in the transmit VCO that was not detected earlier.
1. Remove the VCO BOT can.
2. Check the transmit buffer amplifier in receive mode: Enter the
CCTM command 335 0 to set the transmit-receive switch off.
3. Measure the voltage at pin 6 of Q5001 (see Figure 9.11).
4. Then check the transmit buffer amplifier in transmit mode: Enter the
CCTM command 335 1 to set the transmit-receive switch on.
5. Again measure the voltage at Q5001.
6. If the voltages are correct, the transmit VCO is suspect; go to Step 7.
If they are not, the transmit buffer amplifier is suspect; go to Step 9.
7. Remove the VCO TOP can.
8. Check the transmit VCO circuitry based on Q510
(see Figure 9.10). Conclude with Step 10.
9. Check the buffer circuitry based on Q5001 (see Figure 9.11).
10. If a fault is found, repair the circuit, and confirm that the voltages are
now correct. If they are, go to “Final Tasks” on page 157. If they are
not, or if no fault could be found, replace the board and go to “Final
Tasks” on page 157.
pin 6 of Q5001: 0 V DC (receive mode)
pin 6 of Q5001: 0.7 ± 0.1 V DC (transmit mode)
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9.7 VCO and Related Circuitry (VHF Radios)
Introduction If there is no fault with the power supplies, the PLL inputs and output, and
the loop filter, check the VCO and related circuitry. The procedures in this
section apply only to VHF radios; the VHF frequency bands are defined in
Table 9.5. There are six aspects:
■Task 28: check VCO
■Task 29: repair PLL feedback
■Task 30: repair VCO
■Task 31: check transmit-receive switch
■Task 32: repair switching network
■Task 33: check buffer amplifier.
The measurement points for diagnosing faults in the VCO and related
circuitry are summarized in Figure 9.12.
Table 9.5 Minimum and maximum frequencies for the different VHF frequency bands
Frequency band Frequency in MHz
Minimum Maximum
A4 55 ± 5125 ± 5
B1 84 ± 5200 ± 5
C0 137 ± 5247 ± 5
D1 167 ± 5287 ± 5
218 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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Figure 9.12 Measurement points for the VCO and related circuitry in VHF radios
+5V DEC
PIN1OF
D5004
PIN 1 OF
D5004
PIN3OF
Q5003
PIN 3 OF
Q5003
PIN2OF
Q5001
PIN 2 OF
Q5001
PIN2OF
D5004
PIN 2 OF
D5004
TX PORT
TX PORT
RX PORT
RX PORT
SIGNAL TYPES
RF
ANALOG
CLOCK
DIGITAL
PLL
LOOP
FILTER
AND
SUMMER
FILTERING
OF SUPPLY
FOR VCO
CIRCUITRY
FREQUENCY SYNTHESIZER
PLL FEEDBACK
VCO
BUFFER
AMPLIFIER
AND
COUPLER
D5004
5 V SWITCH
TR SWITCH
SYN TX LO
SYN RX LO1
TRANS-
MITTER
RECEIVER
DIGITAL
BOARD
DIG SYN TR SW
DIG SYN EN
INVERTER
VIA TO CHECK
DIG SYN TR SW
VIA TO CHECK
DIG SYN TR SW
R103
R544
JUNCTION OF
C541 AND R547
JUNCTION OF
C541 AND R547
+3V0 AN
L506
3V
SUPPLY
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Task 28 —
Check VCO Check that the correct receive and transmit frequencies are synthesized.
The receive frequency is that of the VCO output SYN RX LO1 at the RX port
shown in Figure 9.13. The transmit frequency is that of the output SYN TX LO
at the TX port.
1. Enter the CCTM command 335 1 to set the transmit-receive switch
on (transmit mode).
2. Using a frequency counter, proceed as follows to observe the transmit
frequency at the TX port before and after grounding the junction
between C541 and R547 (see Figure 9.13):
While holding the probe from the counter on the TX port, use a pair
of tweezers to momentarily ground the junction. The frequency
should change to:
The loop filter will hold its output steady at 13.3 V. This should result
in a frequency equal to the maximum given in Table 9.5.
3. If the maximum frequency measured in Step 2 is correct, go to
Step 4. If it is incorrect, go to Task 30 , but if no frequency at all is
detected, go to Tas k 3 1 .
4. Enter the CCTM command 335 0 to set the transmit-receive switch
off (receive mode).
5. Proceed as follows to observe the receive frequency at the RX port
before and after applying 3 V DC to the junction of C541 and R547;
there is a convenient 3 V level at R544 (see Figure 9.10):
While holding the probe on the RX port, use the tweezers to
momentarily apply 3 V DC to the junction; do not touch the board
with your hand, and do not allow the tweezers to touch any cans
when you remove them. The frequency should change to:
The loop filter will hold its output steady at about 0V. This should
result in a frequency equal to the minimum given in Table 9.5.
6. If the minimum frequency measured in Step 5 is correct, go to
Task 29 . If it is incorrect, go to Tas k 30. If no frequency is detected,
go to Task 31.
TX port: maximum VCO frequency (see Table 9.5)
RX port: minimum VCO frequency (see Table 9.5)
220 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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Figure 9.13 Synthesizer circuitry under the SYN TOP can (VHF radios, top side)
Tx port
Junction of
C541 and R547
Rx port
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Task 29 —
Repair PLL feedback If both the maximum and minimum VCO frequencies are correct, then the
PLL feedback is suspect.
1. Resolder R542 in position (see Figure 9.13).
2. Remove the VCO BOT can.
3. Replace the components L510 (see Figure 9.14) and IC503
(see Figure 9.13).
Note On A4 band radios there is no L510. Replace L5010 instead.
4. Confirm that the fault in the radio has been removed. If it has, go to
“Final Tasks” on page 157. If it has not, replace the board and go to
“Final Tasks” on page 157.
222 Frequency Synthesizer Fault Finding TM8100/TM8200 Service Manual
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Figure 9.14 Synthesizer circuitry under the VCO BOT can (VHF radios)
Q5003
Q5002
L510
Q5001
D5004
Q5000
Q5003
L5010
SYN TOP
A4 band
Q5002
D5004
Q5001
Q5000
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Task 30 —
Repair VCO If either or both the maximum and minimum frequencies are incorrect, the
VCO circuitry is faulty.
1. Remove the VCO BOT can.
2. Check the VCO. The circuitry is based on Q5000
(see Figure 9.14).
3. If a fault is found, repair it and go to Step 4. If no fault is found, go
to Step 7.
4. Repeat Step 1 and Step 2 of Tas k 2 8 to measure the maximum VCO
frequency.
5. Repeat Step 4 and Step 5 of Ta s k 28 to measure the minimum VCO
frequency.
6. If the frequencies are now correct, resolder R542 in position
(see Figure 9.13), and go to “Final Tasks” on page 157. If they are
still not correct, go to Step 7.
7. Resolder R542 in position (see Figure 9.13). Replace the board and
go to “Final Tasks” on page 157.
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Task 3 1 —
Check Transmit-
Receive Switch
If no frequency is detected in the check of the VCO, first check that the
transmit-receive switch is functioning correctly.
1. Resolder R542 in position (see Figure 9.13).
2. Remove the VCO BOT can.
3. Enter the CCTM command 335 0 to switch on the supply to the RX
port.
4. Measure the voltage at pin 2 of D5004 (see Figure 9.14). (Some RF
noise might be observed.) The voltage should be:
5. Enter the CCTM command 335 1 to switch off the supply.
6. Again measure the voltage at pin 2 of D5004.
7. If the voltages measured in Step 4 and Step 6 are correct, go to
Step 8. If they are not, the switching network is suspect; go to
Tas k 32.
8. Enter the CCTM command 335 1 to switch on the supply to the TX
port.
9. Measure the voltage at pin 1 of D5004 (see Figure 9.14). (Some RF
noise might be observed.) The voltage should be:
10. Enter the CCTM command 335 0 to switch off the supply.
11. Again measure the voltage at pin 1 of D5004.
12. If the voltages measured in Step 9 and Step 11 are correct, go to
Tas k 33. If they are not, the switching network is suspect; go to
Tas k 32.
pin 2 of D5004: 5.0 ± 0.3 V DC (after entry of CCTM 335 0)
pin 2 of D5004: 0 V DC (after entry of CCTM 335 1)
pin 1 of D5004: 5.0 ± 0.3 V DC (after entry of CCTM 335 1)
pin 1 of D5004: 2.1 ± 0.4 V DC (after entry of CCTM 335 0)
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Task 32 —
Repair Switching
Network
If the transmit-receive switch is not functioning correctly, first check the DIG
SYN TR SW line to confirm that the digital board is not the cause. If the digital
board is not faulty, the switching network is suspect.
1. Enter the CCTM command 335 0 to set the transmit-receive switch
off (receive mode). Measure the voltage on the DIG SYN TR SW line at
pin 3 of Q5003 (see Figure 9.14).
2. Enter the CCTM command 335 1 to set the transmit-receive switch
on (transmit mode). Again measure the voltage at Q5003.
3. If the voltages measured in Step 1 and Step 2 are correct, go to
Step 9. If they are not, remove R103 (see Figure 9.7) and go to
Step 4.
4. Enter the CCTM command 335 0 and measure the voltage at the via
between R103 and the digital board (see Figure 9.7).
5. Enter the CCTM command 335 1 and again measure the voltage at
the via between R103 and the digital board.
6. If the voltages measured in Step 4 and Step 5 are correct, go to
Step 7. If they are not, the digital board is faulty; resolder R103 in
position (see Figure 9.7), replace the board and go to “Final Tasks”
on page 157.
7. Check and resolder R103 in position (see Figure 9.7), and check for
continuity between Q5003 (see Figure 9.14) and the digital board
via R103.
8. If no fault is found, go to Step 9. If a fault is found, repair the circuit,
confirm that the voltages are now correct, and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
9. Check the circuitry for the transmit-receive and 5V switches (based
on Q5002 and Q5003) (see Figure 9.14).
10. If a fault is found, repair the circuit, confirm that the voltages are now
correct, and go to “Final Tasks” on page 157. If the repair failed or
the fault could not be found, replace the board and go to “Final
Tasks” on page 157.
pin 3 of Q5003: 5.0 ± 0.3 V DC (after entry of CCTM 335 0)
pin 3 of Q5003: 0 V DC (after entry of CCTM 335 1)
via at R103: 3.3 ± 0.3 V DC (after entry of CCTM 335 0)
via at R103: 0 V DC (after entry of CCTM 335 1)
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Task 3 3 —
Check Buffer
Amplifier
If no VCO frequency is detected but the switching network is not faulty,
check the buffer amplifier. If the amplifier is not faulty, there might be a fault
in the VCO that was not detected earlier.
1. Enter the CCTM command 335 0 to set the transmit-receive switch
off.
2. Measure the voltage at pin 3 of D5004 (see Figure 9.14). (Some RF
noise might be observed.)
3. Measure the voltage at pin 1 of Q5001 (see Figure 9.14).
4. If the voltages measured in Step 2 and Step 3 are not correct, go to
Step 5. If they are, check the VCO circuitry based on Q5000
(see Figure 9.14). Conclude with Step 6.
5. The buffer amplifier is suspect. Check the buffer circuitry (based on
Q5001) (see Figure 9.14).
6. If a fault is found, repair the circuit, and confirm that the voltages are
now correct. If they are, go to “Final Tasks” on page 157. If they are
not, or if no fault could be found, replace the board and go to “Final
Tasks” on page 157.
pin 3 of D5004: 4.2 ± 0.2 V DC
pin 1 of Q5001: 0.7 ± 0.2 V DC
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9.8 Power Supply for FCL
Fault-Diagnosis
Stages Indications of a fault in the FCL will have been revealed by the initial checks
in “Initial Checks” on page 180 and the PLL checks in “Phase-locked
Loop” on page 192. In the latter case a fault with the reference frequency
input from the FCL to the PLL will imply that the FCL is suspect. Fault
diagnosis of the FCL is divided into four stages:
■check power supply
■check VCXO and TCXO outputs
■check signals at TP501 and TP502
■check VCXO and CODEC circuitry.
The checking of the power supply is given in this section in Tas k 3 4 below.
The remaining three stages are covered in “VCXO and TCXO Outputs”
to “VCXO and CODEC Circuitry” respectively. The test and
measurement points for diagnosing faults in the FCL are summarized in
Figure 9.15.
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Figure 9.15 Test and measurement points the FCL circuitry
RF
ANALOG
CLOCK
DIGITAL
SIGNAL TYPES
PSU
LPF
MIXER
VCXO
TCXO
MODULATOR
BUFFER
AMPLIFIER
AGND
DIGITAL
BOARD
CDC VCXO MOD
SYN CDC FCL
BUFFER AMPLIFIER
INTERFACE
CIRCUITRY
RECEIVER
FCL CIRCUITRY
+3V0 AN
SUPPLY
C536 R541
VCXO OUTPUT
AT C536
VCXO OUTPUT
AT C536
PLL
SYN RX OSC C510
TP504
FEEDBACK
SIGNAL
SYN DIG FREF
TCXO OUTPUT
VCXO OUTPUT
AT R522
(PIN 1 OF IC501)
VCXO OUTPUT
AT R522
(PIN 1 OF IC501)
LO INPUT
AT R521
(PIN 4 OF IC501)
LO INPUT
AT R521
(PIN 4 OF IC501)
TP502
DIFFERENCE
FREQUENCY
TP500 TP501
DAC
ADC
CODEC 2
LOOP
VOLTAGE
÷4
LPF
shaded area is A4 band only
LPF SYN
LO INPUT
AT R521
(PIN 4 OF IC501)
LO INPUT
AT R521
(PIN 4 OF IC501)
TP5TP502
÷4
LPF
hdd i A b d l
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Task 34 —
Power Supply If the FCL is suspect, first check that the 3V power supply is not the cause
of the fault.
1. If not already done, remove the board from the chassis and place the
radio in CCTM.
2. Measure the supply +3V0 AN at the via shown in Figure 9.16. The via
is adjacent to the CDC TOP can.
3. If the voltage is correct, go to “VCXO and TCXO Outputs” on
page 230. If it is not, the 3V regulator IC603 is suspect; go to Ta s k 3
of “Power Supply Fault Finding” on page 168.
via adjacent to CDC TOP can: 3.0 ± 0.3 V DC
Figure 9.16 TCXO circuitry under the CDC TOP can
IF TOP CAN
VIA FOR MEASURING 3 V DC SUPPLY
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9.9 VCXO and TCXO Outputs
Task 3 5 —
VCXO Output If the 3V power supply is not faulty, check the VCXO output as follows:
1. Use an oscilloscope probe to check the VCXO output at the
following position:
2. If the signal is correct, go to Task 36. If it is not, go to Step 3.
3. The VCXO circuitry under the VCXO BOT can is faulty. Remove the
VCXO BOT can.
4. Locate and repair the fault in the VCXO (Q501, Q503, XL501 and
associated components) (see Figure 9.18).
5. Confirm the removal of the fault and go to Ta s k 3 6 . If the repair
failed, replace the board and go to “Final Tasks” on page 157.
C536 — probe the via next to C536 (see Figure 9.17). The signal
should be:
VCXO output at C536: sine wave of 1.1 ± 0.2 Vpp on 1.4 ± 0.2 V DC
A4 band: IC509, pin 4 — probe the via next to R5044
(see Figure 9.17). The signal should be:
VCXO output at pin 4 of IC509: square wave of 1.5 ± 0.2 Vpp
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Figure 9.17 FCL circuitry under and adjacent the FCL TOP can
Via for
measuring
VCXO output
Position R527
for Tasks 38
and 39
FCL_TOP
IC506
L501
Q504
IC509
R520
R510
R527
R5044
A4 band
Via for
measuring
VCXO output
Position R527
here for Tasks 38
and 39
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Task 3 6 —
TCXO Output If the VCXO output is correct, check the TCXO output as follows:
1. Use the oscilloscope probe to check the TCXO output at the TP504
test point (see Figure 9.17). The signal is SYN RX OSC and should be:
2. If the signal is correct, go to “Signals at TP501 and TP502” on
page 233. If it is not, go to Step 3.
3. The TCXO circuitry under the CDC TOP can is faulty. Remove the
CDC TOP can.
4. Locate and repair the fault in the TCXO (XL500 and associated
components) (see Figure 9.16).
5. Confirm the removal of the fault and go to “Signals at TP501 and
TP502” on page 233. If the repair failed, replace the board and go to
“Final Tasks” on page 157.
TCXO output at TP504 test point: clipped sine wave of 1.0 ± 0.2 Vpp
Figure 9.18 FCL circuitry under the VCXO BOT can
SYN BOT CAN
CDC BOT CAN
CAN FOR
DIGITAL
BOARD
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9.10 Signals at TP501 and TP502
Introduction If the VCXO and TCXO outputs are correct, the next stage is to check the
signals at the TP501 and TP502 test points. The procedure is divided into
three tasks:
■Task 37: check signal at TP502
■Task 38: check signal at TP501 and ground TP501 if loop is oscillating
■Task 39: check signal at TP502 with TP501 grounded.
These checks will reveal any faults in the mixer and LPF circuitry, and any
additional fault in the VCXO circuitry.
Task 37 —
TP502 Test Point Check the signal at the TP502 test point to determine if there is a fault in the
mixer or LPF (low-pass filter) circuitry:
1. Use the oscilloscope probe to check the difference frequency at the
TP502 test point (see Figure 9.17). The signal is SYN CDC FCL and
should be:
2. If the signal is correct, go to Tas k 3 8 . If it is not, go to Step 3.
3. The mixer or LPF circuitry under the FCL TOP can is faulty. Remove
the FCL TOP can.
4. Locate the fault in the mixer (IC501 and associated components) or
LPF circuitry (IC502 pins 5 to 7, and associated components)
(see Figure 9.17).
A4 band: Check the mixer (IC501, IC506 and associated
components) or LPF circuitry (IC502 pins 5 to 7, and associated
components) (see Figure 9.17). Also check L501 and associated
components and buffer Q504, IC509 and associated components.
5. Repair the circuitry. Note that the TCXO input to the mixer
(see Figure 9.17) should be:
TP502 test point: sine wave of 1.1 ± 0.2 Vpp on 1.5 ± 0.1 V DC
A4 band: The signal should be:
TP502 test point: triangular wave of 1.5 ± 0.2 Vpp on 1.5 ± 0.1 V DC
TCXO input at R521 (pin 4 of IC501):
TCXO input: square wave with frequency of 13 MHz
and amplitude of 3.0 ± 0.2 Vpp
A4 band: TCXO input at R520 (pin 4 of IC506):
TCXO input: square wave with frequency of 10.4MHz
and amplitude of 3.0 ± 0.2 Vpp
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Also, the VCXO input to the mixer (see Figure 9.17), although
noisy and difficult to measure, should be:
6. Confirm the removal of the fault and go to Ta s k 3 8 . If the repair
failed, replace the board and go to “Final Tasks” on page 157.
Task 3 8 —
TP501 Test Point If the signal at the TP502 test point is correct, check the signal at the TP501
test point:
1. With the oscilloscope probe at the TP501 test point
(see Figure 9.17), check the DAC output CDC VCXO MOD. If a
triangular wave is present, go to Step 2. Otherwise go to “VCXO and
CODEC Circuitry” on page 237.
2. A fault is causing the loop to oscillate. If not already done, remove the
FCL TOP can.
3. Check the waveform at the TP500 test point (see Figure 9.17).
The waveform should be an amplified and inverted version of the
waveform at the TP501 test point.
A4 band: TP500 is not marked, but the waveform can be checked at
the via adjacent C518.
4. If the waveform is correct, go to Step 5. If it is not, there is a fault in
the modulator buffer amplifier (IC502 pins 1 to 3, and associated
components) (see Figure 9.17). Rectify the fault and return to Step 1.
5. Connect the
TP501
test point
to ground by resoldering
R527
in the
position shown in
Figure 9.17
. The VCXO loop voltage is forced high.
6. Use the oscilloscope probe to check the VCXO output at C536 —
probe the via next to C536 (see Figure 9.17). The signal should be:
7. If the signal is correct, go to Task 39. If it is not, go to Step 8.
8. The VCXO circuitry is faulty. If not already done, remove the VCXO
BOT can.
9. Locate and repair the fault in the VCXO circuitry (Q501, Q503,
XL501 and associated components) (see Figure 9.18).
10. Confirm the removal of the fault, and go to Tas k 3 9 . If the repair
failed, replace the board and go to “Final Tasks” on page 157.
VCXO input at R522 (pin 1 of IC501):
VCXO input: sine wave of 20 ± 10 mVpp
A4 band: VCXO input at R510 (pin 1 of IC506):
VCXO input: sine wave of 20 ± 10 mVpp
VCXO output at C536: sine wave with frequency of 13.017 MHz and
amplitude of 1.1 ± 0.2 Vpp on 1.4 ± 0.2 V DC
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Task 39 —
TP502 Test Point
(TP501 Grounded)
If the loop was oscillating, Task 38 will have revealed any fault in the
VCXO circuitry. If there was no fault, or if the circuit was repaired, a check
at the TP502 test point is now required. This will show if there are any
additional faults in the mixer or LPF circuitry.
1. Use the oscilloscope probe to check the difference frequency at the
TP502 test point (see Figure 9.17). The signal is SYN CDC FCL and
should be:
2. If the signal is correct, go to Step 6. If it is not, go to Step 3.
3. The mixer circuitry (IC501 and associated components) or the LPF
circuitry (IC502 pins 5 to 7, and associated components) under the
FCL TOP can is faulty (see Figure 9.17). Locate the fault.
4. Repair the circuitry. Note that the TCXO input to the mixer
(see Figure 9.17) should be:
Also, the VCXO input to the mixer (see Figure 9.17), although
noisy and difficult to measure, should be:
5. Confirm the removal of the fault, and go to Step 6. If the repair
failed, resolder R527 in its original position as shown in Figure 9.17,
replace the board and go to “Final Tasks” on page 157.
TP502 test point: sine wave with frequency of at least 15kHz and
amplitude of 1.1 ± 0.2 Vpp on 1.5 ± 0.1 V DC
A4 band: the frequency should be:
TP502 test point: triangular wave with frequency of at least 15kHz and
amplitude of 1.5 ± 0.2 Vpp on 1.5 ± 0.1 V DC
TCXO input at R521 (pin 4 of IC501):
TCXO input: square wave with frequency of 13 MHz
and amplitude of 3.0 ± 0.2 Vpp
A4 band: TCXO input at R520 (pin 4 of IC506):
TCXO input: square wave with frequency of 10.4MHz
and amplitude of 3.0 ± 0.2 Vpp
VCXO input at R522 (pin 1 of IC501):
VCXO input: sine wave of 20 ± 10 mVpp
A4 band: VCXO input at R510 (pin 1 of IC506):
VCXO input: sine wave of 20 ± 10 mVpp
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6. Resolder R527 in its original position as shown in Figure 9.17.
7. Replace all cans.
8. Use the oscilloscope probe to check the difference frequency at the
TP502 test point (see Figure 9.17). The signal is SYN CDC FCL and
should be:
9. If the signal is correct, the fault has been removed; go to “Final
Tasks” on page 157. If the signal is not correct, the repair failed;
replace the board and go to “Final Tasks” on page 157.
TP502 test point: sine wave of 1.1 ± 0.2 Vpp on 1.5 ± 0.1 V DC
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9.11 VCXO and CODEC Circuitry
Introduction If the signals at the TP501 and TP502 test points are correct, two CCTM
checks will reveal any remaining faults. These possible faults concern the
VCXO tank circuit and the CODEC 2 circuitry. There are therefore three
aspects, which are covered in Task 40 to Task 42:
■Task 40: CCTM checks
■Task 41: VCXO tank circuit
■Task 42: CODEC 2 circuitry.
Following any repairs of the VCXO or CODEC 2 circuitry, Task 40 will
need to be repeated to confirm the removal of the fault.
Task 40 —
CCTM Checks If the signals at the TP501 and TP502 test points are correct, or any related
faults were rectified, perform the following CCTM checks:
1. Enter the CCTM command 393 1 1900. Measure the voltage level at
the TP501 test point (see Figure 9.17):
2. Enter the CCTM command 72 and note the lock status.
3. Enter the CCTM command 393 1 –1900. Again measure the voltage
level at the TP501 test point:
4. Enter the CCTM command 72 and note the lock status.
5. If the above voltage levels are not correct or if the FCL is out of lock
in either or both of the above cases, investigate the VCXO tank
circuit; go to Tas k 4 1 .
If the voltage level remains fixed at about 1.5V DC, investigate the
CODEC 2 circuitry; go to Ta s k 4 2 .
If the voltage levels are all correct (following earlier repairs), the fault
has been removed; go to “Final Tasks” on page 157.
Task 41 —
VCXO Tank Circuit If the CCTM checks indicate that the VCXO tank circuit is faulty, repair
the circuit as follows:
1. If not already done, remove the VCXO BOT can.
2. Locate and repair the fault in the VCXO tank circuit (Q501, D501,
D502, XL501 and associated components) (see Figure 9.18).
3. Confirm the removal of the fault and go to Step 4. If the repair failed,
replace the board and go to “Final Tasks” on page 157.
TP501 test point: 1.3 ± 0.2 V DC (after CCTM 393 1 1900)
lock status=xyz (x=RF PLL; y=FCL; z=LO2) (0=not in lock; 1=in lock)
TP501 test point: 2.1 ± 0.2 V DC (after CCTM 393 1 –1900)
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4. Replace all cans.
5. Repeat Ta s k 4 0 to confirm the removal of the fault. If the repair
failed, replace the board and go to “Final Tasks” on page 157.
Task 4 2 —
CODEC 2 Circuitry If the CCTM checks indicate a fault in the CODEC 2 circuitry or with the
digital signals to and from the circuitry, rectify the fault as follows:
1. Most of the CODEC 2 circuitry is situated under the CDC TOP can.
If not already done, remove the CDC TOP can.
2. Check the following digital signals at IC205 (see Figure 9.16):
■pin 10 : DIG CDC2 LRCK
■pin 12 : DIG CDC2 SCLK
■pin 8 : CDC2 DIG SDTO
■pin 9 : DIG CDC2 SDTI.
These signals to and from the digital board should all be active:
3. If the digital signals are correct, the CODEC 2 circuitry is suspect;
go to Step 6. If they are not, go to Step 4.
4. If any or all digital signals are missing, check the connections between
IC205 and the digital board (see Figure 9.16).
5. If there are faults such as open circuits in the connections, repair the
circuitry and repeat Ta s k 4 0 .
If the connections are not faulty, then the digital board is faulty.
Replace the board and go to “Final Tasks” on page 157.
6. The CODEC 2 circuitry comprises IC205 and associated components
under the CDC TOP can (see Figure 9.16) as well as R246 under the
CDC BOT can (see Figure 7.3 on page 168). Locate the fault.
7. Repair the circuitry. Note that, if the circuitry is functioning properly,
probing the TP501 test point (see Figure 9.17) during power-up
will show a five-step staircase signal followed by a random nine-step
staircase signal — this is the expected power-up auto-calibration
sequence.
8. Confirm the removal of the fault, and go to Step 9. If the repair
failed, replace the board and go to “Final Tasks” on page 157.
9. Replace all cans.
10. Repeat Ta s k 4 0 to confirm the removal of the fault. If the repair
failed, replace the board and go to “Final Tasks” on page 157.
digital signals: 3.3 ± 0.3 V
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10 Receiver Fault Finding
Fault Conditions This section covers the diagnosis of faults in the receiver. The fault-diagnosis
procedures consist of 18 tasks grouped into the following sections.
The symptoms of the fault in the receiver circuitry determine which
sections are relevant:
■“Faulty Receiver Sensitivity”
■“Excessive Loss of Sensitivity”
■“Moderate or Slight Loss of Sensitivity”
■“Incorrect RSSI Readings”
■“Faulty Radio Mute”
■“High Receiver Distortion”
If the receiver sensitivity is low, begin with “Faulty Receiver Sensitivity” on
page 240 to determine the extent of the loss in sensitivity.
CCTM Commands The CCTM commands required are listed in Table 10.1. Full details of the
commands are given in “Computer-Controlled Test Mode (CCTM)” on
page 118.
Frequency Bands Where test procedures or figures differ according to the frequency band of
the radio, the frequency band is given in brackets. The frequency band may
be referred to as either ‘VHF’ (very high frequency) or ‘UHF’ (ultra high
frequency) or identified by the frequency sub-band, such as ‘B1’ or ‘H7’.
The product-code label on the radio body will identify the frequency band
as described in “Product Codes” on page 17. A definition of frequency
bands is given in “Defining Frequency Bands” on page 126.
Table 10.1 CCTM commands required for the diagnosis of faults in the receiver
Command Description
72 Read lock status of RF PLL, FCL and LO2 — displays xyz (0=not in lock, 1=in lock)
101 x y 0 Set transmit frequency (x in hertz) and receive frequency (y in hertz) to specified values
376 Read tuning voltage for front-end circuitry — displays voltage x in millivolts
378 Read signal power at output of channel filter — displays power x (square of amplitude
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10.1 Faulty Receiver Sensitivity
Introduction This section covers the determination of the extent of the receiver’s loss of
sensitivity. Depending on the nature of the fault, a reduction in receiver
sensitivity of 1dB is often due to a reduction in receiver gain of many
decibels. It is therefore easier to measure gain loss rather than sensitivity loss.
Consequently, if the receiver sensitivity is too low, first check the receiver
gain. The procedure is given in Task 1 below.
Task 1 —
Determine Extent
of Sensitivity Loss
Determine the receiver gain as follows. The corresponding loss of sensitivity
can then be deduced. Depending on the extent of the loss, continue with
“Excessive Loss of Sensitivity” on page 242 or “Moderate or Slight Loss of
Sensitivity” on page 246 to rectify the fault.
1. Input an RF signal (not necessarily modulated) of –90 dBm (or –84
dBm with a trigger-base radio) at the RF connector.
2. Enter the CCTM command 378 to measure the receiver output level.
3. Note the value x returned for the receiver output level. Depending
on the frequency band in which the radio operates, the value should
be:
Note that a change in the input level of 10dBm should result in a ten-
fold change in x.
4. If necessary, measure the RF voltage at the QN test point
(see Figure 10.1). (There is access through a hole in the IF TOP can.)
For comparison, the voltages corresponding to the above values of x
are:
With an unmodulated RF signal the frequency should be 64.000kHz,
provided that the LO1, FCL and LO2 are locked and on the correct
frequency.
5. Given the value of x, go to the relevant section as follows:
■x < 1500, go to “Excessive Loss of Sensitivity” on page 242
(sensitivity is very low)
■x < 500 000, go to “Moderate or Slight Loss of Sensitivity” on
page 246 (sensitivity is low)
receiver output level x: normally between 500 000 and 6000 000
x = 500 000: 12mVpp
x = 6000 000: 120mVpp
TM8100/TM8200 Service Manual Receiver Fault Finding 241
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Figure 10.1 Receiver circuitry under the IF TOP can (top side)
Q404
UHF
Measurement point
VHF
Q404 Measurement point
IC400
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10.2 Excessive Loss of Sensitivity
Introduction This section covers the case where the receiver has suffered an excessive loss
of sensitivity. As measured in Task 1, the receiver gain will be less than 1500,
which implies a sensitivity that is more than 40dBm too low. The fault-
diagnosis procedure for this case consists of five tasks:
■Task 2: check power supplies
■Task 3: check logic signal
■Task 4: check lock status
■Task 5: check biasing of IF amplifier
■Task 6: check matching circuitry
If the fault does not lie with the power supplies, it is probably in the control,
LO, IF1 or IF2 circuitry.
Task 2 —
Check Power
Supplies
First check the two power supplies 3V0 AN and 3V0 RX for the receiver
circuitry.
1. Remove the board from the chassis.
2. Check for 3.0V DC (3V0 AN) at the TP601 test point near the LO2BOT
can (see Figure 10.2).
3. If the voltage is correct, go to Step 4. If it is not, the 3V regulator
IC603 is suspect; go to Ta s k 3 of “Power Supply Fault Finding” on
page 168.
4. Remove the LO2 BOT can.
5. Check for 3.0V DC (3V0 RX) around the collector feed to Q402 or
Q403 of LO2 (see Figure 10.2).
Alternative measurement points are the collector feed to Q401 of the
RF LNA under the FE TOP can (see Figure 10.3) or Q404 of the IF
amplifier under the IF TOP can (see Figure 10.1).
6. If the voltage is correct, go to Ta s k 3 . If it is not, the 3V RX switch
(based on Q604 and Q605) in the PSU module is suspect; go to
Tas k 3 of “Power Supply Fault Finding” on page 168.
TP601 test point: 3.0V DC
Q402 or Q403 collector: 3.0V DC
TM8100/TM8200 Service Manual Receiver Fault Finding 243
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Figure 10.2 Receiver circuitry under the LO2BOT can (UHF shown)
Figure 10.3 Receiver circuitry under the FE TOP can (top side)
Measurement pointQ401
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Task 3 —
Check Logic Signal If there is no fault with the power supplies, check the logic signal DIG RX EN
that is input from the digital board.
1. Check the logic signal DIG RX EN at pin 8 of IC403 (see Figure 10.2).
The signal is active high. The required status is active.
An alternative measurement point to the above is pin 24 of IC400
under the IF TOP can (see Figure 10.1).
2. If DIG RX EN is active, go to Tas k 4 . If it is not, go to Step 3.
3. Check the signal continuity from the digital board to the receiver.
Repair any fault and go to Step 4. If the digital board itself appears to
be faulty, replace the board and go to “Final Tasks” on page 157.
4. Recalibrate the receiver using the calibration application.
5. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, go to Ta s k 7 .
Task 4 —
Check Lock Status If the logic signal from the digital board is active, as required, check the lock
status of the radio.
1. Enter the CCTM command 72 to determine the lock status.
The status should be normal:
2. If the lock status is normal, go to Tas k 5 . If the LO1 is not in lock, go
to “Frequency Synthesizer Fault Finding” on page 179. If the FCL is
not in lock, go to “Power Supply for FCL” on page 227. If the LO2
is not in lock, go to Step 3.
3. Check the components around IC403, Q402 and Q403
(see Figure 10.2). Repair any fault.
4. Recalibrate the receiver using the calibration application.
5. Confirm the removal of the fault, and go to “Final Tasks” on
page 157. If the repair failed go to Ta s k 7 .
pin 8 of IC403: about 3.0V (active)
lock status: 111 (LO1, FCL, LO2 all in lock)
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Task 5 —
Check Biasing
of IF Amplifier
If the lock status is normal, check the biasing of the IF amplifier.
1. Remove the IF TOP can.
2. Check all components around Q404 of the IF amplifier
(see Figure 10.1).
3. Check the 3V supply voltage at L419; use the measurement point
shown in Figure 10.1.
4. Also check the amplifier bias conditions. First measure Vc between
the collector of Q404 and ground (see Figure 10.1).
5. Secondly, check Ic. To do so, unsolder and raise one terminal of L419
(tombstone position) (see Figure 10.1), connect a multimeter
between this terminal and the pad for the terminal, and measure the
current.
6. If the checks in Step 2 to Step 5 reveal no fault, go to Tas k 6 . If there
is a fault, repair it and go to Step 7.
7. Recalibrate the receiver using the calibration application.
8. Confirm the removal of the fault, and go to “Final Tasks” on
page 157. If the repair failed go to Ta s k 7 .
Task 6 —
Check Matching
Circuitry
Having excluded the IF amplifier, check the matching circuitry for the
crystal filters.
1. Check all remaining components between T401 and IC400 — these
form the matching circuitry for the crystal filters XF400 and XF401
(see Figure 10.1).
2. If the above check reveals no fault, go to Step 3. If there is a fault,
repair it and go to Step 6.
3. Remove the PIN TOP and LPF TOP cans.
4. Make a visual check of the components in the receive path of the PIN
switch and LPF circuits.
5. If the visual check reveals an obvious fault, repair it and go to Step 6.
If there is no obvious fault, go to Ta s k 7.
6. Recalibrate the receiver using the calibration application.
7. Confirm the removal of the fault, and go to “Final Tasks” on
page 157. If the repair failed go to Ta s k 7 .
Vc: 2.0 ± 0.2V
Ic: 1.8 ± 0.5mA
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10.3 Moderate or Slight Loss of Sensitivity
Introduction This section covers the case where the receiver has suffered a moderate or
slight loss of sensitivity. As measured in Task 1, the receiver gain will be less
than 500 000, but not as low as 1500. With a gain less than 40 000, the loss
of sensitivity will be moderate — about 15dBm too low; otherwise it will
be slight — just a few decibels too low. There are three tasks:
■Task 7: front-end calibration and tuning voltages
■Task 8: moderately low receiver sensitivity
■Task 9: slightly low receiver sensitivity
The fault-diagnosis procedures of Task 8 and Task 9 are similar; although
the differences are minor they are important.
Task 7 —
Front-end
Calibration
and Tuning Voltages
If the loss of sensitivity is moderate or slight, the fault is probably in the
front-end tuning circuitry.
1. Using the calibration application, check the calibration of the front-
end tuning circuitry: Open the “Raw Data” page and click the
“Receiver” tab.
2. Record the values listed in the “Rx FE Tune BPF Settings” field — these
are the DAC values of the FE (front-end) tuning voltages for the five
frequencies FE TUNE0 to FE TUNE4.
(FE TUNE0 is the lowest frequency and FE TUNE4 the highest fre-
quency in the radio’s frequency band; the values are given in
Table 10.2.)
3. For each of the frequencies FE TUNE0 to FE TUNE4 in turn, carry out
the following procedure: Enter the CCTM command 101 aa0,
where a is the frequency in hertz.
Enter the CCTM command 376 and record the value returned — this
is the front-end tuning voltage in millivolts.
4. Compare the values measured in Step 2 and Step 3 with the nominal
DAC and voltage values listed in Table 10.2.
5. If the DAC and voltage values are correct, go to Step 8. If they are
not, go to Step 6.
6. Recalibrate the receiver using the calibration application, and check
the DAC and voltage values again.
7. If the DAC and voltage values are now correct, the fault has been
rectified; go to “Final Tasks” on page 157. If they are not, go to
Step 8.
8. Go to Ta s k 8 if the receiver output level x measured in Ta sk 1 was less
than 40 000; otherwise go to Tas k 9 .
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Task 8 —
Moderately Low
Sensitivity
Following the initial investigation in Task 7, check the circuitry as follows
when the sensitivity loss is moderate.
1. Remove the FE TOP can and, if not already done, the IF TOP can.
2. Check the soldering of all the components of the front-end tuning
circuitry from C400 to T401 (see Figure 10.1 and Figure 10.3).
3. Check the 3V supply voltage at L404; use the measurement point
shown in Figure 10.3.
4. Also check the LNA bias conditions. First measure Vc between the
collector of Q401 and ground (see Figure 10.3).
5. Secondly, check Ic. To do so, unsolder and raise one terminal of L404
(tombstone position) (see Figure 10.3), connect a multimeter
between this terminal and the pad for the terminal, and measure the
current.
6. If the checks in Step 2 to Step 5 reveal no fault, go to Step 7. If there
is a fault, repair it and go to Step 8.
7. Check the signal level at the output of LO1 and continue the fault
diagnosis as in “Power Supply for FCL” on page 227.
8. Recalibrate the receiver using the calibration application.
9. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, go to Ta s k 9 .
Vc: 2.7 ± 0.1V
Ic: 10 ± 1mA
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Table 10.2 Front-end tuning voltages and corresponding DAC values
Frequency band
Tuning voltages at five different frequencies
FE TUNE0 FE TUNE1 FE TUNE2 FE TUNE3 FE TUNE4
A4 band
Frequency (MHz)
DAC value
Voltage (V)
65.9
0 to 40
0 to 0.47
72.1
89 ± 15
1.05 ± 0.18
77.1
134 ± 15
1.58 ± 0.18
82.1
173 ± 15
2.04 ± 0.18
88.1
218 ± 15
2.56 ± 0.18
B1 band
Frequency (MHz)
DAC value
Voltage (V)
135.9
37 ± 20
0.44 ± 0.24
145.1
88 ± 15
1.04 ± 0.18
155.1
136 ± 15
1.60 ± 0.18
164.1
174 ± 15
2.04 ± 0.18
174.1
210 ± 15
2.57 ± 0.18
C0 band
Frequency (MHz)
DAC value
Voltage (V)
173.9
41 ± 20
0.48 ± 0.24
187.1
104 ± 15
1.22 ± 0.18
200.1
149 ± 15
1.75 ± 0.18
213.1
187 ± 15
2.20 ± 0.18
225.1
220 ± 15
2.59 ± 0.18
D1 band
Frequency (MHz)
DAC value
Voltage (V)
215.9
42 ± 20
0.5 ± 0.2
228.1
103 ± 15
1.2 ± 0.18
241.1
151 ± 15
1.7 ± 0.18
253.1
187 ± 15
2.2 ± 0.18
266.1
224 ± 10
2.6 ± 0.12
H5 band
Frequency (MHz)
DAC value
Voltage (V)
399.9
0 to 36
0 to 0.43
417.1
94 ± 15
1.11 ± 0.18
435.1
106 ± 15
1.25 ± 0.18
452.1
156 ± 15
1.84 ± 0.18
470.1
191 ± 15
2.25 ± 0.18
H6 band
Frequency (MHz)
DAC value
Voltage (V)
449.9
41 ± 20
0.48 ± 0.24
470.1
91 ± 15
1.07 ± 0.18
490.1
134 ± 15
1.58 ± 0.18
510.1
176 ± 15
2.07 ± 0.18
530.1
210 ± 15
2.47 ± 0.18
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Task 9 —
Slightly Low
Sensitivity
Following the initial investigation in Task 7, check the circuitry as follows
when the sensitivity loss is slight.
1. Remove the FE TOP can and, if not already done, the IF TOP can.
2. Check the soldering of all the components of the front-end tuning
circuitry from C400 to T401 (see Figure 10.1 and Figure 10.3).
3. Check the IF-amplifier bias conditions as in Step 4 and Step 5 of
Task 5.
4. Check the LNA bias conditions as in Step 4 and Step 5 of Tas k 8 .
5. If the checks of Step 2 to Step 4 reveal no fault, go to Step 6. If there
is a fault, repair it and go to Step 7.
6. Check the PIN switch and LPF as in Task 31 to Task 33 of
“Transmitter Fault Finding (40W/50W)” on page 259 or
“Transmitter Fault Finding (25W)” on page 323.
7. Recalibrate the receiver using the calibration application.
8. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
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10.4 Incorrect RSSI Readings
Introduction If the RSSI readings are incorrect, the receiver calibration is suspect.
There are four tasks, which cover the four types of settings concerned:
■Task 10: AGC voltage calibration
■Task 11: FE tune BPF settings
■Task 12: RSSI delta gain
■Task 13: AGC delta gain
If the receiver is properly calibrated but the fault persists, then the receiver
sensitivity is suspect.
Task 1 0 —
AGC Voltage
Calibration
The first settings to check concern the AGC voltage calibration.
1. In the calibration application open the “Raw Data” page and click the
“Receiver” tab.
2. Note the settings listed in the “AGC Voltage Cal Pts” field. The nominal
settings should be as listed in Table 10.3. The AGC values depend
on which demod IC is fitted (IC400). The IC is either an RF9667 or
an RF2667.
3. If the settings are correct, go to Tas k 1 1 . If they are not, go to Step 4.
4. Recalibrate the receiver and check the settings again.
5. If the settings are now correct, go to Step 6. If they are not, go to
Tas k 1 and check the receiver sensitivity.
6. Check if the RSSI fault has been removed. If it has, go to “Final
Tasks” on page 157. If it has not, go to Tas k 1 1 .
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Table 10.3 Nominal AGC data
Parameter AGC voltage (mV)
A4 band:
RF2667 RF9667
AGC0
AGC1
AGC2
1810 ± 40
1985 ± 40
2135 ± 50
1710 ± 40
1845 ± 40
1965 ± 50
B1 band:
RF2667 RF9667
AGC0
AGC1
AGC2
1790 ± 40
1960 ± 40
2110 ± 50
1750 ± 40
1900 ± 40
2040 ± 50
C0 band:
RF2667 RF9667
AGC0
AGC1
AGC2
Not used
1700 ± 40
1840 ± 40
1960 ± 50
D1 band:
RF2667 RF9667
AGC0
AGC1
AGC2
1855 ± 40
2050 ± 40
2220 ± 50
1750 ± 40
1900 ± 40
2050 ± 50
H5 band:
RF2667 RF9667
AGC0
AGC1
AGC2
1860 ± 40
2040 ± 40
2200 ± 50
1725 ± 40
1865 ± 40
2000 ± 50
H6 band:
RF2667 RF9667
AGC0
AGC1
AGC2
1870 ± 40
2050 ± 40
2220 ± 50
1825 ± 40
1970 ± 40
2150 ± 50
Receiver input power (dBm)
Standard radio Trigger-base radio
AGC0
AGC1
AGC2
–50
–60
–68
–44
–54
–62
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Task 1 1 —
FE Tune BPF Settings If the AGC voltage calibration is correct, check the FE tune BPF settings.
1. Note the settings listed in the “FE Tune BPF Settings” field.
The nominal settings should be as listed in Table 10.2.
2. If the settings are correct, go to Tas k 1 2 . If they are not, go to Step 3.
3. Recalibrate the receiver and check the settings again.
4. If the settings are now correct, go to Step 5. If they are not, go to
Tas k 1 of “Faulty Receiver Sensitivity” on page 240 and check the
receiver sensitivity.
5. Check if the RSSI fault has been removed. If it has, go to “Final
Tasks” on page 157. If it has not, go to Tas k 1 2 .
Task 1 2 —
RSSI Delta Gain If the FE tune BPF settings are also correct, check the RSSI delta gain
values.
1. Note the values listed in the “Rx Delta Gain Values” field. The values
should be between 0dBm and about –3dBm.
2. If the values are as expected, go to Tas k 1 3 . If they are not, go to
Step 3.
3. Recalibrate the receiver and check the values again.
4. If the values are now correct, go to Step 5. If they are not, go to
Tas k 1 and check the receiver sensitivity.
5. Check if the RSSI fault has been removed. If it has, go to “Final
Tasks” on page 157. If it has not, go to Tas k 1 3 .
Task 1 3 —
AGC Delta Gain If the RSSI delta gain values are also correct, check the AGC delta gain
values.
1. Note the values listed in the “AGC Delta Gain Values” field. The values
should run gradually from 0dBm to about 35dBm.
2. If the values are as expected, go to Step 6. If they are not, go to
Step 3.
3. Recalibrate the receiver and check the values again.
4. If the values are now correct, go to Step 5. If they are not, go to
Tas k 1 and check the receiver sensitivity.
5. Check if the RSSI fault has been removed. If it has, go to “Final
Tasks” on page 157. If it has not, go to Step 6.
6. In this case all the RSSI calibration settings are correct, but there is
still an RSSI fault. Go to Tas k 1 and check the receiver sensitivity.
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10.5 Faulty Radio Mute
Introduction If the radio mute is faulty, the calibration settings are suspect. There are three
tasks:
■Task 14: determine type of muting selected
■Task 15: noise muting selected
■Task 16: RSSI muting selected
The programming application is required for Task 14, and the calibration
application for Task 15 and Task 16.
Task 14 —
Determine Type of
Muting Selected
First use the programming application to determine the type of muting
selected.
1. In the programming application click the “Basic Settings” page under
the “Networks” heading.
2. Click the “Basic Network Settings” tab.
3. Check the setting in the “Squelch Detect Type” field. Ensure that the
setting is what the Customer expects.
4. If the setting is “Noise Level”, implying that noise muting is selected,
go to Task 15. If the setting is “Signal Strength”, implying that RSSI
muting is selected, go to Tas k 1 6 .
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Task 1 5 —
Noise Muting
Selected
With noise muting selected, check the noise mute settings:
1. In the calibration application open the “Deviation/Squelch” page and
click the “Squelch and Signaling Thresholds” tab.
2. Ensure that, under the “Squelch Thresholds” label, the settings in the
“Country”, “City” and “Hard” fields are what the Customer expects.
3. Open the “Raw Data” page and click the “Mute” tab.
4. Compare the values in the “Mute Noise Readings” field with the
required minimum and maximum values listed in Table 10.4.
5. If the mute noise readings are correct, go to Task 1 and check the
receiver sensitivity. If they are not, go to Step 6.
6. Recalibrate the mute and then check if the mute fault has been
removed.
7. If the fault has been removed, go to “Final Tasks” on page 157. If it
has not, go to Task 1 and check the receiver sensitivity.
Table 10.4 Mute data
Channel spacing SINAD (dB)
Mute noise readings
Minimum noise value Maximum noise value
Narrow (12.5 kHz) 8 1900 2300
20 250 500
Medium (20 kHz) 8 3700 4200
20 1000 1500
Wide (25 kHz) 8 5000 7300
20 2200 3700
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Task 16 —
RSSI Muting
Selected
With RSSI muting selected, check the RSSI mute settings.
1. In the calibration application open the “Deviation/Squelch” page and
click the “Squelch and Signaling Thresholds” tab.
2. Check that the values in the “Opening Pt” fields and the “Hysteresis”
fields under the “Squelch Thresholds” label are what the Customer
expects.
3. If the calibration values are as expected, go to Ta s k 1 0 and check the
RSSI calibration. If they are not, go to Step 4.
4. Adjust the values in the “Opening Pt” and “Hysteresis” fields. Program
the radio with the new values.
5. Check if the mute fault has been removed. If it has, go to “Final
Tasks” on page 157. If it has not, go to Ta s k 1 0 and check the RSSI
calibration.
Figure 10.4 TCXO circuitry under the CDC TOP can (top side)
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10.6 High Receiver Distortion
Introduction If there is high receiver distortion, the TCXO is suspect, or alternatively, the
matching circuitry for the crystal filters XF400 and XF401. There are two
tasks:
■Task 17: TCXO calibration and repair of TCXO
■Task 18: second IF and repair of matching circuitry
Recalibrating the TCXO might often be sufficient to rectify the fault.
Task 1 7 —
TCXO Calibration
and Repair of TCXO
First check the TCXO calibration and, if necessary, repair the TCXO.
1. Use the calibration application to check the TCXO calibration:
Open the “Raw Data” page and click the “Volt Ref/TCXO/VCO/VCXO”
tab.
2. Note the values listed in the “Tx TCXO” and “Rx TCXO” fields of the
“TCXO” group box. The values should be:
3. If the calibration values are correct, go to Step 4. If they are not,
recalibrate the TCXO and go to Step 8.
4. Remove the CDC TOP can.
5. Check the components of the TCXO, which is based on XL500
(see Figure 10.4). Repair any fault.
6. Recalibrate the TCXO and check the TCXO calibration values
again as in Step 1 and Step 2.
7. If the calibration values are now correct, go to Step 8. If they are not,
go to Tas k 18.
8. Check if the distortion fault has been removed. If it has, go to “Final
Tasks” on page 157. If it has not, go to Tas k 1 8 .
Tx TCXO and Rx TCXO values: between +20Hz and –20Hz
TM8100/TM8200 Service Manual Receiver Fault Finding 257
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Task 18 —
Second IF and
Repair of Matching
Circuitry
If the TCXO is not faulty, check the second IF and, if necessary, repair the
matching circuitry.
1. Input a large unmodulated RF input signal exceeding –90dBm at the
RF connector.
2. Use a needle probe to measure the frequency of the signal at the QN
test point — access is through the hole in the IF TOP can
(see Figure 10.1). The frequency is the second IF and should be:
3. If the second IF is correct, go to Step 6. If it is not, go to Step 4.
4. Recalibrate the TCXO.
5. Check if the distortion fault has been removed. If it has, go to “Final
Tasks” on page 157. If it has not, go to Step 6.
6. Remove the IF TOP can.
7. Check the components between T401 and IC400 — these form the
matching circuitry for the crystal filters XF400 and XF401
(see Figure 10.1).
8. Repair any fault, confirm the removal of the fault, and go to “Final
Tasks” on page 157. If the repair failed or no fault could be found,
replace the board and go to “Final Tasks” on page 157.
frequency at QN test point: 64.000kHz
258 Receiver Fault Finding TM8100/TM8200 Service Manual
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11 Transmitter Fault Finding (40W/50W)
Introduction This section covers the diagnosis of faults in the 40W/50W transmitter
circuitry. The main indication of a fault in the transmitter is a reduction in
range. This implies that the power output is wrong or too low. Another type
of fault is manifested when the radio always transmits at full power, even if
set otherwise. Regardless of the fault, the lock status should be normal.
Fault-Diagnosis
Tasks The procedure for diagnosing transmitter faults is divided into tasks, which
are grouped into the following sections:
■“Power Supplies”
■“Transmitter RF Power”
■“Biasing of PA Driver and PAs”
■“RF Signal Path”.
Before beginning the fault diagnosis with “Power Supplies”, note the
following information regarding CCTM commands, frequency bands, can
removal and replacement, and transmit tests.
CCTM Commands The CCTM commands required in this section are listed in Table 11.1.
Full details of the commands are given in “Computer-Controlled Test
Mode (CCTM)” on page 118.
Table 11.1 CCTM commands required for the diagnosis of faults in the transmitter
Command Description
32 Set radio in receive mode
33 Set radio in transmit mode
47 Read temperature near PAs — displays temperature x in degrees celsius and voltage y
101 x y 0 Set transmit frequency (x in hertz) and receive frequency (y in hertz) to specified values
114 xSet DAC value x (in range 0 to 1023) of transmit power
304 Read clamp current at gate of PA driver — displays DAC value x (in range 0 to 255)
304 xSet DAC value x (in range 0 to 255) of clamp current at gate of PA driver
318 Read forward-power level — displays corresponding voltage x in millivolts
319 Read reverse-power level — displays corresponding voltage x in millivolts
326 xSet transmitter power level x (0=off, 1=very low, 2=low, 3=medium, 4=high, 5=maximum)
331 Read bias voltage for first PA — displays DAC value x (in range 0 to 255)
331 xSet DAC value x (in range 0 to 255) of bias voltage for first PA
332 Read bias voltage for second PA — displays DAC value x (in range 0 to 255)
332 xSet DAC value x (in range 0 to 255) of bias voltage for second PA
334 xSet synthesizer on (x=1) or off (x=0) via DIG SYN EN line
335 xSet transmit-receive switch on (x=1) or off (x=0) via DIG SYN TR SW line
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Frequency Bands Where test procedures or figures differ according to the frequency band of
the radio, the frequency band is given in brackets. The frequency band may
be referred to as either ‘VHF’ (very high frequency) or ‘UHF’ (ultra high
frequency) or identified by the frequency sub-band, such as ‘B1’ or ‘H7’.
For example:
A definition of frequency bands is given in “Defining Frequency Bands” on
page 126.
Some fault-diagnosis tasks require programming the radio with the lowest,
centre or highest frequency in the radio’s frequency band. The relevant
frequencies for the different bands are listed in Table 11.2.
Emergency
Frequencies The following frequency ranges are reserved worldwide for use as maritime
emergency frequencies or by distress beacons:
■B1 band: 156.8MHz ± 375kHz
■H5 band: 406.0 to 406.1MHz
Do not program the radio with any frequency in the above ranges.
Can Removal There are five cans shielding the bulk of the transmitter circuitry:
■PAD TOP
■PAF TOP
■DIRC TOP
■PIN TOP
■LPF TOP.
To remove any can, first remove the board from the chassis. In the case of
the PAD TOP and PAF TOP cans, first detach the heat-transfer block from the
main board. Secure the block again after removing the cans. Follow the
procedures given in “Disassembly and Reassembly” on page 129.
Can Replacement Replace all cans that have been removed only after repairing the board.
An exception is the B1 band, however, where the LPF TOP can must be in
place if the transmitter is to operate correctly.
RF output power: > 60W (VHF), > 52W (UHF)
current: < 15A (VHF), < 12A (UHF)
Table 11.2 Lowest, centre and highest frequencies in MHz
Band Lowest
frequency
Centre
frequency
Highest
frequency
B1
H5
H7
136
400
450
155
435
485
174
470
520
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Transmit Tests The following actions need to be taken when carrying out transmit tests:
■secure the board
■ensure the proper antenna load
■limit the duration of transmit tests
■protect against accidental transmissions
■avoid thermal and RF burns.
These points are discussed in more detail in the following sections.
Secure the Board Before conducting any transmit tests, ensure that the board is adequately
secured in the chassis. This is essential if overheating of the radio is to be
avoided. (As mentioned earlier, the heat-transfer block must already be
secured to the main board of the assembly.) It is good practice to secure the
assembly by at least the two external screws and one of the internal screws.
The screws are labelled I and E in Figure 5.3 on page 133. There is no
need, however, to secure the lid of the radio body.
Ensure Proper
Antenna Load The radio has been designed to operate with a 50Ω termination impedance,
but will tolerate a wide range of antenna loading conditions. Nevertheless,
care should be exercised. Normally the RF connector on the board will be
connected to the RF communications test set as shown in Figure 4.2 on
page 112. But for those tests where this connection is not necessary, a 50Ω
load may be used instead. Do not operate the transmitter without such a load
or without a connection to the test set. Failure to do so may result in damage
to the power output stage of the transmitter.
Limit Duration of
Transmit Tests After setting the frequency and power level (if necessary), enter the CCTM
command 33 to perform a transmit test. This command places the radio in
transmit mode. After completing the measurement or check required,
immediately enter the CCTM command 32. This command returns the
radio to the receive mode. Restricting the duration of transmit tests in this
way will further limit the danger of overheating. The reason for this
precaution is that the transmit timers do not function in the CCTM mode.
Protect Against
Accidental
Transmissions
Under certain circumstances the microprocessor can key on the transmitter.
Ensure that all instruments are protected at all times from such accidental
transmissions.
Avoid Thermal
and RF Burns Avoid thermal burns. Do not touch the cooling fins or underside of the
radio body when the transmitter is or has been operating. Avoid RF burns.
Do not touch the antenna or the RF signal path on the circuit board while
the transmitter is operating.
262 Transmitter Fault Finding (40W/50W) TM8100/TM8200 Service Manual
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11.1 Power Supplies
Introduction First check that a power supply is not the cause of the fault. There are two
power supplies and a switch circuit for the transmitter:
■Task 1: 13.8V DC supply from power connector (+13V8 BATT)
■Task 2: switch circuit for 13.8V DC supply
■Task 3: 9V DC supply from 9V regulator in PSU module (+9V0 TX).
The measurement and test points for diagnosing faults in the power supplies
are summarized in Figure 11.1.
Figure 11.1 Measurement and test points for diagnosing faults involving the power supplies for
the transmitter
GND
TEST POINT
GND
TEST POINT
9V0 TX
TEST POINT
9V0 TX
TEST POINT
SIGNAL TYPES
RF
ANALOG
EXCITER
PAs
FRE-
QUENCY
SYNTHE-
SIZER
OTHER
TRANS-
MITTER
CIRCUITRY
TRANSMITTER
INTERFACE
CIRCUITRY
DRIVER
+13.8 V DC SUPPLY
TO PA DRIVER
+13.8 V DC SUPPLY
TO PA DRIVER
+13.8 V DC
SUPPLY TO PAs
+13.8 V DC
SUPPLY TO PAs
L310
POWER
SUPPLY
AGND
+9V0 TX
+13V8 BATT
SWITCH
L306
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Task 1 —
13.8V Power Supply First check the power supply from the power connector.
1. Obtain a needle probe to use for measurements of the power supply
at the PA driver and PAs. If none is available, remove the PAF TOP and
PAD TOP cans.
2. Set the DC power supply to 13.8V, with a current limit of 10A.
3. Program the radio with the highest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 11.2.
4. Enter the CCTM command 326 5 to set the radio to maximum
power.
5. Attempt to place the radio in transmit mode. Enter the CCTM
command 33.
6. If the radio enters the transmit mode, continue with Step 7. If instead
a C03 error is displayed in response to the command 33, go to Tas k 7
in “Transmitter RF Power” on page 269.
7. Measure the voltage at the point on L310 shown in Figure 11.2
(VHF) or Figure 11.3 (UHF). This is the supply at the common
drain of Q309 and Q310, and should be:
8. Also measure the voltage at the point on L306 shown in
Figure 11.3. This is the supply at the drain of Q306, and should be:
9. Enter the CCTM command 32 to place the radio in receive mode.
10. If the power supply measured in Step 7 and Step 8 is not correct, go
to Task 2. If it is, go to Tas k 3.
common drain of Q309 and Q310: more than 13V DC
drain of Q306: more than 13V DC
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Figure 11.2 Point for measuring the power supply to the PAs and PA driver (VHF)
L310
Q310
Q309
Q306
R339
Q308
R350
MEASUREMENT POINT ON L310 POINT 2 ON R 350 MEASUREMENT
POINT ON R339
POINT 1
ON R350
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Figure 11.3 Point for measuring the power supply to the PAs and PA driver (UHF)
Q310
Q309
Q306
R339
Q308
L310
MEASUREMENT POINT ON L310
POINT 1
ON R350
POINT 2 ON R 350 MEASUREMENT
POINT ON R339
R350
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Task 2 —
Check Switch Circuit If the power supply to the drains of the PAs and PA driver is not correct, the
switch circuit is suspect. Check the circuit as follows:
1. Measure the voltage at the point 1 on R350 shown in Figure 11.2
(VHF) or Figure 11.3 (UHF). The voltage should be:
2. If the voltage measured in Step 1 is correct, go to Step 3. If it is not,
check for continuity between R350 and the power connector. Repair
any fault and conclude with Step 8.
3. Measure the voltage at R339 as shown in Figure 11.2 (VHF) or
Figure 11.3 (UHF). The voltage should be:
4. If the voltage measured in Step 3 is correct, go to Step 5. If it is not,
go to Tas k 3 and check the 9V power supply.
5. Measure the voltage at the point 2 on R350 shown in Figure 11.2
(VHF) or Figure 11.3 (UHF). The voltage should be:
6. If the voltage measured in Step 5 is correct, go to Step 7. If it is not,
replace Q308 — see Figure 11.2 (VHF) or Figure 11.3 (UHF) —
and conclude with Step 8.
7. Remove the heat-transfer block from the main board. Replace Q311
(situated on the bottom-side of the main board next to the power
connector). Replace the heat-transfer block, and conclude with
Step 8.
8. Repeat Ta s k 1 to confirm the removal of the fault, and go to “Final
Tasks” on page 157. If the repair failed or the fault could not be
found, replace the board and go to “Final Tasks” on page 157.
point 1 on R350: 13.8V DC
R339: 9V DC
point 2 on R350: < 5V DC
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Task 3 —
9V Power Supply If the supply from the power connector is correct, check the 9V DC supply.
1. Enter the CCTM command 326 1 to set the transmitter power level
very low.
2. Enter the CCTM command 33 to place the radio in transmit mode.
3. Measure the supply voltage between the 9V0 TX test point and the
GND test point (see Figure 11.4).
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the supply measured in Step 3 is correct, go to Ta s k 4 in
“Transmitter RF Power” on page 269. If it is not, the 9V regulator
IC601 and the associated switching circuitry Q603 are suspect; go to
Task 3 of “Power Supply Fault Finding” on page 168.
supply 9V0 TX: 9.0 ± 0.5V DC
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Figure 11.4 Test points for checking the 9V supply, the forward and reverse RF power, and the
inhibiting of the transmitter
VHF UHF IF TOP CAN
VCO
TOP
CAN
IF TOP CAN
DIRC TOP CAN DIRC TOP CAN
D TX INH
TEST POINT
TX INH
TEST POINT
TX INH
TEST POINT
9V0 TX
TEST POINT
9V0 TX
TEST POINT
REV PWR
TEST POINT
REV PWR
TEST POINT
FWD PWR
TEST POINT
FWD PWR
TEST POINT GND
TEST POINT
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11.2 Transmitter RF Power
Introduction If there is no fault with the power supplies, check the transmitter RF power
and correct any fault. The procedure is covered in the following eight tasks:
■Task 4: check forward and reverse powers
■Task 5: check RF output power
■Task 6: power unchanged regardless of setting
■Task 7: check for inhibiting of transmitter
■Task 8: check temperature sensor
■Task 9: power and current are skewed
■Task 10: repair output matching circuitry
■Task 11: power and current are low
The measurement points for diagnosing faults concerning the transmitter
RF power are summarized in Figure 11.5. Data required for the first task
(checking the forward and reverse powers) is supplied in Table 11.3.
Table 11.3 Voltages in millivolts corresponding to nominal forward and reverse powers
Frequency band Forward power (318 command) Reverse power (319 command)
B1 2600 to 3400 < 500
H5 3200 to 3900 < 700
H7 3300 to 4000 < 900
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Figure 11.5 Measurement and test points for diagnosing faults concerning the transmitter
RF power
REV PWR
TEST POINT
REV PWR
TEST POINT
FWD PWR
TEST POINT
FWD PWR
TEST POINT
LEAD TO
TEST SET
LEAD TO
TEST SET
TX INH
TEST POINT
TX INH
TEST POINT
50 TEST LEAD
TO TEST SET
50 TEST LEAD
TO TEST SET
D TX INH
TEST POINT
DTXINH
TEST POINT
RF CON-
NECTOR RECEIVER
LPF DIREC-
TIONAL
COUPLER PAs
BUFFER
AMPLIFIER
BUFFER
AMPLIFIER
POWER
CONTROL
PIN SWITCH
DRIVER EXCITER
BIAS
LIMITER
SHAPER
AND
LEVEL
SHIFTER
SHAPER
AND
LEVEL
SHIFTER
SHAPING
FILTER
DIGITAL
BOARD OR GATE
DIG TX INH
DIG SYN EN
SYN LOCK
SYN TX LO
FRE-
QUENCY
SYNTHE-
SIZER
TX FWD PWR
TX REV PWR
CODEC
AND AUDIO
CIRCUITRY
SIGNAL TYPES
RF
ANALOG
CLOCK
DIGITAL
CDC TX
CDC TX
CDC TX
CDC TX
AND
DRV BIAS
FIN BIAS1
FIN BIAS2
PWR CTL
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Task 4 —
Check Forward and
Reverse Powers
First check the forward and reverse powers for an indication of which part
of the circuitry is suspect.
1. Enter the CCTM command 326 4 to set the transmitter power level
high.
2. Enter the CCTM command 33 to place the radio in transmit mode.
3. Enter the CCTM command 318 to check the forward power.
The value returned is the voltage in millivolts corresponding to the
power level, and should be as shown in Table 11.3.
4. Confirm the above result by checking the level at the FWD PWR test
point (see Figure 11.4) using an oscilloscope.
5. Enter the CCTM command 319 to check the reverse power.
The value returned is the voltage in millivolts corresponding to the
power level, and should be as shown in Table 11.3.
6. Confirm the above result by checking the level at the REV PWR test
point (see Figure 11.4) using an oscilloscope.
If the oscilloscope momentarily indicates a very high reverse power,
then the most likely scenario is that the antenna VSWR threshold has
been exceeded and the PA has shut down to very low power.
7. Enter the CCTM command 32 to place the radio in receive mode.
8. If the values obtained in Step 3 and Step 5 are both correct, and there
is no indication of a momentary high reverse power, go to Tas k 5.
If one or both are incorrect, go to Step 9.
9. Check the connection from the RF connector on the radio to the test
set.
10. If there is no fault, go to Step 11. If there is, rectify the fault and
repeat the above measurements.
11. If the reverse power is momentarily too high, the directional coupler,
PIN switch or LPF is suspect; go to Task 3 1 . Otherwise go to Ta s k 5 .
272 Transmitter Fault Finding (40W/50W) TM8100/TM8200 Service Manual
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Task 5 —
Check RF Output
Power
If the power supplies are correct, check the RF output power of the
transmitter.
1. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum value.
2. If not already done, program the radio with the highest frequency in
the radio’s frequency band: Enter the CCTM command 101 xx 0,
where x is the frequency in hertz. The required values for the
different frequency bands are given in Table 11.2.
3. Enter the CCTM command 33 to place the radio in transmit mode.
4. Note the RF output power measured by the test set, and note the
current reading on the DC power supply.
5. Enter the CCTM command 32 to place the radio in receive mode.
6. Program the radio with the centre frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 11.2.
7. Repeat Step 3 to Step 5.
8. Program the radio with the lowest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 11.2.
9. Repeat Step 3 to Step 5.
10. Depending on the results of the above measurements, proceed to the
task indicated in Table 11.4. Note that the power and current are
considered to be skewed if they are low at one part of the frequency
band and high elsewhere.
RF output power: > 60W (VHF), > 52W (UHF)
current: < 15A (VHF), < 12A (UHF)
Table 11.4 Tasks to be performed according to the results of the power and current measurements
of Task 5
Power Current Task
Correct Correct Task 6 — Power unchanged regardless of setting
Correct Wrong Task 31 — Check power at directional coupler
Skewed Skewed Task 9 — Power and current are skewed
Low (> 0.1W) Low (> 0.5A) Task 11 — Power and current are low
None at RF connector (< 0.1W) Low (> 0.5A) Task 31 — Check power at directional coupler
None at RF connector (< 0.1W) None (< 0.5A) Task 7 — Check for inhibiting of transmitter
TM8100/TM8200 Service Manual Transmitter Fault Finding (40W/50W) 273
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Task 6 —
Power Unchanged
Regardless of
Setting
If all the power and current values measured in Task 5 are correct, it is likely
that the power remains unchanged regardless of the power setting.
1. Enter the following CCTM commands in turn and measure the RF
output power in each case:
■326 4
■326 3
■326 2
■326 1
2. The above measurements should confirm that the power remains
unchanged at all settings. Carry out Task 12 and then Ta s k 1 9 .
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Task 7 —
Check for Inhibiting
of Transmitter
If the transmitter is drawing no current or the wrong current, check
whether it is being inhibited. This check is also required if a CO3 error
occurs in Task 1.
1. If not already done, enter the CCTM command 33 to place the radio
in transmit mode.
2. Check the logic signal at the TX INH test point (see Figure 11.4).
The signal should be:
3. If the signal is inactive as required, go to Step 4. If it is active — about
1.1V — the transmitter is being inhibited; go to Step 5.
4. Enter the CCTM command 32 to place the radio in receive mode,
and go to Ta s k 1 2 in “Biasing of PA Driver and PAs” on page 280.
5. Check the logic signal at the DTXINH test point; see Figure 11.14
on page 298 (VHF) or Figure 11.4 (UHF). The signal should be:
6. If the signal is inactive as required, go to Step 8. If it is active — about
3.2V — the temperature sensor is suspect; go to Step 7.
7. Enter the CCTM command 32 to place the radio in receive mode,
and go to Ta s k 8 .
8. The lock status is possibly no longer normal. Enter the CCTM
command 72 and check the lock status.
9. Enter the CCTM command 32 to place the radio in receive mode.
10. The normal lock status is 110. If it is not, proceed to the relevant
section. If it is, go to Step 11.
11. Check for short circuits on the DIG TX INH line from the DTXINH test
point.
12. Repair any fault, confirm the removal of the fault, and go to “Final
Tasks” on page 157. If the repair failed or no fault could be found,
replace the board and go to “Final Tasks” on page 157.
TX INH test point: about 0V (inactive)
D TX INH test point: about 0V (inactive)
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Task 8 —
Check Temperature
Sensor
If the transmitter is being inhibited and the logic signal at the DTXINH test
point is active, a fault in the temperature sensor may be the cause.
1. Enter the CCTM command 47 to check the temperature reading.
2. Of the two numbers returned, the first is the temperature in degrees
celsius and should be about 25°C. If it is, go to Tas k 1 2 in “Biasing of
PA Driver and PAs” on page 280. If it is not, go to Step 3.
3. If not already done, remove the PAF TOP can.
4. Check D301 and the surrounding components — see Figure 11.6
(UHF shown).
5. If there is no fault, go to “CODEC and Audio Fault Finding” on
page 381. If a fault is found, repair it, confirm the removal of the
fault, and go to “Final Tasks” on page 157. If the repair failed, replace
the board, and go to “Final Tasks” on page 157.
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Figure 11.6 PA circuitry under the PAF TOP can and part of the directional coupler under the
DIRC TOP can (UHF shown)
H5, H7 BANDS
C348
C349
C350
D301
Q310
Q309
TEST PAD
MOUNTING POINT FOR
TEST CAPACITOR
TEMPERATURE SENSOR
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Task 9 —
Power and Current
Are Skewed
If the RF output power and the supply current are skewed, the output
matching is suspect.
1. Remove the DIRC TOP can.
2. Remove the coupling capacitors C348, C349 and C350 —
see Figure 11.6 (UHF shown).
3. Solder one terminal of a 680 pF (VHF) or 82pF (UHF) test capacitor
to the PCB at the point shown in Figure 11.6. Mount the capacitor
vertically. Use a test capacitor of the type GRM111, DLI C17,
Murata 1210, or the equivalent.
4. Solder a 50Ω test lead to the PCB. Solder the outer sheath to the test
pad shown in Figure 11.6, and solder the central wire to the other
terminal of the test capacitor.
5. Connect the test lead to the test set.
6. Program the radio with the highest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 11.2.
7. Enter the CCTM command 33 to place the radio in transmit mode.
8. Note the RF output power measured by the test set, and note the
current reading on the DC power supply.
9. Enter the CCTM command 32 to place the radio in receive mode.
10. Program the radio with the centre frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
11. Repeat Step 7 to Step 9.
12. Program the radio with the lowest frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
13. Repeat Step 7 to Step 9.
14. If the power and current are still skewed, go to Ta s k 1 0 . If the power
and current are correct, remove the test lead and test capacitor,
resolder the coupling capacitors in position, and go to Ta s k 3 3 — the
PIN switch and LPF require checking.
RF output power: > 70W (VHF), > 60W (UHF)
current: < 15A (VHF), < 12A (UHF)
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Task 1 0 —
Repair Output
Matching Circuitry
If the checks in Task 9 show that the power and current are still skewed,
there is a fault in the output matching circuitry.
1. If not already done, remove the PAF TOP can.
2. Check for faulty, shorted or misplaced components in the circuit
between the test capacitor and the common drain of Q309 and Q310
(see Figure 11.6). Repair any fault.
3. Program the radio with the highest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 11.2.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Note the RF output power measured by the test set, and note the
current reading on the DC power supply.
6. Enter the CCTM command 32 to place the radio in receive mode.
7. Program the radio with the centre frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
8. Repeat Step 4 to Step 6.
9. Program the radio with the lowest frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
10. Repeat Step 4 to Step 6.
11. Remove the test lead and test capacitor, and resolder the coupling
capacitors C348, C349 and C350 in position (see Figure 11.6).
12. If the power and current are now correct at all three frequencies, the
fault has been rectified; go to “Final Tasks” on page 157. If they are
not, go to Task 26 in “RF Signal Path” on page 303.
RF output power: > 70W (VHF), > 60W (UHF)
current: < 15A (VHF), < 12A (UHF)
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Task 11 —
Power and Current
Are Low
If the RF output power and the supply current are uniformly low at all
frequencies, one of the PAs is suspect or the input to the PAs is reduced.
Check each PA in turn:
1. For the first PA (Q310), enter the CCTM command 331 to check the
DAC value of final bias 1 (CDC TX FIN BIAS 1). Record the value x
returned.
2. Note the current reading on the DC power supply.
3. Enter the CCTM command 331 1 to turn off final bias 1.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Note the RF output power measured at the test set. This should be
as shown in Table 11.5.
6. If the RF power is correct, go to Step 7 to repeat the check with the
second PA. If it is not, enter the CCTM command 32 to place the
radio in receive mode, and carry out Task 1 2 and then Task 1 3.
7. For the second PA (Q309), enter the CCTM command 332 to check
the DAC value of final bias 2 (CDC TX FIN BIAS 2). Record the value y
returned.
8. Note the current reading on the DC power supply.
9. Enter the CCTM command 332 1 to turn off final bias 2.
10. With the radio still in transmit mode, note the RF output power
measured at the test set. This should be as shown in Table 11.5.
11. Enter the CCTM command 32 to place the radio in receive mode.
12. If the RF power measured in Step 10 is correct, go to “RF Signal
Path” on page 302. If it is not, carry out Ta s k 1 2 and then Ta sk 1 6.
Table 11.5 RF output power of individual RF power amplifiers at different frequencies
Frequency band
Frequency within band
Lowest frequency Centre frequency Highest frequency
B1 38 ± 5W 48 ± 5W 33 ± 5W
H5 16 ± 5W 17 ± 5W 21 ± 5W
H7 25 ± 5W 32 ± 5W 40 ± 5W
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11.3 Biasing of PA Driver and PAs
Introduction The measurements of the transmitter RF output power in “Transmitter RF
Power” may indicate a need to check the biasing of the two PAs and the PA
driver. The procedure is covered in this section. There are thirteen tasks
grouped as follows:
■Task 12: prepare to check biasing
■Task 13 to Task 15: check biasing of first PA
■Task 16 to Task 18: check biasing of second PA
■Task 19 and Task 20: check biasing of PA driver
■Task 21 to Task 24: repair circuitry
The test and measurement points for diagnosing faults in the biasing of the
PAs and PA driver are summarized in Figure 11.7.
Task 1 2 —
Prepare to
Check Biasing
If the transmitter is not being inhibited, check the biasing of the two PAs
and the PA driver. First make the following preparations:
1. Set the current limit on the DC power supply to 3A.
2. Enter the CCTM command 331 to check the DAC value of final bias
1 (CDC TX FIN BIAS 1) at maximum power. Record the value x returned.
3. Enter the CCTM command 332 to check the DAC value of final bias
2 (CDC TX FIN BIAS 2) at maximum power. Record the value y returned.
4. Enter the CCTM command 304 to check the DAC value of the
clamp current at the driver gate. Record the value z returned.
5. Enter the CCTM command 33 to place the radio in transmit mode.
6. Switch off all biases by entering the following CCTM commands in
sequence:
■331 1
■332 1
■304 1
■114 1023
■334 0
■335 0
7. Note the current reading on the DC power supply. This will be less
than 500mA.
8. With the radio still in transmit mode, check the biasing of the PAs and
PA driver, beginning with Tas k 1 3 .
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Figure 11.7 Measurement and test points for diagnosing faults in the biasing of the PAs and PA
driver
PIN
SWITCH
AND LPF
REV PWR
FWD PWR
R336R347
DIREC-
TIONAL
COUPLER PAs
BUFFER
AMPLIFIER
BUFFER
AMPLIFIER
POWER
CONTROL
DRIVER EXCITER
BIAS
LIMITER
SHAPER
AND
LEVEL
SHIFTER
SHAPER
AND
LEVEL
SHIFTER
SHAPING
FILTER
FRE-
QUENCY
SYNTHE-
SIZER
CDC TX DRV BIAS
CDC TX FIN BIAS1
CDC TX FIN BIAS2
CDC TX PWR CTL
TX FWD PWR
TX REV PWR
CODEC
AND AUDIO
CIRCUITRY
SIGNAL TYPES
RF
ANALOG
SET PWR
TEST POINT
SET PWR
TEST POINT
DRV
TEST POINT
DRV
TEST POINT
PIN8OF
IC303
PIN 8 OF
IC303
PIN9OF
IC303
PIN 9 OF
IC303
PIN 10 OF
IC303
PIN 10 OF
IC303
PIN5OF
IC303
PIN 5 OF
IC303
PIN3OF
IC303
PIN 3 OF
IC303
FIN1
TEST POINT
FIN1
TEST POINT
FIN2
TEST POINT
FIN2
TEST POINT
PWR
TEST POINT
PWR
TEST POINT
PIN 14 OF
IC301
PIN 14 OF
IC301
PIN 8 OF
IC301
PIN 8 OF
IC301
PIN 1 OF
IC301
PIN 1 OF
IC301
GATES OF
Q309, Q310
GATES OF
Q309, Q310
GATE OF
Q306
GATE OF
Q306
R396
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Task 1 3 —
Check Biasing
of First PA
Check the biasing of the first PA (Q310).
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 331 x, do not
specify a value x higher than that recorded in Task 12. Fail-
ure to do so may result in the destruction of the PAs.
1. Use a multimeter to measure the voltage at pin 14 of IC301
(see Figure 11.8 and Figure 11.9). The voltage should be:
2. Note the current reading on the DC power supply. As mentioned in
Step 7 of Task 12, this will be less than 500mA.
3. Enter the CCTM command 331 x (where x was recorded in Tas k 1 2 ).
4. Check that the voltage changes to:
5. Also note the current reading. This should increase by an amount
approximately equal to the offset given in Table 11.6.
6. If the voltage and current are both correct, go to Step 7. If the voltage
is correct but not the current, go to Tas k 1 4 . If neither the current
nor the voltage is correct, go to Tas k 1 5 .
7. Enter the CCTM command 331 1 to switch off final bias 1, and go to
Tas k 16.
pin 14 of IC301: < 100mV (initially)
pin 14 of IC301: 2 to 5V (after entry of CCTM 331 x)
Table 11.6 Gate biases for the PAs and PA driver at high power
Frequency band
Offset currents in mA
First PA Second PA PA driver
B1 1690 1690 150
H5 1800 1800 400
H7 1800 1800 600
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Figure 11.8 Test points and components of the shaping filter (VHF)
R340
R334
R347
R342
C324
C322
R336
R333
IC303
IC301
B1 BAND
DIRC TOP CAN
DRV TEST POINT
REV PWR TEST POINT
FWD PWR TEST POINT
PWR TEST POINT IF TOP CAN
SET PWR TEST POINT
FIN2 TEST POINT
FIN1 TEST POINT
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Figure 11.9 Test points and components of the shaping filter (UHF)
IC301
R334
IC303
R333
R336
R347
R342
C324
C322
H5, H7 BANDS
DIRC TOP CAN
FWD PWR TEST POINT
REV PWR TEST POINT
IF TOP CANPWR TEST POINT
SET PWR TEST POINT
VCO TOP CAN
DRV TEST POINT
FIN2 TEST POINT
FIN1 TEST POINT
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Task 14 —
Shaper and
Level Shifter
If the voltage measured in Task 13 is correct but not the current, either the
first PA or the shaper and level shifter for the PA is suspect.
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 331 x, do not
specify a value x higher than that recorded in Task 12. Fail-
ure to do so may result in the destruction of the PAs.
1. If the PAF TOP can has already been removed, go to Step 5 If it has not,
go to Step 2.
2. Enter the CCTM command 32 to place the radio in receive mode.
3. Remove the PAF TOP can.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Enter the CCTM command 331 x (where x was recorded in Tas k 1 2 ).
6. Check that the voltage at the gate of Q310 is (see Figure 11.10):
7. Enter the CCTM command 32 to place the radio in receive mode.
8. If the voltage measured above is correct, Q310 is faulty; replace the
board and go to “Final Tasks” on page 157. If it is not correct, go to
Step 9.
9. Check the circuitry between pin 14 of IC301 and the gate of Q310
(see Figure 11.10). If a fault is found, repair it, confirm the removal
of the fault, and go to “Final Tasks” on page 157. If the repair failed
or Q310 itself is faulty, replace the board and go to “Final Tasks” on
page 157.
gate of Q310: 2 to 5V
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Figure 11.10 PA circuitry under the PAF TOP can (UHF shown)
H5, H7 BANDS
Q310
Q309
CIRCUITRY BETWEEN
IC301 AND PAs
VIA TO GATE OF Q310
VIA TO GATE OF Q309
VIA TO PIN 14 OF IC301
VIA TO PIN 8 OF IC301
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Task 15 —
Shaping Filter for
Power Control
If neither the voltage nor the current measured in Task 13 is correct, then
the shaping filter for the power-control circuitry or the CODEC and audio
circuitry is suspect.
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 331 x, do not
specify a value x higher than that recorded in Task 12.
Failure to do so may result in the destruction of the PAs.
1. Use the multimeter to measure the voltage at the FIN1 test point
(see Figure 11.8 and Figure 11.9). The voltage should be:
2. Enter the CCTM command 331 x (where x was recorded in Task 1 2).
3. Check that the voltage changes to:
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the voltage measured above is correct, go to Step 6. If it is not, go
to “CODEC and Audio Fault Finding” on page 381.
6. Check IC301 and the surrounding shaping-filter circuitry
(see Figure 11.8 and Figure 11.9). If a fault is found, repair it,
confirm the removal of the fault, and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
FIN1 test point: 18 ± 2mV (initially)
FIN1 test point: 1.1 to 2.7V (after entry of CCTM 331 x)
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Task 1 6 —
Check Biasing
of Second PA
If the biasing of the first PA is correct, check that of the second PA (Q309).
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 332 y, do not
specify a value y higher than that recorded in Task 12.
Failure to do so may result in the destruction of the PAs.
1. Use the multimeter to measure the voltage at pin 8 of IC301
(see Figure 11.8 and Figure 11.9). The voltage should be:
2. Note the current reading on the DC power supply. As mentioned in
Step 7 of Task 12, the current will be less than 500mA.
3. Enter the CCTM command 332 y (where y was recorded in Tas k 1 2 ).
4. Check that the voltage changes to:
5. Also note the current reading. This should increase by an amount
approximately equal to the offset given in Table 11.6.
6. If the voltage and current are both correct, go to Step 7. If the voltage
is correct but not the current, go to Tas k 1 7 . If neither the current
nor the voltage is correct, go to Tas k 1 8 .
7. Enter the CCTM command 332 1 to switch off final bias 2, and go to
Tas k 19.
pin 8 of IC301: < 100mV (initially)
pin 8 of IC301: 2 to 5V (after entry of CCTM 332 y)
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Task 17 —
Shaper and
Level Shifter
If the voltage measured in Task 16 is correct but not the current, either the
second PA or the shaper and level shifter for the PA is suspect.
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 332 y, do not
specify a value y higher than that recorded in Task 12.
Failure to do so may result in the destruction of the PAs.
1. If the PAF TOP can has already been removed, go to Step 5. If it has
not, go to Step 2.
2. Enter the CCTM command 32 to place the radio in receive mode.
3. Remove the PAF TOP can.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Enter the CCTM command 332 y (where y was recorded in Tas k 1 2 ).
6. Check that the voltage at the gate of Q309 is (see Figure 11.10):
7. Enter the CCTM command 32 to place the radio in receive mode.
8. If the voltage is correct, Q309 is faulty; replace the board and go to
“Final Tasks” on page 157. If it is not, go to Step 9.
9. Check the circuitry between pin 8 of IC301 and the gate of Q309
(see Figure 11.6). If a fault is found, repair it, confirm the removal
of the fault, and go to “Final Tasks” on page 157. If the repair failed
or Q309 itself is faulty, replace the board and go to “Final Tasks” on
page 157.
gate of Q309: 2 to 5V
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Task 1 8 —
Shaping Filter for
Power Control
If neither the voltage nor the current measured in Task 16 is correct, then
the shaping filter for the power-control circuitry or the CODEC and audio
circuitry is suspect.
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 332 y, do not
specify a value y higher than that recorded in Task 12.
Failure to do so may result in the destruction of the PAs.
1. Use the multimeter to measure the voltage at the FIN2 test point
(see Figure 11.8 and Figure 11.9). The voltage should be:
2. Enter the CCTM command 332 y (where y was recorded in Tas k 1 2 ).
3. Check that the voltage changes to:
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the voltage measured above is correct, go to Step 6. If it is not, go
to “CODEC and Audio Fault Finding” on page 381.
6. Check IC301 and the surrounding shaping-filter circuitry
(see Figure 11.8 and Figure 11.9). If a fault is found, repair it,
confirm the removal of the fault, and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
FIN2 test point: 18 ± 2V (initially)
FIN2 test point: 1.1 to 2.7V (after entry of CCTM 332 y)
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Task 19 —
Biasing of PA Driver
—
DRV test point
If there is no fault in the biasing of the PAs, investigate the biasing of the PA
driver (Q306). First check the DRV test point.
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 304 z, do not
specify a value z higher than that recorded in Task 12.
Failure to do so may result in the destruction of the
PA dr iver.
1. Note the current reading on the DC power supply. As mentioned in
Step 7 of Task 1 2, the current will be less than 500mA.
2. Enter the CCTM command 304 z (where z was recorded in Ta s k 1 2 )
to switch on the clamp current.
3. Note the current reading on the DC power supply.
4. Compare the above current readings. The current should increase by
an amount approximately equal to the offset given in Table 11.6.
If it does, go to Tas k 2 1 . If it does not, go to Step 5.
5. Check as follows that the voltage from the DAC is changing:
First enter the CCTM command 304 1 to switch off the bias.
6. Measure the voltage at the DRV test point (CDC TX DRV BIAS)
(see Figure 11.8 and Figure 11.9). The voltage should be:
7. Enter the CCTM command 304 z (where z was recorded in Ta s k 1 2 )
to change the DAC value of the clamp current.
8. The voltage should increase to:
9. If the voltage does change, go to Ta sk 2 0 . If it does not, go to
Step 10.
10. Enter the CCTM command 32 to place the radio in receive mode,
and go to “CODEC and Audio Fault Finding” on page 381.
DRV test point: < 0.1V (after entry of CCTM 304 1)
DRV test point: 0.8 to 2.5V (after entry of CCTM 304 z)
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Task 2 0 —
Biasing of
PA Driver —
SET PWR test point
If the voltage at the DRV test point is correct, check that at the SET PWR test
point.
1. Check the voltage at the SET PWR test point (see Figure 11.8 and
Figure 11.9):
2. If the voltage is correct, go to Step 3. If it is not, go to Ta s k 2 1 .
3. If the PAD TOP can has already been removed, go to Step 7. If it has
not, go to Step 4.
4. Enter the CCTM command 32 to place the radio in receive mode.
5. Remove the PAD TOP can.
6. Enter the CCTM command 33 to place the radio in transmit mode.
7. Check the voltage on the gate of Q306 (see Figure 11.11 and
Figure 11.12):
8. Enter the CCTM command 32 to place the radio in receive mode.
9. If the voltage is correct, replace Q306; confirm the removal of the
fault and go to “Final Tasks” on page 157. If it is not, go to Ta s k 2 3 .
SET PWR test point: 2 to 5V
gate of Q306: 2 to 5V
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Figure 11.11 PA driver circuitry under the PAD TOP can (VHF)
PAD TOP
Q3504
B1 BAND
R327
C310
R324
Q306
COMPONENTS C310,
R324 AND R327
GATE OF Q306
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Figure 11.12 PA driver circuitry under the PAD TOP can (UHF)
PAD TOP
H5, H7 BANDS
Q306
R324
C310
R327
GATE OF Q306
COMPONENTS C310,
R324 AND R327
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Task 21 —
Check Power
Control
Check the power-control circuitry if the clamp current for the PA driver is
correct or if the voltage at the SET PWR test point is incorrect.
Important Ensure that the current limit on the DC supply is 3A.
And, when entering the CCTM command 304 z, do not
specify a value z higher than that recorded in Task 12. Fail-
ure to do so may result in the destruction of the PA driver.
1. Enter the CCTM command 304 z (where z was recorded in Task 12).
2. Note the current reading on the DC power supply.
3. Enter the CCTM command 114 0 to switch off the power.
4. Note the current reading on the DC power supply.
5. Compare the above current readings. The current should decrease by
an amount approximately equal to the offset given in Table 11.6.
If it does, go to Task 26 in “RF Signal Path” on page 303. If it does
not, go to Step 6.
6. Check that the voltage from the DAC is changing. Measure the
voltage at the PWR test point (CDC TX PWR CTL) (see Figure 11.8 and
Figure 11.9).
7. Enter the CCTM command 114 1023. The voltage should increase
to:
8. Enter the CCTM command 32 to place the radio in receive mode.
9. If the voltage at the PWR test point increases as required, go to
Task 22 . If it does not, go to “CODEC and Audio Fault Finding” on
page 381.
PWR test point: 2.4 ± 0.1V
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Figure 11.13 Circuitry under the DIRC TOP can
VHF UHF
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Task 22 —
Directional Coupler
and Buffer
Amplifiers
Following the checks in Task 19 to Task 21, locate the fault and repair the
circuitry as described in the remaining tasks of the section. In this task any
faults in the directional coupler or the buffer amplifiers will be located.
1. Cycle the power.
2. Enter the CCTM command 326 5 to set the transmitter to maximum
power. Enter the CCTM command 33 to place the radio in transmit
mode.
3. Measure the voltage at pin 9 of IC303 in the power-control circuit
(see Figure 11.8 and Figure 11.9).
4. The above voltage should be as given in Table 11.7. If it is, go to
Task 24 . If it is not, go to Step 5.
5. Check the voltage at the FWD PWR test point (pin 5 of IC303) and at
the REV PWR test point (pin 3 of IC303) (see Figure 11.8 and
Figure 11.9). Note that the probe impedance may affect these
measurements.
6. Enter the CCTM command 32 to place the radio in receive mode.
7. The voltages measured in Step 5 should be as given in Table 11.7.
If they are, go to Step 10. If the FWD PWR voltage is incorrect, go to
Step 8. If the REV PWR voltage is incorrect, go to Step 9.
8. Remove the DIRC TOP can. Check the components of the directional
coupler (see Figure 11.13) and go to Step 11.
9. Remove the DIRC TOP can. Check D305 and R3035 (VHF) or R383
(UHF) (see Figure 11.13). If there is no fault, the PIN switch or
LPF or both are suspect; go to Task 33. If there is a fault, go to
Step 11.
10. In the buffer amplifiers, check R340 (see Figure 11.8 for VHF and
Figure 11.14 for UHF) and R341 (see Figure 11.14 and
Figure 11.15).
Table 11.7 Voltages at IC303 at maximum power (70 W for VHF, and 60W for UHF)
Frequency band Frequency (MHz)
Voltage (V)
Pin 9 Pin 3 (REV PWR) Pin 5 (FWD PWR)
B1 136
155
174
2.6 ± 0.5
2.9 ± 0.5
3.2 ± 0.5
0.4 ± 0.3
0.4 ± 0.3
0.5 ± 0.3
3.1 ± 0.5
3.4 ± 0.5
3.9 ± 0.5
H5 400
435
470
2.8 ± 0.5
3.0 ± 0.5
3.3 ± 0.5
0.6 ± 0.4
0.6 ± 0.4
0.5 ± 0.4
3.3 ± 0.5
3.7 ± 0.5
3.9 ± 0.5
H7 450
485
520
3.9 ± 0.5
4.1 ± 0.5
4.4 ± 0.5
0.6 ± 0.4
0.8 ± 0.4
0.8 ± 0.4
4.4 ± 0.5
4.6 ± 0.5
5.0 ± 0.5
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11. Repair any fault revealed by the above checks. Replace IC303 if none
of the other components is faulty (see Figure 11.8 and
Figure 11.9).
12. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
Task 2 3 —
Power Control
for PA Driver
In this task any faults in the path between the power-control circuit and the
PA driver will be located, as well as any fault with the PA driver.
1. Check for short circuits at the gate of the PA driver Q306. Check
R333, R336 (see Figure 11.8 and Figure 11.9), C310, R324 and
R327 (see Figure 11.11 and Figure 11.12) between the power-
control circuit and Q306.
2. Repair any fault revealed by the checks in Step 1. If none of the
above-mentioned components is faulty, replace Q306
(see Figure 11.11 and Figure 11.12).
3. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
Figure 11.14 Components of concern on the bottom-side of the main board (VHF)
B1 BAND
C319
R396
R341
COPPER PLATE
NB BOT CAN
VCO BOT CAN
D311
D TX INH TEST POINT
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Figure 11.15 Components of concern on the bottom-side of the main board (UHF)
H5, H7 BANDS
C319
R341
R340
R396
COPPER PLATE
VCO BOT CAN
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Task 2 4 —
Power Control In this task any faults in the power-control circuitry will be located:
1. Measure the voltage at pin 8 of IC303 (see Figure 11.8 and
Figure 11.9) in the power-control circuit. The voltage should be:
2. If the voltage is correct, go to Step 3. If it is not, enter the CCTM
command 32 and return to Ta s k 2 3 .
3. Measure the voltage at pin 10 of IC303 in the power-control circuit.
The voltage should be:
4. If the voltage is correct, go to Step 5. If it is not, go to Ta s k 2 5 .
5. Enter the CCTM command 32 to place the radio in receive mode.
6. Check C322, C324, R342, R347 (see Figure 11.8 and
Figure 11.9) and R396 (see Figure 11.14 and Figure 11.15) in the
power-control circuit. Repair any fault. Replace IC303 if none of the
other components is faulty.
7. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
pin 8 of IC303: 7.4 ± 0.5V
pin 10 of IC303: 4.8 ± 0.5V
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Task 25 —
Shaping Filter In this task any faults in the shaping-filter circuitry will be located.
1. With the radio still in transmit mode, measure the voltage at pin 1 of
IC301 (see Figure 11.8 and Figure 11.9) in the shaping-filter cir-
cuit. The voltage should be:
2. Enter the CCTM command 32 to place the radio in receive mode.
3. If the voltage measured in Step 1 is correct, go to Step 4. If it is not,
go to Step 5.
4. Check the components R334 (see Figure 11.8 and Figure 11.9)
and C319 (see Figure 11.14 and Figure 11.15) and go to Step 6.
5. Check the components between the PWR test point and pin 1 of
IC301 (see Figure 11.8 and Figure 11.9) and go to Step 6.
6. Repair any fault revealed by the checks in Step 4 and Step 5. Replace
IC301 if none of the other components is faulty.
7. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
pin 1 of IC301: 4.8 ± 0.5V
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11.4 RF Signal Path
Introduction The RF signal path extends from the output of the frequency synthesizer to
the LPF. This section of circuitry will require investigation either following
certain checks in “Transmitter RF Power” or if the biasing checks of
“Biasing of PA Driver and PAs” reveal no fault. The procedure is divided
into ten tasks grouped as follows:
■Task 26 to Task 30: initial RF signal path
■Task 31 and Task 32: directional coupler
■Task 33 and Task 34: PIN switch
■Task 35: LPF
The initial signal path includes the exciter and PA driver. The directional
coupler, PIN switch, and LPF make up the final signal path.
The measurement points for diagnosing faults in the signal path are
summarized in Figure 11.16.
Figure 11.16 Measurement points for diagnosing faults in the RF signal path
TEST
CAPACITOR
TEST
CAPACITOR
L314
RF CON-
NECTOR
RECEIVER
LPF
DIREC-
TIONAL
COUPLER
PAs
PIN
SWITCH
DRIVER EXCITER
FRE-
QUENCY
SYNTHE-
SIZER
SIGNAL TYPES
RF
ANALOG
SYNTHESIZER
OUTPUT
SYN TX LO
PA DRIVER
OUTPUT AT
DRAIN OF Q306
STAGE 2
OUTPUT
AT C3509
STAGE 1
OUTPUT
AT C3505
50 TEST
LEAD TO
TEST SET
50 TEST
LEAD TO
TEST SET
STAGE 3
EXCITER
OUTPUT
GATES OF
Q309, Q310
C307 C3500
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Task 26 —
Output of
Frequency
Synthesizer
The first point to check in the initial RF signal path is the output SYN TX LO
from the frequency synthesizer. This signal is input to the exciter at C300.
1. For test purposes select a representative power level and frequency
from Table 11.8 (B1), Table 11.9 (H5) or Table 11.10 (H7).
(Note that the data for these tables were obtained using an
RFP5401A RF probe.)
2. To set the power level, enter the CCTM command 326 x, where x
defines the level. To set the frequency, enter the CCTM command
101 x x 0, where x is the frequency in hertz.
3. Enter the CCTM command 33 to place the radio in transmit mode.
4. Use an RFP5401A RF probe or the equivalent to measure the RF
voltage after C3500 (see Figure 11.17). Earth the probe to the
FCL TOP can adjacent to the PA driver circuitry. The required voltage
should be as given in Table 11.8 (B1), Table 11.9 (H5) or
Table 11.10 (H7).
5. Enter the CCTM command 32 to place the radio in receive mode.
6. If the voltage measured above is correct, go to Ta s k 2 7 . If it is not, go
to Step 7.
7. Check C3500 (see Figure 11.17). If C3500 is not faulty, go to
“Frequency Synthesizer Fault Finding” on page 179. If C3500 is
faulty, replace it and return to Step 2.
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Figure 11.17 PA driver circuitry under the PAD TOP can (UHF shown)
PAD TOP
Q3504
C317
C389 Q306
C3500
C3505
C3509
C307
Q3501
Q3502
Q3505
H5, H7 BANDS
OUTPUT OF PA DRIVER
OUTPUT OF STAGE 3
OF EXCITER AT C307
R3525
JUNCTION OF
R3525 AND C3512
OUTPUT OF STAGE 2
OF EXCITER AT C3509
FCL TOP CAN
SYNTHESIZER
OUTPUT AT C3500
OUTPUT OF STAGE 2 OF
EXCITER AT C3505
C3509 (B1 BAND)
OUTPUT OF STAGE 2
OF EXCITER
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Table 11.8 RF voltages along the initial RF signal path of the VHF radio (B1 band)
Power
level (W)
Frequency
(MHz)
RF voltages (V)
Synthesizer
output
Exciter
stage 1
Exciter
stage 2
Exciter
stage 3
Driver
output
10 136
155
174
0.3 ± 0.1
0.3 ± 0.1
0.2 ± 0.1
0.6 ± 0.2
0.6 ± 0.2
0.7 ± 0.2
2.7 ± 0.5
2.2 ± 0.5
1.7 ± 0.5
4.0 ± 0.5
3.7 ± 0.5
4.0 ± 0.5
9.9 ± 0.5
8.4 ± 0.5
8.4 ± 0.5
15 136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.6 ± 0.2
0.6 ± 0.2
0.7 ± 0.2
2.7 ± 0.5
2.2 ± 0.5
1.7 ± 0.5
4.0 ± 0.5
3.7 ± 0.5
4.0 ± 0.5
11.8 ± 0.5
10.0 ± 0.5
10.0 ± 0.5
25 136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.6 ± 0.2
0.6 ± 0.2
0.7 ± 0.2
2.7 ± 0.5
2.2 ± 0.5
1.7 ± 0.5
4.0 ± 0.5
3.7 ± 0.5
4.0 ± 0.5
14.3 ± 0.5
13.5 ± 0.5
14.7 ± 0.5
50 136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.6 ± 0.2
0.6 ± 0.2
0.7 ± 0.2
2.7 ± 0.5
2.2 ± 0.5
1.7 ± 0.5
4.0 ± 0.5
3.7 ± 0.5
4.0 ± 0.5
15.6 ± 0.5
15.0 ± 0.5
15.6 ± 0.5
70 136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.6 ± 0.2
0.6 ± 0.2
0.7 ± 0.2
2.7 ± 0.5
2.2 ± 0.5
1.7 ± 0.5
4.0 ± 0.5
3.7 ± 0.5
4.0 ± 0.5
24.5 ± 0.5
29.0 ± 0.5
22.0 ± 0.5
Table 11.9 RF voltages along the initial RF signal path of the UHF radio (H5 band)
Power
level (W)
Frequency
(MHz)
RF voltages (V)
Synthesizer
output
Exciter
stage 1
Exciter
stage 2
Exciter
stage 3
Driver
output
10 400
435
470
0.3 ± 0.1
0.4 ± 0.1
0.3 ± 0.1
1.2 ± 0.2
2.4 ± 0.2
1.1 ± 0.2
4.2 ± 0.5
2.7 ± 0.5
2.1 ± 0.5
9.2 ± 0.5
6.8 ± 0.5
4.8 ± 0.5
3.0 ± 0.5
2.9 ± 0.5
2.0 ± 0.5
15 400
435
470
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
1.2 ± 0.2
2.4 ± 0.2
1.1 ± 0.2
4.2 ± 0.5
2.7 ± 0.5
2.1 ± 0.5
9.2 ± 0.5
6.8 ± 0.5
4.8 ± 0.5
4.1 ± 0.5
3.8 ± 0.5
2.5 ± 0.5
20 400
435
470
0.4 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
1.2 ± 0.2
2.4 ± 0.2
1.1 ± 0.2
4.2 ± 0.5
2.7 ± 0.5
2.1 ± 0.5
9.2 ± 0.5
6.8 ± 0.5
4.8 ± 0.5
4.8 ± 0.5
4.2 ± 0.5
3.0 ± 0.5
40 400
435
470
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
1.2 ± 0.2
2.4 ± 0.2
1.1 ± 0.2
4.2 ± 0.5
2.7 ± 0.5
2.1 ± 0.5
9.2 ± 0.5
6.8 ± 0.5
4.8 ± 0.5
4.6 ± 0.5
4.0 ± 0.5
2.9 ± 0.5
60 400
435
470
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
1.2 ± 0.2
2.4 ± 0.2
1.1 ± 0.2
4.2 ± 0.5
2.7 ± 0.5
2.1 ± 0.5
9.2 ± 0.5
6.8 ± 0.5
4.8 ± 0.5
8.1 ± 0.5
7.3 ± 0.5
5.3 ± 0.5
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Table 11.10 RF voltages along the initial RF signal path of the UHF radio (H7 band)
Power
level (W)
Frequency
(MHz)
RF voltages (V)
Synthesizer
output
Exciter
stage 1
Exciter
stage 2
Exciter
stage 3
Driver
output
10 450
485
520
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
1.1 ± 0.2
1.0 ± 0.2
1.2 ± 0.2
2.2 ± 0.5
1.9 ± 0.5
0.9 ± 0.5
5.7 ± 0.5
3.4 ± 0.5
2.4 ± 0.5
2.5 ± 0.5
2.0 ± 0.5
0.9 ± 0.5
15 450
485
520
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
1.1 ± 0.2
1.0 ± 0.2
1.2 ± 0.2
2.2 ± 0.5
1.9 ± 0.5
0.9 ± 0.5
5.7 ± 0.5
3.4 ± 0.5
2.4 ± 0.5
3.1 ± 0.5
2.4 ± 0.5
1.1 ± 0.5
20 450
485
520
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
1.1 ± 0.2
1.0 ± 0.2
1.2 ± 0.2
2.2 ± 0.5
1.9 ± 0.5
0.9 ± 0.5
5.7 ± 0.5
3.4 ± 0.5
2.4 ± 0.5
3.6 ± 0.5
2.9 ± 0.5
1.4 ± 0.5
40 450
485
520
0.2 ± 0.1
0.1 ± 0.1
0.1 ± 0.1
1.1 ± 0.2
1.0 ± 0.2
1.2 ± 0.2
2.2 ± 0.5
1.9 ± 0.5
0.9 ± 0.5
5.7 ± 0.5
3.4 ± 0.5
2.4 ± 0.5
3.8 ± 0.5
3.2 ± 0.5
1.5 ± 0.5
60 450
485
520
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
1.1 ± 0.2
1.0 ± 0.2
1.2 ± 0.2
2.2 ± 0.5
1.9 ± 0.5
0.9 ± 0.5
5.7 ± 0.5
3.4 ± 0.5
2.4 ± 0.5
7.8 ± 0.5
4.8 ± 0.5
2.8 ± 0.5
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Task 27 —
Output of First
Stage of Exciter
If the synthesizer output is correct, check the output at C3505 of the first
stage of the exciter circuit.
1. If not already done, remove the PAD TOP can.
2. Enter the CCTM command 326 x, where x defines the power level
selected in Task 26.
3. Enter the CCTM command 101 x x 0, where x is the frequency
selected in Task 26.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Measure the RF voltage after C3505 (see Figure 11.17). (Use an
RFP5401A RF probe or the equivalent.) The required voltage
should be as given in Table 11.8 (B1), Table 11.9 (H5) or
Table 11.10 (H7).
6. Enter the CCTM command 32 to place the radio in receive mode.
7. If the voltage measured above is correct, go to Ta s k 2 9 . If it is not, go
to Step 8.
8. Check the components around Q3501 (see Figure 11.17).
9. Repair any fault revealed by the above checks. Replace Q3501
(see Figure 11.17) if none of the other components is faulty.
10. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
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Task 2 8 —
Output of Second
Stage of Exciter
If the output of the first stage of the exciter circuit is correct, check that of
the second stage at C3509:
1. With the radio still in transmit mode, measure the RF voltage after
C3509 (see Figure 11.17). (Use an RFP5401A RF probe or the
equivalent.) The required voltage should be as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
2. If the voltage is correct, go to Ta s k 3 0 . If it is not, go to Step 3.
3. Enter the CCTM command 32 to place the radio in receive mode.
4. Check the components around Q3502 (see Figure 11.17).
5. Repair any fault revealed by the above checks. Replace Q3502
(see Figure 11.17) if none of the other components is faulty.
6. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
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Task 29 —
Output of Third
Stage of Exciter
If the output of the second stage of the exciter circuit is correct, check that
of the third and final stage at C307.
1. With the radio still in transmit mode, measure the RF voltage after
C307 (see Figure 11.17). (Use an RFP5401A RF probe or the
equivalent.) The required voltage should be as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
2. If the voltage is correct, go to Task 3 0. If it is not, go toStep 3.
3. With the radio still in transmit mode, measure the RF voltage at the
junction of R3525 and C3512 (see Figure 11.17). The voltage
should be:
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the voltage measured in Step 3 is correct, go to Step 7. If it is not,
go to Step 6.
6. Check the components around Q3504 (see Figure 11.17). Repair
any fault. Replace Q3504 if none of the other components is faulty.
Conclude with Step 8.
7. Check the components around Q3505 (see Figure 11.17). Repair
any fault. Replace Q3505 if none of the other components is faulty.
8. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
junction of R3525 and C3512: 1.3 ± 0.2V (VHF)
1.8 ± 0.2V (UHF)
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Task 3 0 —
Output of PA Driver If the exciter output is correct, check the output of the PA driver at the
drain of Q306. If necessary, also check the signal at the gates of the PAs
Q309 and Q310. This is the last point in the initial RF signal path.
1. With the radio still in transmit mode, measure the RF voltage at the
drain of Q306 (B1) or after C317 and C389 (other bands). See
Figure 11.17 and use an RFP5401A RF probe or the equivalent.)
The required voltage should be as given in Table 11.8 (B1),
Table 11.9 (H5) or Table 11.10 (H7).
2. Enter the CCTM command 32 to place the radio in receive mode.
3. If the voltage measured above is correct, go to Step 7. If it is not, go
to Step 4.
4. Check the components between C307 and Q306
(see Figure 11.17).
5. If the above checks reveal a fault, go to Step 6. If they do not, go to
Tas k 12 in “Biasing of PA Driver and PAs” on page 280.
6. Repair the fault. Confirm the removal of the fault and go to “Final
Tasks” on page 157. If the repair failed, replace the board and go to
“Final Tasks” on page 157.
7. If not already done, remove the PAF TOP can.
8. Enter the CCTM command 326 5 to set the power level to the
maximum, and then the command 33 to place the radio in transmit
mode.
9. Measure the RF voltage at the gates of the PAs Q309 and Q310
(see Figure 11.18 and Figure 11.19).
10. Enter the CCTM command 32 to place the radio in receive mode.
11. If an RF voltage is present, there is no fault in the initial RF signal
path; go to Task 31. If there is no RF voltage, go to Step 12.
12. Check the components of the interstage matching circuitry between
the PA driver Q306 and the gates of the PAs Q309 and Q310
(see Figure 11.18 and Figure 11.19).
13. If a fault is found, repair it, confirm the removal of the fault, and go
to “Final Tasks” on page 157. If the repair failed or the fault could
not be found, replace the board and go to “Final Tasks” on page 157.
TM8100/TM8200 Service Manual Transmitter Fault Finding (40W/50W) 311
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Figure 11.18 Components of the interstage matching circuitry between the PA driver Q306 and the
PAs Q309 and Q310 (VHF)
B1 BAND
Q310
Q309
Q306
PAF TOP CAN PAD TOP CAN
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Figure 11.19 Components of the interstage matching circuitry between the PA driver Q306 and the
PAs Q309 and Q310 (UHF)
H5, H7 BANDS
Q310
Q309
Q306
PAF TOP CAN PAD TOP CAN
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Task 31 —
Check Power at
Directional Coupler
If, as determined in Task 26 to Task 30, there is no fault in the initial RF
signal path, investigate the final signal path. This part of the circuitry may
also require investigation following certain checks in “Transmitter RF
Power”. Begin by checking the directional coupler as follows:
1. If not already done, remove the DIRC TOP can.
2. Remove the coupling capacitors C348, C349, C350
(see Figure 11.20).
3. Solder one terminal of a 80pF (VHF) or 82pF (UHF) test capacitor
to the PCB at the point shown in Figure 11.20. Mount the capacitor
vertically. Use a test capacitor of the type GRM111, DLI C17,
Murata 1210, or the equivalent.
4. Solder a 50Ω test lead to the PCB: Solder the outer sheath to the test
pad shown in Figure 11.20, and solder the central wire to the other
terminal of the test capacitor.
5. Connect the test lead to the test set.
6. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum.
7. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
8. Enter the CCTM command 33 to place the radio in transmit mode.
9. Measure the RF output power. This should be:
10. Enter the CCTM command 32 to place the radio in receive mode.
11. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
12. Repeat Step 8 to Step 10.
13. If the power measured in both the above cases exceeds 70W (VHF)
or 60W (UHF), go to Step 14. If it does not, go to Tas k 3 2 .
14. Remove the test lead and test capacitor, resolder the coupling
capacitors in position, and go to Task 33.
RF output power: more than 70W (VHF)
more than 60W (UHF)
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Figure 11.20 Circuitry under the DIRC TOP can, and the points for attaching the test lead and test
capacitor
VHF UHF
Mounting point
for test capacitor
Test pad
Test pad
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Task 32 —
Repair Circuitry If the RF output power measured in Task 31 is low, there is a fault in the
circuit between the common drain of the PAs and the test capacitor.
1. If not already done, remove the PAF TOP can.
2. Check for faulty, shorted or misplaced components in the circuit
between the test capacitor and the common drain of Q309 and Q310
(see Figure 11.6).
3. Repair any fault revealed by the above checks and go to Step 5. If no
fault could be found, go to Step 4.
4. Remove the test lead and test capacitor, resolder the coupling
capacitors C348, C349 and C350 in position (see Figure 11.20),
and go to Tas k 2 6 .
5. With the test lead still connected to the test set, enter the CCTM
command 326 5 to set the transmitter power level to the maximum.
6. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
7. Enter the CCTM command 33 to place the radio in transmit mode.
8. Measure the RF output power. This should be:
9. Enter the CCTM command 32 to place the radio in receive mode.
10. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
11. Repeat Step 7 to Step 9.
12. Remove the test lead and test capacitor, and resolder the coupling
capacitors C348, C349 and C350 in position (see Figure 11.20).
13. If the power in both the above cases is now correct, the fault has been
rectified; go to “Final Tasks” on page 157. If it is not, the repair
failed; replace the board and go to “Final Tasks” on page 157.
RF output power: more than 70W (VHF)
more than 60W (UHF)
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Task 3 3 —
Check PIN Switch In checking the final RF signal path, if no fault is found in the directional
coupler, then check the PIN switch next. The PIN switch may also require
investigation following certain checks in “Transmitter RF Power”.
1. Remove the LPF TOP can.
2. Remove the three blocking capacitors C361, C362 and C363
(see Figure 11.21).
3. Solder one terminal of a 56 pF (VHF) or 18 pF (UHF) test capacitor
to the PCB at the point shown in Figure 11.21. Mount the capacitor
vertically. Use a test capacitor of the type GRM111, DLI C17,
Murata 1210, or the equivalent.
4. Solder a 50 Ω test lead to the PCB. Solder the outer sheath to the test
pad shown in Figure 11.21, and solder the central wire to the other
terminal of the test capacitor.
5. Connect the test lead to the test set.
6. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum.
7. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
8. Enter the CCTM command 33 to place the radio in transmit mode.
9. Measure the RF output power. This should be:
10. Enter the CCTM command 32 to place the radio in receive mode.
11. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
12. Repeat Step 8 to Step 10.
13. If the power in both the above cases exceeds 70W (VHF) or 60W
(UHF), go to Step 14. If it does not, the circuitry of the PIN switch
is suspect; go to Task 3 4.
14. Remove the test lead and test capacitor, resolder the blocking
capacitors in position, and go to Ta sk 3 5.
RF output power: more than 70W (VHF)
more than 60W (UHF)
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Figure 11.21 Circuitry under the PIN TOP can, and points for attaching the test lead and test capacitor
H5, H7 BANDS
B1 BAND
C361
C362
C363
D307
C361
C362
C363
D3507
TEST PAD TEST PAD
MOUNTING POINT FOR
TEST CAPACITOR
VHF UHF
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Task 3 4 —
Repair PIN switch If the RF power at the PIN switch is low, the switch is not drawing the
expected current or the diode is faulty. Check the circuit as follows:
1. Remove the PIN TOP can.
2. Perform a diode check of D307 (VHF) or D3507 (UHF)
(see Figure 11.21). If it is not faulty, go to Step 3. If it is, replace
D307 or D3507, and go to Step 4.
3. Check the +9V0_TX supply to the PIN switch via the following
resistors on the bottom-side of the PCB (see Figure 11.22 and
Figure 11.23):
■VHF: R389 and R390
■UHF: R3000, R389 and R390
If any resistor is faulty, replace the resistor as well as D307 (VHF) or
D3507 (UHF). (A faulty resistor is likely to have resulted in damage
to D307 or D3507.)
4. With the test lead still connected to the test set, enter the CCTM
command 326 5 to set the transmitter power level to the maximum.
5. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
6. Enter the CCTM command 33 to place the radio in transmit mode.
Again measure the RF output power. This should be:
7. Enter the CCTM command 32 to place the radio in receive mode.
8. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
9. Repeat Step 5 to Step 7.
10. Remove the test lead and test capacitor, and resolder the blocking
capacitors C361, C362 and C363 (see Figure 11.21) in position.
11. If the power in both the above cases is now correct, the fault has been
rectified; go to “Final Tasks” on page 157. If it is not, the repair
failed; replace the board and go to “Final Tasks” on page 157.
RF output power: more than 70W VHF)
more than 60W (UHF)
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Figure 11.22 Components of concern on the bottom-side of the main board (VHF)
B1 BAND
R389
R390
NB BOT CAN
COPPER PLATE
VCO BOT CAN
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Figure 11.23 Components of concern on the bottom-side of the main board (UHF)
H5, H7 BANDS
R3000
R389
R390
COPPER PLATE
VCO BOT CAN
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Figure 11.24 Circuitry under the LPF TOP can
B1 BAND H5, H7 BANDS
VHF UHF
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Task 3 5 —
Check Components
of LPF
If there are no faults in the final RF signal path up to and including the PIN
switch, then the fault should lie in the LPF. Check the LPF as follows:
1. If not already done, remove the LPF TOP can.
2. Connect the RF connector to the test set.
3. Check the capacitors and inductors of the LPF between the PIN
switch and the RF connector. See Figure 11.24. Check for shorts,
open circuits, and faulty components. Repair any fault.
4. In the case of the B1 band, replace the LPF TOP can before continuing.
5. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum.
6. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
7. Enter the CCTM command 33 to place the radio in transmit mode.
8. Measure the RF output power. This should be:
9. Enter the CCTM command 32 to place the radio in receive mode.
10. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 11.8
(B1), Table 11.9 (H5) or Table 11.10 (H7).
11. Repeat Step 7 to Step 9.
12. If the power in both the above cases exceeds 70W (VHF) or 60W
(UHF), the fault has been rectified; go to “Final Tasks” on page 157.
If it does not, the repair failed; replace the board and go to “Final
Tasks” on page 157.
RF output power: more than 70W (VHF)
more than 60W (UHF)
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12 Transmitter Fault Finding (25W)
Introduction This section covers the diagnosis of faults in the 25W transmitter circuitry.
The main indication of a fault in the transmitter is a reduction in range.
This implies that the power output is wrong or too low. Another type of
fault is manifested when the radio always transmits at full power, even if set
otherwise. Regardless of the fault, the lock status should be normal.
Fault-Diagnosis
Tasks The procedure for diagnosing transmitter faults is divided into tasks, which
are grouped into the following sections:
■“Power Supplies”
■“Transmitter RF Power”
■“Biasing of PA Driver and PAs”
■“RF Signal Path”.
Before beginning the fault diagnosis with “Power Supplies”, note the
following information regarding CCTM commands, frequency bands, can
removal and replacement, and transmit tests.
CCTM Commands The CCTM commands required in this section are listed in Table 12.1.
Full details of the commands are given in “Computer-Controlled Test
Mode (CCTM)” on page 118.
Table 12.1 CCTM commands required for the diagnosis of faults in the transmitter
Command Description
32 Set radio in receive mode
33 Set radio in transmit mode
47 Read temperature near PAs — displays temperature x in degrees celsius and voltage y
101 x y 0 Set transmit frequency (x in hertz) and receive frequency (y in hertz) to specified values
114 xSet DAC value x (in range 0 to 1023) of transmit power
304 Read clamp current at gate of PA driver — displays DAC value x (in range 0 to 255)
304 xSet DAC value x (in range 0 to 255) of clamp current at gate of PA driver
318 Read forward-power level — displays corresponding voltage x in millivolts
319 Read reverse-power level — displays corresponding voltage x in millivolts
326 xSet transmitter power level x (0=off, 1=very low, 2=low, 3=medium, 4=high, 5=maximum)
331 Read bias voltage for first PA — displays DAC value x (in range 0 to 255)
331 xSet DAC value x (in range 0 to 255) of bias voltage for first PA
332 Read bias voltage for second PA — displays DAC value x (in range 0 to 255)
332 xSet DAC value x (in range 0 to 255) of bias voltage for second PA
334 xSet synthesizer on (x=1) or off (x=0) via DIG SYN EN line
335 xSet transmit-receive switch on (x=1) or off (x=0) via DIG SYN TR SW line
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Frequency Bands Where test procedures or figures differ according to the frequency band of
the radio, the frequency band is given in brackets. The frequency band may
be referred to as either ‘VHF’ (very high frequency) or ‘UHF’ (ultra high
frequency) or identified by the frequency sub-band, such as ‘B1’ or ‘H7’.
For example:
A definition of frequency bands is given in “Defining Frequency Bands” on
page 126.
Emergency
Frequencies The following frequency ranges are reserved worldwide for use as maritime
emergency frequencies or by distress beacons:
■B1 band: 156.8MHz ± 375kHz
■D1 band: 243MHz ± 5kHz
■H5 band: 406.0 to 406.1MHz.
Do not program the radio with any frequency in the above ranges.
Can Removal There are five cans shielding the bulk of the transmitter circuitry:
■PAD TOP
■PAF TOP
■DIRC TOP
■PIN TOP
■LPF TOP.
To remove any can, first remove the board. In the case of the PAD TOP and
PAF TOP cans, first detach the heat-transfer block from the board. Secure the
block again after removing the cans. Follow the procedures given in
“Disassembly and Reassembly” on page 129.
Can Replacement Replace all cans that have been removed only after repairing the board.
This applies to the A4, B1, C0, D1, H5 and H6 bands. For certain other
bands the transmitter will not operate correctly unless all the cans are fitted.
RF output power: > 35W
current: < 8A (VHF), < 9A (UHF)
Table 12.2 Lowest, centre and highest frequencies in MHz
Band Lowest
frequency
Centre
frequency
Highest
frequency
A4
B1
C0
D1
H5
H6
66
136
174
216
400
450
77
155
199.5
241
435
490
88
174
225
266
470
530
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Transmit Tests The following points need to be borne in mind when carrying out transmit
tests:
■secure board
■ensure proper antenna load
■limit duration of transmit tests
■protect against accidental transmissions
■avoid thermal and RF burns.
These points are discussed in more detail below.
Secure Board Before conducting any transmit tests, ensure that the board is adequately
secured in the chassis. This is essential if overheating of the radio is to be
avoided. (As mentioned earlier, the heat-transfer block must already be
secured to the board of the assembly.) It is good practice to secure the
assembly by at least the two external screws and one of the internal screws.
The screws are labelled I and E in Figure 5.3 on page 133. There is no
need, however, to secure the lid of the radio body.
Ensure Proper
Antenna Load The radio has been designed to operate with a 50Ω termination impedance,
but will tolerate a wide range of antenna loading conditions. Nevertheless,
care should be exercised. Normally the RF connector on the board will be
connected to the RF communications test set as shown in Figure 4.2 on
page 112. But for those tests where this connection is not necessary, a 50Ω
load may be used instead. Do not operate the transmitter without such a load
or without a connection to the test set. Failure to do so might result in
damage to the power output stage of the transmitter.
Limit Duration of
Transmit Tests After setting the frequency and power level (if necessary), enter the CCTM
command 33 to perform a transmit test. This command places the radio in
transmit mode. After completing the measurement or check required,
immediately enter the CCTM command 32. This command returns the
radio to the receive mode. Restricting the duration of transmit tests in this
way will further limit the danger of overheating. The reason for this
precaution is that the transmit timers do not function in the CCTM mode.
Protect Against
Accidental
Transmissions
Under certain circumstances the microprocessor can key on the transmitter.
Ensure that all instruments are protected at all times from such accidental
transmissions.
Avoid Thermal
and RF Burns Avoid thermal burns. Do not touch the cooling fins or underside of the
radio body when the transmitter is or has been operating. Avoid RF burns.
Do not touch the antenna or the RF signal path on the circuit board while
the transmitter is operating.
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12.1 Power Supplies
Introduction First check that a power supply is not the cause of the fault. There are two
power supplies and a switch circuit for the transmitter:
■Task 1: 13.8V DC supply from power connector (+13V8 BATT)
■Task 2: switch circuit for 13.8V DC supply
■Task 3: 9V DC supply from 9V regulator in PSU module (+9V0 TX).
The measurement and test points for diagnosing faults in the power supplies
are summarized in Figure 12.1.
Figure 12.1 Measurement and test points for diagnosing faults involving the power supplies for
the transmitter
GND
TEST POINT
GND
TEST POINT
9V0 TX
TEST POINT
9V0 TX
TEST POINT
SIGNAL TYPES
RF
ANALOG
EXCITER
PAs
FRE-
QUENCY
SYNTHE-
SIZER
OTHER
TRANS-
MITTER
CIRCUITRY
TRANSMITTER
INTERFACE
CIRCUITRY
DRIVER
+13.8 V DC SUPPLY
TO PA DRIVER
+13.8 V DC SUPPLY
TO PA DRIVER
+13.8 V DC
SUPPLY TO PAs
+13.8 V DC
SUPPLY TO PAs
L310
POWER
SUPPLY
AGND
+9V0 TX
+13V8 BATT
SWITCH
L306
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Task 1 —
13.8V Power Supply First check the power supply from the power connector.
1. Obtain a needle probe to use for measurements of the power supply
at the PA driver and PAs. If none is available, remove the PAF TOP and
PAD TOP cans.
2. Set the DC power supply to 13.8V, with a current limit of 9A.
3. Program the radio with the highest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 12.2.
4. Enter the CCTM command 326 5 to set the radio to maximum
power.
5. Attempt to place the radio in transmit mode. Enter the CCTM
command 33.
6. If the radio enters the transmit mode, continue with Step 7. If instead
a C03 error is displayed in response to the command 33, go to Tas k 7
in “Transmitter RF Power” on page 336.
7. Measure the voltage at the point on L310 shown in Figure 12.2.
This is the supply at the common drain of Q309 and Q310, and
should be:
8. Also measure the voltage at the point on L306 shown in
Figure 12.3. This is the supply at the drain of Q306, and should be:
9. Enter the CCTM command 32 to place the radio in receive mode.
10. If the power supply measured in Step 7 and Step 8 is not correct, go
to Task 2. If it is, go to Tas k 3 .
common drain of Q309 and Q310: more than 13V DC
drain of Q306: more than 13V DC
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Figure 12.2 Point for measuring the power supply to the PAs (UHF shown)
H5/H6 BANDS SHOWN
MEASUREMENT POINT ON L310
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Figure 12.3 Point for measuring the power supply to the PA driver (VHF shown)
C310
R324
R327
C317
C389
Q306
Q308
R350
L306
PAD TOP
MEASUREMENT
POINT ON L306
MEASUREMENT
POINT ON R339
D1 BAND
R339
POINT 2 ON R350POINT 1 ON R350
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Task 2 —
Check Switch Circuit If the power supply to the drains of the PAs and PA driver is not correct, the
switch circuit is suspect. Check the circuit as follows:
1. Measure the voltage at the point 1 on R350 shown in Figure 12.3.
The voltage should be:
2. If the voltage measured in Step 1 is correct, go to Step 3. If it is not,
check for continuity between R350 and the power connector. Repair
any fault and conclude with Step 8.
3. Measure the voltage at R339 as shown in Figure 12.3. The voltage
should be:
4. If the voltage measured in Step 3 is correct, go to Step 5. If it is not,
go to Tas k 3 and check the 9V power supply.
5. Measure the voltage at the point 2 on R350 shown in Figure 12.3.
The voltage should be:
6. If the voltage measured in Step 5 is correct, go to Step 7. If it is not,
replace Q308 — see Figure 12.3 — and conclude with Step 8.
7. Remove the heat-transfer block from the board. Replace Q311
(situated on the bottom-side of the board next to the power
connector). Replace the heat-transfer block, and conclude with
Step 8.
8. Repeat Ta s k 1 to confirm the removal of the fault, and go to “Final
Tasks” on page 157. If the repair failed or the fault could not be
found, replace the board and go to “Final Tasks” on page 157.
Task 3 —
9V Power Supply If the supply from the power connector is correct, check the 9V DC supply.
1. Enter the CCTM command 326 1 to set the transmitter power level
very low.
2. Enter the CCTM command 33 to place the radio in transmit mode.
3. Measure the supply voltage between the 9V0 TX test point and the
GND test point (see Figure 12.4).
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the supply measured in Step 3 is correct, go to Task 4 in
“Transmitter RF Power” on page 334. If it is not, the 9V regulator
IC601 and the associated switching circuitry Q603 are suspect; go to
Tas k 3 of “Power Supply Fault Finding” on page 168.
point 1 on R350: 13.8V DC
R339: 9V DC
point 2 on R350: < 5V DC
supply 9V0 TX: 9.0 ± 0.5V DC
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Figure 12.4 Test points for checking the 9V supply, the forward and reverse RF power, and the
inhibiting of the transmitter
DIRC TOP CAN
IF TOP CAN
VCO TOP CAN (UHF ONLY)
D TX INH
TEST POINT
TX INH
TEST POINT
REV PWR
TEST POINT
FWD PWR
TEST POINT
GND TEST POINT
9V0 TX TEST POINT
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12.2 Transmitter RF Power
Introduction If there is no fault with the power supplies, check the transmitter RF power
and correct any fault. The procedure is covered in the following eight tasks:
■Task 4: check forward and reverse powers
■Task 5: check RF output power
■Task 6: power unchanged regardless of setting
■Task 7: check for inhibiting of transmitter
■Task 8: check temperature sensor
■Task 9: power and current are skewed
■Task 10: repair output matching circuitry
■Task 11: power and current are low
The measurement points for diagnosing faults concerning the transmitter
RF power are summarized in Figure 12.5. Data required for the first task
(checking the forward and reverse powers) are supplied in Table 12.3.
Table 12.3 Voltages in millivolts corresponding to nominal forward and reverse powers
Frequency band Forward power (318 command) Reverse power (319 command)
A4 2700 to 3900 <700
B1 1100 to 2000 <500
C0 1100 to 2000 <500
D1 1600 to 2500 <700
H5 2500 to 3500 <1000
H6 2800 to 3900 <1000
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Figure 12.5 Measurement and test points for diagnosing faults concerning the transmitter
RF power
REV PWR
TEST POINT
REV PWR
TEST POINT
FWD PWR
TEST POINT
FWD PWR
TEST POINT
LEAD TO
TEST SET
LEAD TO
TEST SET
TX INH
TEST POINT
TX INH
TEST POINT
50 TEST LEAD
TO TEST SET
50 TEST LEAD
TO TEST SET
D TX INH
TEST POINT
DTXINH
TEST POINT
RF CON-
NECTOR RECEIVER
LPF DIREC-
TIONAL
COUPLER PAs
BUFFER
AMPLIFIER
BUFFER
AMPLIFIER
POWER
CONTROL
PIN SWITCH
DRIVER EXCITER
BIAS
LIMITER
SHAPER
AND
LEVEL
SHIFTER
SHAPER
AND
LEVEL
SHIFTER
SHAPING
FILTER
DIGITAL
BOARD OR GATE
DIG TX INH
DIG SYN EN
SYN LOCK
SYN TX LO
FRE-
QUENCY
SYNTHE-
SIZER
TX FWD PWR
TX REV PWR
CODEC
AND AUDIO
CIRCUITRY
SIGNAL TYPES
RF
ANALOG
CLOCK
DIGITAL
CDC TX DRV BIAS
CDC TX FIN BIAS1
CDC TX FIN BIAS2
CDC TX PWR CTL
AND
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Task 4 —
Check Forward and
Reverse Powers
First check the forward and reverse powers for an indication of which part
of the circuitry is suspect.
1. Enter the CCTM command 326 4 to set the transmitter power level
high.
2. Enter the CCTM command 33 to place the radio in transmit mode.
3. Enter the CCTM command 318 to check the forward power.
The value returned is the voltage in millivolts corresponding to the
power level, and should be as shown in Table 12.3.
4. Confirm the above result by checking the level at the FWD PWR test
point (see Figure 12.4) using an oscilloscope.
5. Enter the CCTM command 319 to check the reverse power.
The value returned is the voltage in millivolts corresponding to the
power level, and should be as shown in Table 12.3.
6. Confirm the above result by checking the level at the REV PWR test
point (see Figure 12.4) using an oscilloscope.
If the oscilloscope momentarily indicates a very high reverse power,
then the most likely scenario is that the antenna VSWR threshold has
been exceeded and the PA has shut down to very low power.
7. Enter the CCTM command 32 to place the radio in receive mode.
8. If the values obtained in Step 3 and Step 5 are both correct, and there
is no indication of a momentary high reverse power, go to Ta s k 5 .
If one or both are incorrect, go to Step 9.
9. Check the connection from the RF connector on the radio to the test
set.
10. If there is no fault, go to Step 11. If there is, rectify the fault and
repeat the above measurements.
11. If the reverse power is momentarily too high, the directional coupler,
PIN switch or LPF is suspect; go to Task 2 9. Otherwise go to Tas k 5 .
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Task 5 —
Check RF Output
Power
If the power supplies are correct, check the RF output power of the
transmitter.
1. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum value.
2. If not already done, program the radio with the highest frequency in
the radio’s frequency band: Enter the CCTM command 101 xx 0,
where x is the frequency in hertz. The required values for the
different frequency bands are given in Table 12.2.
3. Enter the CCTM command 33 to place the radio in transmit mode.
4. Note the RF output power measured by the test set, and note the
current reading on the DC power supply.
5. Enter the CCTM command 32 to place the radio in receive mode.
6. Program the radio with the centre frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 12.2.
7. Repeat Step 3 to Step 5.
8. Program the radio with the lowest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz. The required values for the different frequency bands are
given in Table 12.2.
9. Repeat Step 3 to Step 5.
10. Depending on the results of the above measurements, proceed to the
task indicated in Table 12.4. Note that the power and current are
considered to be skewed if they are low at one part of the frequency
band and high elsewhere.
RF output power: > 30W
current: < 8A (VHF), < 9A (UHF)
Table 12.4 Tasks to be performed according to the results of the power and current measurements
of Task 5
Power Current Task
Correct Correct Task 6 — Power unchanged regardless of setting
Correct Wrong Task 29 — Check power at directional coupler
Skewed Skewed Task 9 — Power and current are skewed
Low (> 0.1W) Low (> 0.5A) Task 11 — Power and current are low
None at RF connector (< 0.1W) Low (> 0.5A) Task 29 — Check power at directional coupler
None at RF connector (< 0.1W) None (< 0.5A) Task 7 — Check for inhibiting of transmitter
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Task 6 —
Power Unchanged
Regardless of
Setting
If all the power and current values measured in Task 5 are correct, it is likely
that the power remains unchanged regardless of the power setting.
1. Enter the following CCTM commands in turn and measure the RF
output power in each case:
■326 4
■326 3
■326 2
■326 1
2. The above measurements should confirm that the power remains
unchanged at all settings. Carry out Tas k 1 2 and then Ta s k 1 9 .
Task 7 —
Check for Inhibiting
of Transmitter
If the transmitter is drawing no current or the wrong current, check
whether it is being inhibited. This check is also required if a CO3 error
occurs in Task 1.
1. If not already done, enter the CCTM command 33 to place the radio
in transmit mode.
2. Check the logic signal at the TX INH test point (see Figure 12.4).
The signal should be:
3. If the signal is inactive as required, go to Step 4. If it is active — about
1.1V — the transmitter is being inhibited; go to Step 5.
4. Enter the CCTM command 32 to place the radio in receive mode,
and go to Ta s k 1 2 in “Biasing of PA Driver and PAs” on page 342.
5. Check the logic signal at the DTXINH test point (see Figure 12.4).
The signal should be:
6. If the signal is inactive as required, go to Step 8. If it is active — about
3.2V — the temperature sensor is suspect; go to Step 7.
7. Enter the CCTM command 32 to place the radio in receive mode,
and go to Ta s k 8 .
8. The lock status is possibly no longer normal. Enter the CCTM
command 72 and check the lock status.
9. Enter the CCTM command 32 to place the radio in receive mode.
10. The normal lock status is 110. If it is not, proceed to the relevant
section. If it is, go to Step 11.
11. Check for short circuits on the DIG TX INH line from the DTXINH test
point.
TX INH test point: about 0V (inactive)
D TX INH test point: about 0V (inactive)
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12. Repair any fault, confirm the removal of the fault, and go to “Final
Tasks” on page 157. If the repair failed or no fault could be found,
replace the board and go to “Final Tasks” on page 157.
Task 8 —
Check Temperature
Sensor
If the transmitter is being inhibited and the logic signal at the DTXINH test
point is active, a fault in the temperature sensor might be the cause.
1. Enter the CCTM command 47 to check the temperature reading.
2. Of the two numbers returned, the first is the temperature in degrees
celsius and should be about 25°C. If it is, go to Task 12 in “Biasing of
PA Driver and PAs” on page 342. If it is not, go to Step 3.
3. If not already done, remove the PAF TOP can.
4. Check D301 and the surrounding components — see Figure 12.6.
5. If there is no fault, go to “CODEC and Audio Fault Finding” on
page 381. If a fault is found, repair it, confirm the removal of the
fault, and go to “Final Tasks” on page 157. If the repair failed, replace
the board and go to “Final Tasks” on page 157.
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Figure 12.6 PA circuitry under the PAF TOP can and part of the directional coupler under the DIRC TOP
can (VHF shown)
PAF TOP
D301
Q310
Q309
D1 BAND
TEMPERATURE SENSOR
C350
C349
C348
MOUNTING POINT
FOR TEST CAPACITOR
TEST PAD
DIRC
TOP
SOLDER OUTER
SHEATH TO GND
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Task 9 —
Power and Current
Are Skewed
If the RF output power and the supply current are skewed, the output
matching is suspect.
1. Remove the DIRC TOP can.
2. Remove the coupling capacitors C348, C349 and C350 —
see Figure 12.6.
3. Solder one terminal of a test capacitor to the PCB at the point shown
in Figure 12.6. Mount the capacitor vertically. Use a test capacitor
of the type GRM111, DLI C17, Murata 1210, or the equivalent.
The value of the capacitor depends on the frequency band of
the radio:
■A4 — 100pF
■B1, C0, D1 — 680pF
■H5, H6 — 82pF.
4. Solder a 50Ω test lead to the PCB. Solder the outer sheath in the
position shown in Figure 12.6, and solder the central wire to the
other terminal of the test capacitor.
5. Connect the test lead to the test set.
6. Program the radio with the highest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz.
7. Enter the CCTM command 33 to place the radio in transmit mode.
8. Note the RF output power measured by the test set, and note the
current reading on the DC power supply.
9. Enter the CCTM command 32 to place the radio in receive mode.
10. Program the radio with the centre frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
11. Repeat Step 7 to Step 9.
12. Program the radio with the lowest frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
13. Repeat Step 7 to Step 9.
14. If the power and current are still skewed, go to Ta s k 1 0 . If the power
and current are correct, remove the test lead and test capacitor,
resolder the coupling capacitors in position, and go to Ta s k 3 1 — the
PIN switch and LPF require checking.
RF output power: > 35W
current: < 8A (VHF), < 9A (UHF)
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Task 1 0 —
Repair Output
Matching Circuitry
If the checks in Task 9 show that the power and current are still skewed,
there is a fault in the output matching circuitry.
1. If not already done, remove the PAF TOP can.
2. Check for faulty, shorted or misplaced components in the circuit
between the test capacitor and the common drain of Q309 and Q310
(see Figure 12.6). Repair any fault.
3. Program the radio with the highest frequency in the radio’s frequency
band: Enter the CCTM command 101 x x 0, where x is the frequency
in hertz.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Note the RF output power measured by the test set, and note the
current reading on the DC power supply.
6. Enter the CCTM command 32 to place the radio in receive mode.
7. Program the radio with the centre frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
8. Repeat Step 4 to Step 6.
9. Program the radio with the lowest frequency in the band: Enter the
CCTM command 101 x x 0, where x is the frequency in hertz.
10. Repeat Step 4 to Step 6.
11. Remove the test lead and test capacitor, and resolder the coupling
capacitors C348, C349 and C350 in position (see Figure 12.6).
12. If the power and current are now correct at all three frequencies, the
fault has been rectified; go to “Final Tasks” on page 157. If they are
not, go to Task 25 in “RF Signal Path” on page 362.
RF output power: > 35W
current: < 8A (VHF), < 9A (UHF)
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 341
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Task 11 —
Power and Current
Are Low
If the RF output power and the supply current are uniformly low at all
frequencies, one of the PAs is suspect or the input to the PAs is reduced.
Check each PA in turn:
1. For the first PA (Q310), enter the CCTM command 331 to check the
DAC value of final bias 1 (CDC TX FIN BIAS 1). Record the value x
returned.
2. Note the current reading on the DC power supply.
3. Enter the CCTM command 331 1 to turn off final bias 1.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Note the RF output power measured at the test set. This should be
as shown in Table 12.5.
6. If the RF power is correct, go to Step 7 to repeat the check with the
second PA. If it is not, enter the CCTM command 32 to place the
radio in receive mode, and carry out Task 1 2 and then Task 1 3.
7. For the second PA (Q309), enter the CCTM command 332 to check
the DAC value of final bias 2 (CDC TX FIN BIAS 2). Record the value y
returned.
8. Note the current reading on the DC power supply.
9. Enter the CCTM command 332 1 to turn off final bias 2.
10. With the radio still in transmit mode, note the RF output power
measured at the test set. This should be as shown in Table 12.5.
11. Enter the CCTM command 32 to place the radio in receive mode.
12. If the RF power measured in Step 10 is correct, go to “RF Signal
Path” on page 361. If it is not, carry out Ta s k 1 2 and then Ta sk 1 6.
Table 12.5 RF output power of individual RF power amplifiers at different frequencies
Frequency band
Frequency within band
Lowest frequency Centre frequency Highest frequency
A4 24 ± 5W 25 ± 5W 25 ± 5W
B1 29 ± 5W 34 ± 5W 29 ± 5W
C0 23 ± 5W 22 ± 5W 17 ± 5W
D1 33 ± 5 W 28 ± 5 W 29 ± 5 W
H5 5 ± 5W 12 ± 5W 27 ± 5W
H6 13 ± 5W 19 ± 5W 28 ± 5W
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12.3 Biasing of PA Driver and PAs
Introduction The measurements of the transmitter RF output power in “Transmitter RF
Power” might indicate a need to check the biasing of the two PAs and the
PA driver. The procedure is covered in this section. There are thirteen tasks
grouped as follows:
■Task 12: prepare to check biasing
■Task 13 to Task 15: check biasing of first PA
■Task 16 to Task 18: check biasing of second PA
■Task 19 and Task 20: check biasing of PA driver
■Task 21 to Task 24: repair circuitry
The test and measurement points for diagnosing faults in the biasing of the
PAs and PA driver are summarized in Figure 12.7.
Task 1 2 —
Prepare to
Check Biasing
If the transmitter is not being inhibited, check the biasing of the two PAs
and the PA driver. First make the following preparations:
1. Set the current limit on the DC power supply to 2A.
2. Enter the CCTM command 331 to check the DAC value of final bias
1 (CDC TX FIN BIAS 1) at maximum power. Record the value x returned.
3. Enter the CCTM command 332 to check the DAC value of final bias
2 (CDC TX FIN BIAS 2) at maximum power. Record the value y returned.
4. Enter the CCTM command 304 to check the DAC value of the
clamp current at the driver gate. Record the value z returned.
5. Enter the CCTM command 33 to place the radio in transmit mode.
6. Switch off all biases by entering the following CCTM commands in
sequence:
■331 1
■332 1
■304 1
■114 1023
■334 0
■335 0
7. Note the current reading on the DC power supply. This will be less
than 500mA.
8. With the radio still in transmit mode, check the biasing of the PAs and
PA driver, beginning with Tas k 1 3 .
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Figure 12.7 Measurement and test points for diagnosing faults in the biasing of the PAs and PA
driver
PIN
SWITCH
AND LPF
R336R347
DIREC-
TIONAL
COUPLER PAs
BUFFER
AMPLIFIER
BUFFER
AMPLIFIER
POWER
CONTROL
DRIVER EXCITER
BIAS
LIMITER
SHAPER
AND
LEVEL
SHIFTER
SHAPER
AND
LEVEL
SHIFTER
SHAPING
FILTER
FRE-
QUENCY
SYNTHE-
SIZER
CDC TX DRV BIAS
CDC TX FIN BIAS1
CDC TX FIN BIAS2
CDC TX PWR CTL
TX FWD PWR
TX REV PWR
CODEC
AND AUDIO
CIRCUITRY
SIGNAL TYPES
RF
ANALOG
SET PWR
TEST POINT
SET PWR
TEST POINT
DRV
TEST POINT
DRV
TEST POINT
PIN8OF
IC303
PIN 8 OF
IC303
PIN9OF
IC303
PIN 9 OF
IC303
PIN 10 OF
IC303
PIN 10 OF
IC303
PIN5OF
IC303
PIN 5 OF
IC303
FIN1
TEST POINT
FIN1
TEST POINT
FIN2
TEST POINT
FIN2
TEST POINT
PWR
TEST POINT
PWR
TEST POINT
PIN 14 OF
IC301
PIN 14 OF
IC301
PIN8OF
IC301
PIN 8 OF
IC301
PIN1OF
IC301
PIN 1 OF
IC301
GATES OF
Q309, Q310
GATES OF
Q309, Q310
GATE OF
Q306
GATE OF
Q306
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Task 1 3 —
Check Biasing
of First PA
Check the biasing of the first PA (Q310).
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 331 x, do not
specify a value x higher than that recorded in Task 12.
Failure to do so might result in the destruction of the PAs.
1. Use a multimeter to measure the voltage at pin 14 of IC301
(see Figure 12.8). The voltage should be:
2. Note the current reading on the DC power supply. As mentioned in
Step 7 of Task 12, this will be less than 500mA.
3. Enter the CCTM command 331 x (where x was recorded in Tas k 1 2 ).
4. Check that the voltage changes to:
5. Also note the current reading. This should increase by an amount
approximately equal to the offset given in Table 12.6.
6. If the voltage and current are both correct, go to Step 7. If the voltage
is correct but not the current, go to Tas k 1 4 . If neither the current
nor the voltage is correct, go to Tas k 1 5 .
7. Enter the CCTM command 331 1 to switch off final bias 1, and go to
Tas k 16.
pin 14 of IC301: < 100mV (initially)
pin 14 of IC301: 2 to 5V (after entry of CCTM 331 x)
Table 12.6 Gate biases for the PAs and PA driver at high power
Frequency band
Offset currents in mA
First PA Second PA PA driver
A4 750 750 300
B1 750 750 300
C0 750 750 300
D1 800 800 300
H5 1000 1000 450
H6 1000 1000 450
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Figure 12.8 Test points and components of the shaping filter
DIRC TOP CAN
IF TOP CAN
VCO TOP CAN (UHF ONLY)
SET PWR
TEST POINT
FWD PWR
TEST POINT
PWR TEST POINT FIN1 TEST POINT FIN2 TEST POINT
DRV TEST POINT
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Figure 12.9 PA circuitry under the PAF TOP can (VHF shown)
D301
PAF TOP
CIRCUITRY BETWEEN
IC301 AND PAs
VIA TO GATE OF Q309
VIA TO GATE OF Q310
Q310
Q309
D1 BAND
VIA TO PIN 14 OF 1C301
VIA TO PIN 8 OF IC301
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Task 14 —
Shaper and
Level Shifter
If the voltage measured in Task 13 is correct but not the current, either the
first PA or the shaper and level shifter for the PA is suspect.
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 331 x, do not
specify a value x higher than that recorded in Task 12.
Failure to do so might result in the destruction of the PAs.
1. If the PAF TOP can has already been removed, go to Step 5. If it has not,
go to Step 2.
2. Enter the CCTM command 32 to place the radio in receive mode.
3. Remove the PAF TOP can.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Enter the CCTM command 331 x (where x was recorded in Tas k 1 2 ).
6. Check that the voltage at the gate of Q310 is (see Figure 12.9):
7. Enter the CCTM command 32 to place the radio in receive mode.
8. If the voltage measured above is correct, Q310 is faulty; replace the
board and go to “Final Tasks” on page 157. If it is not correct, go to
Step 9.
9. Check the circuitry between pin 14 of IC301 and the gate of Q310
(see Figure 12.9). If a fault is found, repair it, confirm the removal
of the fault, and go to “Final Tasks” on page 157. If the repair failed
or Q310 itself is faulty, replace the board and go to “Final Tasks” on
page 157.
gate of Q310: 2 to 5V
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Task 1 5 —
Shaping Filter for
Power Control
If neither the voltage nor the current measured in Task 13 is correct, then
the shaping filter for the power-control circuitry or the CODEC and audio
circuitry is suspect.
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 331 x, do not
specify a value x higher than that recorded in Task 12.
Failure to do so might result in the destruction of the PAs.
1. Use the multimeter to measure the voltage at the FIN1 test point
(see Figure 12.8). The voltage should be:
2. Enter the CCTM command 331 x (where x was recorded in Tas k 1 2 ).
3. Check that the voltage changes to:
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the voltage measured above is correct, go to Step 6. If it is not, go
to “CODEC and Audio Fault Finding” on page 381.
6. Check IC301 and the surrounding shaping-filter circuitry
(see Figure 12.8). If a fault is found, repair it, confirm the removal
of the fault, and go to “Final Tasks” on page 157. If the repair failed,
replace the board and go to “Final Tasks” on page 157.
FIN1 test point: 18 ± 2mV (initially)
FIN1 test point: 1.1 to 2.7V (after entry of CCTM 331 x)
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Task 16 —
Check Biasing
of Second PA
If the biasing of the first PA is correct, check that of the second PA (Q309).
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 332 y, do not
specify a value y higher than that recorded in Task 12.
Failure to do so might result in the destruction of the PAs.
1. Use the multimeter to measure the voltage at pin 8 of IC301
(see Figure 12.8). The voltage should be:
2. Note the current reading on the DC power supply. As mentioned in
Step 7 of Task 1 2, the current will be less than 500mA.
3. Enter the CCTM command 332 y (where y was recorded in Tas k 1 2 ).
4. Check that the voltage changes to:
5. Also note the current reading. This should increase by an amount
approximately equal to the offset given in Table 12.6.
6. If the voltage and current are both correct, go to Step 7. If the voltage
is correct but not the current, go to Task 17. If neither the current
nor the voltage is correct, go to Task 18 .
7. Enter the CCTM command 332 1 to switch off final bias 2, and go to
Task 19 .
pin 8 of IC301: < 100mV (initially)
pin 8 of IC301: 2 to 5V (after entry of CCTM 332 y)
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Task 1 7 —
Shaper and
Level Shifter
If the voltage measured in Task 16 is correct but not the current, either the
second PA or the shaper and level shifter for the PA is suspect.
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 332 y, do not
specify a value y higher than that recorded in Task 12.
Failure to do so might result in the destruction of the PAs.
1. If the PAF TOP can has already been removed, go to Step 5. If it has not,
go to Step 2.
2. Enter the CCTM command 32 to place the radio in receive mode.
3. Remove the PAF TOP can.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Enter the CCTM command 332 y (where y was recorded in Tas k 1 2 ).
6. Check that the voltage at the gate of Q309 is (see Figure 12.9):
7. Enter the CCTM command 32 to place the radio in receive mode.
8. If the voltage is correct, Q309 is faulty; replace the board and go to
“Final Tasks” on page 157. If it is not, go to Step 9.
9. Check the circuitry between pin 8 of IC301 and the gate of Q309
(see Figure 12.9). If a fault is found, repair it, confirm the removal
of the fault, and go to “Final Tasks” on page 157. If the repair failed
or Q309 itself is faulty, replace the board and go to “Final Tasks” on
page 157.
gate of Q309: 2 to 5V
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Task 18 —
Shaping Filter for
Power Control
If neither the voltage nor the current measured in Task 16 is correct, then
the shaping filter for the power-control circuitry or the CODEC and audio
circuitry is suspect.
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 332 y, do not
specify a value y higher than that recorded in Task 12.
Failure to do so might result in the destruction of the PAs.
1. Use the multimeter to measure the voltage at the FIN2 test point
(see Figure 12.8). The voltage should be:
2. Enter the CCTM command 332 y (where y was recorded in Tas k 1 2 ).
3. Check that the voltage changes to:
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the voltage measured above is correct, go to Step 6. If it is not, go
to “CODEC and Audio Fault Finding” on page 381.
6. Check IC301 and the surrounding shaping-filter circuitry
(see Figure 12.8). If a fault is found, repair it, confirm the removal
of the fault, and go to “Final Tasks” on page 157. If the repair failed,
replace the board and go to “Final Tasks” on page 157.
FIN2 test point: 18 ± 2V (initially)
FIN2 test point: 1.1 to 2.7V (after entry of CCTM 332 y)
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Task 1 9 —
Biasing of
PA Driver —
DRV test point
If there is no fault in the biasing of the PAs, investigate the biasing of the PA
driver (Q306). First check the DRV test point.
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 304 z, do not
specify a value z higher than that recorded in Task 12.
Failure to do so might result in the destruction of the PA
driver.
1. Note the current reading on the DC power supply. As mentioned in
Step 7 of Task 12, the current will be less than 500mA.
2. Enter the CCTM command 304 z (where z was recorded in Ta s k 1 2 )
to switch on the clamp current.
3. Note the current reading on the DC power supply.
4. Compare the above current readings. The current should increase by
an amount approximately equal to the offset given in Table 12.6.
If it does, go to Ta s k 2 1 . If it does not, go to Step 5.
5. Check as follows that the voltage from the DAC is changing:
First enter the CCTM command 304 1 to switch off the bias.
6. Measure the voltage at the DRV test point (CDC TX DRV BIAS)
(see Figure 12.8). The voltage should be:
7. Enter the CCTM command 304 z (where z was recorded in Ta s k 1 2 )
to change the DAC value of the clamp current.
8. The voltage should increase to:
9. If the voltage does change, go to Tas k 2 0 . If it does not, go to
Step 10.
10. Enter the CCTM command 32 to place the radio in receive mode,
and go to “CODEC and Audio Fault Finding” on page 381.
DRV test point: < 0.1V (after entry of CCTM 304 1)
DRV test point: 0.8 to 2.5V (after entry of CCTM 304 z)
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Task 20 —
Biasing of
PA Driver —
SET PWR test point
If the voltage at the DRV test point is correct, check that at the SET PWR test
point.
1. Check the voltage at the SET PWR test point (see Figure 12.8):
2. If the voltage is correct, go to Step 3. If it is not, go to Tas k 2 1.
3. If the PAD TOP can has already been removed, go to Step 7. If it has
not, go to Step 4.
4. Enter the CCTM command 32 to place the radio in receive mode.
5. Remove the PAD TOP can.
6. Enter the CCTM command 33 to place the radio in transmit mode.
7. Check the voltage on the gate of Q306 (see Figure 12.10):
8. Enter the CCTM command 32 to place the radio in receive mode.
9. If the voltage is correct, replace Q306; confirm the removal of the
fault and go to “Final Tasks” on page 157. If it is not, go to Tas k 2 3 .
SET PWR test point: 2 to5V
gate of Q306: 2 to 5V
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Figure 12.10 PA driver circuitry under the PAD TOP can (VHF shown)
R308
R324
C310
R327
C301
Q303
C313
Q300
C300
C317
C389
Q306
PAD TOP
D1 BAND
COMPONENTS
C310, R324, R327
GATE OF Q306
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Task 21 —
Check Power
Control
Check the power-control circuitry if the clamp current for the PA driver is
correct or if the voltage at the SET PWR test point is incorrect.
Important Ensure that the current limit on the DC supply is 2A.
And, when entering the CCTM command 304 z, do not
specify a value z higher than that recorded in Task 12. Fail-
ure to do so might result in the destruction of the PA driver.
1. Enter the CCTM command 304 z (where z was recorded in Task 12).
2. Note the current reading on the DC power supply.
3. Enter the CCTM command 114 0 to switch off the power.
4. Note the current reading on the DC power supply.
5. Compare the above current readings. The current should decrease by
an amount approximately equal to the offset given in Table 12.6.
If it does, go to Task 25 in “RF Signal Path” on page 362. If it does
not, go to Step 6.
6. Check that the voltage from the DAC is changing. Measure the
voltage at the PWR test point (CDC TX PWR CTL) (see Figure 12.8).
7. Enter the CCTM command 114 1023. The voltage should increase
to:
8. Enter the CCTM command 32 to place the radio in receive mode.
9. If the voltage at the PWR test point increases as required, go to
Task 22 . If it does not, go to “CODEC and Audio Fault Finding” on
page 381.
PWR test point: 2.4 ± 0.1V
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Figure 12.11 Circuitry under the DIRC TOP can (UHF shown)
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Task 22 —
Directional Coupler
and Buffer
Amplifier
Following the checks in Task 19 to Task 21, locate the fault and repair the
circuitry as described in the remaining tasks of the section. In this task any
faults in the directional coupler or buffer amplifier will be located.
1. Cycle the power.
2. Enter the CCTM command 326 5 to set the transmitter to maximum
power.
3. Enter the CCTM command 33 to place the radio in transmit mode.
4. Measure the voltage at pin 9 of IC303 in the power-control circuit
(see Figure 12.8).
5. The above voltage should be as given in Table 12.7. If it is, go to
Task 24 . If it is not, go to Step 6.
6. Check the voltage at pin 5 of IC303 (or use the FWD PWR test point)
(see Figure 12.8). Note that the probe impedance might affect the
measurement.
7. Enter the CCTM command 32 to place the radio in receive mode.
8. The voltage measured in Step 6 should be as given in Table 12.7.
If it is not, go to Step 9. If it is, go to Step 11.
Table 12.7 Voltages at IC303 at maximum power (40 W)
Frequency band Frequency (MHz)
Voltage (V)
Pin 9 Pin 5 (FWD PWR)
A4 66
77
88
1.3 ± 0.5
1.5 ± 0.5
1.7 ± 0.5
1.1 ± 0.5
1.3 ± 0.5
1.4 ± 0.5
B1 136
155
174
2.2 ± 0.5
2.3 ± 0.5
2.5 ± 0.5
1.9 ± 0.5
2.1 ± 0.5
2.3 ± 0.5
C0 174
199.5
225
1.6 ± 0.5
1.8 ± 0.5
1.9 ± 0.5
3.0 ± 0.5
3.4 ± 0.5
3.7 ± 0.5
D1 216
241
266
2.2 ± 0.5
2.2 ± 0.5
2.3 ± 0.5
4.3 ± 0.5
4.3 ± 0.5
4.7 ± 0.5
H5 400
435
470
3.4 ± 0.5
3.8 ± 0.5
4.0 ± 0.5
3.3 ± 0.5
3.7 ± 0.5
3.9 ± 0.5
H6 450
490
530
3.9 ± 0.5
4.2 ± 0.5
4.7 ± 0.5
3.8 ± 0.5
4.1 ± 0.5
4.6 ± 0.5
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9. Remove the DIRC TOP can.
10. Check the components of the directional coupler (see Figure 12.11)
and go to Step 12.
11. Check R340 between pins 6 and 7 of IC303 in the buffer amplifier
(see Figure 12.12), and then go to Step 12.
12. Repair any fault revealed by the above checks. Replace IC303 if none
of the other components is faulty (see Figure 12.8).
13. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
Task 2 3 —
Power Control
for PA Driver
In this task any faults in the path between the power-control circuit and the
PA driver will be located, as well as any fault with the PA driver.
1. Check for short circuits at the gate of the PA driver Q306. Check
R333, R336 (see Figure 12.8), C310, R324 and R327
(see Figure 12.10) between the power-control circuit and Q306.
2. Repair any fault revealed by the checks in Step 1. If none of the
above-mentioned components is faulty, replace Q306
(see Figure 12.10).
3. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
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Figure 12.12 Components of concern on the bottom-side of the board (VHF shown)
R390
R389
R3000
C319
R340
C345
R396
R3009
COPPER PLATE
VCO BOT CAN
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Task 2 4 —
Power Control
and Shaping Filter
In this task any faults in the power-control and shaping-filter circuitry will
be located:
1. Measure the voltage at pin 8 of IC303 (see Figure 12.8) in the
power-control circuit. The voltage should be:
2. If the voltage is correct, go to Step 3. If it is not, enter the CCTM
command 32 and return to Ta s k 2 3 .
3. Measure the voltage at pin 10 of IC303 (see Figure 12.8) in the
power-control circuit. The voltage should be:
4. If the voltage is correct, go to Step 5. If it is not, go to Step 8.
5. Enter the CCTM command 32 to place the radio in receive mode.
6. Check C322, C324, R342, R347 (see Figure 12.8) in the power-
control circuit.
7. Repair any fault revealed by the checks in Step 5. Replace IC303
(see Figure 12.8) if none of the other components is faulty. Confirm
the removal of the fault and go to “Final Tasks” on page 157. If the
repair failed, replace the board and go to “Final Tasks” on page 157.
8. Measure the voltage at pin 1 of IC301 (see Figure 12.8) in the
shaping-filter circuit. The voltage should be:
9. Enter the CCTM command 32 to place the radio in receive mode.
10. If the voltage measured in Step 8 is correct, go to Step 11. If it is not,
go to Step 12.
11. Check the components R334 (see Figure 12.8) and C319
(see Figure 12.12) and go to Step 13.
12. Check the components between the PWR test point and pin 1 of
IC301 (see Figure 12.8) and go to Step 13.
13. Repair any fault revealed by the checks in Step 11 and Step 12.
Replace IC301 (see Figure 12.8) if none of the other components
is faulty. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
pin 8 of IC303: 7.4 ± 0.5V
pin 10 of IC303: 4.8 ± 0.5V
pin 1 of IC301: 4.8 ± 0.5V
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12.4 RF Signal Path
Introduction The RF signal path extends from the output of the frequency synthesizer to
the LPF. This section of circuitry will require investigation either following
certain checks in “Transmitter RF Power” or if the biasing checks of
“Biasing of PA Driver and PAs” reveal no fault. The procedure is divided
into nine tasks grouped as follows:
■Task 25 to Task 28: initial RF signal path
■Task 29 and Task 30: directional coupler
■Task 31 and Task 32: PIN switch
■Task 33: LPF
The initial signal path includes the exciter and PA driver. The directional
coupler, PIN switch, and LPF make up the final signal path.
The measurement points for diagnosing faults in the signal path are
summarized in Figure 12.13.
Figure 12.13 Measurement points for diagnosing faults in the RF signal path
TEST
CAPACITOR
TEST
CAPACITOR
L314
RF CON-
NECTOR
RECEIVER
LPF
DIREC-
TIONAL
COUPLER
PAs
PIN
SWITCH
DRIVER EXCITER
FRE-
QUENCY
SYNTHE-
SIZER
SIGNAL TYPES
RF
ANALOG
SYNTHESIZER
OUTPUT
SYN TX LO
PA DRIVER
OUTPUT AT
DRAIN OF Q306
BUFFER
OUTPUT
AT C313
50 TEST
LEAD TO
TEST SET
50 TEST
LEAD TO
TEST SET
EXCITER
OUTPUT
GATES OF
Q309, Q310
C301 C300
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Task 2 5 —
Output of
Frequency
Synthesizer
The first point to check in the initial RF signal path is the output SYN TX LO
from the frequency synthesizer. This signal is input to the exciter at C300.
1. For test purposes select a representative power level and frequency
from Table 12.8 (A4 band), Table 12.9 (B1 band), Table 12.10
(C0 band), Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
(Note that the data for these tables were obtained using an
RFP5401A RF probe.)
2. To set the power level, enter the CCTM command 326 x, where x
defines the level. To set the frequency, enter the CCTM command
101 x x 0, where x is the frequency in hertz.
3. Enter the CCTM command 33 to place the radio in transmit mode.
4. Use an RFP5401A RF probe or the equivalent to measure the RF
voltage after C300 (see Figure 12.14). Earth the probe to the FCL TOP
can adjacent to the PA driver circuitry. The required voltage should
be as given in Table 12.8 (A4 band), Table 12.9 (B1 band),
Table 12.10 (C0 band), Table 12.11 (D1 band) or Table 12.12
(H5, H6 bands).
5. Enter the CCTM command 32 to place the radio in receive mode.
6. If the voltage measured above is correct, go to Ta s k 2 6 . If it is not, go
to Step 7.
7. Check C300 (see Figure 12.14). If C300 is not faulty, go to
“Frequency Synthesizer Fault Finding” on page 179. If C300 is
faulty, replace it and return to Step 2.
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 363
© Tait Electronics Limited June 2006
Figure 12.14 PA driver circuitry under the PAD TOP can (UHF shown)
Synthesizer output at C300
Exciter output at C301
Driver output
Buffer output at C313
364 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
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Table 12.8 RF voltages along the initial RF signal path of the VHF radio (A4 band)
Power level
(W)
Frequency
(MHz)
RF voltages (V)
Synthesizer
output
Buffer
output
Exciter
output
Driver
output
166
77
88
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
2.7 ± 0.5
2.3 ± 0.5
2.6 ± 0.5
0.98 ± 0.5
1.25 ± 0.5
0.97 ± 0.5
566
77
88
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
2.7 ± 0.5
2.4 ± 0.5
2.6 ± 0.5
1.8 ± 0.5
2.5 ± 0.5
1.9 ± 0.5
12 66
77
88
0.3 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
0.5 ± 0.1
0.4 ± 0.1
2.8 ± 0.5
2.4 ± 0.5
2.6 ± 0.5
2.5 ± 0.5
3.5 ± 0.5
2.7 ± 0.5
26 66
77
88
0.3 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
0.5 ± 0.1
0.4 ± 0.1
2.9 ± 0.5
2.3 ± 0.5
2.6 ± 0.5
3.2 ± 0.5
4.3 ± 0.5
3.1 ± 0.5
40 66
77
88
0.4 ± 0.1
0.3 ± 0.1
0.8 ± 0.1
0.6 ± 0.1
0.8 ± 0.1
0.5 ± 0.1
3.0 ± 0.5
2.3 ± 0.5
2.8 ± 0.5
7.1 ± 0.5
7.0 ± 0.5
6.1 ± 0.5
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 365
© Tait Electronics Limited June 2006
Table 12.9 RF voltages along the initial RF signal path of the VHF radio (B1 band)
Power level
(W)
Frequency
(MHz)
RF voltages (V)
Synthesizer
output
Buffer
output
Exciter
output
Driver
output
1 136
155
174
0.3 ± 0.1
0.3 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.2 ± 0.1
2.4 ± 0.5
2.5 ± 0.5
2.6 ± 0.5
1.8 ± 0.5
1.0 ± 0.5
1.5 ± 0.5
5136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.2 ± 0.1
2.5 ± 0.5
2.6 ± 0.5
2.6 ± 0.5
3.0 ± 0.5
1.5 ± 0.5
2.6 ± 0.5
12 136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
2.5 ± 0.5
2.6 ± 0.5
2.7 ± 0.5
4.2 ± 0.5
2.0 ± 0.5
3.8 ± 0.5
26 136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
2.4 ± 0.5
2.4 ± 0.5
2.5 ± 0.5
3.3 ± 0.5
1.7 ± 0.5
4.5 ± 0.5
40 136
155
174
0.3 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
0.3 ± 0.1
2.5 ± 0.5
2.5 ± 0.5
2.5 ± 0.5
8.2 ± 0.5
5.5 ± 0.5
7.7 ± 0.5
Table 12.10 RF voltages along the initial RF signal path of the VHF radio (C0 band)
Power level
(W)
Frequency
(MHz)
RF voltages (V)
Synthesizer
output
Buffer
output
Exciter
output
Driver
output
1 174
199.5
225
0.4 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.5 ± 0.1
0.6 ± 0.1
0.4 ± 0.1
3.2 ± 0.5
3.1 ± 0.5
2.6 ± 0.5
1.5 ± 0.1
1.9 ± 0.1
1.3 ± 0.1
5174
199.5
225
0.5 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.6 ± 0.1
0.7 ± 0.1
0.4 ± 0.1
2.8 ± 0.5
3.0 ± 0.5
2.6 ± 0.5
3.0 ± 0.1
3.6 ± 0.1
2.7 ± 0.1
12 174
199.5
225
0.4 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.5 ± 0.1
0.7 ± 0.1
0.4 ± 0.1
2.4 ± 0.5
3.0 ± 0.5
2.6 ± 0.5
4.4 ± 0.1
5.1 ± 0.1
4.0 ± 0.1
26 174
199.5
225
0.5 ± 0.1
0.3 ± 0.1
0.6 ± 0.1
0.7 ± 0.1
0.8 ± 0.1
0.5 ± 0.1
2.4 ± 0.5
2.8 ± 0.5
2.4 ± 0.5
5.0 ± 0.1
5.7 ± 0.1
5.5 ± 0.1
40 174
199.5
225
0.4 ± 0.1
0.5 ± 0.1
0.8 ± 0.1
0.8 ± 0.1
0.9 ± 0.1
0.4 ± 0.1
2.7 ± 0.5
2.9 ± 0.5
2.8 ± 0.5
6.7 ± 0.1
8.1 ± 0.1
7.5 ± 0.1
366 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
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Table 12.11 RF voltages along the initial RF signal path of the VHF radio (D1 band)
Power level
(W)
Frequency
(MHz)
RF voltages (V)
Synthesizer
output
Buffer
output
Exciter
output
Driver
output
1216
241
266
0.3 ± 0.1
0.4 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
3.8 ± 0.5
3.7 ± 0.5
3.5 ± 0.5
1.3 ± 0.5
1.0 ± 0.4
2.3 ± 0.9
5216
241
266
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
3.3 ± 0.5
3.2 ± 0.5
3.6 ± 0.5
3 ± 1
3 ± 1
6 ± 2
12 216
241
266
0.4 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
3.3 ± 0.5
3.6 ± 0.5
3.2 ± 0.5
4 ± 2
4 ± 2
9 ± 4
26 216
241
266
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
3.8 ± 0.5
3.5 ± 0.5
3.4 ± 0.5
4 ± 2
5 ± 2
12 ± 5
40 216
241
266
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.2 ± 0.1
3.3 ± 0.5
3.3 ± 0.5
3.6 ± 0.5
12 ± 5
9 ± 4
20 ± 8
Table 12.12 RF voltages along the initial RF signal path of the UHF radio (H5 and H6 bands)
Power level (W) Frequency (MHz) RF voltages (V)
H5
band
H6
band
Synthesizer
output
Buffer
output
Exciter
output
Driver
output
1 400
435
470
450
490
530
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
4.5 ± 0.5
4.6 ± 0.5
3.9 ± 0.5
2.3 ± 0.5
1.5 ± 0.5
0.8 ± 0.5
5400
435
470
450
490
530
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.4 ± 0.1
0.4 ± 0.1
4.6 ± 0.5
4.6 ± 0.5
3.6 ± 0.5
3.6 ± 0.5
2.6 ± 0.5
1.2 ± 0.5
12 400
435
470
450
490
530
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
3.9 ± 0.5
4.0 ± 0.5
3.4 ± 0.5
4.5 ± 0.5
3.9 ± 0.5
1.7 ± 0.5
26 400
435
470
450
490
530
0.2 ± 0.1
0.1 ± 0.1
0.1 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
3.8 ± 0.5
3.6 ± 0.5
3.0 ± 0.5
4.6 ± 0.5
4.5 ± 0.5
1.8 ± 0.5
40 400
435
470
450
490
530
0.2 ± 0.1
0.2 ± 0.1
0.2 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
0.3 ± 0.1
4.2 ± 0.5
3.6 ± 0.5
3.2 ± 0.5
8.6 ± 0.5
8.2 ± 0.5
2.5 ± 0.5
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 367
© Tait Electronics Limited June 2006
Task 26 —
Output of Buffer in
Exciter Circuit
If the synthesizer output is correct, check the output at C313 of the buffer
amplifier in the exciter circuit.
1. If not already done, remove the PAD TOP can.
2. Enter the CCTM command 326 x, where x defines the power level
selected in Task 25.
3. Enter the CCTM command 101 x x 0, where x is the frequency
selected in Task 25.
4. Enter the CCTM command 33 to place the radio in transmit mode.
5. Measure the RF voltage after C313 (see Figure 12.14). (Use an
RFP5401A RF probe or the equivalent.) The required voltage
should be as given in Table 12.8 (A4 band), Table 12.9 (B1 band),
Table 12.10 (C0 band), Table 12.11 (D1 band) or Table 12.12
(H5, H6 bands).
6. Enter the CCTM command 32 to place the radio in receive mode.
7. If the voltage measured above is correct, go to Tas k 27. If it is not, go
to Step 8.
8. Check the components around Q300 (see Figure 12.14).
9. Repair any fault revealed by the above checks. Replace Q300
(see Figure 12.14) if none of the other components is faulty.
10. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
Task 27 —
Output of Exciter If the output of the buffer amplifier is correct, check that of the exciter
at C301.
1. With the radio still in transmit mode, measure the RF voltage after
C301 (see Figure 12.14). (Use an RFP5401A RF probe or the
equivalent.) The required voltage should be as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
2. If the voltage is correct, go to Task 2 8. If it is not, go to Step 3.
3. Enter the CCTM command 32 to place the radio in receive mode.
4. Check the components between C313 and Q303, and between
Q303 and R308 (see Figure 12.14).
5. Repair any fault revealed by the above checks. Replace Q303
(see Figure 12.14) if none of the other components is faulty.
6. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
368 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
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Task 2 8 —
Output of PA Driver If the exciter output is correct, check the output of the PA driver at the
drain of Q306. If necessary, also check the signal at the gates of the PAs
Q309 and Q310. This is the last point in the initial RF signal path.
1. With the radio still in transmit mode, measure the RF voltage at the
drain of Q306 (A4, B1, C0) or after C317 and C389 (D1, H5, H6)
(see Figure 12.14). (Use an RFP5401A RF probe or the equiva-
lent.) The required voltage should be as given in Table 12.8 (A4),
Table 12.9 (B1), Table 12.10 (C0), Table 12.11 (D1) or
Table 12.12 (H5, H6).
2. Enter the CCTM command 32 to place the radio in receive mode.
3. If the voltage measured above is correct, go to Step 7. If it is not, go
to Step 4.
4. Check the components between C301 and Q306
(see Figure 12.14).
5. If the above checks reveal a fault, go to Step 6. If they do not, go to
Tas k 12 in “Biasing of PA Driver and PAs” on page 342.
6. Repair the fault. Confirm the removal of the fault and go to “Final
Tasks” on page 157. If the repair failed, replace the board and go to
“Final Tasks” on page 157.
7. If not already done, remove the PAF TOP can.
8. Enter the CCTM command 326 5 to set the power level to the
maximum, and then the command 33 to place the radio in transmit
mode.
9. Measure the RF voltage at the gates of the PAs Q309 and Q310
(see Figure 12.15).
10. Enter the CCTM command 32 to place the radio in receive mode.
11. If an RF voltage is present, there is no fault in the initial RF signal
path; go to Task 29. If there is no RF voltage, go to Step 12.
12. Check the components of the interstage matching circuitry between
the PA driver Q306 and the gates of the PAs Q309 and Q310
(see Figure 12.15).
13. If a fault is found, repair it, confirm the removal of the fault, and go
to “Final Tasks” on page 157. If the repair failed or the fault could
not be found, replace the board and go to “Final Tasks” on page 157.
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 369
© Tait Electronics Limited June 2006
Figure 12.15 Components of the interstage matching circuitry between the PA driver Q306 and the
PAs Q309 and Q310 (UHF shown)
PAF TOP can PAD TOP can
370 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Task 2 9 —
Check Power at
Directional Coupler
If, as determined in Task 25 to Task 28, there is no fault in the initial RF
signal path, investigate the final signal path. This part of the circuitry may
also require investigation following certain checks in “Transmitter RF
Power”. Begin by checking the directional coupler as follows:
1. If not already done, remove the DIRC TOP can.
2. Remove the coupling capacitors C348, C349, C350
(see Figure 12.16).
3. Solder one terminal of a test capacitor to the PCB at the point shown
in Figure 12.16. Mount the capacitor vertically. Use a test capacitor
of the type GRM111, DLI C17, Murata 1210, or the equivalent.
The value of the capacitor depends on the frequency band of
the radio:
■A4 — 100pF
■B1, C0, D1 — 680pF
■H5, H6 — 82pF.
4. Solder a 50Ω test lead to the PCB. Solder the outer sheath in the
position shown in Figure 12.16, and solder the central wire to the
other terminal of the test capacitor.
5. Connect the test lead to the test set.
6. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum.
7. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4), Table 12.9 (B1), Table 12.10 (C0), Table 12.11 (D1) or
Table 12.12 (H5, H6).
8. Enter the CCTM command 33 to place the radio in transmit mode.
9. Measure the RF output power. This should exceed 35W.
10. Enter the CCTM command 32 to place the radio in receive mode.
11. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4), Table 12.9 (B1), Table 12.10 (C0), Table 12.11 (D1) or
Table 12.12 (H5, H6).
12. Repeat Step 8 to Step 10.
13. If the power measured in both the above cases exceeds 35W, go to
Step 14. If it does not, go to Tas k 3 0 .
14. Remove the test lead and test capacitor, resolder the coupling
capacitors in position, and go to Ta sk 3 1.
RF output power: more than 35W
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 371
© Tait Electronics Limited June 2006
Figure 12.16 Circuitry under the DIRC TOP can, and the points for attaching the
test lead and test capacitor (UHF shown)
MOUNTING POINT
FOR TEST
CAPACITOR
SOLDER OUTER
SHEATH TO GND
372 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Task 3 0 —
Repair Circuitry If the RF output power measured in Task 29 is low, there is a fault in the
circuit between the common drain of the PAs and the test capacitor.
1. If not already done, remove the PAF TOP can.
2. Check for faulty, shorted or misplaced components in the circuit
between the test capacitor and the common drain of Q309 and Q310
(see Figure 12.6).
3. Repair any fault revealed by the above checks and go to Step 5. If no
fault could be found, go to Step 4.
4. Remove the test lead and test capacitor, resolder the coupling
capacitors C348, C349 and C350 in position (see Figure 12.16),
and go to Ta s k 2 5 .
5. With the test lead still connected to the test set, enter the CCTM
command 326 5 to set the transmitter power level to the maximum.
6. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
7. Enter the CCTM command 33 to place the radio in transmit mode.
8. Measure the RF output power. This should exceed 35 W.
9. Enter the CCTM command 32 to place the radio in receive mode.
10. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
11. Repeat Steps Step 7 to Step 9.
12. Remove the test lead and test capacitor, and resolder the coupling
capacitors C348, C349 and C350 in position (see Figure 12.16).
13. If the power in both the above cases is now correct, the fault has been
rectified; go to “Final Tasks” on page 157. If it is not, the repair
failed; replace the board and go to “Final Tasks” on page 157.
RF output power: more than 35W
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 373
© Tait Electronics Limited June 2006
Task 31 —
Check PIN Switch In checking the final RF signal path, if no fault is found in the directional
coupler, then check the PIN switch next. The PIN switch may also require
investigation following certain checks in “Transmitter RF Power” on
page 332.
1. Remove the PIN TOP can.
2. Remove the three blocking capacitors C361, C362 and C363
(see Figure 12.17).
3. Solder one terminal of a test capacitor to the PCB at the point shown
in Figure 12.17. Mount the capacitor vertically. Use a test capacitor
of the type GRM111, DLI C17, Murata 1210, or the equivalent.
The value of the capacitor depends on the frequency band of
the radio:
■A4 — 100pF
■B1, C0, D1 — 33pF
■H5, H6 — 22pF.
4. Solder a 50W test lead to the PCB. Solder the outer sheath in the
position shown in Figure 12.17, and solder the central wire to the
other terminal of the test capacitor.
5. Connect the test lead to the test set.
6. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum.
7. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
8. Enter the CCTM command 33 to place the radio in transmit mode.
9. Measure the RF output power. This should exceed 35W.
10. Enter the CCTM command 32 to place the radio in receive mode.
11. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
12. Repeat Step 8 to Step 10.
13. If the power in both the above cases exceeds 35 W, go to Step 14. If it
does not, the circuitry of the PIN switch is suspect; go to Tas k 3 2 .
14. Remove the test lead and test capacitor, resolder the blocking
capacitors in position, and go to Task 33.
RF output power: more than 35W
374 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 12.17 Circuitry under the PIN TOP can, and points for attaching the test lead and test capacitor
(UHF shown)
MOUNTING POINT
FOR TEST
CAPACITOR
SOLDER OUTER
SHEATH TO GND
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 375
© Tait Electronics Limited June 2006
Task 32 —
Repair PIN switch If the RF power at the PIN switch is low, the switch is not drawing the
expected current or the diode is faulty. Check the circuit as follows:
1. Perform a diode check of D307 (see Figure 12.17). If it is not faulty,
go to Step 2. If it is, replace D307 and go to Step 3.
2. Check the +9V0_TX supply to the PIN switch via the following
resistors on the bottom-side of the PCB (see Figure 12.18 and
Figure 12.19):
■A4 — R3000 and R389
■B1 — R3000, R389 and R390
■C0 — R3000 and R389
■D1 — R3000 and R390
■H5, H6 — R3000 and R389.
If any resistor is faulty, replace the resistor as well as D307. (A faulty
resistor is likely to have resulted in damage to D307.)
3. With the test lead still connected to the test set, enter the CCTM
command 326 5 to set the transmitter power level to the maximum.
4. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
5. Enter the CCTM command 33 to place the radio in transmit mode.
6. Again measure the RF output power. This should exceed 35W.
7. Enter the CCTM command 32 to place the radio in receive mode.
8. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
9. Repeat Step 5 to Step 7.
10. Remove the test lead and test capacitor, and resolder the blocking
capacitors C361, C362 and C363 (see Figure 12.17) in position.
11. If the power in both the above cases is now correct, the fault has been
rectified; go to “Final Tasks” on page 157. If it is not, the repair
failed: replace the board and go to “Final Tasks” on page 157.
RF output power: more than 35W
376 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 12.18 Components of concern on the bottom-side of the board (C0, D1 bands)
R390
R389
R3000
C319
R340
C345
R396
R3009
COPPER PLATE
VCO BOT CAN
TM8100/TM8200 Service Manual Transmitter Fault Finding (25W) 377
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Figure 12.19 Components of concern on the bottom-side of the board (A4, B1, H5/H6 bands)
B1 BAND
COPPER PLATE
VCO BOT CAN
NB BOT CAN
COPPER PLATE
VCO BOT CAN
H5, H6 BANDS
A4 BAND
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Figure 12.20 Circuitry under the LPF TOP can (top side)
VHF UHF
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Task 33 —
Check Components
of LPF
If there are no faults in the final RF signal path up to and including the PIN
switch, then the fault should lie in the LPF. Check the LPF as follows:
1. Remove the LPF TOP can.
2. Connect the RF connector to the test set.
3. Check the capacitors and inductors of the LPF between the PIN
switch and the RF connector. See Figure 12.20. Check for shorts,
open circuits, and faulty components. Repair any fault.
4. Enter the CCTM command 326 5 to set the transmitter power level
to the maximum.
5. Enter the CCTM command 101 x x 0, where x is the lowest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
6. Enter the CCTM command 33 to place the radio in transmit mode.
7. Measure the RF output power. This should exceed 35W.
8. Enter the CCTM command 32 to place the radio in receive mode.
9. Enter the CCTM command 101 x x 0, where x is the highest
frequency (in hertz) for maximum power, as given in Table 12.8
(A4 band), Table 12.9 (B1 band), Table 12.10 (C0 band),
Table 12.11 (D1 band) or Table 12.12 (H5, H6 bands).
10. Repeat Step 6 to Step 8.
11. If the power in both the above cases exceeds 35 W, the fault has been
rectified; go to “Final Tasks” on page 157. If it does not, the repair
failed; replace the board and go to “Final Tasks” on page 157.
RF output power: more than 35W
380 Transmitter Fault Finding (25W) TM8100/TM8200 Service Manual
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13 CODEC and Audio Fault Finding
Fault Conditions This section covers the diagnosis of faults in the CODEC and audio
circuitry. There are five conditions that indicate a possible fault in the
circuitry:
■no speaker audio or speaker audio is distorted
■no speaker audio at auxiliary connector
■receiver does not operate
■no transmit modulation or modulation is distorted
■no transmit modulation despite modulation at auxiliary connector
In the first case regarding the speaker audio, the green STATUS LED will be
operating correctly and all unmute criteria will be satisfied. In the second
case the receiver will be operating normally. In the third case the assumption
is that the receiver and power-supply circuitry were checked and no faults
were found. In the fourth case regarding the transmit modulation, the radio
will be transmitting the correct amount of RF power. In the fifth case the
transmitter will be operating normally.
Fault-Diagnosis
Procedures The procedures for diagnosing the above faults are given below in the
following sections. In each case, however, first carry out the tasks of “Power
Supplies” on page 382. Also note that the conditions concerning the
auxiliary connector can both occur at the same time. In this case carry out
both “No Speaker Audio at Auxiliary Connector” on page 391 and “Faulty
Modulation Using Auxiliary Connector” on page 402.
CCTM Commands The CCTM commands required in this section are listed in Table 13.1.
Full details of the commands are given in “Computer-Controlled Test
Mode (CCTM)” on page 118.
Table 13.1 CCTM commands required for the diagnosis of faults in the CODEC and audio circuitry
Command Description
21 Unmute received audio
32 Set radio in receive mode
33 Set radio in transmit mode
110 xSet level x (in range 0 to 255) of audio volume
323 x y Generate audio tone AUD TAP IN at tap point x of tap type y
324 x y Output audio signal at tap point x of tap type y to AUD TAP OUT
400 xSelect channel with channel number x
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13.1 Power Supplies
Introduction First check that a power supply is not the cause of the fault. Of these
supplies, the 3.3V DC supply (+3V3) will already have been checked in
“Power Supply Fault Finding” on page 163. The remaining supplies that
need to be checked are:
■Task 1: 9V DC supply from 9V regulator (+9V0)
■Task 2: 3V DC supply from 3V regulator (+3V0 AN)
■Task 3: 2.5V DC supply from 2.5V regulator (+2V5 CDC)
Two other supplies used in the CODEC and audio circuitry are a 1.8V DC
supply (+1V8) from the digital board and the 13.8V DC supply (+13V8 BATT)
from the power connector. Faults in these supplies are dealt with elsewhere.
Task 1 —
9V Power Supply First check the 9V DC supply (+9V0), which is required by IC201.
1. Remove the board from the chassis.
2. Remove the CDC BOT can.
3. Measure the voltage +9V0 at pin 4 of IC201 (see Figure 13.1).
4. If the voltage is correct, go to Ta s k 2 . If it is not, go to Step 5.
5. The fault will be at IC201 (see Figure 13.1), since any fault with the
9V regulator in the PSU module will already have been rectified.
Therefore, check the soldering of IC201. Repair any fault.
6. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
Task 2 —
3V Power Supply If the 9V supply is correct, check the 3V DC supply (+3V0 AN) next.
1. Measure the voltage +3V0 AN at the TP601 test point
(see Figure 13.1).
2. If the voltage is correct, go to Ta s k 3 . If it is not, go to Step 3.
3. The 3V regulator IC603 is suspect (see Figure 13.1). Check the
regulator as described in Ta s k 3 of “Power Supply Fault Finding” on
page 168.
pin 4 of IC201: 9.0 ± 0.3V DC
TP601 test point: 2.9 ± 0.3V DC
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Task 3 —
2.5V Power Supply If the 9V and 3V supplies are correct, the remaining power supply to check
is the 2.5V DC supply (+2V5 CDC).
1. Measure the voltage +2V5 CDC at pin 5 of IC604 (see Figure 13.1).
2. If the voltage is correct, go to Step 4. If it is not, go to Step 3.
3. The 2.5V regulator IC604 is suspect (see Figure 13.1). Check the
regulator as described in Task 3 of “Power Supply Fault Finding” on
page 168.
4. Proceed to the section relevant to the fault exhibited:
■“Faulty Speaker Audio” (distorted or no speaker audio)
■“No Speaker Audio at Auxiliary Connector” (no speaker audio at
auxiliary connector)
■“Faulty Receiver” (receiver does not operate)
■“Faulty Modulation” (distorted or no transmit modulation)
■“Faulty Modulation Using Auxiliary Connector” (modulation at
auxiliary connector only)
Further details are given in the introduction to the section.
Figure 13.1 Power-supply circuitry for the CODEC and audio circuitry under the CDC BOT can
LO2 BOT CAN
CAN FOR
DIGITAL
BOARD
pin 5 of IC604: 2.5 ± 0.3V DC
384 CODEC and Audio Fault Finding TM8100/TM8200 Service Manual
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13.2 Faulty Speaker Audio
Introduction This section covers the case where the green STATUS LED is operating
correctly and all unmute criteria are satisfied, but there is either no speaker
audio or the speaker audio is distorted. There are four tasks:
■Task 4: check audio power amplifier
■Task 5: check speaker outputs
■Task 6: check ITF VOL WIP DC input signal
■Task 7: check ITF RX BEEP IN input signal
The next section deals with the case where there is no speaker audio at the
auxiliary connector.
Figure 13.2 Circuitry in the vicinity of IC202 (top side)
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Task 4 —
Check Audio
Power Amplifier
If there is no fault with the power supplies, check the inputs to the audio PA
as follows. This check is only applicable, however, if the output of the voice-
band CODEC is correct and the signal level varies as the volume is varied.
1. Use the programming application to find the frequency selected for
channel 1.
2. In user mode apply an on-channel RF signal of –47dBm with 60%,
1kHz deviation. The channel must not have signalling enabled.
Set the volume to maximum.
3. Use an oscilloscope probe to check the output of the voice-band
CODEC at the TP200 test point (see Figure 13.2). The signal
should be:
4. If the above signal is correct, go to Step 5. If it is not, go to Ta s k 7 .
5. Vary the volume control. This should cause the signal level at the
TP200 test point (see Figure 13.2) to vary. If it does, go to Step 6.
If it does not, go to Tas k 6 .
6. Check the voltage at pin 11 of IC202 (see Figure 13.2):
7. If the voltage is correct, go to Step 9. If it is not, check for and repair
any faults in the level-translation circuits incorporating Q200 and
Q201 (see Figure 13.2).
8. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
9. Check the digital signals DIG AUD PA EN1 at R200 and DIG AUD PA EN2 at
R202 (see Figure 13.2):
10. If the signals are correct, go to Ta s k 5 . If they are not, check the
programming and test set-up; otherwise the digital board is faulty;
replace the board and go to “Final Tasks” on page 157.
TP200 test point: sine wave of 100mVpp with 0.6V DC offset
pin 11 of IC202: at least 8V DC
R200 (DIG AUD PA EN1): 3.3V DC
R202 (DIG AUD PA EN2): 0.0V DC
386 CODEC and Audio Fault Finding TM8100/TM8200 Service Manual
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Task 5 —
Check Speaker
Outputs
If the inputs to the audio PA are not faulty, check the speaker outputs from
the PA.
1. Check the positive and negative speaker outputs AUD ITF SPK+ and AUD
ITF SPK– at pins 3 and 8 respectively of IC202 (see Figure 13.2):
2. If the speaker outputs are correct, go to Step 5. If they are not, go to
Step 3.
3. Check for and repair any soldering faults around IC202
(see Figure 13.2), or else replace IC202.
4. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
5. With the volume at maximum, check each speaker output at pins 3
and 8 of IC202 (see Figure 13.2):
6. If the speaker outputs are correct, the fault is unknown (it could be
intermittent); replace the board and go to “Final Tasks” on page 157.
If there is no AC, go to Step 7.
7. Check that C204 and R214 (see Figure 13.2) are not faulty and are
correctly soldered. Repair any fault.
8. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
pin 3 of IC202 (AUD ITF SPK+): approximately half-rail bias
pin 8 of IC202 (AUD ITF SPK–): approximately half-rail bias
pin 3 of IC202 (AUD ITF SPK+): approximately 9.5Vpp AC
pin 8 of IC202 (AUD ITF SPK–): approximately 9.5Vpp AC
TM8100/TM8200 Service Manual CODEC and Audio Fault Finding 387
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Figure 13.3 Circuitry under the CDC TOP can, and adjacent interface circuitry
Junction of
R234 and R235
Junction of
R708 and C706
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Task 6 —
Check ITF VOL WIP DC
Input Signal
If the output of the voice-band CODEC is correct, but the signal level does
not vary as the volume control is varied, check the ITF VOL WIP DC signal.
1. Check the voltage on the VOL WIP DC line at the junction of R708 and
C706 (see Figure 13.3). As the volume varies, the voltage should
vary as follows.
2. If the voltage varies as expected, go to Step 5. If it does not, go to
Step 3.
3. Check the control-head connector SK100. Repair or replace the
connector if necessary.
4. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
5. Remove the CDC TOP can.
6. Check the voltage at the junction of R234 and R235
(see Figure 13.3). As the volume varies, the voltage should vary as
follows.
7. If the voltage varies as expected, CODEC 1 (IC204) is suspect;
replace the board and go to “Final Tasks” on page 157. If it does not,
go to Step 8.
8. Check for continuity across R234, and check that R235 is properly
soldered (see Figure 13.3). Repair any fault.
9. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
junction of R708 and C706: 0.0 to 1.2V as volume varies
junction of R234 and R235: 0.0 to 0.6V as volume varies
TM8100/TM8200 Service Manual CODEC and Audio Fault Finding 389
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Figure 13.4 Circuitry under the CDC BOT can
LO2 BOT CAN
CAN FOR
DIGITAL
BOARD
JUNCTION OF R218 AND IC204CDC AUD TAP OUT
390 CODEC and Audio Fault Finding TM8100/TM8200 Service Manual
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Task 7 —
Check ITF RX BEEP IN
Input Signal
If the output of the voice-band CODEC is not correct, check the
ITF RX BEEP IN signal.
1. If not already done, remove the CDC BOT can.
2. Check the signal at the junction of R218 and IC204
(see Figure 13.4). The signal should be:
3. If the signal is correct, go to Step 4. If it is not, either CODEC 1
(IC204) or the digital board is faulty; replace the board and go to
“Final Tasks” on page 157.
4. Check for continuity between the TP200 test point and IC204 via
R214, R215 (see Figure 13.2) and R218 (see Figure 13.4).
Repair any fault; if necessary, replace R214, R215 or R218.
5. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
junction of R218 and IC204: sine wave about 1Vpp with 1.2V DC offset
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13.3 No Speaker Audio at Auxiliary Connector
Introduction This section covers the case where the receiver operates normally but there
is no speaker audio at the auxiliary connector. In other words, there is no
signal at pin 13 (AUD TAP OUT) of the connector. The fault-diagnosis
procedure comprises two tasks:
■Task 8: check signal from CODEC
■Task 9: check LPF and buffer amplifier in CODEC circuitry
These tasks need to be followed by those of “Faulty Modulation Using
Auxiliary Connector” on page 402 if there is also a fault with the transmit
modulation using the auxiliary connector.
Figure 13.5 Circuitry in the vicinity of the internal-options connector SK102 (top side)
Internal-options
connector
392 CODEC and Audio Fault Finding TM8100/TM8200 Service Manual
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Task 8 —
Check Signal
from CODEC
First generate an appropriate audio test signal and check whether the signal
is present at the output of the CODEC circuitry.
1. Enter the CCTM command 400 x, where x is a valid channel number.
(A suitable channel will depend on the programming of the radio.)
2. Enter the CCTM command 21 to force unmuting of the received
audio signal.
3. Enter the CCTM command 110 128 to set the audio level at its
midpoint.
4. At the test set apply 60%, 1kHz modulation to the RF signal. Reduce
the volume to a minimum.
5. Enter the CCTM command 324 r5.
6. Check that the received signal is present at pin 2 (AUD TAP OUT) of the
internal-options connector SK102 (see Figure 13.5) (alternatively,
the measurement point for CDC AUD TAP OUT shown in Figure 13.4).
The signal should be:
7. If the above signal is correct, go to Step 8. If it is not, go to Task 9.
8. Check the components in the path from pin 13 of the auxiliary
connector SK101 to the CODEC and audio circuitry. These are
C719 and L708 (see Figure 13.6) and the link R747
(see Figure 13.5). Also check the auxiliary connector itself. Repair
any fault.
9. Confirm the removal of the fault and go to Step 10. If the repair failed
or the fault could not be found, replace the board and go to “Final
Tasks” on page 157.
10. If there is also a fault with the transmit modulation, notwithstanding
modulation at the auxiliary connector, go to Tas k 1 5 of “Faulty
Modulation Using Auxiliary Connector” on page 402. If there is no
other fault, go to “Final Tasks” on page 157.
pin 2 of internal-options connector: received signal with 2.4V DC offset
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Figure 13.6 Circuitry in the vicinity of the auxiliary connector (bottom side)
AUXILIARY CONNECTOR
SK101
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Task 9 —
Check LPF and
Buffer Amplifier
If there is no test signal at the internal-options connector, then either
CODEC 1 is faulty or there is a fault in the LPF or buffer amplifier.
1. Remove the CDC BOT can.
2. Check the signal at the junction between R224 and IC204
(see Figure 13.7). This should be:
3. If the above signal is correct, go to Step 4. If it is not, CODEC 1
(IC204) is faulty; replace the board and go to “Final Tasks” on
page 157.
4. Check the voltage at pin 1 of IC201 (see Figure 13.7).
5. If the voltage is correct, go to Step 6. If it is not, check the LPF circuit
based on IC201 (pins 1 to 3) (see Figure 13.7). Repair any fault and
conclude with Step 9.
6. Check the voltage at pin 7 of IC201 (see Figure 13.7).
7. If the voltage is correct, go to Step 8. If it is not, check the buffer
amplifier based on IC201 (pins 5 to 7) (see Figure 13.7). Repair any
fault and conclude with Step 9.
8. Check R207 and R208 (see Figure 13.7). Repair any fault and
conclude with Step 9.
9. Confirm the removal of the fault and go to Step 10. If the repair failed
or the fault could not be found, replace the board and go to “Final
Tasks” on page 157.
10. If there is also a fault with the transmit modulation, notwithstanding
modulation at the auxiliary connector, go to “Faulty Modulation
Using Auxiliary Connector” on page 402. If there is no other fault,
go to “Final Tasks” on page 157.
junction of R224 and IC204: 0.7Vpp with 2.4V DC offset
pin 1 of IC201: 1.2V
pin 7 of IC201: 2.4V
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Figure 13.7 Circuitry under the CDC BOT can
LO2 BOT CAN
CAN FOR DIGITAL BOARD
JUNCTION
OF R224
AND IC204
396 CODEC and Audio Fault Finding TM8100/TM8200 Service Manual
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13.4 Faulty Receiver
Introduction This section covers the case where the receiver does not operate, although
there is no apparent fault in the receiver circuit itself. There are two tasks:
■Task 10: check level shifter
■Task 11: check QN test point
The latter check will isolate the module at fault if the level shifter is not the
cause of the problem.
Task 1 0 —
Check Level Shifter Check the operation of the base-band CODEC and receiver AGC as
described below. This concerns the level-shifter circuit. It is assumed that the
receiver and power-supply circuitry were checked and no faults were found.
1. If not already done, remove the CDC BOT can.
2. With no RF signal applied, check the voltage at pin 14 of IC201
(see Figure 13.7):
3. If the above voltage is correct, go to Ta s k 1 1 . If it is not, go to Step 4.
4. Check the voltage at pin 12 of IC201 (see Figure 13.7):
5. If the above voltage is correct, go to Step 8. If it is not, go to Step 6.
6. Check for and repair any shorts to ground at the junction of R238
and pin 12 of IC201 (see Figure 13.7).
7. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
8. Check the circuitry (R238, R239, R240) around pins 12, 13 and 14
of IC201 (see Figure 13.7). Repair any fault.
9. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
pin 14 of IC201: more than 2.5V DC
pin 12 of IC201: more than 1V DC
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Task 11 —
Check QN Test P o i nt If the level shifter is not faulty, check the signal at the QN test point. This will
ascertain whether the digital board, CODEC 1, or the receiver is at fault.
1. Use the programming application to find the frequency selected for
channel 1.
2. Apply a strong on-channel signal.
3. Check that a sine wave is present at the QN test point (there is access
through a hole in the IF TOP can — see Figure 13.8).
4. If there is a sine wave present, go to Step 5. If there is not, go to
“Receiver Fault Finding” on page 239.
5. Either the digital board or CODEC 1 (IC204) is faulty; replace the
board and go to “Final Tasks” on page 157.
Figure 13.8 Circuitry in the vicinity of the CDC TOP can (UHF shown)
Junction of
C708 and C732
QN test point: sine wave
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13.5 Faulty Modulation
Introduction This section covers the case where the radio transmits the correct amount of
RF power, but there is either no modulation or the modulation is distorted.
There are three tasks:
■Task 12: initial checks
■Task 13: check 2.3V DC supply
■Task 14: check bias network
The initial checks will determine whether the frequency synthesizer, the
2.3V supply, or the bias network is at fault.
Task 1 2 —
Initial Checks Carry out the following checks to isolate the part of the circuitry that is
faulty.
1. Apply a 1kHz audio signal of 20 mVpp at the microphone input on
the control head.
2. Enter the CCTM command 33 to place the radio in transmit mode.
(The frequency is that of channel 1.)
3. Check that the 1kHz signal appears at the TP503 test point
(see Figure 13.8).
4. Enter the CCTM command 32 to place the radio in receive mode.
5. If the 1kHz signal is present, go to “Frequency Synthesizer Fault
Finding” on page 179. If it is not, go to Step 6.
6. With no microphone connected, check the voltage at the junction of
C708 and C732 (CH MIC AUD) (see Figure 13.8):
7. If the above voltage is correct, go to Tas k 1 4; the bias network is
suspect. If it is not, go to Tas k 1 3 ; the 2.3V supply is suspect.
TP503 test point: 1kHz signal
junction of C708 and C732: approximately 3V
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Figure 13.9 Circuitry in under the CDC BOT can
LO2 BOT CAN
CAN FOR
DIGITAL
BOARD
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Task 1 3 —
Check 2.3V Supply If the CH MIC AUD signal is not as expected, the 2.3V supply needs to be
checked.
1. If not already done, remove the CDC BOT can.
2. Check the voltage across C202 (see Figure 13.9):
3. If the above voltage is correct, go to Ta s k 1 4 . If it is not, go to Step 4.
4. Check the soldering of R209, and check for shorts to ground at C202
(see Figure 13.9). Repair any fault.
5. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
Task 1 4 —
Check Bias Network If the signal at the TP503 test point is incorrect, but the other checks in the
above tasks reveal no fault, check the bias network.
1. Remove the CDC TOP can.
2. Check the voltage at the junction of R229 and R232
(see Figure 13.10):
3. If the voltage is correct, go to Step 4. If it is not, go to Step 5.
4. CODEC 1 (IC204) is faulty; replace the board and go to “Final
Tasks” on page 157.
5. Check the soldering of R229 and R232, and check for shorts across
R232 (see Figure 13.10). Repair any fault.
6. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed or the fault could not be found, replace
the board and go to “Final Tasks” on page 157.
voltage across C202: 3V
junction of R229 and R232: 1.5V DC
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Figure 13.10 Circuitry under the CDC TOP can
ITF AUD TAP IN
JUNCTION OF R237 AND R241
JUNCTION OF
R229 AND R232
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13.6 Faulty Modulation Using Auxiliary Connector
Introduction This section covers the case where the transmitter operates normally but
there is no modulation (although there is modulation at the auxiliary
connector). There are two tasks:
■Task 15: apply AUD TAP IN signal
■Task 16: check CODEC 2 device
If there was also a fault with the speaker audio at the auxiliary connector, it
is assumed that this has now been rectified.
Task 1 5 —
Apply AUD TAP IN
Signal
First check the modulation and, if necessary, the DC offset.
1. Enter the CCTM command 33 to place the radio in transmit mode.
(The frequency is that of channel 1.)
2. Check the modulation via the microphone input.
3. Enter the CCTM command 32 to place the radio in receive mode.
4. If the modulation is correct, go to Step 5. If it is not, go to Ta s k 1 2
of “Faulty Modulation” on page 398.
5. Apply a 1kHz AC-coupled signal of 0.7Vpp at pin 7 (AUD TAP IN) of
the auxiliary connector (alternatively, as ITF AUD TAP IN at the junction
of R237 and R241 — see Figure 13.10).
6. Enter the CCTM command 323 t5.
7. Check the DC offset voltage at pin 7:
8. If the above DC offset is correct, go to Step 9. If it is not, go to
Step 11.
9. Remove the CDC TOP can.
10. Check for and repair any soldering faults around IC205, or else
replace IC205 (see Figure 13.10). Conclude with Step 12.
11. Check for shorts at pin 7 of the auxiliary connector. If there are none,
go to Tas k 1 6 . If there are, repair the fault and conclude with Step 12.
12. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
pin 7 of auxiliary connector: approximately 1.5V DC offset
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Task 16 —
Check CODEC 2
Device
If the DC offset measured in Task 15 is incorrect but there is no fault with
the auxiliary connector, check the CODEC 2 device.
1. Remove the CDC TOP can.
2. Check the voltage at both ends of R241 (see Figure 13.10):
3. If the voltages are correct, go to Step 4. If they are not, go to Step 6.
4. Check for and repair any soldering faults around IC205, or else
replace IC205 (see Figure 13.10).
5. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
6. Remove R241.
7. Check the voltage at pin 3 of IC205 (see Figure 13.10):
8. If the above voltage is correct, go to Step 9. If it is not, replace the
board and go to “Final Tasks” on page 157.
9. Check for and repair any soldering faults around R241 and IC205
(see Figure 13.10).
10. Confirm the removal of the fault and go to “Final Tasks” on
page 157. If the repair failed, replace the board and go to “Final
Tasks” on page 157.
R241: 1.5V DC at both ends
pin 3 of IC205: 1.5V DC
404 CODEC and Audio Fault Finding TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
TM8100/TM8200 Service Manual Fault Finding of Control Head with Graphical Display 405
© Tait Electronics Limited June 2006
14 Fault Finding of Control Head with
Graphical Display
Overview This section describes the fault finding of the control head with graphical
display for the following faults:
■power supply faulty (initial check)
■LCD display faulty
■LCD backlighting faulty
■LCD contrast faulty
■LCD heating faulty
■function key LEDs or status LEDs faulty
■keypad backlighting faulty
■ON/OFF key faulty
■function, scroll, or selection keys faulty
■speaker faulty
■volume control faulty
■PTT faulty
The faults can be detected by visual inspection (refer to “Check the
User Interface” on page 153) or using the CCTM commands in Table 14.1
on page 406.
General The following applies for all fault finding procedures:
Important Do not disconnect or connect the control head while
power is supplied to the radio.
■To connect to ground use one of the screw bosses of the metal
spaceframe or the screw bosses of the radio body.
■If the radio does not switch on when power is supplied, the radio may
be programmed to go into the status it was in when powered down.
Connect a known good control head, power up the radio, and change
the relevant setting in the programming application. Remember to
program the original setting before returning the radio to the customer.
■For disassembly and re-assembly instructions, refer to “Disassembling
and Reassembling the Control Head” on page 141.
■If the repair fails or no fault could be found, replace the control-head
board.
■After completing the repair, carry out the tasks in “Initial Tasks” on
page 149.
406 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
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14.1 CCTM Commands
The following CCTM commands are used during the fault finding of the
control head:
Table 14.1 CCTM commands for fault finding of the control head
CCTM command Entry at keyboard Response on screen
1000 – All function key LEDs and status LEDs
sequentially switches the function key LEDs and
the status LEDs on and off
1000 0 = off
1000 1 = on
none
1001 – Individual function key LEDs and
status LEDs
switches individual LEDs on and off
1001 x y
where x is the LED number (0=F1,
1=F4, 2=yellow, 3=green, 4=red),
and y is the state (0=off, 1=on)
none
1002 – LED intensity
sets the LED intensity
1002 0 = off
1002 1 = low
1002 2 = medium
1002 3 = high
none
1003 – Keypad backlighting
Activate keypad backlighting at specified
intensity
1003 0 = off
1003 1 = low
1003 2 = medium
1003 3 = high
none
1004 – LCD backlighting
Activate LCD backlighting at specified intensity
1004 0 = off
1004 1 = low
1004 2 = medium
1004 3 = high
none
1005 – LCD contrast
sets the LCD contrast (16 levels)
1005 x
where x is the contrast level
(0 to 15)
none
1006 – LCD elements
switches all LCD elements on and off
1006 0 = off
1006 1 = on
none
1007 – LCD temperature sensor
Reads the LCD temperature sensor
1007 value between 00 (0)
and FF (255)
1008 – LCD heating
switches the LCD heating on and off
1008 0 = off
1008 1 = on
1009 – Key press
detects and notifies individual key press and
release events
1009 0 = off
1009 1 = on
serial output
1010 – Volume potentiometer
reads and notifies the volume potentiometer
setting
1010 value between 00 (0)
and FF (255)
1011 – Microphone
selects the microphone input source
1011 0 = microphone connector
1011 2 = covert microphone
none
TM8100/TM8200 Service Manual Fault Finding of Control Head with Graphical Display 407
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The following CCTM commands are used during the fault finding of the
remote control-head kit:
Table 14.2 CCTM commands for fault finding of the remote control-head kit
CCTM command Entry at keyboard Response on screen
1012 – Remote kit
turns the audio amplifier on and off
1012 0 = off
1012 1 = on
none
1013 – Mute audio amplifier
mutes and unmutes the audio amplifier
1012 0 = mute
1012 1 =unmute
none
1014 – Digital potentiometer
reads the digital potentiometer
1014 value between 0 and
255
1017 – Audio amplifier gain
sets the audio amplifier gain (4 levels)
1017 x
where x is the gain (0 to 3)
none
408 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
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14.2 Power Supply Faulty
A 3.3V regulator (U1) converts the switched 13.8V supply from the radio
body to 3.3V. A 1.5V regulator (U203) converts the 3.3V to 1.5V.
A power-sense module (U202) verifies the outputs of the voltage regulators
and—in the case of a fault—creates a power reset signal which is processed
by the FPGA. If the start-up of the control head fails, the radio body reduces
the switched 13.8V supply shortly after power is supplied.
For all faults, check that the supply voltages are correct:
1. Check the 3.3V supply voltage between E202 and C210.
If the signal is correct, continue with Step 4.
If the signal is not correct, visually inspect the components E202,
D201, L201, R205, and R206 for open or shorted contacts.
Replace if necessary. Continue with Step 2.
2. Check the 13.8V supply voltage (9.7V to 17.2V) between pin 2 of
the control-head connector J103 and pin 8 of U1.
If the signal is correct, continue with Step 3.
Note A fault in the control head can cause the radio body to reduce the
switched 13.8V supply shortly after power is supplied. In this case,
the control head must be supplied directly through pin 2 of con-
nector J103.
Figure 14.1 Circuit diagram of the power supply circuitry
J103
6
2
13V8 L1
C205
C207
C11 D1R16
R17
R208
Q201
C206
C12
C13R18
INH
COMP
SYNC
VCC
GND
U1 VREF
FB
OUT
2
4
3
8
1
6
5
7GND
L201
D201
R205
R206
C14
+
E202
C210
3V3
IN OUT
U203
EN RST
GND
36
1
24
5
3V3
PFI U202 PFO
MR RST
WDI WDI
GND
5
31
67
82
4
E203 1V5
C204
R201
S201
D203
D203
K1
K2
AA
AA
3V3
FPGA
R210
C201
C202
R202
R204
DNI
PWR WDT
MR
PWR RESET
1V5
3V3
1
2
R203
Control-
Head
Connector
E202/C210: 3.3V
J103 pin 2: 13.8V (Vs=9.7V…17.2V)
U1 pin 8: 13.8V (Vs=9.7V…17.2V)
TM8100/TM8200 Service Manual Fault Finding of Control Head with Graphical Display 409
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If the signal is not correct, check the 13.8V supply voltage from the
radio body. Return to Step 1.
3. Check the inhibit signal at pin 3 of U1.
If the signal is above 2.2V, visually inspect the components D1, R16,
R17, R208, and Q201 for open or shorted contacts. Replace if nec-
essary. Return to Step 1.
If the signal is low, replace U1. Return to Step 1.
4. Check the 1.5V supply voltage at pin 4 of U203.
If the signal is correct, continue with Step 6.
If the signal is not correct, continue with Step 5.
5. Check E203 for continuity.
If E203 is correct, continue with Step 6
If E203 is faulty, replace E203 and return to Step 4.
6. U202 detects a possible power failure and generates an output signal
on pin 7. Check whether this signal is low.
If pin 4 measures 3.3V and pin 7 is low, replace U202.
If pin 4 measures 3.3V and pin 7 is high, replace U203.
U1 pin 3: high: >2.2V, low: < 0.7V
D1: Vs – 5.1V
U203 pin 4: 1.5V
E203: 1.5V
U202 pin 4: 3.3V
U202 pin 7: 3.3V
Figure 14.2 PCB layout of the power supply circuitry
top side
Junction of C210 and E202
410 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
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14.3 LCD Display Faulty
The LCD module is connected to the control-head board via the LCD
connector. The LCD module display is controlled by a serial data link to the
FPGA. A faulty LCD display can be caused by the following:
■a loose or dirty LCD loom connection,
■a faulty LCD, or
■a fault on the control-head board
Note This section only deals with the display of the LCD. For faults of
the LCD backlighting, refer to “LCD Backlighting Faulty” on
page 412.
Note If some of the LCD pixels are faulty (usually complete rows or
lines), send CCTM command 1006 1 to activate all LCD pixels.
If some of the LCD pixels are faulty, replace the LCD.
If the LCD display is faulty:
1. Disconnect the LCD loom, visually inspect and clean the contacts,
and reconnect the LCD loom. Visually inspect connector J102 for
open or shorted contacts.
Figure 14.3 Circuit diagram of the LCD circuitry
3V3
LCD BACKLIGHT CTRL
Q102
3V3
LCD HEATER CTRL
Q102
LCD RESETN
LCD D/C
LCD DAT
LCD SCLK
LCD CEN
R4
R5
R6
R7
R8
LCD RESETN
LCD D/C
LCD DAT
LCD SCLK
LCD CEN
LED
3V3
HEATER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16 15
E108
C102 C103
C101
J102
LCD Connector
FPGA
U601
LCD RESETN
2
1
2
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2. Check the 3.3V supply voltage at pin 2 of the LCD connector J102.
If the signal is not correct, refer to “Power Supply Faulty” on
page 408.
Tip For a quick check of the LCD without having to disassemble the
control head, connect a good LCD to the control head, or discon-
nect the LCD loom and connect it to a good control head.
3. Replace the LCD. Carefully remove the protective plastic film from
the LCD. Take care not to scratch the soft polarizer material on the
top side of the LCD.
4. Use an oscilloscope to check the signals of pins 3 to 7 of connector
J102.
If any of the signals are missing or distorted, remove can E100 and
check for continuity between the FPGA and the LCD connector.
If necessary, replace the corresponding 100Ω resistor(s) R4 to R8.
J102 pin 2: 3.3V
J102 pins 3 to 7: The signals should be switching 0 to 3.3V in bursts of
0.125ms at approximately 1s intervals.
Figure 14.4 PCB layout of the LCD circuitry
top side
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14.4 LCD Backlighting Faulty
The backlighting incorporated in the LCD module is controlled by a data
line from the FPGA, which switches a transistor on MOSFET Q102.
Note The LCD backlighting has four brightness settings: off=GND,
on=3.3V, and two intermediate settings which are implemented
by pulse-width modulation.
For a circuit diagram and PCB layout, refer to Figure 14.3 on page 410 and
Figure 14.4 on page 411.
If the LCD backlighting is faulty:
1. Make sure that LCD backlighting has been enabled in the program-
ming application.
2. Check the 3.3V supply voltage at pin 1 (S1) of Q102.
If the signal is correct, continue with Step 3.
If the signal is not correct, refer to “Power Supply Faulty” on
page 408
3. Send CCTM command 1004 3 to switch on LCD backlighting.
4. Check the signal at pin 2 (G1) of Q102.
If the signal is correct, continue with Step 5.
If the signal is not correct, visually inspect pin 2 for open contact.
Otherwise the FPGA is faulty and the control-head board must be
replaced.
5. Check the signal at pin 7 (DA1) of Q102.
If the signal is correct, continue with Step 6.
If the signal is not correct, replace Q102.
6. Visually inspect whether the contact of pin 8 of connector J102 is
open or shorted. Check the signal at pin 8 of connector J102.
If the signal is correct, replace the LCD.
Q102 pin 1 (S1): 3.3V
Q102 pin 2 (G1): GND (with backlighting switched on)
Q102 pin 7 (D1A): 3.3V (with backlighting switched on)
J102 pin 8: 3.3V (with backlighting switched on)
TM8100/TM8200 Service Manual Fault Finding of Control Head with Graphical Display 413
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14.5 LCD Heating Faulty
The heating incorporated in the LCD module is controlled by a data line
from the FPGA, which switches a transistor on MOSFET Q102.
A temperature signal from the LCD module is converted to a digital signal
by an analog/digital converter (U601) and processed by the FPGA.
Note The temperature sensor signal is independent from the heating
and is also used to control the LCD contrast.
For a circuit diagram and PCB layout, refer to Figure 14.3 on page 410 and
Figure 14.4 on page 411.
If the LCD heating is faulty:
1. Check the temperature sensor signal at pin 14 of J102.
If the signal is below 0.7V (low) or above 2.5V, (high), the LCD tem-
perature sensor is faulty.
2. Send CCTM command 1007 to read the temperature sensor value.
If the value does not correspond to the ambient temperature, U601
is faulty.
3. Check the 3.3V supply voltage at pin 3 (S2) of Q102.
If the signal is not correct, refer to “Power Supply Faulty” on
page 408.
4. Check the signal at pin 4 (G2) of Q102.
If the signal is not correct, visually inspect pin 4 for open contact.
Otherwise the FPGA is faulty and the control-head board must be
replaced.
5. Check the signal at pin 5 (DA2) of Q102.
If the signal is missing, replace Q102.
6. Visually inspect pins 10 and 12 of connector J102 for open or shorted
contacts.
7. Check the signal at pins 10 and 12 of connector J102.
If the signal is not correct, replace the LCD.
J102 pin 14: 1.52V at 30°C, 1.58V at 25°C, 1.64V at 20°C, 1.69V at 15°C
Q102 pin 3 (S2): GND
Q102 pin 4 (G2): GND (with heating switched on)
Q102 pin 5 (D2A): 3.3V (with heating switched on)
J102 pins 10 and 12: 3.3V (with heating switched on)
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14.6 Function Key LEDs or Status LEDs Faulty
The function key LEDs (F1 and F4) and the red, green and amber status
LEDs each are controlled by an FPGA signal and a transistor (Q604 to
Q608). The brightness level is controlled by two FPGA signals, resulting in
four intensity levels (off, low, medium and high).
LED Faulty If one of the function key LEDs or status LEDs is faulty:
1. Send CCTM command 1001 x 1 (where x is the LED number:
0=F1, 1=F4, 2=amber, 3=green, 4=red) to activate the relevant
LED.
2. Check the resistors R34, R35, and R36 in the paths of the green
LEDs.
3. Measure the voltage at the point between the LED and the transistor.
If the voltage is incorrect, replace the LED.
4. Replace the corresponding transistor.
LED Intensity Faulty If the intensity of the LEDs is faulty:
1. Send CCTM command 1001 0 1 to activate the LED of the F1 key.
2. Send CCTM command 1002 3 to set the LED intensity level to high.
Figure 14.5 Circuit diagram of the function key LEDs and status LEDs
IND BRIGHT1 R601
FPGA
IND BRIGHT2
LED FUNC 1
LED FUNC 4
LED IND TX
LED IND RX
LED IND BUSY
3V3
R602
R603 R604
R34
0
D613
F1 Key
3V3
R605
R35
0
D614
F4 Key
Q604 Q605
3V3
R609
D615
Red
Q606
3V3
R612
R36
0
D616
Green
Q607
3V3
R616
D617
Amber
Q608
R34: 0Ω
R35: 0Ω
R36: 0Ω
D613/Q604 (F1 key LED):
D614/Q605 (F4 key LED):
D615/Q606 (red status LED):
D616/Q607 (green status LED):
D617/Q608 (amber status LED):
1.87V (on)
1.87V (on)
1.92V (on)
1.87V (on)
1.89V (on)
1.40V (off)
1.40V (off)
1.57V (off)
1.40V (off)
1.48V (off)
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3. Check the resistors R601 and R602, and replace if necessary.
If the resistors are okay, the FPGA is faulty and the control-head
board must be replaced.
R601: 2.2kΩ
R602: 5.62kΩ
Figure 14.6 PCB layout of the function key LED and status LED circuitry
bottom side
top side
top side
bottom side
bottom side
416 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
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14.7 Keypad Backlighting Faulty
The keypad backlighting LEDs are controlled by two FPGA signals and two
transistors (Q2), resulting in four intensity levels (off, low, medium and
high). The keypad backlighting LEDs are arranged in two groups for the
main keypad and one group for the on/off keypad, each group consisting of
three LEDs.
One LED or
One Group of LEDs
Faulty
If one LED or one group of three LEDs is faulty:
1. Send CCTM command 1003 x (where x is the intensity: 0=off,
1=low, 2=medium, 3=high) to switch on keypad backlighting.
2. Check the 13.8V supply voltage of the relevant branch.
3. From top to bottom, check the resistor, the three LEDs, and the
transistor of the relevant branch for continuity.
All LEDs Faulty or
Intensity Faulty If all LEDs are faulty or the intensity is faulty:
1. Send CCTM command 1003 x (where x is the intensity: 0=off,
1=low, 2=medium, 3=high) to switch on keypad backlighting.
Figure 14.7 Circuit diagram of the keypad backlighting circuitry
R607
KEY BRIGHT0
3V3
Q2
1
47K
10K
3V3
Q2
2
47K
10K
R611
KEY BRIGHT1
13V8
R615
D608
Q603
D610
D607
R613
R30
13V8
R618
D612
Q609
D611
D609
R617
13V8
R619
D618
Q610
D606
D605
R614
FPGA
Main Keypad
On/Off
Keypad
R30: 4.7Ω
D607: 1.9V (on)
D610: 1.9V (on)
D608: 1.9V (on)
Q603: 1.9V (on)
R615: 56Ω
R617: 4.7Ω
D607: 1.9V (on)
D609: 1.9V (on)
D611: 1.9V (on)
Q609: 1.9V (on)
R618: 56Ω
R614: 4.7Ω
D605: 1.9V (on)
D606: 1.9V (on)
D618: 1.9V (on)
Q610: 1.9V (on)
R619: 56Ω
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2. With the intensity set to high, check the signals at pins 2 (B1) and 5
(B2) of Q2.
If any of these signals are incorrect, the FPGA is faulty and the con-
trol-head board must be replaced.
3. Check the signals at pins 6 (C1) and 3 (C2) of Q2. Check the signals
at pins 1 (E1) and 4 (E2) of Q2.
If any of these signals are incorrect, Q2 is faulty.
4. Check the resistors R607, 611, and R613 for shorted or open
circuits.
Q2 pin 2 (B1): GND
Q2 pin 5 (B2): GND
Q2 pin 6 (C1): 3.3V
Q2 pin 3 (C2): 3.3V
Q2 pin 1 (E1): 3.3V
Q2 pin 4 (E2): 3.3V
R607: 3.3kΩ
R611: 2.2kΩ
R613: 1kΩ
Figure 14.8 PCB layout of the keypad backlighting circuitry
top side
bottom side
top side
top side
418 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
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14.8 On/Off Key Faulty
When battery power (13.8V) is applied to the radio, a press of the ON/OFF key
will create an active low signal (CH ON OFF) back to the radio body to initiate
the power-on or power-off sequence. This key-press will also be detected
by the FPGA of the control head through Q611 as an active high signal
(POWERONOFF3V3). For more information on the start-up process, refer to
“Software Architecture” on page 47.
If the ON/OFF key is faulty:
1. Use isopropyl alcohol and a soft lens-cleaning cloth to clean the pads
S610 on the control-head board for the ON/OFF key.
2. Check the CH ON OFF signal level from the radio at pin 9 of the control-
head connector J103.
If the signal is approx. 13V, continue with Step 5.
If near or at ground, continue with Step 3.
3. Visually inspect pin 9 of connector J103 for open or shorted contacts.
4. Verify the source of the signal to pin 9 of connector J103 from the
radio (without the control-head connector).
5. Visually inspect R610, R606, and R624 for short-circuit to adjacent
components. Replace if necessary. Return to Step 2.
6. Visually inspect R610 for shorted or open circuits. Repair if
necessary. Retest switch.
7. Verify continuity between R610 and switch S610, and continuity
between switch S610 and ground.
If the continuity cannot be restored, replace the control-head board.
Figure 14.9 Circuit diagram of the ON/OFF key
J103 pin 9: 13V
J103 9
CH ON OFF
Control-Head
Connector
13V8
S610
1
2
3V3
POWER ON OFF 3V3 FPGA
Power
On/Off
R626
R627R610
R606
R628
Q611
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Figure 14.10 PCB layout of the power on/off key circuitry
top side bottom side
420 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
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14.9 Function, Scroll, or Selection Keys Faulty
The eight keys of the main keypad (function, scroll, and selection keys) are
connected to the FPGA by an array of three columns and three rows.
During idle operation, the KEY ROW signals are driven low by the FPGA and
the KEY COL signals (pulled high by an external resistor) are monitored for
activity by the FPGA. A key-press will generate a high-to-low transition on
the associated column KEY COL signal. This, in turn, will initiate a sequence of
high output levels on the KEY ROW signals to identify which key was pressed.
The signal at the column side of the switch should be 3.3V. The row side of
the switch should be GND. A successful press will cause transition on
associated KEY_COL signal to low.
Note CCTM command 1009 can be used to monitor keypad press and
release events.
One Key Faulty If an individual key is faulty:
1. Use isopropyl alcohol and a soft lens-cleaning cloth to clean the pad
of the PCB switch contacts.
2. Visually inspect both PCB switch contacts (A and B) of a key for
short-circuits. Repair if necessary.
Figure 14.11 Circuit diagram of the function, scroll, and selection keys
KEY COL1
KEY COL2
KEY COL3
3
V
3
D604
D604
3
V
3
D620
D620
3
V
3
D602
D602
S601A
1
2
S601B
1
2
S602A
1
2
S602B
1
2
3
V
3 3
V
3
R620 R621
S603A
1
2
S603B
1
2
3
V
3
R622
Right Selection Key F3 KeyF4 Key
R623
KEY ROW1
R624
R625
KEY ROW2
KEY ROW3
S604A
1
2
S604B
1
2
S605A
1
2
S605B
1
2
S606A
1
2
S606B
1
2
Scroll-Down Key Left Selection KeyScroll-Up Key
S607A
1
2
S607B
1
2
S608A
1
2
S608B
1
2
F1 KeyF2 Key
FPGA
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Several Keys Faulty The keys can be grouped into columns and rows of three or two keys, as
illustrated in Figure 14.11.
If one column of keys is faulty:
1. Visually inspect the associated resistor and diodes for open or shorted
circuits.
If one row of keys is faulty:
1. Visually inspect the associated resistor for open or shorted circuits.
F2 key
F4 key
scroll-up key
R620
D602
F1 key
right selection key
scroll-down key
R621
D620
F3 key
left selection key
R622
D604
F3 key
F4 key
right selection key
R623 scroll-up key
scroll-down key
left selection key
R624 F1 key
F2 key
R625
Figure 14.12 PCB layout of the function, scroll, and selection key circuitry
top side
bottom side
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14.10 Speaker Faulty
The two speaker lines (SPK+ and SPK–) are connected to the speaker
connector (J104) which is connected to the control-head connector (J103)
through two ferrite beads (L105 and L106).
If the speaker functions only intermittently or the audio level is low:
1. Check the continuity from the speaker connector J104 to pin 18
(SPK+) and pin 17 (SPK–) of the control-head connector J103.
2. Inspect E105 and E106.
3. Replace the speaker.
4. If there is still a fault, go to “Volume Control Faulty” on page 424.
Figure 14.13 Circuit diagram of the speaker circuitry
J103
18
SPKR+
Control-Head
Connector E105
17
SPKR– E106 J104
Speaker
Connector
1
2
TM8100/TM8200 Service Manual Fault Finding of Control Head with Graphical Display 423
© Tait Electronics Limited June 2006
Figure 14.14 PCB layout of the speaker circuitry
top side
bottom side
424 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
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14.11 Volume Control Faulty
The voltage level of the volume control potentiometer is converted to a
digital signal by an analog/digital converter, processed by the FPGA and
transmitted to the main board.
Note This section only describes faults to the volume control caused by
the control head, which has been established during the initial
servicing tasks by means of elimination test. For fault finding of
the amplifier circuitry of the main board, refer to “Faulty Speaker
Audio” on page 384.
If the volume control works only intermittently, works only at full volume,
or does not work at all:
1. Check that the voltage between pins CW and WIP of the volume-
control potentiometer RV1 varies linearly between about 0V and
3.3V.
If the voltage is not correct, replace the potentiometer RV1
2. Send CCTM command 1010 to read the volume potentiometer.
If the signal is not correct, remove can E100 and replace the
analog/digital converter U601.
If the signal is correct, replace the speaker.
Figure 14.15 Circuit diagram of the volume control circuitry
RV1: 0 to 3.3V
No volume: reading 0 (1V)
Full volume: reading 255 (3.3V)
FPGA ADC DO U601
CH1
3
VCC
8
DO 6
4
3V3
3V3
VOL WIP DC
R105
RV101
TM8100/TM8200 Service Manual Fault Finding of Control Head with Graphical Display 425
© Tait Electronics Limited June 2006
Figure 14.16 PCB layout of the volume control circuitry
top side
bottom side
426 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
14.12 PTT Faulty
The PTT signal from the microphone connector is connected to the FPGA
via a resistor (R25) and relayed to the radio as a digital command.
Note This section only describes faults to the PTT caused by the con-
trol head, which has been established during the initial servicing
tasks by means of elimination test.
If the PTT is faulty:
1. With no PTT switch and hookswitch operated, check whether pin 4
of J106 is 4V.
If the signal is correct, continue with Step 2.
If the signal is incorrect, inspect R25 for open or shorted contacts.
Repair if necessary. Repeat Step 1.
2. With the PTT switch operated, check whether the same 4V are
pulled to ground on the other side of R25.
If the signal is correct, continue with Step 3.
If the signal is incorrect, inspect D106 and C108 for short-circuits.
Repair if necessary.
3. Verify continuity between R25 and the FPGA. Repair PCB track if
possible.
Figure 14.17 Circuit diagram of the PTT circuitry
J106 pin 4: 4V
R25: GND
J106
Microphone
Connector
FPGA
4
FP PTT R25 MIC PTT
C108 D106
TM8100/TM8200 Service Manual Fault Finding of Control Head with Graphical Display 427
© Tait Electronics Limited June 2006
Figure 14.18 PCB layout of PTT circuitry
top side
bottom side
428 Fault Finding of Control Head with Graphical Display TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
TM8100/TM8200 Service Manual Fault Finding of Control Head with 1- 2- or 3-Digit Display 429
© Tait Electronics Limited June 2006
15 Fault Finding of Control Head with
1- 2- or 3-Digit Display
Overview This section describes the fault finding of the control head with 1-, 2- or 3-
digit display for the following faults:
■display faulty but not LEDs
■some LEDs faulty
■all LEDs faulty
■display and all LEDs faulty
■some but not all keys faulty
■all keys faulty
■speaker faulty
■volume control faulty
The faults can be detected by visual inspection (refer to “Check the
User Interface” on page 153).
General The following applies for all fault finding procedures:
Important Do not disconnect or connect the control head while
power is supplied to the radio.
■If the radio does not switch on when power is supplied, the radio may
be programmed to go into the status it was in when powered down.
Connect a known good control head, power up the radio, and change
the relevant setting in the programming application. Remember to
program the original setting before returning the radio to the customer.
■For disassembly and re-assembly instructions, refer to “Disassembling
and Reassembling the Control Head” on page 141.
■If the repair fails or no fault could be found, replace the control-head
board.
■After completing the repair, carry out the tasks in “Initial Tasks” on
page 149.
430 Fault Finding of Control Head with 1- 2- or 3-Digit Display TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 15.1 Top side of the control-head board (2-digit control head shown)
pads for LCDpads for LCD
pads for keys
TM8100/TM8200 Service Manual Fault Finding of Control Head with 1- 2- or 3-Digit Display 431
© Tait Electronics Limited June 2006
Figure 15.2 Bottom side of the control-head board (2-digit control head shown)
pins of RV1
432 Fault Finding of Control Head with 1- 2- or 3-Digit Display TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
15.1 Display Faulty but not LEDs
Elastomeric Strips
Faulty If all the LEDs function correctly but the display functions only partially or
not at all, first check the elastomeric strips:
1. Disconnect the control-head loom from the control head. Remove
the control-head board.
2. Remove the elastomeric strips and check the conductors in the strips
for continuity. Replace the strips if they are faulty.
3. Ensure that the conductors along the edges of the strips are clean.
Use isopropyl alcohol and a soft lens-cleaning cloth to clean the
edges.
4. Use isopropyl alcohol and a soft lens-cleaning cloth to clean the pads
for the LCD on the control-head board.
5. Insert the elastomeric strips in their slots in the space-frame.
6. Re-assemble the control-head board.
7. Reconnect the control-head loom to the control head and test the
user interface. If the fault has been removed, return to “Initial Tasks”
on page 149. If it has not, replace the LCD as follows.
LCD Faulty If the elastomeric strips are not the cause of the fault, replace the LCD:
1. Disconnect the control-head loom. Remove the control-head board
and disassemble the control head.
2. Remove the LCD.
3. Use isopropyl alcohol and a soft lens-cleaning cloth to clean the
electrical contact points on the spare LCD. Carefully remove the
protective plastic film from the LCD. Take care not to scratch the soft
polariser material on both sides of the LCD.
4. Re-assemble the control head.
5. Reconnect the control-head loom and test the user interface. If the
fault has been removed, return to “Initial Tasks” on page 149. If it has
not, go to Step 6.
6. The control-head board is suspect. Level-1 service centres should
replace the board. Level-2 service centres should attempt to repair the
board as follows.
TM8100/TM8200 Service Manual Fault Finding of Control Head with 1- 2- or 3-Digit Display 433
© Tait Electronics Limited June 2006
Control-Head Board
Faulty If neither the elastomeric strips nor the LCD are faulty, check the relevant
components on the control-head board:
1. Use an oscilloscope to display the signal at pin 5 of IC5
(see Figure 15.2). The signal should be a square wave with a fre-
quency of about 60Hz and an amplitude that alternates between 0.0
and 3.3V. If the signal is correct, go to Step 3. If it is not, go to Step 2.
2. Replace IC2 (see Figure 15.2). Test the user interface. If the fault has
been removed, return to “Initial Tasks” on page 149. If it has not, go
to Step 3.
3. Use the oscilloscope to display the signal at pin 12 of IC7 (see
Figure 15.2). The signal should be a square wave with a frequency of
about 120Hz and an amplitude that alternates between 0.0 and 3.3V.
If the signal is correct, replace IC5 and go to Step 4. If it is not,
replace IC7 and go to Step 4.
4. Test the user interface. If the fault has been removed, return to “Initial
Tasks” on page 149. If it has not, the repair failed; replace the
control-head board.
15.2 Some LEDs Faulty
If the display functions correctly but one or more (but not all) of the LEDs
D1 to D18 are faulty:
1. Disconnect the control-head loom. Remove the control-head board.
Reconnect the loom to the board.
2. Use a multimeter to measure the forward voltage across each faulty
LED. See Figure 15.1. The voltage should be 2.0±0.4V DC. If it is,
go to Step 3. If it is not, replace the LED and go to Step 4.
3. If the forward voltage is correct, the LED is functional but the
associated switching transistor is suspect. Replace the transistor
corresponding to the LED in question. The switching transistors
associated with the LEDs D1 to D18 are Q1 to Q4. See Figure 15.2.
Continue with Step 4.
4. Test the user interface. If the fault has been removed, re-assemble the
control-head board, and return to “Initial Tasks” on page 149. If it
has not, replace the control-head board and return to “Initial Tasks”
on page 149.
434 Fault Finding of Control Head with 1- 2- or 3-Digit Display TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
15.3 All LEDs Faulty
If the display functions correctly but all the LEDs are faulty:
1. Disconnect the control-head loom.
2. Replace IC3 which drives the switching transistors for the LEDs.
See Figure 15.2.
3. Reconnect the loom and test the user interface. If the fault has been
removed, return to “Initial Tasks” on page 149. If it has not, replace
the control-head board and return to “Initial Tasks” on page 149.
15.4 Display and All LEDs Faulty
If the display and all LEDs are faulty:
1. Use a multimeter to measure the 3.3 V DC supply voltage across C1
(see Figure 15.2). If it is correct, go to Step 3. If it is not, go to Step 2.
2. Check for shorts to ground of the 3.3 V supply. Repair any fault and
go to Step 8.
3. Use the multimeter to check that the RST line at pin 6 of IC7 is high.
The level should be 3.3 V. If it is, go to Step 5. If it is not, go to
Step 4.
4. Check for continuity in the LCD driver circuitry D22 (not fitted for
3-digit control head), C12 and R27 (see Figure 15.2). Repair any
fault and go to Step 8. If there is no continuity fault, replace IC7 and
go to Step 8.
5. Use the multimeter to check that the OE line at pin 8 of IC5 is low.
The level should be less than 0.6 V. If it is, replace IC7 and go to
Step 8. If it is not, go to Step 6.
6. Check that the voltage at pins 4, 10 and 14 of IC5 is 3.3 V DC.
Also check that pin 7 of IC5 is at ground. If the voltages are correct,
replace IC7 and go to Step 8. If they are not, go to Step 7.
7. Check for continuity between IC5 and the control-head connector
SK1. Also check for shorts to ground between IC5 and SK1. Repair
any fault and go to Step 8.
8. Confirm the removal of the fault. If the fault has been removed,
return to “Initial Tasks” on page 149. If it has not, replace the
control-head board and return to “Initial Tasks” on page 149.
TM8100/TM8200 Service Manual Fault Finding of Control Head with 1- 2- or 3-Digit Display 435
© Tait Electronics Limited June 2006
15.5 Some but not All Keys Faulty
If one or more (but not all) of the keys are faulty, repair the control head as
follows:
1. Disconnect the control-head loom and remove the control-head
board.
2. Use isopropyl alcohol and a soft lens-cleaning cloth to clean the pads
on the control-head board for those keys that are faulty.
3. Re-install the control-head board.
4. Reconnect the control-head loom and test the keys. If the fault has
been removed, return to “Initial Tasks” on page 149. If it has not, go
to Step 5.
5. Replace the keypad.
6. Re-assemble the control head. Reconnect the control-head loom,
test the keys to confirm the removal of the fault, and return to “Initial
Tasks” on page 149.
15.6 All Keys Faulty
If all the keys, with the exception of the ON/OFF key, are faulty:
1. Disconnect the control-head loom. Replace IC4, which reads the
status of the keys. See Figure 15.2.
2. Reconnect the control-head loom and test the keys to confirm the
removal of the fault. If the fault has been removed, return to “Initial
Tasks” on page 149. If it has not, replace the control-head board and
return to “Initial Tasks” on page 149.
436 Fault Finding of Control Head with 1- 2- or 3-Digit Display TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
15.7 Speaker Faulty
If the speaker functions only intermittently or the audio level is low:
1. Replace the speaker.
2. Check the continuity from the speaker connector SK2 to pin 17
(SPK–) and pin 18 (SPK+) of the control-head connector SK1 (see
Figure 15.2). If there is no fault, go to Step 3. If there is still a fault,
go to “Volume Control Faulty”.
3. Reconnect the control-head loom, test the speaker to confirm the
removal of the fault, and return to “Initial Tasks” on page 149.
15.8 Volume Control Faulty
If the volume control works only intermittently, works only at full volume,
or does not work at all:
1. Disconnect the control-head loom.
2. Check that the resistance between pins 1 and 2 of the volume-control
potentiometer RV1 varies linearly between about 0Ω and 10kΩ. (see
Figure 15.2). If it does, go to Step 3. If it does not, go to Step 6.
3. Replace the speaker.
4. Re-assemble the control head. Reconnect the control-head loom.
Confirm the removal of the fault, and return to “Initial Tasks” on
page 149.
5. Remove the control-head board.
6. Replace the potentiometer RV1. See Figure 15.1.
7. Re-assemble the control-head board. Reconnect the control-head
loom. Confirm the removal of the fault, and return to “Initial Tasks”
on page 149.
TM8100/TM8200 Service Manual Spare Parts 437
© Tait Electronics Limited June 2006
16 Spare Parts
Introduction This section lists all serviceable parts (except PCB components) of the
■radio body (Figure 16.1, Figure 16.2, and Table 16.1)
■control head with graphical display (Figure 16.3 and Table 16.2)
■control heads with 1-, 2- or 3-digit display (Figure 16.4, Table 16.3 and
Table 16.4)
■RJ45 control head (Figure 16.5 and Table 16.5).
Figure 16.1 Spare parts of the radio body (sheet 1 of 2)
B
Cx4
D
E
x2
Gx5
F
I
C1)
1!
1@
J
H
438 Spare Parts TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 16.2 Spare parts of the radio body (sheet 2 of 2)
G
1$
2)
x3
3641z_01
1#x2
1(
1%
2@
1^
2!
x2
1& 1*
TM8100/TM8200 Service Manual Spare Parts 439
© Tait Electronics Limited June 2006
Table 16.1 Spare parts of the radio body
Pos. Description Qty. IPN Spares Kit
BCover 1 – TMAA22-02 mech. kit
CScrew M4 x 16 6 349-02067-xx TMAA22-02 mech. kit
DLid 1 312-01091-xx –
EBung for aperture for external options connector 1 302-50000-xx TMAA22-02 mech. kit
FMain seal 1 362-01109-xx TMAA22-02 mech. kit
GScrew M3 x 10 8 349-02066-xx TMAA22-02 mech. kit
HMain-board assembly (50W/40W radios)
Main-board assembly (25W radios)
1
1
XMAB14-yyzz
XMAB12-yyzz
TMAA22-14yyzz
TMAA22-12yyzz
IBung for auxiliary connector 1 302-50001-xx TMAA22-02 mech. kit
JSeal for RF connector 1 362-01113-xx TMAA22-02 mech. kit
1) Chassis (50W/40W radio)
Chassis (25W radio)
1
1
303-11301-xx
303-11225-xx
–
–
1! Gap pad for chassis (50W/40W radio only) 1 369-01048-xx TMAA22-02 mech. kit
TMAA22-98 gap pad kit
1@ Control-head seal 1 362-01115-xx TMAA22-02 mech. kit
TMAA22-07 seals kit
1# Screw for power connector (50W/40W radio)
Screw for power connector (25W radio)
2
2
346-10022-07
346-10030-08
–
1$ Auxiliary connector [SK101] 1 240-02022-xx –
1% Inner foam seal for auxiliary connector 1 362-01110-xx TMAA22-02 mech. kit
1^ Outer foam seal for auxiliary connector 1 362-01112-xx TMAA22-02 mech. kit
1& Lock-nut for auxiliary connector 1 354-01043-xx TMAA22-02 mech. kit
1* Rubber seal for power connector (50W/40W radio)
Rubber seal for power connector (25W radio)
1
1
362-01127-xx
362-01114-xx
TMAA22-02 mech. kit
1( Power connector [PL100] (50W/40W radio)
Power connector [PL100] (25W radio)
1
1
240-00040-xx
240-00027-xx
–
2) Gap pad for copper plate (50W/40W radio only) 1 369-01049-xx TMAA22-02 mech. kit
TMAA22-98 gap pad kit
2! Heat-transfer block 1 308-13147-xx –
2@ Antenna connector [SK103] (mini-UHF), or
Antenna connector [SK103] (BNC)
(both incl. lock washer and hexagonal nut)
1
1
240-00029-xx
240-00028-xx
–
The characters xx in an IPN stand for the issue number. Items will always be the latest issue at the time the
radio is manufactured.
The characters yy in an IPN or spares kit number stand for the abbreviated frequency band.
For more information, refer to “Frequency Bands” on page 15.
The characters zz in an IPN or spares kit number stand for the type of RF connector (00=BNC, 01=mini-UHF).
440 Spare Parts TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 16.3 Spare parts of the control head with graphical display
C
E
F
G
G
1)
H
I
J
1!
1^
1@
1#
1$
1&
x2
x4
D
B
1%
TM8100/TM8200 Service Manual Spare Parts 441
© Tait Electronics Limited June 2006
Table 16.2 Spare parts of the control head with graphical display
Pos. Description Qty. IPN Spares Kita
BM4 x 12 Taptite screw 2 349-02058-xx TMAA22-08
CAdaptor flange 1 349-02067-xx
301-00020-xx
TMAA22-08
DControl-head loom (with female-female adaptor)
– female-female adaptor
1 219-02882-xx
240-00021-41
TMAA22-08
E3 x 10 PT screw 4 346-10030-xx TMAA22-08
FControl-head board 1 – TMAA22-09 (x3)
GSeal 2 362-01124-xx TMAA22-08
HShort light pipe 1 262-00003-xx TMAA22-08
ILong light pipe 1 262-00004-xx TMAA22-08
JSpace-frame 1 319-30077-xx TMAA22-08
1) Speaker clamp 1 303-50111-xx TMAA22-08
1! Speaker 1 252-00011-xx TMAA22-08
1@ LCD assembly (including LCD seal)b1 – TMAA22-95 (x3)
1# Main keypad 1 311-03121-xx TMAA22-08
1$ Power keypad 1 311-03120-xx TMAA22-08
1% Concealed microphone (optional) 1 – TMAA02-07
1^ Front-panel assembly 1 – TMAA22-08
1& Knob for volume-control potentiometer 1 311-01054-xx TMAA22-08
The characters xx in an IPN stand for the issue number. Items will always be the latest issue at the time the
radio is manufactured.
a. Spares kit TMAA22-08 contains an assembled control head without control-head board, concealed microphone
and LED assembly.
b. The LCD seal IPN 362-01126-xx is part of the LCD assembly and must be replaced whenever the LCD is replaced.
This seal is included in the TMAA22-95 kit.
442 Spare Parts TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 16.4 Spare parts of the control heads with 1, - 2- or 3-digit display
J
B
1^
G
I
H
1)
1&
1#
1%
1$
F
E
1!
3828z_01
Dx3
B
C
E
F
x2
G
H
1)
J
1@
1$
1#
1!
I
TM8100/TM8200 Service Manual Spare Parts 443
© Tait Electronics Limited June 2006
Table 16.3 Spare parts of the control heads with 1- or 2-digit display
Pos. Description Qty. IPN Spares Kita
BControl-head loom (with female/female adaptor)
– female-female adaptor
1 219-02882-xx
210-00021-41
TMAA22-01 and 90
CControl-head options board (optional)
– dynamic microphone board 1 – TMAA02-06
D3 x 8 PT screw 3 346-10030-08 TMAA22-01 and 90
EControl-head board (2-digit display)
Control-head board (1-digit display)
1
1
–
–
TMAA22-03 (x6)
TMAA22-91 (x6)
FElastomeric strip 2 209-00011-xx TMAA22-01 and 90
GSpace-frame 1 319-30073-xx TMAA22-01 and 90
HFront-panel assembly 1 – TMAA22-01 and 90
IKnob for volume-control potentiometer 1 311-01054-xx TMAA22-01 and 90
JSpeaker 1 252-00011-xx TMAA22-01 and 90
1) Concealed microphone (optional) 1 – TMAA02-06
1! LCD 1 008-00031-xx TMAA22-01 and 90
1@ Keypad 1 311-03114-xx TMAA02-01 and 90
1# Short light pipe 1 262-00003-xx TMAA22-01 and 90
1$ Long light pipe 1 262-00004-xx TMAA22-01 and 90
The characters xx in an IPN stand for the issue number. Items will always be the latest issue at the time the
radio is manufactured.
a. Spares kit TMAA22-01 contains an assembled 2-digit-display control head without the control-head board.
Spares kit TMAA22-90 contains an assembled 1-digit-display control head without the control-head board.
Neither spares kit includes the optional parts of the concealed microphone.
444 Spare Parts TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Table 16.4 Spare parts for the 3-digit display
Pos. Description Qty. IPN
BControl-head loom (with female/female adaptor)
– female-female adaptor
1 219-02882-xx
210-00021-41
CControl-head options board (optional) – TMAA02-06
D3 x 8 PT screw 3 346-10030-08
EControl-head board (3-digit display) 1 XMAC60
FElastomeric strip 2 209-00011-xx
GSpace-frame 1 319-30073-xx
HFront-panel assembly 1 –
IKnob for volume-control potentiometer 1 311-01054-xx
JSpeaker 1 252-00011-xx
1) Concealed microphone (optional) 1 TMAA02-06
1! LCD 1 008-00036-xx
1@ Keypad 1 311-03130-xx
1# Short light pipe 1 262-00003-xx
1$ Long light pipe 1 262-00004-xx
The characters xx in an IPN stand for the issue number. Items will always be the
latest issue at the time the radio is manufactured.
TM8100/TM8200 Service Manual Spare Parts 445
© Tait Electronics Limited June 2006
Figure 16.5 Spare parts of the RJ45 control head
Table 16.5 Spare parts of the RJ45 control head
Pos. Description Qty. IPN
BControl-head board 1 XMAC30
CControl-head loom (with female/female adaptor)
– female-female adaptor
1 219-02882-xx
210-00021-41
D3 x 8 PT screw 3 346-10030-08
EPCB bracket 1 302-10063-xx
FFront panel 1 316-06843-xx
GRJ45 bung 2 302-50002-xx
B
D
E
F
G
x4
C
Torx T10
5lb·in (0.6N·m)
x2
446 Spare Parts TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
TM8100/TM8200 Service Manual 447
© Tait Electronics Limited June 2006
TM8100 mobiles
TM8200 mobiles
Chapter 3
Accessories
448 TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Chapter 3 – Accessories
17 TMAA01-01 Line-Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . .451
17.1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
17.2 Configuring the Line-Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . 451
17.3 Installing the Line-Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
17.4 Programming Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
17.5 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
17.6 Line-Interface Board Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
17.7 Line-Interface Board Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
17.8 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
17.9 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
18 TMAA01-02 RS-232 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
18.1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
18.2 Installing the RS-232 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
18.3 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
18.4 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
19 TMAA01-05 Options-Extender Board . . . . . . . . . . . . . . . . . . . . . . . .479
19.1 Changing the Options-Extender Links. . . . . . . . . . . . . . . . . . . . . . . . . 479
19.2 Installing the Options-Extender Board . . . . . . . . . . . . . . . . . . . . . . . . . 481
19.3 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
19.4 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
20 TMAA02-02 DTMF Microphone . . . . . . . . . . . . . . . . . . . . . . . . . . . .489
20.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
20.2 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
20.3 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
20.4 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
20.5 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
21 TMAA02-06 Support Kit for Concealed & Dynamic Microphones . . . . .493
21.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
21.2 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
21.3 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
21.4 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
TM8100/TM8200 Service Manual 449
© Tait Electronics Limited June 2006
22 TMAA02-07 Concealed Microphone . . . . . . . . . . . . . . . . . . . . . . . . .501
22.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
22.2 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
23 TMAA02-08 Keypad Microphone . . . . . . . . . . . . . . . . . . . . . . . . . . .503
23.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
23.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
23.3 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
23.4 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
24 TMAA03-02 Security Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .507
24.1 Installing the Security Bracket and Radio . . . . . . . . . . . . . . . . . . . . . . . 508
24.2 Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
24.3 Removing a Radio from the Security Bracket . . . . . . . . . . . . . . . . . . . 509
24.4 Replacing the Radio in the Security Bracket . . . . . . . . . . . . . . . . . . . . 509
24.5 Disassembling the Security Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
24.6 Re-Ordering Extra Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
25 Installing a Remote Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511
25.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
25.2 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
25.3 Servicing the Remote Kit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
25.4 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
26 Installing an Enhanced Remote Kit . . . . . . . . . . . . . . . . . . . . . . . . . .527
26.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
26.2 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
26.3 Servicing the Remote Control-Head Installation Parts . . . . . . . . . . . . . 534
26.4 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
27 TMAA04-04 Crossband Linking Cable . . . . . . . . . . . . . . . . . . . . . . . .543
27.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
27.2 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
27.3 Operational Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
27.4 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
27.5 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
28 TMAA04-05 Ignition Sense Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549
28.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
28.2 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
450 TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
29 TMAA10-01 Desktop Microphone . . . . . . . . . . . . . . . . . . . . . . . . . . .551
29.1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
29.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
29.3 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
29.4 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
29.5 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
30 TMAA10-02 Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .555
30.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
30.2 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
30.3 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
31 TMAA10-03 and TMAA10-06 High-Power Remote Speakers . . . . . . . .559
31.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
32 TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit . . . . . .561
32.1 VOX Operation (TMAA10-05 Hands-Free Kit) . . . . . . . . . . . . . . . . . 561
32.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
32.3 Radio Programming for the TMAA10-04 Remote PTT Kit. . . . . . . . . 563
32.4 Radio Programming for the TMAA10-05 Hands-Free Kit . . . . . . . . . . 564
32.5 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
32.6 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
32.7 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
33 TMAA10-07 Desktop Microphone . . . . . . . . . . . . . . . . . . . . . . . . . . .569
33.1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
33.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
33.3 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
33.4 Radio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
33.5 Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
34 TOPA-SV-024 Test Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .571
34.1 Test Equipment Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
34.2 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
34.3 PCB Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 451
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17 TMAA01-01 Line-Interface Board
Note These instructions refer to line-interface PCB issue 220-65202-02
or later. On earlier issue PCBs, SK1 pin 5 is ground.
The TMAA01-01 line-interface board provides both audio and
digital interfaces for a variety of systems. The interfaces available are:
■an isolated 600Ω audio interface which is capable of both
simplex operation on a two-wire system, or duplex operation on
a four-wire system
■a keying interface which allows for two-wire keying or single
line bi-directional keying
■a variable delay timer
■a logic sense control.
The line-interface board fits inside the radio in the options cavity
and is connected to the main PCB by the internal options loom.
The high-density 15-way D-range connector mounted on the line-
interface board fits through the external options connector hole
provided in the radio chassis.
17.1 Operation
One of the control head function keys may be programmed to toggle the
line-interface board on and off. When the function key LED is glowing,
the line-interface board is on and when the LED is off, the line-interface
board is off.
Refer to “Programming Information” on page 458 for information on the
radio programming procedure.
17.2 Configuring the Line-Interface Board
Important This equipment contains devices which are susceptible to
damage from static charges. Refer to “ESD Precautions”
on page 108 for more information.
Important This kit does not meet the IP54 protec-
tion standard. Care must be taken when a
radio with a TMAA01-01 line-interface
board kit installed is being operated in an
environment where there is water, dust or
other environmental hazards.
external options
connector
internal options
connector
D-range
hood parts
D-range plug
line-interface boar
d
line-interface
installation parts
internal options
loom
external options
cover seal
452 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
17.2.1 Adjustment Points on the Line-Interface Board
The following table describes the line-interface adjustment points.
Adjustments are made by setting the DIP switches on S1 to either “on” or
“off ” and by three variable resistors (RV1, RV2 and RV3).
17.2.2 Test Equipment Setup
The following diagram shows the setup of the test equipment used when
a d j u s t i n g RV 1 , RV 2 a n d RV 3 .
Table 17.1 Line-interface board adjustment points
Function Selection 1 Selection 2
two-wire audio interface DIP1 on DIP2 off
four-wire audio interface DIP1 off DIP2 on
busy/gate = busy DIP3 on DIP4 off
busy/gate = rx-gate DIP3 off DIP4 on
busy/gate logic
(active high)
DIP5 on DIP6 off
busy/gate logic
(active low)
DIP5 off DIP6 on
bi-directional keying line DIP7 on
two-wire keying DIP 7 off
enable gate/keying delay DIP8 on
gate/keying delay adjust RV1
audio line out level adjust RV2
audio line in level adjust RV3
time delay range W1 open
line-interface board
top side
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 453
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:
17.2.3 Configuration Procedure
The line-interface board configuration must be completed before the board
is installed in the radio, as the top side of the line-interface board is not
accessible once the board is screwed to the radio lid. To configure the line-
interface board, carry out the following steps.
1. Program the radio in which the line-interface board is being
installed with default line-interface test settings. The default test
settings are explained in the following tables.
Note A general description of IOP_GPIO lines used with the line-
interface board is given in Table 17.6 on page 458.
Figure 17.1 Line-interface test equipment setup1
1. Note: On PCB issue 220-65202-01 and earlier, pin 5 of SK1 is ground.
Table 17.2 Line-interface default test settings in the Programmable I/O form, Digital tab
Pin Direction Label Action Active Debounce Signal State Mirrored
IOP_GPIO1 Input PTT External PTT 1 Low 60 None None
IOP_GPIO2 Output 0 No Action Low None None None
IOP_GPIO3 Output BUSY Busy Status High None None None
IOP_GPIO4 Output FKEY F1 Key Status1High None Latching None
1. One of the four control head function keys may be selected to control the line-interface AUX line,
which turns the line-interface board on and off. For the associated LED to reflect the status of the
line-interface board, the Function Key Action field on the Key Settings form must be set to Action
Digital Output Line.
454 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2. Set the DIP switches on the line-interface board (S1) to the following
default test settings:
■DIP1 on (two-wire audio interface)
■DIP2 off
■DIP3 off
■DIP4 on (busy/gate = rx-gate)
■DIP5 on (busy/gate logic active high)
■DIP6 off
■DIP7 off (two-wire keying)
■DIP8 off (time delay disabled).
Disassemble the radio in order to gain access to the options cavity. For
detailed disassembly instructions, refer to “Disassembly and
Reassembly” on page 129.
3.
Note When installing the internal options loom, take care that it is
folded in the way shown in Figure 17.2.
Connect the internal options loom between SK2 on the line-inter-
face board and SK102 on the radio’s main PCB.
4. Set up the test equipment shown in
Figure 17.1
, and follow the
adjustment procedure for RV1, RV2 and RV3 described in the following
section.
17.2.4 Adjusting RV1, RV2 and RV3
Setting the Keying
Time Delay (RV1) The keying time delay circuit is used to prevent the burst of noise occurring
before a mobile is able to mute the audio when the carrier signal disappears.
The keying time delay is used in conjuction with the keying signal
(SK1 pin 1).
Set DIP8 on, and adjust RV1 for the required time delay. Rotate RV1
clockwise to increase the delay, and counterclockwise to reduce the delay.
Table 17.3 Line-interface settings in the Programmable I/O form, Audio tab
Rx/PTT Type Tap In Tap In Type Tap In Unmute Tap Out Tap Out Type Tap Out Unmute
Rx None A-Bypass In On PTT R7 D - Split Busy Detect
EPTT1 T5 A-Bypass In On PTT None C-Bypass 0 On PTT
Table 17.4 Line-interface settings in the PTT form, External PTT (1) tab
Field Setting
Advanced PTT PTT Transmission Type Voice
Audio Source Audio Tap In
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 455
© Tait Electronics Limited June 2006
Note If the W1 link is fitted, the maximum time delay available is
reduced from 5 seconds to approximately 2.5 seconds.
Setting the Line
Output Level (RV2) Monitor the line output (SK1 pins 14 and 15) and apply an on-channel
signal from the RF signal generator at an output level of -47dBm,
modulated to 60% of system deviation, at 1kHz AF.
Adjust the RV2 for a line output level of -10dBm.
Setting the Line
Input Level (RV3) Apply a line input signal of -10dBm and key the transmitter.
■For a two-wire configuration, apply the line input signal to pins 14 and
15 on SK1.
■For a four-wire configuration, apply the line input signal to pins 4 and
10 on SK1.
Adjust RV3 until 60% of system deviation at 1kHz is achieved.
17.3 Installing the Line-Interface Board
Note The line-interface board link options must be set before the board
is installed in the radio, as the top side of the line-interface board
is not accessible once the board is screwed to the radio lid.
17.3.1 Parts Required
The following table describes the parts required to install a line-interface
board in a radio. The parts marked with an asterisk (*) are not shown in
Figure 17.2 and are used to connect to the radio’s external
options connector.
Table 17.5 Line-interface installation parts required
Quantity Internal Part Number Description Figure 17.2
Reference
1 362-01111-XX1
1. Contact Technical Support for the exact IPN.
foam seal d
1 362-01108-XXacover seal 1!
2 347-00011-00 4-40x3/16 screws 1@
2 354-01043-00 screw-lock fasteners h
6 349-02062-00 M3x8 screws j
*1 240-00032-00 D-range plug —
*1 240-06010-29 D-range hood —
456 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
17.3.2 Installation Procedure
1. Disassemble the radio in order to gain access to the options cavity.
For detailed disassembly instructions, refer to “Disassembly and
Reassembly” on page 129.
The circled numbers in the following instructions refer to items in the
diagram on page 457.
2. Remove the top cover and lid b from the radio to access the
options cavity.
3. Remove the external options connector bung c, if it is fitted.
4. On the inside of the radio lid place the foam seal d over the external
options connector cavity e.
5. With the top side of the line-interface board f facing the radio lid,
guide the external options connector g into the external options
connector cavity.
6. Screw the external options connector to the radio lid using the two
screw-lock fasteners h.
Tighten the fasteners to a torque of 0.9N·m (8lbf·in).
Important The external options connector screw-lock fasteners must
be tightened correctly before screwing the line-interface
board onto the mounting posts i.
7. Screw the line-interface board to the mounting posts on the radio lid
using six M3x8 self-tapping screws j.
Tighten the M3x8 screws to a torque of 1.9N·m (17lbf·in)
Important For the line-interface board to be installed correctly in the
radio’s options cavity, the internal options connector
loom 1) must be looped in the way shown in the diagram
on page 457.
8. Plug the unattached end of internal options connector loom 1) into
the internal options connector on the radio main PCB.
9. Refit the radio lid and top cover to the radio and screw the external
options cover seal 1! over the external options connector, using the
two 4-40x3/16 screws 1@.
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 457
© Tait Electronics Limited June 2006
Figure 17.2 Installing the line-interface board
bradio lid hscrew-lock fasteners
cexternal options connector bung imounting posts
dfoam seal jM3x8 self-tapping screws
eexternal options connector cavity 1) internal options loom
fline-interface board 1! external options cover seal
gexternal options connector 1@ 4-40x3/16 screws
b
c
e
h
i
1@
1!
j
1)
d
f
g
458 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
17.4 Programming Information
The lines from the radio’s internal options connector that are used by the
line-interface board are IOP_GPIO1 to IOP_GPIO4. The behaviour of
these lines is configured in the Programmable I/O and PTT forms of the
programming application. Refer to the online help of the programming
application for more information.
The following table explains the required input and output line-interface
connections.
s
Table 17.6 Line-interface input and output connections
Radio Signal Function Comments
GPIO1 PTT FROM OPT This signal causes the radio to transmit. This normally
requires External PTT1 to be set up in the Digital tab of
the Programmable I/O form and the External PTT (1) tab
of the PTT form.
GPIO2 Busy/Gate This active high signal allows connection to the Busy/Gate
output signal. If this is not used, the Action field is set to
No Action and the Active field is set to Low.
GPIO3 Busy/Gate (Keying Line) This active high signal allows connection to the Busy/
Gate output signal. This signal also allows the single line
keying functionality.
GPIO4 AUX This allows the line-interface board to be disabled. One of
the four control head function keys is selected to control
this AUX line.
For the associated LED to reflect the status of the line-
interface board, the Function Key Action field on the Key
Settings form must be set to Action Digital Output Line.
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 459
© Tait Electronics Limited June 2006
17.5 Interface Specification
The following tables summarize the signals used for the line-interface board
on the internal options connector (SK2 on the line-interface board) and the
external options connector (SK1 on the line-interface board).
Table 17.7 Internal options connector (SK2) — pins and signals
Pin Radio Signal Line-Interface
Signal Description
1 13V8_SW
13V8 FROM RADIO switched 13V8 supply from the radio
2 AUD_TAP_OUT AUDIO TAP OUT
Programmable tap point out of the receive or
transmit audio chain.
3AGND AGND
analogue ground
4 AUX_MIC_AUD —
not connected
5 RX_BEEP_IN —
not connected
6 AUD_TAP_IN AUD_TAP_IN
Programmable tap point into the receive or
transmit audio chain.
7 RX_AUD —
not connected
8RSSI — not connected
9 IOP_GPIO1 PTT FROM OPT
IOP_GPIO1 from the radio
3V3 logic level, 5V tolerant
10 IOP_GPIO2 SECONDARY BUSY
IOP_GPIO2 from the radio
3V3 logic level, 5V tolerant
11 IOP_GPIO3 BUSY
IOP_GPIO3 from the radio
3V3 logic level, 5V tolerant
12 IOP_GPIO4 AUX
IOP_GPIO4 from the radio
3V3 logic level, 5V tolerant
13 IOP_GPIO5 GPIO5
IOP_GPIO5 from the radio
3V3 logic level, 5V tolerant
14 IOP_GPIO6 — not connected
15 IOP_GPIO7 — not connected
16
DGND
AGND
analogue ground
17
IOP_RXD
RXD
asynchronous serial port - receive data
18
IOP_TXD
TXD
asynchronous serial port - transmit data
B
D
F
H
J
1!
1#
1%
1&
C
E
G
I
1)
1@
1$
1^
1*
top view
460 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
17.6 Line-Interface Board Application
The following diagram shows the control of two radios operated together,
crossband or repeater linked.
Table 17.8 External options connector (SK1) — pins and signals
Pin Signal Description
1 KEYING signal line keying
2 RS-422
serial data TX-
11 RS-422/RS-232
serial data TX+/RS-232 TXD
3 PTT-IN bi-directional keying input
4 4W_LINE_IN - 4-wire line in negative
10 4W_LINE_IN + 4-wire line in positive
5 RS-422/RS-232 serial data RX+/RS-232 RXD
6 RS-422 serial data RX-
7GND
ground
8 — not connected
9 13V8 FROM RADIO switched 13.8V supply from the radio
12 BUSY/GATE busy or receiver gate output. 5V CMOS logic level.
13 — not connected
14 4W_LINE_OUT - 4-wire line out negative or 2-wire line in/out negative
15 4W_LINE_OUT + 4-wire line out positive or 2-wire line in/out positive
front view
Figure 17.3 Two radios connected as a repeater/crossband link
keying
logic
SK2
TXD
AUD_TAP_OUT
AGND
DGND
PTT FROM OPT
RXD
13V8
—
—
—
—
AUD_TAP_IN
BUSY
2° BUSY
AUX
GPIO5
—
—
KEYING
PTT_IN
BUSY/GATE
LINE IN+
LINE IN-
LINE OUT+
LINE OUT-
AGND
13V8_SW
11
2
1
3
12
9
4
5
6
SK1
15
14
10
11
2
1
3
12
9
4
5
6
15
14
10
keying
logic
KEYING
PTT_IN
BUSY/GATE
RS-422/RS-232 TX
RS-422 TX
LINE IN+
LINE IN-
LINE OUT+
LINE OUT-
AGND
13V8_SW
11 11
22
11
33
1212
99
1010
44
1515
1414
5
6
5
6
SK1SK2
external
options
connector
external
options
connector
internal
options
connector
internal
options
connector
line-interface board line-interface board
18
18
17
17
9
9
10
15
12
12
11
11
6
6
7
10
4
13
5
11
2
2
14
8
7
10
4
13
5
14
8
1616
3
18
17
9
10
12
11
6
1
2
16
3
18
17
9
15
12
11
6
2
16
3
3
TXD
IOP_TXD
AUD_TAP_OUTAUD_TAP_OUT
AUX_MIC_AUD
AGND
AGND
DGND
DGND
PTT FROM OPT
IOP_GPIO1
RX_AUD
RXD
IOP_RXD
RX_BEEP_IN
13V8
—
—
—
—
13V8_SW
AUD_TAP_INAUD_TAP_IN
RSSI
IOP_GPIO2
BUSY
2° BUSY
IOP_GPIO3
AUX
IOP_GPIO4
IOP_GPIO5 GPIO5
IOP_GPIO6
IOP_GPIO7
1
IOP_TXD
AUD_TAP_OUT
AUX_MIC_AUD
AGND
DGND
IOP_GPIO1
RX_AUD
IOP_RXD
RX_BEEP_IN
13V8_SW
AUD_TAP_IN
RSSI
IOP_GPIO2
IOP_GPIO3
IOP_GPIO4
IOP_GPIO5
IOP_GPIO6
IOP_GPIO7
—
—
5
6
RS-422/RS-232 RX
RS-422 RX
RS-422/RS-232 TX
RS-422 TX
RS-422/RS-232 RX
RS-422 RX
5
6
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 461
© Tait Electronics Limited June 2006
17.7 Line-Interface Board Specifications
Input Voltage 10.8V to 16VDC
Operating Temperature Range -10°C to +60°C ambient
DC Input Current <40mA total (+13.8V supply)
Line Input Sensitivity (60% deviation) -20dBm to +6dBm (600Ω)
Line Output Level (60% deviation) -20dBm to +6dBm (600Ω)
Line Impedance 600Ω
Return Loss (300Hz to 3kHz) >20dB relative to 600Ω
Line Output Filter Response (stopband)
2 pole
6 pole
-12dB/octave, f >4kHz
-36dB/octave, f >4kHz
17.7.1 Radio With Line-Interface Board: Receiver + Line Output
Receiver Frequency Response*
Receiver Processed
Bandwidth
Response
Receiver Unprocessed
*relative to 1kHz, 60% deviation
300Hz to 3kHz (standard
400Hz to 3kHz (CTCSS)
+1, -3dB relative to -6dB/octave
+1, -3dB (300Hz to 3kHz)
Test Signal -46dBm RF*, 0dBm line output,
audio tap T4
*60% deviation at 1kHz
Signal-to-Noise Ratio
Narrow Bandwidth
Wide Bandwidth
>40dB
>43dB
Mute Ratio >60dB
Distortion*
Narrow Bandwidth
Wide Bandwidth
*30kHz bandwidth distortion meter
<4%
<4%
462 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
17.7.2 Radio With Line-Interface Board: Receiver + Line Input
Transmitter Frequency Response*
Bandwidth
Response
*relative to 1kHz, 20% deviation, below
limiting
300Hz to 3kHz
+1, -3dB relative to -6dB/octave
Test Signal 0dBm line input*, audio tap T1
*60% deviation at 1kHz
Signal-to-Noise Ratio*
Narrow Bandwidth
Wide Bandwidth
*demodulated, filtered 300Hz to 3kHz and
de-emphasised 750µs rms
>40dB
>43dB
Mute Ratio >60dB
Distortion*
*demodulated, filtered 15kHz low pass
<3%
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 463
© Tait Electronics Limited June 2006
17.8 Circuit Description
17.8.1 Audio Interface
When the line-interface board is used for repeater applications, the audio
passed between the two radios must be of such a level that the message is able
to be repeated intelligibly. The audio interface is therefore capable of
handling a wide range of input and output levels (-20 to +6dBm). The
audio interface is also capable of using either a two- or four-wire isolated
interface formats, which are selectable using S1.
The input to the line driver IC (U5) is the AUDIO TAP OUT line from
the radio. This line is a software-programmabable tap point which can be
chosen from various audio signals available within the radio and is coupled
through a capacitor into the audio line out level control (RV2). This variable
resister is AC coupled into the line driver (U5) which is used in a bridged-
output format, with gain set to provide the necessary 21dB gain.
The resistors on the output of the line driver provides the necessary 600Ω
terminating impedance, but also cause a 50% loss of signal. This is
compensated for by the higher-than-necessary gain of the line driver. Line
out protection is provided by two zener diodes, and the transformer (T1)
provides isolation.
The audio interface is capable of using a two- or four-wire interface, so a
tap is taken from one side of the balanced line out and is feed directly into
the line input level control (RV3). When using a four-wire interface, the
signal comes in through a second isolation transformer, T2. T2 is terminated
with 600Ω and also acts as a voltage divider. This means that the signal level
at RV3 will be identical to the level at RV3 when using a two-wire interface.
To achieve the required output level the non-inverting AC amplifier (U7)
has a gain of 10, which provides the necessary 13dB of gain. The output of
the amplifier is AC coupled into the AUDIO_TAP_IN line (pin 6 of SK2).
17.8.2 Logic Interface
The line-interface board is able to provide simple interface solutions with
other radios. Logic is used to control keying of both radios as well as
providing time delays to prevent squelch or cycling problems. The logic uses
gates rather than discrete components.
The choice of which input controls BUSY/GATE can be selected using
switches 3 and 4 of S1, while the sense of BUSY/GATE (pin 12 of SK1) can
be selected using switches 5 and 6. Switch 7 accommodates either a two-
line keying system or a single bi-directional keying line.
464 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
The comparators (in U1) operate off a single sided regulated 5V supply.
U1 pins 2,4 and 5 provide receiver gate delay. Once the busy signal is not
active, C4 charges through R12 and causes U4 to go low. Once charging
exceeds the voltage at U1 pin5. This also locks out the keying state until this
delay has occurred (U6 pin 5).
17.8.3 Data Communication
The Line Interface circuitry is designed to provide RS-232 and RS-422 data
communication. RS-232 is provided by U9, but if RS-422 is required, U9
is removed and replaced by U2 and U10. Also resistors R15,16,43 and 47
need to be fitted.
17.8.4 Power Supply
The power supply for the line-interface board comes from the radio via
the internal options connector and is a 13.8V switched supply. Digital
logic components are used in the line-interface board so there is a 5V
regulator provided.
Initially the 13.8V from the radio is filtered and used for the audio line
driver (U5) with reference to analogue ground. This 13.8V is also used to
supply the 5V regulator, which is filtered separately for either 5V digital or
analogue devices. A simple voltage divider is used to provide a 2.5V half-rail
for the digital and a 2.2V rail for the analogue sections.
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 465
© Tait Electronics Limited June 2006
Ref. IPN Description Ref. IPN Description
17.9 PCB Information
17.9.1 TMAA01-01 Parts List (PCB IPN 220-65202-04)
C1 014-08100-03 Cap Tant SMD 10u 35v 20% D
C2 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C3 014-07470-01 Cap Tant SMD 4u7 25v 10% B
C4 014-18100-05 Cap Tant SMD 10u 10v 10% A
C5 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C7 014-07470-01 Cap Tant SMD 4u7 25v 10% B
C8 018-14100-00 Cap 0603 1n 50v X7r ±10%
C9 018-14100-00 Cap 0603 1n 50v X7r ±10%
C10 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C12 015-26220-08 CAP CER 220N 50V 10% 0805 X7R
C13 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C14 018-14100-00 Cap 0603 1n 50v X7r ±10%
C15 018-14100-00 Cap 0603 1n 50v X7r ±10%
C16 014-06220-00 Cap Tant SMD 2.2Mf 50v
C17 015-26220-18 AP CER 220N 50V 10% 0805 X7R
C18 016-08470-01 Cap Elec SMD 47uf 6*4 16v
C19 018-15100-00 Cap 0603 10n 50v X7r ±10%
C20 018-15100-00 Cap 0603 10n 50v X7r ±10%
C21 014-07470-01 Cap Tant SMD 4u7 25v 10% B
C22 018-15100-00 Cap 0603 10n 50v X7r ±10%
C25 015-26220-18 AP CER 220N 50V 10% 0805 X7R
C26 018-13150-00 Cap 0603 150p 50v NPO ±5%
C27 015-26220-08 Cap 0805 220n 10% X7r 16v
C28 015-26220-18 AP CER 220N 50V 10% 0805 X7R
C29 018-15100-00 Cap 0603 10n 50v X7r ±10%
C30 018-15100-00 Cap 0603 10n 50v X7r ±10%
C31 018-15100-00 Cap 0603 10n 50v X7r ±10%
C32 018-15100-00 Cap 0603 10n 50v X7r ±10%
C35 015-26220-18 AP CER 220N 50V 10% 0805 X7R
C37 018-15100-00 Cap 0603 10n 50v X7r ±10%
C38 018-15100-00 Cap 0603 10n 50v X7r ±10%
C39 018-15100-00 Cap 0603 10n 50v X7r ±10%
C40 018-15100-00 Cap 0603 10n 50v X7r ±10%
C41 018-15100-00 Cap 0603 10n 50v X7r ±10%
D1 001-10084-47 Diode SMD BZX84C4V7 Zen SOT23
D2 001-10099-01 Diode BAV99w Dual Ss
D4 001-10070-01 Diode BAV70W Dual Ss SOT323
D5 001-10084-51 Diode SMD BZX84C5V1 Zen SOT23
D6 001-10084-51 Diode SMD BZX84C5V1 Zen SOT23
D7 001-10084-51 Diode SMD BZX84C5V1 Zen SOT23
D8 001-10099-01 Diode BAV99w Dual Ss
D9 001-10084-51 Diode SMD BZX84C5V1 Zen SOT23
D10 001-10099-01 Diode BAV99w Dual Ss
D11 001-10099-01 Diode BAV99w Dual Ss
D12 001-10284-51 Diode SMD BZX284B5V1 Zensod110
E1 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
E2 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
E3 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
E4 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
FL1 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
FL2 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
FL3 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
FL4 057-10120-03 Ind 0805 120e@100m .2 Emi Supr
FL5 057-11220-02 Ind 0603 Blm11a221 Emi Supr
FL6 057-11220-02 Ind 0603 Blm11a221 Emi Supr
FL7 057-11220-02 Ind 0603 Blm11a221 Emi Supr
FL8 057-11220-02 Ind 0603 Blm11a221 Emi Supr
FL9 012-14100-00 Cap Cer SMD 1N Array EMI Supr
Q1 000-10084-71 Xstr BC847BW NPN SOT323
Q2 000-10084-71 Xstr BC847BW NPN SOT323
Q3 000-10084-71 Xstr BC847BW NPN SOT323
R1 036-02100-03 RES Pwr 1218 10R 5% 1W
RV1 042-05100-06 Res Pre TH 10k 6mm Top
R2 038-15100-10 RES 0603 10k 1% 1/10W
RV2 042-05100-06 Res Pre TH 10k 6mm Top
R3 038-14100-10 RES 0603 1k0 1% 1/10W
RV3 042-05100-06 Res Pre TH 10k 6mm Top
R4 038-15100-10 RES 0603 10k 1% 1/10W
R5 038-16470-00 RES 0603 470k 5% 1/10W
R8 038-17100-10 RES 0603 1M 1% 1/10W
R9 036-02100-03 RES Pwr 1218 10R 5% 1W
R10 038-13100-10 RES 0603 100R 1% 1/10W
R11 038-14330-10 RES 0603 3k3 1% 1/10W
R12 038-14560-00 RES 0603 5k6 5% 1/10W
R13 038-16330-10 RES 0603 330k 1% 1/10W
R14 038-16330-10 RES 0603 330k 1% 1/10W
R15A 038-13680-00 RES 0603 680R 5% 1/10W
R16A 038-13120-00 RES 0603 120R 5% 1/10W
R17 038-13680-00 RES 0603 680R 5% 1/10W
R18 038-15100-10 RES 0603 10k 1% 1/10W
R19 036-13270-00 RES 0805 270R 5% 1/8W
R20 038-15100-10 RES 0603 10k 1% 1/10W
R21 038-14330-10 RES 0603 3k3 1% 1/10W
R22 038-10000-00 RES 0603 0R
R23 038-15100-10 RES 0603 10k 1% 1/10W
R24 038-14330-10 RES 0603 3k3 1% 1/10W
R25 038-15100-10 RES 0603 10k 1% 1/10W
R26 038-15470-10 RES 0603 47k 1% 1/10W
R27 038-15820-10 RES 0603 82k 1% 1/10W
R28 038-15470-10 RES 0603 47k 1% 1/10W
R29 038-16120-10 RES 0603 120k 1% 1/10W
R30 038-15470-10 RES 0603 47k 1% 1/10W
R31 038-15470-10 RES 0603 47k 1% 1/10W
R32 038-16120-10 RES 0603 120k 1% 1/10W
R34 038-12560-00 RES 0603 56R 5% 1/10W
R35 038-14100-10 RES 0603 1k0 1% 1/10W
R36 038-15470-10 RES 0603 47k 1% 1/10W
R37 038-15100-10 RES 0603 10k 1% 1/10W
R38 038-15120-10 RES 0603 12k 1% 1/10W
R39 038-16180-00 RES 0603 180k 5% 1/10W
R40 038-13180-10 RES 0603 180R 1% 1/10W
R41 038-13180-10 RES 0603 180R 1% 1/10W
R43A 038-13680-00 RES 0603 680R 5% 1/10W
R44 038-13680-00 RES 0603 680R 5% 1/10W
R45 038-13330-00 RES 0603 330R 5% 1/10W
R47A 038-13120-00 RES 0603 120R 5% 1/10W
R48 038-16120-10 RES 0603 120k 1% 1/10W
R49 038-16150-10 RES 0603 150k 1% 1/10W
R50 038-15120-10 RES 0603 12k 1% 1/10W
R51 038-16120-10 RES 0603 120k 1% 1/10W
R52 038-15470-10 RES 0603 47k 1% 1/10W
R53 038-10000-00 RES 0603 0R
R54 038-10000-00 RES 0603 0R
R55 038-10000-00 RES 0603 0R
R56 038-12560-00 RES 0603 56R 5% 1/10W
S1 230-10010-44 Sw SMD Spst 16dil X8
SK1 240-00011-67 Skt 15w Drng Ra Slim Dsub 7912
SK2 240-10000-11 Conn SMD 18w Skt M/Match
T1 054-00010-18 Xfmr Line SMD 600 Ohm P2781
T2 054-00010-18 Xfmr Line SMD 600 Ohm P2781
U1 002-10339-00 IC SMD LM339 4x CMplt S014
U3 002-10740-40 IC 74AHCT04 SOIC14 Hex Inv
U4 002-10740-80 IC 74AHCT08 SOIC14 4x2IP AND
U5 002-10854-10 IC TDA8541T 1w Audio Amp
U6 002-10740-80 IC 74AHCT08 SOIC14 4x2IP AND
U7 002-10003-58 IC SMD LM358 Dual 0-Amp
U8 002-10078-05 IC SMD 78l05 5v Reg
U9 002-10002-02 IC SMD ADM202E RS232/Esd S016
220-65202-04 PCB TMA 600R LINE INTFC
402-00012-0X MANL f/instr TMAA01-01
600-00009-00 Pkg Kit Opt 15w parts:
240-00032-00 Plg 15w Drng Hi-D UL-CSA P/Mtg
240-06010-29 Conn 9w Hood/Cvr Lets
600-00010-00 Pkg Kit Opt Int parts:
219-00329-00 Loom TMA Int Opt
347-00011-00 Scrw 4-40*3/16 Unc P/P Blk
349-02062-00 Scrw M3*8 T/T P/T ContiR
354-01043-00 Fsnr Scrw Lok 1pr 4-40
362-01108-01 Seal Drng Cvr 9way TMA
362-01111-00 Seal Drng 9way TMA
466 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Ref. PCB Circuit Ref. PCB Circuit Ref. PCB Circuit
17.9.2 TMAA01-01 Grid Reference List (PCB IPN 220-65202-04)
C1 B2 2:A2
C2 B1 2:A2
C3 C5 2:A4
C4 F6 1:D5
C5 D8 2:G3
C7 B6 2:A4
C8 D2 2:F6
C9 D2 2:G6
C10 B6 2:B4
C12 E2 1:K3
C13 F8 2:C3
C14 D2 2:B6
C15 C2 2:C6
C16 C7 1:B10
C17 E3 1:K4
C18 E3 1:J7
C19 E6 1:A9
C20 C6 1:A9
C21 F3 1:K8
C22 D6 1:A10
C24 C1 2:G8
C25 E5 1:H2
C26 F5 1:H3
C27 G4 1:G3
C28 F4 1:H4
C29 E5 1:A12
C30 D6 1:A11
C31 C1 1:J13
C32 C1 1:H13
C33 B1 2:G8
C35 D5 1:J9
C37 E8 2:E3
C38 D8 2:E3
C39 E8 2:E3
C40 E8 2:E4
C41 D8 2:E4
D1 E1 1:C11
D2 D2 1:F12
1:G12
D4 D6 1:C10
1:B10
D5 B3 1:J12
D6 C2 1:K12
D7 C3 1:J12
D8 G5 1:H4
D9 B2 1:H12
D10 D2 1:E12
D11 C2 1:D12
D12 B5 2:A3
E1 C2 2:C6
E2 D2 2:C6
E3 C1 2:C7
E4 D1 2:C7
FL1 D2 2:G6
FL2 D2 2:F6
FL3 D1 2:G7
FL4 D1 2:F7
FL5 E3 1:K11
FL6 D3 1:J11
FL7 C3 1:J11
FL8 C3 1:H11
FL9 C1 1:D13
1:G13
1:E13
MT1 B9 2:A5
MT2 G9 2:A6
MT3 A6 2:A6
MT4 G6 2:A7
MT5 A1 2:A7
MT6 G1 2:A8
Q1 G5 1:E9
Q2 E2 1:G10
Q3 C6 1:D4
R1 B1 2:B2
R2 D6 1:E7
R3 D2 1:E12
R4 F8 2:G3
R5 E6 1:E6
R8 E6 1:D5
R9 C6 2:B3
R10 B6 2:A4
R11 C4 1:D2
R12 E6 1:E5
R13 E6 1:E5
R14 C7 1:E4
R15A A7 2:E8
R15 F8 2:G5
R16A A7 2:E8
R16 E8 2:F5
R17 E8 2:F5
R18 F7 1:E6
R19 F7 1:D5
R20 D6 1:D4
R21 C4 1:D2
R22 D1 2:B8
R23 D7 1:B8
R24 C3 1:G2
R25 F5 1:E9
R26 E2 1:G9
R27 D7 1:B9
R28 E7 1:B9
R29 E7 1:B10
R30 E3 1:F9
R31 D2 1:G11
R32 D7 1:B10
R34 F5 1:D9
R35 C2 1:D12
R36 E2 1:E11
R37 D6 1:B11
R38 E3 1:K4
R39 E4 1:K7
R40 E4 1:K8
R41 D4 1:J8
R43A A7 2:E9
R43 C8 2:C4
R44 C8 2:B4
R45 C4 1:H10
R46 E8 2:F2
R47A A7 2:E9
R47 C8 2:C4
R48 F5 1:H3
R49 E5 1:H3
R50 F4 1:G3
R51 F5 1:H3
R52 D2 1:D12
R53 C3 1:H11
R54 D3 1:J11
R55 F8 2:F3
R56 E3 1:F10
R57 F9 2:F2
RV1 E7 1:E5
RV2 F2 1:K3
RV3 F4 1:H5
S1 G3 1:D5
1:D11
1:F4
1:G4
1:G9
1:J9
1:H9
1:F9
SK1 D1 2:B8
2:F9
2:C8
2:G9
SK1 D1 1:K13
1:J13
1:H13
1:B13
1:G13
1:D13
1:E13
SK2 B3 2:F1
2:C1
2:B1
2:G1
SK2 B3 1:C1
1:H1
1:D1
1:G1
1:F1
1:K1
T1 D4 1:J11
T2 C4 1:H11
TP1 B4 1:D2
TP2 B3 1:F2
TP3 B4 1:D2
TP4 B3 1:G2
TP5 D2 1:E13
TP6 C2 1:G12
TP7 C2 1:D13
U1 E7 1:C5
1:E6
1:B9
1:A11
1:C4
U2 E8 2:F3
U3 F5 1:G6
1:G7
1:F2
1:B6
1:C10
1:A9
U4 E5 1:B6
1:A10
1:E8
1:F3
U5 E3 1:J7
U6 D5 1:A8
1:C10
1:B11
1:B7
1:D3
U7 E4 1:H3
1:J3
1;A12
U8 B5 2:A3
U9 D8 2:E3
U10 C8 2:C3
W1 C7 1:E4
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 467
© Tait Electronics Limited June 2006
17.9.3 Line-Interface Board Layout (top side)
IPN 220-65202-04
468 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
17.9.4 Line-Interface Board Layout (bottom side)
IPN 220-65202-04
TM8100/TM8200 Service Manual TMAA01-01 Line-Interface Board 469
© Tait Electronics Limited June 2006
17.9.5 Line-Interface Board Circuit Diagram
470 TMAA01-01 Line-Interface Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
TM8100/TM8200 Service Manual TMAA01-02 RS-232 Board 471
© Tait Electronics Limited June 2006
18 TMAA01-02 RS-232 Board
The TMAA01-02 RS-232 board fits inside the radio in the
options cavity and is connected to the main PCB by the internal
options connector and loom.
The RS-232 signals are then made available on the 9-way D-
range connector mounted on the RS-232 board. This connector
fits through the external options connector hole provided in the
radio chassis.
18.1 Operation
The TMAA01-02 RS-232 board provides a suitable interface to external
devices requiring full RS-232 level compatibility. As well as supporting
transmit and receive data lines, the board also supports RTS and CTS
hardware flow control lines.
18.1.1 Hardware Flow Control
Although the serial transmit and receive lines are dedicated connections on
the internal options connector, the RTS and CTS lines have to be assigned.
For hardware flow control, these lines are set up in the programming
application. RTS should be assigned to IOP_GPIO3 and CTS should be
assigned to IOP_GPIO1.
Refer to the online help of the programming application for
more information.
Important The radio does not meet the IP54 protec-
tion standard once an RS-232 board has
been installed unless the external options
cover seal is installed.
Important To comply with EN 301 489-5, all
cables connected to the external options
connector must be less than three metres
(10 feet) in length.
external options
connector
internal options
connector
RS-232
board
D-range
hood parts
D-range plug
RS-232 board
installation parts
internal options
loom
external options
cover seal
472 TMAA01-02 RS-232 Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
18.2 Installing the RS-232 Board
Important This equipment contains devices which are susceptible to
damage from static charges. Refer to “ESD Precautions”
on page 108 for more information.
18.2.1 Parts Required
The following table describes the parts required to install an RS-232 board in
a radio. The parts marked with an asterisk (*) are not shown in Figure 18.1
and are used to connect to the radio’s external options connector.
18.2.2 Installation Procedure
1. Disassemble the radio in order to gain access to the options cavity.
For detailed disassembly instructions, refer to “Disassembly and
Reassembly” on page 129.
The circled numbers in the following instructions refer to items in the
diagram on page 473.
2. Remove the top cover and lid b from the radio to access the
options cavity.
3. Remove the external options connector bung c, if it is fitted.
4. On the inside of the radio lid place the foam seal d over the external
options connector cavity e.
5. Plug one end of the internal options connector loom into the internal
options connector on the RS-232 board.
6. With the top side of the RS-232 board f facing the radio lid, guide
the external options connector g into the external options
connector cavity.
Table 18.1 RS-232 installation parts required
Quantity Internal Part Number Description Figure 18.1
Reference
1 362-01111-XX1
1. Contact Technical Support for the exact IPN.
foam seal d
1 362-01108-XXacover seal 1!
2 347-00011-00 4-40x3/16 screws 1@
2 354-01043-00 screw-lock fasteners h
4 349-02062-00 M3x8 screws j
*1 240-00034-00 D-range plug —
*1 240-06010-29 D-range hood —
TM8100/TM8200 Service Manual TMAA01-02 RS-232 Board 473
© Tait Electronics Limited June 2006
Important The external options connector screw-lock fasteners must
be tightened correctly before screwing the RS-232 board
onto the mounting posts i.
7. Screw the external options connector to the radio lid using the two
screw-lock fasteners h.
Tighten the fasteners to a torque of 0.9N·m (8lbf·in).
8. Screw the RS-232 board to the mounting posts on the radio lid using
four M3x8 self-tapping screws j.
Tighten the M3x8 screws to a torque of 1.9N·m (17lbf·in)
Important For the RS232 board to be installed correctly in the radio’s
options cavity, the internal options connector loom 1)
must
be looped in the way shown in the diagram on page 473.
9. Plug the unattached end of internal options connector loom 1) into
the internal options connector on the radio main PCB.
10. Refit the radio lid and top cover to the radio and screw the external
options cover seal 1! over the external options connector, using the
two 4-40x3/16 screws 1@.
Figure 18.1 RS-232 board installation
bradio lid hscrew-lock fasteners
cexternal options connector bung imounting posts
dfoam seal jM3x8 self-tapping screws
eexternal options connector cavity 1) internal options loom
fRS-232 board 1! external options cover seal
gexternal options connector 1@ 4-40x3/16 screws
b
c
e
h
i
j
1@
1!
1)
d
f
g
474 TMAA01-02 RS-232 Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
18.3 Interface Specification
The following tables summarize the signals used for the RS-232 board on the
internal options connector (SK1 on the RS-232 board) and the external
options connector (SK2 on the RS-232 board).
Note The TM8000 3DK Hardware Developer’s Kit Application
Manual contains a detailed electrical specification for the signals
available on the radio’s internal options connector. This manual is
part of the 3DK Resource CD, which can be purchased using
product code TMAA30-01.
Table 18.2 Internal options connector—pins and signals
Pin Connector
Signal Description
1 13V8_SW
switched 13V8 supply from the radio
2 AUD_TAP_OUT
Programmable tap point out of the receive or transmit audio chain.
DC-coupled
3AGND
analogue ground
4 AUX_MIC_AUD
Auxiliary microphone input, with electret microphone biasing
provided.
Dynamic microphones are not supported.
5 RX_BEEP_IN
receive sidetone input, AC-coupled
6 AUD_TAP_IN
Programmable tap point into the receive or transmit audio chain.
DC-coupled
7 RX_AUD
not connected
8 RSSI
analogue RSSI output
9-15 IOP_GPIO1 to
IOP_GPIO7
programmable function and direction
16
DGND digital ground
17
IOP_RXD an RS-232 compliant asynchronous serial port - receive data
18
IOP_TXD an RS-232 compliant asynchronous serial port - transmit data
B
D
F
H
J
1!
1#
1%
1&
C
E
G
I
1)
1@
1$
1^
1*
top view
Table 18.3 External options connector (SK2) — pins and signals
Pin Signal Direction
2 serial transmit data
output from the radio
3 serial receive data
input to the radio
5 data ground
—
7 RTS using IOP_GPIO3
input to the radio
8 CTS using IOP_GPIO1
output from the radio
front view
TM8100/TM8200 Service Manual TMAA01-02 RS-232 Board 475
© Tait Electronics Limited June 2006
Ref. IPN Description Ref. IPN Description
18.4 PCB Information
18.4.1 TMAA01-02 Parts List (PCB IPN 220-01740-01)
C1 014-07100-02 Cap Tant SMD 1u0 16v 20% A
C2 018-14100-00 Cap 0603 1n 50v X7r ±10%
C3 018-14100-00 Cap 0603 1n 50v X7r ±10%
C4 018-14100-00 Cap 0603 1n 50v X7r ±10%
C5 018-14100-00 Cap 0603 1n 50v X7r ±10%
C6 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C7 014-07470-11 Cap Tant 4u7 10V 20% 0603
C8 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C9 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C10 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C11 018-14100-00 Cap 0603 1n 50v X7r ±10%
C12 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C13 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C14 018-14100-00 Cap 0603 1n 50v X7r ±10%
C15 018-14100-00 Cap 0603 1n 50v X7r ±10%
C16 018-14100-00 Cap 0603 1n 50v X7r ±10%
C17 018-14100-00 Cap 0603 1n 50v X7r ±10%
C18 018-14100-00 Cap 0603 1n 50v X7r ±10%
LK1 036-14100-10 RES 0805 1k 1% 1/8W
LK3 036-14100-10 RES 0805 1k 1% 1/8W
R1 038-15100-10 RES 0603 10k 1% 1/10W
R2 038-15100-10 RES 0603 10k 1% 1/10W
R3 038-15100-10 RES 0603 10k 1% 1/10W
R4 038-15100-10 RES 0603 10k 1% 1/10W
R8 038-13100-10 RES 0603 100R 1% 1/10W
R9 038-13100-10 RES 0603 100R 1% 1/10W
R10 038-13100-10 RES 0603 100R 1% 1/10W
R13 038-13100-10 RES 0603 100R 1% 1/10W
SK1 240-10000-11 Conn SMD 18w Skt M/Match
SK2 240-06009-20 Conn DIP D-Sub 9W Female TM8K
U1 002-10740-40 IC 74AHCT04 SOIC14 Hex Inv
U2 002-10078-00 IC SMD MC78M05CDT5v Reg0.5a
U3 002-10022-22 IC SMD ST202E RS232/ESD SO16
220-01740-01 PCB TMA RS232 Options
402-00019-0X F/Inst TMAA01-02 RS232 Brd
600-00010-00 Pkg Kit Opt Int parts:
219-00329-00 Loom TMA Int Opt
347-00011-00 Scrw 4-40*3/16 Unc P/P Blk
349-02062-00 Scrw M3*8 T/T P/T ContiR
354-01043-00 Fsnr Scrw Lok 1pr 4-40
362-01108-01 Seal Drng Cvr 9way TMA
362-01111-00 Seal Drng 9way TMA
600-00012-00 Pkg Kit Opt 9w parts:
240-00034-00 Plg 9w Drng UL-CSA Pnl Mtg
240-06010-29 Conn 9w Hood/Cvr Lets
476 TMAA01-02 RS-232 Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
18.4.2 RS-232 Board Layout (top side)
IPN 220-01740-01
TM8100/TM8200 Service Manual TMAA01-02 RS-232 Board 477
© Tait Electronics Limited June 2006
18.4.3 RS-232 Board Layout (bottom side)
IPN 220-01740-01
478 TMAA01-02 RS-232 Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
18.4.4 RS-232 Board Circuit Diagram
TM8100/TM8200 Service Manual TMAA01-05 Options-Extender Board 479
© Tait Electronics Limited June 2006
19 TMAA01-05 Options-Extender Board
The TMAA01-05 options-extender board provides external
access to most of the signal lines provided by the radio’s internal
options connector.
The options-extender board fits inside the radio in the options
cavity and is connected to the main PCB by the internal options
connector and loom.
The internal options connector signals are then made available on
the high-density 15-way D-range connector mounted on the
options-extender board. This connector fits through the external
options connector hole provided in the radio chassis.
19.1 Changing the Options-Extender Links
The options-extender board configuration must be completed before the
board is installed in the radio, as the top side of the options-extender board
is not accessible once the board is screwed to the radio lid.
Important This equipment contains devices which are susceptible to
damage from static discharges. Refer to “ESD Precautions”
on page 108 for more information.
The options-extender board has various link options which allow the user
to re-configure the outputs available on the external options connector. The
outputs that can be made available by changing linking resistors are:
■the 5V supply line, and
■the RX_BEEP_IN line.
In both cases, these lines replace other lines that are available when the
linking resistors are in the factory-set configuration. Note that there is no
external connection available for the RX_AUD line.
Important The radio does not meet the IP54 protec-
tion standard once an options-extender
board has been installed unless the exter-
nal options cover seal is installed.
Important To comply with EN 301 489-5, all
cables connected to the external options
connector must be less than three metres
(10 feet) in length.
external options
connector
internal options
connector
options-
extender
board
D-range
hood parts
D-range plug
options-extender
installation parts
internal options
loom
external options
cover seal
480 TMAA01-05 Options-Extender Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
19.1.1 Power Supply Line
The power supply output available on pin 2 of the external options
connector is factory-set to 13.8V. The output on this pin can be changed to
5V if R11 (a 0Ω surface mount resistor) is moved to position R10.
Figure 19.1 at the top of the page shows the component locations.
Important The maximum current for the 5V supply line is 400mA.
19.1.2 RX_BEEP_IN Line
If the RX_BEEP_IN line is required on the external options connector,
it must replace one of the following lines:
■IOP_RSSI
■AUD_TAP_IN
■AUX_MIC_AUD
■AUD_TAP_OUT.
The following table explains the resistor link changes required and
Figure 19.1 at the top of the page shows the component locations.
Figure 19.1 Options-extender board linking resistor locations
power supply line
RX_BEEP_IN line
Table 19.1 RX_BEEP_IN resistor changes
RX_BEEP_IN Line Replaces Remove Resistor Add Resistor
IOP_RSSI R2 R3
AUD_TAP_IN R4 R5
AUX_MIC_AUD R6 R7
AUD_TAP_OUT R8 R9
TM8100/TM8200 Service Manual TMAA01-05 Options-Extender Board 481
© Tait Electronics Limited June 2006
19.2 Installing the Options-Extender Board
19.2.1 Parts Required
The following table describes the parts required to install an options-extender
board in a radio. The parts marked with an asterisk (*) are not shown in
Figure 19.2 and are used to connect to the radio’s external options connector.
19.2.2 Installation Procedure
1. Disassemble the radio in order to gain access to the options cavity.
For detailed disassembly instructions, refer to “Disassembly and
Reassembly” on page 129.
Refer to the diagram on the following page and the instructions below.
2. Remove the top cover and lid b from the radio to access the
options cavity.
3. Remove the external options connector bung c, if it is fitted.
4. On the inside of the radio lid place the foam seal d over the external
options connector cavity e.
5. With the top side of the options-extender board f facing the radio
lid, guide the external options connector g (the D-range connector
on the options-extender board) into the external options connector
cavity.
6. Screw the external options connector to the radio lid using the two
screw-lock fasteners h.
Tighten the fasteners to a torque of 0.9N·m (8lbf·in).
Important The external options connector screw-lock fasteners must
be tightened correctly before screwing the options-
extender board onto the mounting posts i.
Table 19.2 Options-extender installation parts required
Quantity Internal Part Number Description Figure 19.2
Reference
1 362-01111-XX1
1. Contact Technical Support for the exact IPN.
foam seal d
1 362-01108-XXacover seal 1!
2 347-00011-00 4-40x3/16 screws 1@
2 354-01043-00 screw-lock fasteners h
4 349-02062-00 M3x8 screws j
*1 240-00032-00 D-range plug —
*1 240-06010-29 D-range hood —
482 TMAA01-05 Options-Extender Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
7. Screw the options-extender board to the mounting posts on the radio
lid using four M3x8 self-tapping screws j.
Tighten the M3x8 screws to a torque of 1.9N·m (17lbf·in)
Important For the options-extender board to be installed correctly in
the radio’s options cavity, the internal options connector
loom 1) must be looped in the way shown in Figure 19.2.
8. Plug the unattached end of internal options connector loom 1) into
the internal options connector on the radio main PCB.
9. Refit the radio lid and top cover to the radio and screw the external
options cover seal 1! over the external options connector, using the
two 4-40x3/16 screws 1@.
Figure 19.2 Options-extender board installation
bradio lid hscrew-lock fasteners
cexternal options connector bung imounting posts
dfoam seal jM3x8 self-tapping screws
eexternal options connector cavity 1) internal options loom
foptions-extender board 1! external options cover seal
gexternal options connector 1@ 4-40x3/16 screws
b
c
e
h
i
j
1@
1!
1)
df
g
TM8100/TM8200 Service Manual TMAA01-05 Options-Extender Board 483
© Tait Electronics Limited June 2006
19.3 Interface Specification
The following tables summarize the signals used for the options-extender
board on the internal options connector (SK1 on the options-extender board)
and the external options connector (SK2 on the options-extender board).
Note The TM8000 3DK Hardware Developer’s Kit Application
Manual (product code MMAA30-01-00-807) contains a detailed
electrical specification for the signals available on the radio’s inter-
nal options connector. This manual is part of the 3DK Resource
CD, which can be purchased using product code TMAA30-01.
Table 19.3 Internal options connector—pins and signals
Pin Connector
Signal Description
1 13V8_SW
switched 13V8 supply from the radio
2 AUD_TAP_OUT
Programmable tap point out of the receive or transmit audio chain.
DC-coupled
3AGND
analogue ground
4 AUX_MIC_AUD
Auxiliary microphone input, with electret microphone biasing
provided.
Dynamic microphones are not supported.
5 RX_BEEP_IN
receive sidetone input, AC-coupled
6 AUD_TAP_IN
Programmable tap point into the receive or transmit audio chain.
DC-coupled
7 RX_AUD
not connected
8 RSSI
analogue RSSI output
9-15 IOP_GPIO1 to
IOP_GPIO7
programmable function and direction
16
DGND digital ground
17
IOP_RXD an RS-232 compliant asynchronous serial port - receive data
18
IOP_TXD an RS-232 compliant asynchronous serial port - transmit data
B
D
F
H
J
1!
1#
1%
1&
C
E
G
I
1)
1@
1$
1^
1*
top view
484 TMAA01-05 Options-Extender Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Table 19.4 External options connector (SK2) — pins and signals
Pin Signal Description
2 13V8_SW1
13V8 supply
6 AUD_TAP_OUTb
Programmable tap point out of the Rx or Tx audio
chain. DC-coupled
7AGND
analogue ground
11 AUX_MIC_AUDb
Auxiliary microphone input, with electret microphone
biasing provided.
Dynamic microphones are not supported.
1 AUD_TAP_INb
Programmable tap point into the Rx or Tx audio chain.
DC-coupled.
3 RSSI2
analogue RSSI output
15 IOP_GPIO13
programmable function and direction
14 IOP_GPIO2c
programmable function and direction
13 IOP_GPIO3c
programmable function and direction
10 IOP_GPIO4c
programmable function and direction
9 IOP_GPIO5c
programmable function and direction
5 IOP_GPIO6c
programmable function and direction
4 IOP_GPIO7c
programmable function and direction
8 IOP_RXD
an RS-232 compliant asynchronous serial port -
receive data
12 IOP_TXD
an RS-232 compliant asynchronous serial port -
transmit data
1. This can be configured to be 5V. Refer to “Power Supply Line” on page 480.
2. This can be re-configured to be RX_BEEP_IN. Refer to “RX_BEEP_IN Line” on page 480.
3. 3V3 CMOS output via 1kΩ series resistance. 5V tolerant input.
front view
TM8100/TM8200 Service Manual TMAA01-05 Options-Extender Board 485
© Tait Electronics Limited June 2006
Ref. IPN Description Ref. IPN Description
C1 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C2 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C3 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C4 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C5 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C6 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C7 018-15100-00 Cap 0603 10n 50v X7r ±10%
C8 014-08100-30 Cap Tant SMD 100u 10v Loesr D
C9 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C10 016-08470-01 Cap Elec SMD 47uf 6*4 16v
C11 014-08100-30 Cap Tant SMD 100u 10v Loesr D
C12 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C13 016-08470-01 Cap Elec SMD 47uf 6*4 16v
C14 018-15100-00 Cap 0603 10n 50v X7r ±10%
C15 018-15100-00 Cap 0603 10n 50v X7r ±10%
C16 018-15100-00 Cap 0603 10n 50v X7r ±10%
C17 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C18 015-06470-01 Cap Cer 1206 470n X7r 20% 50v
C19 018-13470-00 Cap 0603 470p 50v X7r±10%
C20 018-13470-00 Cap 0603 470p 50v X7r±10%
C21 018-13470-00 Cap 0603 470p 50v X7r±10%
C22 018-13470-00 Cap 0603 470p 50v X7r±10%
C23 018-13470-00 Cap 0603 470p 50v X7r±10%
C24 018-13470-00 Cap 0603 470p 50v X7r±10%
C25 018-13470-00 Cap 0603 470p 50v X7r±10%
C26 018-13470-00 Cap 0603 470p 50v X7r±10%
C27 018-13470-00 Cap 0603 470p 50v X7r±10%
C28 018-15100-00 Cap 0603 10n 50v X7r ±10%
C29 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C30 018-14100-00 Cap 0603 1n 50v X7r ±10%
C31 018-14100-00 Cap 0603 1n 50v X7r ±10%
C32 018-14100-00 Cap 0603 1n 50v X7r ±10%
C33 018-14100-00 Cap 0603 1n 50v X7r ±10%
C34 018-14100-00 Cap 0603 1n 50v X7r ±10%
C35 018-14100-00 Cap 0603 1n 50v X7r ±10%
C36 018-14100-00 Cap 0603 1n 50v X7r ±10%
D1 001-10014-03 Diode SMD MBRS140T3 Sch
D2 001-10099-01 Diode BAV99w Dual Ss
D3 001-10099-01 Diode BAV99w Dual Ss
D4 001-10099-01 Diode BAV99w Dual Ss
D5 001-10099-01 Diode BAV99w Dual Ss
D6 001-10099-01 Diode BAV99w Dual Ss
D7 001-10099-01 Diode BAV99w Dual Ss
D8 001-10099-01 Diode BAV99w Dual Ss
IC1 002-10020-20 IC SMD ADM202 Rs-232 Con S0-16
IC2 002-10267-40 IC LM2674 S08 Swtch Volt Regul
L1 057-10100-65 Ind SMD Pwr Cdrh6D38 100UH .65
L2 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L3 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L4 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L5 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L6 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L7 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L8 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L9 057-10010-45 Ind SMD Pwr CDRH2D18 10UH .43A
L10 057-10010-45 Ind SMD Pwr CDRH2D18 10UH .43A
L11 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
L12 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L13 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L14 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L15 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
L16 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L17 057-10010-20 Ind 0603 Blm11-B102s 0.1a
L18 057-10010-20 Ind 0603 Blm11-B102s 0.1a
R2 036-10000-00 RES 0805 0R 1/8W
R4 036-10000-00 RES 0805 0R 1/8W
R6 036-10000-00 RES 0805 0R 1/8W
R8 036-10000-00 RES 0805 0R 1/8W
R11 036-10000-00 RES 0805 0R 1/8W
R12 038-13100-10 RES 0603 100R 1% 1/10W
R13 038-13100-10 RES 0603 100R 1% 1/10W
R14 038-13100-10 RES 0603 100R 1% 1/10W
R15 038-13100-10 RES 0603 100R 1% 1/10W
R16 038-13100-10 RES 0603 100R 1% 1/10W
R17 038-13100-10 RES 0603 100R 1% 1/10W
R18 038-13100-10 RES 0603 100R 1% 1/10W
R19 038-13100-10 RES 0603 100R 1% 1/10W
SK1 240-10000-11 Conn SMD 18w Skt M/Match
SK2 240-00011-67 Skt 15w Drng Ra Slim Dsub 7912
220-65203-00 PCB TM8000 Options Extender
402-00008-0X MANL f/instr TMAA01-05
600-00009-00 Pkg Kit Opt 15w parts:
240-00032-00 Plg 15w Drng Hi-D UL-CSA P/Mtg
240-06010-29 Conn 9w Hood/Cvr Lets
600-00010-00 Pkg Kit Opt Int parts:
219-00329-00 Loom TMA Int Opt
347-00011-00 Scrw 4-40*3/16 Unc P/P Blk
349-02062-00 Scrw M3*8 T/T P/T ContiR
354-01043-00 Fsnr Scrw Lok 1pr 4-40
362-01108-01 Seal Drng Cvr 9way TMA
362-01111-00 Seal Drng 9way TMA
19.4 PCB Information
19.4.1 TMAA01-05 Parts List (PCB IPN 220-65203-00)
Ref. PCB Circuit Ref. PCB Circuit Ref. PCB Circuit
486 TMAA01-05 Options-Extender Board TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
19.4.2 TMAA01-05 Grid Reference List (PCB IPN 220-65203-00)
C1 D5 1G4
C10 F3 1G5
C11 E3 1G8
C12 E2 1G8
C13 F2 1G5
C14 D2 1E2
C15 D2 1D2
C16 D2 1D2
C17 E1 1G9
C18 B1 1G2
C19 B1 1F8
C2 D4 1F2
C20 B1 1C2
C21 B1 1A2
C22 C1 1B3
C23 C1 1D2
C24 C1 1B3
C25 C1 1C3
C26 C1 1B2
C27 D1 1F8
C28 D1 1E2
C29 F1 1G4
C3 D4 1G4
C30 C4 1D1
C31 C4 1C1
C32 C4 1C1
C33 C4 1B1
C34 C4 1B1
C35 C4 1B1
C36 C4 1A1
C4 D4 1G2
C5 D4 1G4
C6 E4 1G7
C7 F3 1G7
C8 E3 1G8
C9 F3 1G6
D1 G3 1G7
D2 B2 1A2
D3 C2 1D2
D4 C2 1C3
D5 B2 1C2
D6 C2 1C3 1B3
D7 C2 1B3
D8 C2 1B2
IC1 D4 1F3
IC2 F3 1G6
L1 F4 1G7
L10 F2 1G5
L11 E2 1G9
L12 D2 1E2
L13 D2 1D2
L14 D2 1E2
L15 F1 1G5
L16 B1 1F7
L17 D1 1F7
L18 D1 1E2
L2 B2 1C2
L3 B2 1A2
L4 C2 1B3
L5 C2 1D2
L6 C2 1B3
L7 C2 1C3
L8 C2 1B2
L9 E2 1G9
R1 B4 1A2
R10 D1 1F9
R11 D1 1G9
R12 C4 1D2
R13 C4 1C2
R14 C4 1C2
R15 C4 1B2
R16 C4 1B2
R17 C4 1B2
R18 C4 1A2
R19 C3 1E2
R2 B3 1E2
R20 B2 1F2
R21 D2 1F2
R3 C3 1E2
R4 B3 1E2
R5 C3 1E2
R6 B3 1E2
R7 C3 1E2
R8 B3 1D2
R9 C3 1D2
SK1 B3 1D2
1G2
1E2
1F2
1D1
1C1
1B1
1A1
SK2 D1 1D9
1C9
1A9
1B9
1E9
1F9
TM8100/TM8200 Service Manual TMAA01-05 Options-Extender Board 487
© Tait Electronics Limited June 2006
19.4.3 Options-Extender Board Layout (top side)
19.4.4 Options-Extender Board Layout (bottom side)
IPN 220-65203-00
IPN 220-65203-00
488 TMAA01-05 Options-Extender Board TM8100/TM8200 Service Manual
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19.4.5 Options-Extender Board Circuit Diagram
TM8100/TM8200 Service Manual TMAA02-02 DTMF Microphone 489
© Tait Electronics Limited June 2006
20 TMAA02-02 DTMF Microphone
The TMAA02-02 DTMF microphone plugs into the
microphone socket on the radio control head, and enables users
to make calls to a PABX or PSTN.
To make a call, enter the required number using the DTMF keypad
and the DTMF microphone generates audible DTMF tones as the
microphone keys are pressed. Press the PTT key and speak clearly
into the microphone then release the PTT key when you have
finished speaking.
The microphone button operates a hookswitch, which is closed
when the microphone is connected to the microphone clip and open
when the microphone is removed from the microphone clip. The
function of the hookswitch is determined by the radio programming.
Note The TMAA02-02 DTMF microphone is not suitable for use with
PTT signalling. An example of PTT signalling is leading ANI.
20.1 Installation
Installing the
Microphone Important The DTMF microphone grommet must be installed when-
ever the microphone is plugged into the microphone
socket. When installed, the grommet has two functions:
■to prevent damage to the microphone socket when
there is movement of the microphone cord, and
■to ensure that the control head is sealed against water,
dust and other environmental hazards.
1. Plug the DTMF microphone cord into the microphone socket on the
radio control head.
2. Slide the microphone grommet along the microphone cord and push
two adjacent corners of the grommet into the microphone socket cavity.
3. Squeeze the grommet and push the remaining corners into position.
4. Check that the grommet is seated correctly in the cavity.
PTT key
grommet
microphone
button not shown
(to rear of
microphone)
Figure 20.1 Correct DTMF microphone grommet seating
microphone
grommet
control head
490 TMAA02-02 DTMF Microphone TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Installing the
Microphone Clip Install the microphone clip in the most convenient location for the radio
user. It must be within easy reach of the user, but in such a position that the
microphone PTT key cannot be inadvertently activated or jammed on.
Connect the microphone clip to the negative supply if hookswitch
operation is required.
20.2 Adjustment
Remove the DTMF microphone back cover and set the DTMF tone level
to approximately 60% deviation (±3kHz for wide bandwidth radios and
±1.5kHz for narrow bandwidth radios).
20.3 Radio Programming
The following table shows the settings required for CH_GPIO1 in the
Programmable I/O form of the programming application. When
CH_GPIO1 is set to Send Mic Audio To Spkr, then DTMF tones are fed
into the radio’s speaker at a reduced volume whenever a key on the DTMF
microphone is pressed. This gives the radio user confidence that the tones
are being transmitted.
Refer to the online help of the programming application for more
information.
Table 20.1 DTMF microphone settings in the Programmable I/O form, Digital tab
Pin Direction Label Action Active Debounce Signal State Mirrored To
CH_GPIO1 Input None Send Mic Audio
To Spkr
High None None None
TM8100/TM8200 Service Manual TMAA02-02 DTMF Microphone 491
© Tait Electronics Limited June 2006
20.4 Interface Specification
The following table and diagram summarizes the signals used for the DTMF
microphone on the radio’s microphone connector and shows the interface
between the DTMF microphone and the radio.
.
Table 20.2 DTMF microphone connector—pins and signals
Pin Signal Colour Description
1 — — not connected
2 13V8_SW red power supply (switched)
3 — yellow not connected
4 MIC_PTT black PTT and hookswitch
5 MIC_AUD white audio from the microphone
6 AGND blue analogue ground
7 — — not connected
8 MIC_GPIO1 green mute out
Figure 20.2 DTMF microphone to radio interface
492 TMAA02-02 DTMF Microphone TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
20.5 Circuit Description
The microphone has a standard 12-key telephone keypad. When one of the
keypad keys is pressed, a DTMF tone specific to that key is generated on the
MIC_AUD line (pin 5). For the duration of the tone, the tone generator
activates the PTT, so that the user is not required to press the PTT key to
transmit each tone.
TM8100/TM8200 Service Manual TMAA02-06 Support Kit for Concealed & Dynamic Microphones 493
© Tait Electronics Limited June 2006
21 TMAA02-06 Support Kit for Concealed &
Dynamic Microphones
The support kit for concealed and dynamic microphones can be
used in two main applications:
■to monitor activity around the radio if the radio is placed in
emergency mode, and
■to support the use of a dynamic microphone, such as that used in
the TMAA10-02 handset.
The concealed and dynamic microphone support board plugs onto
the radio’s control head PCB and contains circuitry for a pre-
amplifier and a microphone switch circuit. The concealed electret
microphone is installed inside the speaker grille of the control head.
21.1 Installation
Important This equipment contains devices which are susceptible to
damage from static discharges. Refer to “ESD Precautions”
on page 108 for more information.
Disassembling the
Radio Control Head To install the concealed-microphone capsule and concealed and dynamic
microphone support board, the control head must be removed from the
radio and disassembled. For detailed disassembly instructions, refer to
“Disassembly and Reassembly” on page 129.
Installing the
Microphone
Capsule and
Dynamic
Microphone Board
1. Disassemble the control head in order to gain access to the speaker
grille. This will mean removing the control head PCB, the space
frame, and the speaker.
2. Drill a 1mm diameter hole in the
concealed-microphone cavity b in
the position indicated by the small
‘dimple’ c.
P2
P3
concealed microphone
(capsule, rubber seal & wires)
concealed & dynamic
microphone support
board
bc
494 TMAA02-06 Support Kit for Concealed & Dynamic Microphones TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Important To maintain the IP54 protection class, great care must be
taken when installing the microphone capsule and seal d
into the concealed-microphone cavity.
3. Push the microphone capsule and seal
into the concealed-microphone
cavity, with the capsule wires e
towards the speaker grille f.
4. Reassemble the control head. This
includes reinstalling the speaker g,
the space frame h and the control
head PCB i.
Plug the speaker lead into the speaker
connector j.
5. On the control head PCB, solder the positive concealed-microphone
wire to the MIC+ pad 1) and the negative wire to AGND 1!.
Note
The positive wire on the microphone capsule is identified by a red stripe.
6. On the control head PCB, remove R11 1@ and
solder P2 1# and P3 1$ in the positions shown.
7. Plug S2 1% and S3 1^ on the concealed and
dynamic microphone support board onto P2
and P3 on the control head PCB.
8. Re-install the control head on the radio body.
21.2 Radio Programming
When the support kit for concealed and dynamic microphones is installed
in a radio, two fields in the UI Preferences form of the programming
application may need to be changed.
■Enable Options Board Preamp: select this field if a dynamic
microphone is installed. An example of an accessory that uses a dynamic
microphone is the TMAA10-02 handset.
■
Emergency Mic
: select
Concealed
if a concealed microphone is installed.
Refer to the online help of the programming application for more information.
efd
1!
h
gij 1#
1@ 1$
1)
1%
1^
TM8100/TM8200 Service Manual TMAA02-06 Support Kit for Concealed & Dynamic Microphones 495
© Tait Electronics Limited June 2006
21.3 Interface Specification
The following table and diagram summarizes the signals used for the
concealed and dynamic microphone support kit and shows the interface
between the support kit and the radio control head.
Table 21.1 Concealed and dynamic microphone support board—pins and signals
Pin Signal Colour
1 CH_LE SPI latch signal to latch microphone select data into
the concealed and dynamic microphone board
2 D2-D3 data from the control head shift register
3 OE enables the output of the shift register of the audio
switch
4 CH_SPI_CLK SPI clock signal to clock microphone select data into
concealed and dynamic microphone board
5 +13V8_SW power for analogue parts
6 +3V3 power for digital parts
7 RST initialise the concealed and dynamic microphone
board shift register
8 DGND digital ground
1 MIC_AUD_IN-P1 microphone audio from microphone interface
2 MIC_AUD_OUT processed microphone signal output to radio
3 — not connected
4 MIC_AUD_OUT processed microphone signal output to radio
5 MIC+ audio from the concealed microphone
6 AGND analogue ground
BDFH
CEGI
S2 top view
BDF
CEG
S3 top view
Figure 21.1 Concealed and dynamic microphone support kit to radio interface
496 TMAA02-06 Support Kit for Concealed & Dynamic Microphones TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Ref. IPN Description Ref. IPN Description
21.4 PCB Information
21.4.1 TMAA02-06 Parts List (PCB IPN 220-01712-01)
C1 015-26330-08 Cap Cer 0805 330n 5% 10v X7r
C2 015-26330-08 Cap Cer 0805 330n 5% 10v X7r
C3 018-15100-00 Cap 0603 10n 50v X7r +-10%
C4 015-26330-08 Cap Cer 0805 330n 5% 10v X7r
C5 018-16100-00 Cap 0603 100n 16vx7r+-10%
C6 018-16100-00 Cap 0603 100n 16vx7r+-10%
C7 018-16100-00 Cap 0603 100n 16vx7r+-10%
C8 018-16100-00 Cap 0603 100n 16vx7r+-10%
C10 018-16100-00 Cap 0603 100n 16vx7r+-10%
IC1 002-13740-53 IC 74LV4053 Mux/Demux Tssop16
IC2 002-13745-95 IC 74LV595 8BIT SHIFTREG TSSOP
Q1 000-10084-71 Xstr BC847BW NPN SOT323
Q2 000-10085-71 Xstr SMD BC857BW PNP SOT323
Q3 000-10084-62 Xstr BC846S Dual SOT363 NPN
Q4 001-10099-01 Diode BAV99w Dual Ss
R1 038-14220-00 Res 0603 2k2 1/16w +-5%
R2 038-14680-00 Res 0603 6k8 1/16w +-5%
R3 038-14470-00 Res 0603 4k7 1/16w +-5%
R4 038-15470-10 Res 0603 47k 1/16w+-1%
R5 038-14100-10 Res 0603 1k0 1/16w +-1%
R6 038-15330-10 Res 0603 33k 1%
R13 038-15100-10 Res 0603 10k 1/16w +-1%
R14 038-14100-10 Res 0603 1k0 1/16w +-1%
R15 038-14100-10 Res 0603 1k0 1/16w +-1%
R16 038-15470-10 Res 0603 47k 1/16w+-1%
R17 038-15150-10 Res 0603 15K 1% WDS
R18 038-15470-10 Res 0603 47k 1/16w+-1%
R20 036-10000-00 Res M/F SMD 0805 0e 0.125w
S2 240-10002-00 Skt SMD 8w 2x4 Lo-Prof 2mm
S3 240-10001-00 Skt SMD 6w 2x3 Lo-Prof 2mm
P2 240-10004-00 Hdr SMD 8w 2x4 Lo-Prof 2mm
P3 240-10003-00 Hdr SMD 6w 2x3 Lo-Prof 2mm
220-01712-01 Pcb Dynamic/Covert Mic
252-00010-41 Mic Capsule Electret 2.7*6mm
369-01031-00 Rbbr Mic Upper A3M2751 T3K
402-00007-XX MANL I/INSTR TMAA02-06
TM8100/TM8200 Service Manual TMAA02-06 Support Kit for Concealed & Dynamic Microphones 497
© Tait Electronics Limited June 2006
21.4.2 Concealed and Dynamic Microphone Support Board (top side)
IPN 220-01712-01
498 TMAA02-06 Support Kit for Concealed & Dynamic Microphones TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
21.4.3 Concealed and Dynamic Microphone Support Board (bottom side)
IPN 220-01712-01
TM8100/TM8200 Service Manual TMAA02-06 Support Kit for Concealed & Dynamic Microphones 499
© Tait Electronics Limited June 2006
21.4.4
Concealed and Dynamic Microphone Board
Circuit Diagram
500 TMAA02-06 Support Kit for Concealed & Dynamic Microphones TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
TM8100/TM8200 Service Manual TMAA02-07 Concealed Microphone 501
© Tait Electronics Limited June 2006
22 TMAA02-07 Concealed Microphone
The concealed microphone can be used to monitor activity around
the radio if the radio is placed in emergency mode, and is installed
beside the speaker grille of the graphical-display control head.
22.1 Installation
Important This equipment contains devices which are susceptible to
damage from static discharges. Refer to “ESD Precautions”
on page 108 for more information.
Removing the Radio
Control Head To install the concealed-microphone capsule, the control head must be
removed from the radio.
Important During this procedure, take care that the control-head seal
is not damaged. Damage to this seal reduces environmental
protection.
1. On the underside of the radio,
insert a 5mm (3/16 inch) flat-
bladed screwdriver between the
control head and the control-head
seal, in either position or .
Insertion points and are
lever points and are indicated on
the radio chassis by a dot-dash-dot pattern (•–•).
2. Use the screwdriver to lift the control head off the chassis clip, then
repeat in the other position.
3. Unplug the control head loom from the radio body.
Installing the
Microphone
Capsule
1. Unscrew the two screws holding the adaptor flange to the control
head. The adaptor flange can now be separated from the control head.
2. Drill a 1mm diameter
hole in the concealed-
microphone cavity b,
in the position
indicated by the small
‘dimple’ c.
concealed microphone
(capsule, rubber seal & wires)
lever point
control-head seal
indication of
lever point
1
2
12
12
c
b
502 TMAA02-07 Concealed Microphone TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Important To maintain the IP54 protection class, great care must be
taken when installing the microphone capsule and seal d
into the concealed-microphone cavity.
3. Push the microphone capsule and
seal into the concealed-
microphone cavity.
4. On the control head PCB, solder
the negative wire to the
COV MIC- pad e and the positive
concealed-microphone wire to the
COV MIC+ pad f.
Note The positive wire on the micro-
phone capsule is identified by a
red stripe.
5. Re-install adaptor flange onto the control head.
6. Plug the control head loom
onto the control
head connector .
7. Insert the bottom edge of the
control head onto the two clips
in the front of the radio
chassis , then snap
into place.
22.2 Radio Programming
When the concealed microphone is installed in a radio for use in emergency
situations, a field in the UI Preferences form, Audio tab of the programming
application may need to be selected.
■Emergency Mic: select Concealed.
Refer to the online help of the programming application for more information.
efd
2
1
2
1
2
TM8100/TM8200 Service Manual TMAA02-08 Keypad Microphone 503
© Tait Electronics Limited June 2006
23 TMAA02-08 Keypad Microphone
The TMAA02-08 keypad microphone plugs into the
microphone socket on the graphical-display radio control
head, and enables users to make calls to other radios, groups,
or to a PABX or PSTN. The types of call that you can make
depends on the way your radio has been programmed.
As well as the PTT key, there are twelve alphanumeric keys,
two scroll keys, and a left and right selection key on the keypad
microphone. The selection keys and scroll keys duplicate the
keys on the control head and the 12 alphanumeric keys on the
keypad microphone are used to dial call strings and enter text.
The microphone button operates a hookswitch, which is
closed when the microphone is connected to the microphone
clip, and open when the microphone is removed from the
microphone clip. The function of the hookswitch is
determined by the way the radio is programmed.
23.1 Operation
Dialling Characters If an incorrect character has been dialled, use the left selection key on either
the microphone keypad or control head to clear it and move
back one character.
Dialling Text
Messages When the keypad microphone is used to enter a text message, the
microphone keys have special functions. Use the key to toggle between
upper and lower case characters and use the left selection key to delete
a character from the display.
The alphanumeric keys to are used to enter letters, numbers and
punctuation. Repeated presses of these keys will give you the characters
shown in the table below.
PTT key
scroll keys
grommet
right selection keyleft selection key
alphanumeric
keys
Key Characters Key Characters
.,?!1 P QRS7
ABC2 T UV8
DE F 3 W XYZ 9
GHI 4 space0
JKL5 *
MN O 6
504 TMAA02-08 Keypad Microphone TM8100/TM8200 Service Manual
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23.2 Installation
Installing the
Microphone Important The keypad microphone grommet must be installed when-
ever the microphone is plugged into the microphone
socket. When installed, the grommet has two functions:
■to prevent damage to the microphone socket when
there is movement of the microphone cord, and
■to ensure that the control head is sealed against water,
dust and other environmental hazards.
1. Make sure the radio is turned off, then plug the keypad microphone
cord into the microphone socket on the radio control head.
Important The radio will only recognize the presence of the keypad
microphone when the radio is powered on, so that if the
microphone is plugged in after the radio has been powered
on, it will not recognize the keypad microphone. Also, if
the keypad microphone is plugged in on power up but is
later unplugged, then plugged back in, the radio will not
recognize it again until the next power cycle.
2. Slide the microphone grommet along the microphone cord and push
two adjacent corners of the grommet into the microphone
socket cavity.
3. Squeeze the grommet and push the remaining corners into position.
4. Check that the grommet is seated correctly in the cavity.
Installing the
Microphone Clip Install the microphone clip in the most convenient location for the radio
user. It must be within easy reach of the user, but in such a position that the
microphone PTT key cannot be inadvertently activated or jammed on.
Figure 23.1 Correct keypad microphone grommet seating
microphone
grommet
control head
TM8100/TM8200 Service Manual TMAA02-08 Keypad Microphone 505
© Tait Electronics Limited June 2006
23.3 Radio Programming
The radio does not need to be programmed to recognize the presence of a
keypad microphone, as this is automatically done when the radio is
powered on. However, there are a few related fields that should be
configured, as required, to enable the keypad microphone to be
used effectively.
Note Yo u must power-cycle the radio after replacing the keypad micro-
phone with a programming lead, in order to read or program
the radio.
UI Preferences Form
(TM8100 radios) Set the Control Head Mic Gain to Low.
Conventional Forms In conventional mode, there are check boxes labelled Selcall Call Dialling,
DTMF Call Dialling and Phone Patch Call Dialling. There is also an
option Conventional Dialling Type field, where you can program the
radio to dial labels or channels from the default display.
Refer to the online help of the programming application for more information
about these programming options.
MPT1327 Trunked
Forms In MPT1327 trunked mode, there may be check boxes labelled DTMF
Dialling, PABX Calls and PSTN Calls. These check boxes need to be
selected before you can make these types of calls.
Refer to the online help of the programming application for more information
about these programming options.
23.4 Interface Specification
The following table and diagram summarizes the signals used for the keypad
microphone on the radio’s microphone connector and shows the interface
between the keypad microphone and the radio.
Table 23.1 Keypad microphone connector—pins and signals
Pin Signal Colour Description
1 RX audio — not connected
2 13.8V black power supply
3 TXD green transmit serial data
4 PTT white PTT and hookswitch
5 MIC blue audio from the microphone
6 GND red ground
7 RXD yellow receive serial data
8 IO — not connected
506 TMAA02-08 Keypad Microphone TM8100/TM8200 Service Manual
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TM8100/TM8200 Service Manual TMAA03-02 Security Bracket 507
© Tait Electronics Limited June 2006
24 TMAA03-02 Security Bracket
The TMAA03-02 security bracket can be used in place of the standard
U-bracket in locations where you want to stop opportunistic removal of the
radio by a third party, or where you want to have a quick release setup that
allows you to swap over radios (e.g. leasing situation). The security bracket
also provides electrical isolation to the radio.
The parts of the TMAA03-02 security bracket are illustrated in Figure 24.1.
Figure 24.1 Parts of the TMAA03-02 security bracket
Description Quantity
Bsecurity bracket cradle base 1 Eshort mounting rails for TM8100 2
Cslide locks 1 left
1 right
screws (M4x25 T/T P/T ContiR) -
for attaching short mounting rails
to TM8100 radio (not pictured)
4
Dslide lock key 2 Ftall mounting rails for TM8200 2
self-tapping screws (10Gx20 hex/
poz) - for fixing security bracket in
place (not pictured)
4 screws (M4x30 T/T P/T ContiR) -
for attaching tall mounting rails to
TM8200 (not pictured)
4
anti-vibration washers for self-
tapping screws (not pictured)
4
Note: B and C are pre-assembled
B
D
Mounting rails (see E and F)
C
F
E
508 TMAA03-02 Security Bracket TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
24.1 Installing the Security Bracket and Radio
24.2 Installation Planning
Before installing the security bracket, make sure that the site you have
chosen for the installation meets the following criteria:
1. The site has enough height for the radio to be easily installed
and removed.
The measurements given at the bottom of Figure 24.1 are the heights
of the radios and base only. Allow extra space for manipulation.
Note You will need more space if you are installing a TM8200 radio.
2. The site has enough depth for the radio.
Check that the front and rear overhang of the radios will fit where you
are mounting the security bracket.
3. The site allows for good air circulation, particularly at the rear of
the radio.
Installation
Procedure Important The security bracket must be securely installed. Otherwise
there is a risk that the whole assembly of the radio and secu-
rity bracket may become loose over time, or as a result of
serious impact.
Note Because some model control heads are taller than others, each
security bracket kit comes with two different heights of mounting
rail and mounting screws, depending on the radio type you
are installing.
Once you have identified a suitable site for the security bracket and radio,
installation is as follows:
1. Use the four self-tapping screws and washers to fix the security
bracket base in place. The base actually has five screw holes available,
but the centre screw hole does not need to be used. The layout and
dimensions of the five screw holes is identical to the T2000 cradle.
2. Depending on whether you are installing a TM8100 or TM8200
radio, select the correct height mounting rails and screws, and attach
a rail to each side of the bottom of the radio body (two screws per rail,
minimum torque 20in.lbf [2.26N.m]).
3. To insert the radio, with the mounting rails attached, into the security
bracket base, check that the left and right slide locks are open.
TM8100/TM8200 Service Manual TMAA03-02 Security Bracket 509
© Tait Electronics Limited June 2006
4. If the slide locks are closed, open them by inserting the slide lock key
into the keyhole. Rotate the key 90° (it will slip into a detent),
and pull.
Two slide lock keys are supplied so that you can either use them both
at once, or so that you can keep one as a spare.
5. Place the radio over the security bracket base so that the feet of the
mounting rails fit securely into the base.
6. Close the slide locks by pressing them into the base. You should hear
an audible click as the internal spring lock mechanism engages.
Warning!! For continued safe operation, replace and do
not re-use Security Bracket once it has been
involved in a crash greater than 50km/h.
24.3 Removing a Radio from the Security Bracket
Remove the radio from the security bracket as follows:
1. Open the slide locks by inserting the slide lock key into the keyhole.
Rotate the key 90° (it will slip into a detent), and pull. The pull will
be need to be quite firm to open each slide lock.
2. Remove the radio and its mounting rails by lifting it up and out of
the security bracket base.
3. If required, remove the mounting rails from the radio body base by
unscrewing them.
24.4 Replacing the Radio in the Security Bracket
To replace the radio in a security bracket, first follow the steps in
“Removing a Radio from the Security Bracket” on page 509, and then
follow from step 2 in “Installing the Security Bracket and Radio” on
page 508.
24.5 Disassembling the Security Bracket
Disassemble the security bracket as follows:
1. Remove the radio from the security bracket by following the steps in
“Removing a Radio from the Security Bracket” on page 509.
2. Unscrew the four self-tapping screws holding the security bracket
base in place.
510 TMAA03-02 Security Bracket TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
24.6 Re-Ordering Extra Parts
The following parts can be re-ordered separately in case of loss, or in
situations where, for example, one security bracket is installed where several
different radios may be installed at different times.
Part Part Number Quantity
Security Crdl Key TM8
(slide lock key)
319-60004-XX1
1. Contact Technical Support for the exact IPN.
2
Security Crdl Mtg Short TM8
(short mounting rails for TM8100)
319-60002-XXa2
Scrw M4*25 T/T P/T ContiR
(for attaching short mounting rails to TM8100 radio)
349-02063-XXa4
Security Crdl Mtg Tall TM8
(tall mounting rails for TM8200)
319-60003-XXa2
Scrw M4*30 T/T P/T ContiR
(for attaching tall mounting rails to TM8200 radio)
349-02068-XXa4
TM8100/TM8200 Service Manual Installing a Remote Kit 511
© Tait Electronics Limited June 2006
25 Installing a Remote Kit
A TMAA03-16 or TMAA03-25 remote kit can be used to install the control
head of a graphical-display radio remotely from the radio body. The diagram
below shows the parts used for this installation.
Note Although the torso interface is similar in appearance to the dual-
RJ45 on the telemetry radio, the control head on the telemetry
radio cannot be used for remote installation.
Note The interfaces in the TMAA03-16 or TMAA03-25 remote kit
appear similar to the TMAA03-03, TMAC34-0T or
TMAC34-1T. However, the interfaces in the remote kits are not
compatible with TMAA03-03, TMAC34-0T or TMAC34-1T
control-head interfaces.
25.1 Installation
Warning!! Mount the remote U-bracket with the remote
control-head assembly and the U-bracket with
the radio body securely. These units must not
break loose in the event of a collision. Unse-
cured radio units are dangerous to the
vehicle occupants.
Caution Observe the installation warnings and safety regula-
tions in the installation procedures of the radio.
Important This equipment contains devices which are susceptible to
damage from static discharges. Refer to “ESD Precautions”
on page 108 for more information.
Note Torx T10 and T20 screwdrivers are required for most of the screws
in this installation.
The circled numbers in the following sections refer to the items in Figure 25.1
on page 512.
remote U-bracket
control-head interface
remote cable torso interface
512 Installing a Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
25.1.1 Overview
Installing the control head remotely is done in six steps:
1. Remove the control head from the radio body, if necessary.
2. Install the torso interface b onto the radio body.
3. Mount the remote U-bracket d in the required position.
4. Install the control-head interface c onto the control head and install
the remote control-head assembly in the remote U-bracket.
5. Mount the U-bracket in the required position and install the radio
body in the U-bracket.
6. Route the remote cable e between the remote control-head
assembly and the radio body.
25.1.2 Parts Required
The following diagram identifies the parts for remote control-
head installation and shows how they fit together.
Figure 25.1 Parts for remote control-head installation
btorso interface hRJ45 bung
ccontrol-head interface icontrol-head interface loom
dremote U-bracket jtorso-interface loom
eremote cable 1) earthing tag
fself-drilling screw 1! earthing-tag screw
gthumb screw 1@ remote cable grommets
c
b
f
g
d
e
i
1)
j
1!
1@
h
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25.1.3 Removing the Control Head from the Radio Body (if necessary)
Caution During this procedure, take care that the control-
head seal is not damaged. Damage to this seal
reduces environmental protection.
1. On the underside of the radio,
insert a 5mm (3/16 inch) flat-
bladed screwdriver between the
control head and the control-head
seal, in the positions shown.
Insertion points and are lever
points and are indicated on the
radio chassis by a dot-dash-dot pattern (•–•).
2. Use the screwdriver to lift the control head off the chassis clip, then
repeat in the other position.
3. Unplug the control-head loom from the radio body.
The control head is now separate from the radio body.
25.1.4 Installing the Torso Interface
The torso interface must be installed onto the radio body, in place of the
control head.
1. Screw the solder tag 1) onto one of the screw bosses on the
radio chassis.
2. Plug the torso-interface loom j
onto the control-head connector.
3. Insert the bottom edge of the
torso interface b onto the two
clips in the front of the radio
chassis, then snap into place.
4. Remove the bung h covering
the outer RJ45 connector. The
remote cable e will plug into this
connector once the installation is complete.
Important The inner RJ45 cavity is not used and has no connector
installed so the RJ45-cavity bung must be installed at
all times.
This ensures that the torso interface is sealed against water,
dust and other environmental hazards.
lever point
control-head seal
indication of
lever point
j
1)
b
h
514 Installing a Remote Kit TM8100/TM8200 Service Manual
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25.1.5 Mounting the Remote U-Bracket
The remote U-bracket with its self-drilling screws, is used to install the remote
control-head assembly on the dashboard or on any sufficiently flat surface.
Caution When drilling holes in the vehicle, check that drilling
at the selected points will not damage existing wiring.
Important Check that the remote U-bracket is not distorted when the
screws are tightened.
1. Drill any holes required for cables and install suitable grommets or
bushings in the holes.
2. If precise positioning is required, predrill 3mm (1/8 inch) pilot
holes for the self-drilling screws. Reduce the hole size in metal that
is less than 1mm (1/32 inch) thick.
3. Screw the remote U-bracket in the chosen mounting position using the
self-drilling screws provided. Use all four screws provided.
25.1.6 Installing the Control-Head Interface
With the control head separated from the radio body, the control-head
interface c must be installed on the rear of the control head.
1. Undo the two Torx T-20 screws
on the adaptor flange of the
control head, and remove the
adaptor flange.
2. Unplug the control-head loom.
The adaptor flange and control-
head loom are not used for the
remote control-head installation.
Keep the two screws for step (4).
3. Plug the control-head interface
loom i into the connector on
the control head.
Important When fitting the control-head interface to the control-
head, be careful not to damage the space-frame seal.
4. Use the two screws from step (2) to fit the control-head interface to
the control head through the two screw holes at the rear of the
control-head interface.
adaptor flange
control head loom
control head
space-frame seal
TM8100/TM8200 Service Manual Installing a Remote Kit 515
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Installing the
Remote Control-
Head Assembly in
the Remote
U-Bracket
1. Position the control-head assembly in the remote U-bracket and
position it for a good viewing angle.
Note Adjusting the contrast on the control-head display may also
improve its readability.
2. Screw the remote control-head assembly into position using the two
thumb screws provided.
25.1.7 Mounting the U-Bracket and Installing the Radio Body
Mounting the
U-Bracket Install the U-bracket on any sufficiently flat surface, using self-drilling screws
and washers.
Caution When drilling holes in the vehicle, check that drilling
at the selected points will not damage existing wiring,
petrol tanks, fuel lines, brake pipes or battery cables.
Important When mounting the U-bracket, check whether the
mounting surface needs to be reinforced.
Important Install the U-bracket using at least four screws.
1. If the U-bracket is being mounted over a curved surface, bend the
U-bracket tabs slightly, to match the surface shape.
2. Drill any holes required for cables and install suitable grommets or
bushings in the holes.
Important Check that the U-bracket is not distorted when the screws
are tightened.
3. If precise positioning is required, predrill 3mm (1/8 inch) pilot
holes for the self-drilling screws. Reduce the hole size in metal that
is less than 1mm (1/32 inch) thick.
4. Screw the U-bracket in the chosen mounting position using the self-
drilling screws washers.
Installing the Radio
Body in the
U-Bracket
1. Connect the antenna and power cables to the rear of the radio.
2. Position the radio body in the U-bracket so that the holes in the
U-bracket line up with the holes in the radio chassis.
3. Screw the radio into position using the four thumb screws.
516 Installing a Remote Kit TM8100/TM8200 Service Manual
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25.1.8 Connecting the Remote Cable
Caution When drilling holes in the vehicle, check that drilling
at the selected points will not damage existing wiring,
petrol tanks, fuel lines, brake pipes or battery cables.
1. Drill any holes required for cables and install suitable grommets or
bushings in the holes.
2. Plug one end of the remote cable into the control-head interface.
3. Run the remote cable to the torso interface and plug it into the
RJ45 connector without a bung.
Installing the
Remote-Cable
Grommets
Install both the remote cable grommets, using the following procedure.
Important The remote cable grommets must be installed whenever the
remote cable is plugged into the RJ45 sockets. When
installed, the grommets have two functions:
■to prevent damage to the RJ45 sockets when there is
movement of the remote cable, and
■
to ensure that the radio and remote control-head assembly
is sealed against water, dust and other environmental
hazards.
1. Slide the grommet along the remote cable and push two adjacent
corners of the grommet into the RJ45 socket cavity.
2. Squeeze the grommet and push the remaining corners into position.
3. Check that the grommet is seated correctly in the cavity.
Figure 25.2 Correct remote cable grommet seating
microphone
grommet
control head
TM8100/TM8200 Service Manual Installing a Remote Kit 517
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25.2 Circuit Description
Figure 25.3 shows a block diagram of the remote control-head installation.
The control heads contain circuit boards with RS-485 driver components
and an audio amplifier or attenuator.
Figure 25.3 Block diagram of remote control-head installation
518 Installing a Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
25.3 Servicing the Remote Kit Parts
25.3.1 Disassembling the Torso Interface
Disassemble only as much as is necessary to replace the defective parts.
Re-assembly is carried out in reverse order of disassembly.
1. Remove the remote cable from the RJ45 connector.
2. Release the clips of the PCB bracket E and remove the control-
head board B.
3. Disconnect the torso-interface loom C.
4. Unscrew the four PT type screws D and remove the PCB bracket E.
Figure 25.4 Parts of the torso interface
Description IPN
Bcontrol-head board
Ctorso-interface loom 219-02882-00
D3 x 8 PT screw (x4) 346-10030-XXa
EPCB bracket 302-10063-XXa
Ffront panel 316-06843-XXa
Glabel 365-01751-XXa
HRJ45 bung 302-50002-XXa
a Contact Technical Support for the exact IPN.
B
D
F
x4
C
G
H
E
TM8100/TM8200 Service Manual Installing a Remote Kit 519
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25.3.2 Disassembling the Control-Head Interface
Disassemble only as much as necessary to replace the defective parts or to
swap the Micromatch connector loom. Re-assembly is carried out in reverse
order of disassembly.
1. Remove the remote cable from the RJ45 connector.
2. Unscrew the seven PT type screws B and remove the PCB C.
3. Remove the control-head interface loom (not illustrated).
Figure 25.5 Parts of the control-head interface
Description IPN
B3 x 8 PT screw (x5) 346-10030-XXa
Ccontrol-head interface PCB
Dcontrol-head interface 316-06842-XXa
control-head interface loom219-02914-00
a Contact Technical Support for the exact IPN.
D
x5
B
C
Ref. IPN Description Ref. IPN Description
520 Installing a Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
C101 015-06470-01 Cap Cer 1206 470n X7r 20% 50v
C102 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C103 015-07220-08 Cap Cer 1206 2u2 16v X7r
C104 015-07220-08 Cap Cer 1206 2u2 16v X7r
C105 015-26220-18 CAP CER 0805 220N 10% X7R 50V
C106 018-14470-00 Cap 0603 4n7 50v X7r±10%
C107 015-23270-05 Cap 0805 270p 1% 200v Grm40
C108 015-23270-05 Cap 0805 270p 1% 200v Grm40
C109 018-14470-00 Cap 0603 4n7 50v X7r±10%
C110 015-23270-05 Cap 0805 270p 1% 200v Grm40
C111 015-23270-05 Cap 0805 270p 1% 200v Grm40
C112 015-07220-08 Cap Cer 1206 2u2 16v X7r
C113 018-14470-00 Cap 0603 4n7 50v X7r±10%
C114 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C115 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C116 015-07220-08 Cap Cer 1206 2u2 16v X7r
C117 015-07470-20 CAP Cer 1206 4u7 10% 25V X7R
D101 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D102 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D103 001-10153-00 Diode SMD SM15T30a TranSIl Smc
D104 001-00010-47 Diode 1SMA5923 8v2 1.5w Zen
D105 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D106 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D107 001-10084-33 Diode SMD BZX84C3V3 Zen SOT23
E101 057-10020-02 Ind 0603 BlM18pg300 Emi Supr
E102 057-10020-02 Ind 0603 BlM18pg300 Emi Supr
E103 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E104 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E105 057-10020-02 Ind 0603 BlM18pg300 Emi Supr
E106 057-10020-02 Ind 0603 BlM18pg300 Emi Supr
E107 057-10020-02 Ind 0603 BlM18pg300 Emi Supr
E108 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E109 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
F101 265-10150-00 Fuse SMD 1A 50V 0805 UL Cert
J100 240-00016-00 Conn RJ45 Shld 8P8C LP RA TH
J101 240-10000-11 Conn SMD 18w Skt M/Match
Q101 000-10084-73 Xstr BC847BPNNPN/PNP SOT363
R101 038-10000-00 Res 0603 Zero 0hm 1/16w ± 5%
R102 036-03100-10 Res 2512 100R 5% 1W
R103 036-03100-10 Res 2512 100R 5% 1W
R104 038-13100-10 Res 0603 100R 1/10w 1%
R105 038-15100-10 Res 0603 10k 1/10w 1%
R106 038-14220-00 Res 0603 2k2 1/10w 5%
R107 038-15100-10 Res 0603 10k 1/10w 1%
R108 038-13560-10 Res 0603 560R 1/10w 1%
R109 038-13100-10 Res 0603 100R 1/10w 1%
R110 036-02270-10 Res 1206 27.0e 1%
R111 036-02270-10 Res 1206 27.0e 1%
R112 038-13100-10 Res 0603 100R 1/10w 1%
R113 038-12100-10 Res 0603 10e 1%
R114 038-15100-10 Res 0603 10k 1/10w 1%
R115 038-16150-10 Res 0603 150k 1%
R116 038-16330-10 Res 0603 330k 1/10w 1%
R117 038-14270-00 Res 0603 2k7 1/10w 5%
R118 038-13560-10 Res 0603 560R 1/10w 1%
R119 038-16100-10 Res 0603 100k 1/10w 1%
R120 038-14220-00 Res 0603 2k2 1/10w 5%
R121 038-13560-10 Res 0603 560R 1/10w 1%
R122 038-13390-10 Res 0603 390R 1/10w 1%
R123 038-16100-10 Res 0603 100k 1/10w 1%
U101 002-10078-00 IC SMD MC78M05CDT5v Reg0.5a
U102 002-10014-85 IC ADM1485 RS485 Transc S08
220-02122-02 PCB MFx Single Rmt Head I/F
Mechanical Parts for the Control-Head Interface and
the Torso Interface
219-02882-00 Loom Control Head TMA
219-02914-00 Loom MFX Remote Head
219-02918-00 Cbl Rmt Ctrl Hd Kit
302-10062-00 Brkt Remote Head TM8200
302-10063-00 Brkt PCB Remote TM8200 Body
316-06842-00 Pnl Rear TM8200 MF2
316-06843-00 Pnl Frt Remote TM8200 MF0
349-02062-00 Scrw M3*8 T/T P/T ContiR
402-00020-00 F/Inst TMAA03-16 Sngl Hd Rmt
302-05263-00 Brkt U Thumb Scrw TMA
302-50002-00 Bung RJ45 MFO
353-05007-00 Wshr Rubber M4*19*1.0 S/A
354-01052-00 Fsnr Bush PSM SHK-B-M4 Ins
349-00060-00 Scrw 10GX20 SLFDRL Hex/Poz TMA
Remote Cable Parts
219-02918-00 Cbl Rmt Ctrl Hd Kit, comprising:
240-02158-00 Conn Shld RJ45 Shortbody Plg
360-02022-00 Grommet Mic TMA
25.4 PCB Information
25.4.1 Control-Head Interface (PCB IPN 220-02122-02)
Parts List
TM8100/TM8200 Service Manual Installing a Remote Kit 521
© Tait Electronics Limited June 2006
Ref. PCB Circuit Ref. PCB Circuit Ref. PCB Circuit
C101 F3 1D2
C102 F2 1D3
C103 K1 1D5
C104 F4 1E3
C105 E4 1D3
C106 G1 1C4
C107 F1 1C2
C108 G1 1C3
C109 E4 1C3
C110 F4 1B2
C111 F4 1B2
C112 M3 1E5
C113 M3 1D5
C114 M3 1E6
C115 M3 1D6
C116 M4 1D6
C117 M4 1D6
D101 J2 1C4 1C5
D102 J1 1C4
D103 G4 1E2
D104 J4 1E3
D105 F4 1D4 1D3
D106 D4 1B2
D107 M4 1D7
E101 F3 1B2
E102 F4 1B3
E103 G1 1C3
E104 G1 1C3
E105 K3 1D1
E106 D3 1D1
E107 E4 1D2
E108 E4 1C2
E109 K1 1D5
F101 F3 1D2
J100 E4 1C1
J101 L2 1C7
MT100 A3 1E1
MT101 J3 1E1
Q101 M2 1E5
R101 K3 1D1
R102 G4 1E3
R103 G4 1E3
R104 D4 1B3
R105 K1 1B6
R106 K2 1C5
R107 K2 1B5
R108 M2 1B6
R109 E4 1D3
R110 G2 1C4
R111 G1 1C4
R112 G1 1C4
R113 M2 1E4
R114 M3 1E5
R115 M3 1E6
R116 M3 1E6
R117 M2 1D5
R118 M3 1D5
R119 M3 1D6
R120 M3 1D6
R121 M4 1E7
R122 L4 1D6
R123 K2 1B6
U101 G3 1D3
U102 K1 1C5
Grid Reference List
522 Installing a Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Board Layout
IPN 220-02122-02
TM8100/TM8200 Service Manual Installing a Remote Kit 523
© Tait Electronics Limited June 2006
Circuit Diagram
Ref. IPN Description Ref. IPN Description
Ref. PCB Circuit Ref. PCB Circuit Ref. PCB Circuit
524 Installing a Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
C1 015-06470-01 Cap Cer 1206 470n X7r 20% 50v
C2 018-14470-00 Cap 0603 4n7 50v X7r±10%
C3 015-07220-08 Cap Cer 1206 2u2 16v X7r
C4 018-13470-00 Cap 0603 470p 50v X7r±10%
C5 018-13470-00 Cap 0603 470p 50v X7r±10%
C6 018-14470-00 Cap 0603 4n7 50v X7r±10%
C7 015-23270-05 Cap 0805 270p 1% 200v Grm40
C8 015-23270-05 Cap 0805 270p 1% 200v Grm40
C9 018-15330-00 Cap 0603 33n 50v X7r10%
C10 015-23270-05 Cap 0805 270p 1% 200v Grm40
C11 015-23270-05 Cap 0805 270p 1% 200v Grm40
D1 001-10000-99 Diode SMD BAV99 D-Sw SOT23
DS1 008-00014-74 LED Hp Red Rang PCB Mtg
D2 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D3 001-10000-99 Diode SMD BAV99 D-Sw SOT23
E1 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E2 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E3 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E4 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E5 057-10020-02 Ind 0603 BlM18pg300 Emi Supr
J1 240-10000-11 Conn SMD 18w Skt M/Match
J3 240-00016-00 Conn RJ45 Shld 8P8C LP RA TH
Q1 000-10561-60 XSTR BCX56-16 AF NPN SOT89
R1 038-13100-10 Res 0603 100R 1/10w 1%
R3 038-15100-10 Res 0603 10k 1/10w 1%
R4 038-13100-10 Res 0603 100R 1/10w 1%
R5 038-16100-10 Res 0603 100k 1/10w 1%
R6 038-14220-00 Res 0603 2k2 1/10w 5%
R7 038-15100-10 Res 0603 10k 1/10w 1%
R8 038-13560-10 Res 0603 560R 1/10w 1%
R9 038-13560-10 Res 0603 560R 1/10w 1%
R10 036-02270-10 Res 1206 27.0e 1%
R11 036-02270-10 Res 1206 27.0e 1%
R12 038-13120-00 Res 0603 120R 1/10w 5%
R13 038-16100-10 Res 0603 100k 1/10w 1%
R14 036-05100-01 Res M/F 1206 10k 5%
U1 002-10078-00 IC SMD MC78M05CDT5v Reg0.5a
U2 002-10014-85 IC ADM1485 RS485 Transc S08
220-02123-01 PCB Single Rmt Radio I/F
25.4.2 RJ-45 Control Head (PCB IPN 220-02123-01)
Parts List
Grid Reference List
C1 F2 1B1
C10 M2 1B6
C11 M2 1B7
C2 H2 1D3
C3 J1 1D4
C4 J2 1D5
C5 L2 1D5
C6 L2 1C6
C7 M2 1C6
C8 M2 1C6
C9 N2 1C6
D1 K2 1C4 1D4
D2 K1 1C5 1D5
D3 L2 1D6 1E6
DS1 F2 1B1
E1 L2 1C5
E2 M2 1B6
E3 M2 1D6
E4 L2 1C6
E5 N2 1D6
J1 H2 1D1
J3 N2 1C7
MT1 R2 1B4
Q1 F2 1B1
R1 F2 1B1
R10 L2 1D5
R11 L2 1C5
R12 L2 1C5
R13 L2 1D5
R14 M2 1E6
R2 H2 1D2
R3 G2 1D3
R4 H2 1D3
R5 K2 1D3
R6 J2 1D4
R7 J2 1D4
R8 K1 1D5
R9 L2 1C5
TP2 M1 1B4
U1 D2 1B2
U2 K1 1C4
TM8100/TM8200 Service Manual Installing a Remote Kit 525
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Board Layout
IPN 220-02123-01
526 Installing a Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Circuit Diagram
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 527
© Tait Electronics Limited June 2006
26 Installing an Enhanced Remote Kit
The control head of a graphical-display radio can be installed remotely from
the radio body. The diagram below shows the parts used for this installation.
Note Although the torso interface is similar in appearance to the RJ45
control head on the telemetry radio, the control head on the
telemetry radio cannot be used for remote installation.
26.1 Installation
Warning!! Mount the remote U-bracket with the remote
control-head assembly and the U-bracket with
the radio body securely. These units must not
break loose in the event of a collision. Unse-
cured radio units are dangerous to the
vehicle occupants.
Caution Observe the installation warnings and safety regula-
tions in the installation procedures of the radio.
Important This equipment contains devices which are susceptible to
damage from static discharges. Refer to “ESD Precautions”
on page 108 for more information.
Note Torx T10 and T20 screwdrivers are required for most of the screws
in this installation.
The circled numbers in the following sections refer to the items in Figure 26.1
on page 528.
TMAA03-03 remote
control-head back
(includes remote U-bracket)
TMAA04-01 remote cable
TMAC34-0T (TM8200) or
TMAC34-1T(TM9100)
torso interface
remote U-bracket
control-head interface
528 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
26.1.1 Overview
Installing the control head remotely is done in six steps:
1. Remove the control head from the radio body, if necessary.
2. Install the torso interface b onto the radio body.
3. Mount the remote U-bracket d in the required position.
4. Install the control-head interface c onto the control head and install
the remote control-head assembly in the remote U-bracket.
5. Mount the U-bracket in the required position and install the radio
body in the U-bracket.
6. Route the remote cable e between the remote control-head
assembly and the radio body.
26.1.2 Parts Required
The following diagram identifies the parts for remote control-
head installation and shows how they fit together.
Figure 26.1 Parts for remote control-head installation
btorso interface hRJ45 bung
ccontrol-head interface icontrol-head interface loom
dremote U-bracket jtorso-interface loom
eremote cable 1) earthing tag
fself-drilling screw 1! earthing-tag screw
gthumb screw 1@ remote cable grommets
c
b
f
g
d
e
h
i
1)
j
1!
1@
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 529
© Tait Electronics Limited June 2006
26.1.3 Removing the Control Head from the Radio Body (if necessary)
Caution During this procedure, take care that the control-
head seal is not damaged. Damage to this seal
reduces environmental protection.
1. On the underside of the radio,
insert a 5mm (3/16 inch) flat-
bladed screwdriver between the
control head and the control-head
seal, in the positions shown.
Insertion points and are lever
points and are indicated on the
radio chassis by a dot-dash-dot pattern (•–•).
2. Use the screwdriver to lift the control head off the chassis clip, then
repeat in the other position.
3. Unplug the control-head loom from the radio body.
The control head is now separate from the radio body.
26.1.4 Installing the Torso Interface
The torso interface must be installed onto the radio body, in place of the
control head.
1. Screw the solder tag 1) onto one of the screw bosses on the
radio chassis.
2. Plug the torso-interface loom j
onto the control-head connector.
3. Insert the bottom edge of the
remote control head b onto the
two clips in the front of the radio
chassis, then snap into place.
4. Remove one of the bungs h
covering the RJ45 connectors.
The remote cable e will plug
into this connector once the installation is complete.
If the remote cable is not installed in the RJ45 cavity, then
the RJ45 bung must be installed. This ensures that the torso
interface is sealed against water, dust and other
environmental hazards.
lever point
control-head seal
indication of
lever point
j
1)
b
h
530 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
26.1.5 Mounting the Remote U-Bracket
The remote U-bracket with its self-drilling screws, is used to install the remote
control-head assembly on the dashboard or on any sufficiently flat surface.
Caution When drilling holes in the vehicle, check that drilling
at the selected points will not damage existing wiring.
Important Check that the remote U-bracket is not distorted when the
screws are tightened.
1. Drill any holes required for cables and install suitable grommets or
bushings in the holes.
2. If precise positioning is required, predrill 3mm (1/8 inch) pilot
holes for the self-drilling screws. Reduce the hole size in metal that
is less than 1mm (1/32 inch) thick.
3. Screw the remote U-bracket in the chosen mounting position using the
self-drilling screws provided. Use all four screws provided.
26.1.6 Installing the Control-Head Interface
With the control head separated from the radio body, the control-head
interface c must be installed on the rear of the control head.
1. Undo the two Torx T-20 screws
on the adaptor flange of the
control head, and remove the
adaptor flange.
2. Unplug the control-head loom.
The adaptor flange and control-
head loom are not used for the
remote control-head installation.
Keep the two screws for step (4).
3. Plug the control-head interface
loom i into the connector on
the control head.
Important When fitting the control-head interface to the control-
head, be careful not to damage the space-frame seal.
4. Use the two screws from step (2) to fit the control-head interface to
the control head through the two screw holes at the rear of the
control-head interface.
Changing the
Remote U-Bracket
Orientation
The control-head interface is configured for installation with the RJ45
socket facing downwards (U-bracket below control head, as in Figure 26.1).
If the RJ45 socket is required to face upwards (control head hanging from
adaptor flange
control head loom
control head
space-frame seal
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 531
© Tait Electronics Limited June 2006
U-bracket), the control-head interface loom i must be moved, so that it
can reach the control head connector.
To move the control-head interface loom:
1. Undo the seven Torx T-10 screws on the control-head board, and
remove the control-head interface board from the
control-head interface.
2. Change the control-head interface loom i to the
opposite connector.
3. Reinstall the control-head interface board.
Installing the
Remote Control-
Head Assembly in
the Remote
U-Bracket
1. Position the control-head assembly in the remote U-bracket and
position it for a good viewing angle.
Note Adjusting the contrast on the control-head display may also
improve its readability.
2. Screw the remote control-head assembly into position using the two
thumb screws provided.
26.1.7 Mounting the U-Bracket and Installing the Radio Body
Mounting the
U-Bracket Install the U-bracket on any sufficiently flat surface, using self-drilling screws
and washers.
Caution When drilling holes in the vehicle, check that drilling
at the selected points will not damage existing wiring,
petrol tanks, fuel lines, brake pipes or battery cables.
Important When mounting the U-bracket, check whether the
mounting surface needs to be reinforced.
Important Install the U-bracket using at least four screws.
1. If the U-bracket is being mounted over a curved surface, bend the
U-bracket tabs slightly, to match the surface shape.
2. Drill any holes required for cables and install suitable grommets or
bushings in the holes.
Important Check that the U-bracket is not distorted when the screws
are tightened.
3. If precise positioning is required, predrill 3mm (1/8 inch) pilot
holes for the self-drilling screws. Reduce the hole size in metal that
is less than 1mm (1/32 inch) thick.
532 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
4. Screw the U-bracket in the chosen mounting position using the self-
drilling screws washers.
Installing the Radio
Body in the
U-Bracket
1. Connect the antenna and power cables to the rear of the radio.
2. Position the radio body in the U-bracket so that the holes in the
U-bracket line up with the holes in the radio chassis.
3. Screw the radio into position using the four thumb screws.
26.1.8 Connecting the Remote Cable
Caution When drilling holes in the vehicle, check that drilling
at the selected points will not damage existing wiring,
petrol tanks, fuel lines, brake pipes or battery cables.
1. Drill any holes required for cables and install suitable grommets or
bushings in the holes.
2. Plug one end of the remote cable into the control-head interface.
3. Run the remote cable to the torso interface and plug it into the
RJ45 connector without a bung.
Installing the
Remote-Cable
Grommets
Install both the remote cable grommets, using the following procedure.
Important The remote cable grommets must be installed whenever the
remote cable is plugged into the RJ45 sockets. When
installed, the grommets have two functions:
■to prevent damage to the RJ45 sockets when there is
movement of the remote cable, and
■
to ensure that the radio and remote control-head assembly
is sealed against water, dust and other environmental
hazards.
1. Slide the grommet along the remote cable and push two adjacent
corners of the grommet into the RJ45 socket cavity.
2. Squeeze the grommet and push the remaining corners into position.
3. Check that the grommet is seated correctly in the cavity.
Figure 26.2 Correct remote cable grommet seating
microphone
grommet
control head
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 533
© Tait Electronics Limited June 2006
26.2 Circuit Description
Figure 26.3 shows a block diagram of the remote control-head installation.
Both control heads contain a circuit board with audio amplifiers and RS-
485 driver components.
Figure 26.3 Block diagram of remote control-head installation
534 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
26.3 Servicing the Remote Control-Head Installation Parts
26.3.1 Disassembling the Torso Interface
Disassemble only as much as is necessary to replace the defective parts.
Re-assembly is carried out in reverse order of disassembly.
1. Release the clip of the PCB bracket E and remove the control-
head board B.
2. Disconnect the torso-interface loom C.
3. Unscrew the four PT type screws D and remove the PCB bracket E.
Figure 26.4 Parts of the torso interface
Description IPN
Bcontrol-head board
Ctorso-interface loom 219-02882-XXa
D3 x 8 PT screw (x4) 346-10030-XXa
EPCB bracket 302-10063-XXa
Ffront panel 316-06843-XXa
Glabel 365-01751-XXa
HRJ45 bung 302-50002-XXa
a Contact Technical Support for the exact IPN.
B
D
F
x4
C
G
H
E
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 535
© Tait Electronics Limited June 2006
26.3.2 Disassembling the Control-Head Interface
Disassemble only as much as necessary to replace the defective parts or to
swap the Micromatch connector loom. Re-assembly is carried out in reverse
order of disassembly.
1. Unscrew the seven PT type screws B and remove the PCB C.
2. Remove the control-head interface loom (not illustrated).
Figure 26.5 Parts of the control-head interface
Description IPN
B3 x 8 PT screw (x7) 346-10030-XXa
Ccontrol-head interface PCB
Dcontrol-head interface 316-06842-XXa
control-head interface loom219-02914-XXa
a Contact Technical Support for the exact IPN.
D
x7
B
C
Ref. IPN Description Ref. IPN Description
536 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
26.4 PCB Information
26.4.1 TMAA03-03 Control-Head Interface (PCB IPN 220-01721-04)
Parts List
C1 016-08100-03 Cap Elec SMD 10uF 35V 105/2000
C100 018-14100-00 Cap 0603 1n 50v X7r ±10%
C101 018-14100-00 Cap 0603 1n 50v X7r ±10%
C102 015-02470-06 Cap Cer 1210 47p NPO 500v
C103 015-02470-06 Cap Cer 1210 47p NPO 500v
C110 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C300 015-06470-01 Cap Cer 1206 470n X7r 20% 50v
C301 016-07470-01 Cap Elec SMD 4u7 6*4 16v 20%
C310 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C312 014-07470-05 Cap Tant SMD 4u7 16v 10% A
C320 016-08100-03 Cap Elec SMD 10uF 35V 105/2000
C400 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C401 015-07220-08 Cap Cer 1206 2u2 16v X7r
C410 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C411 018-13100-00 Cap 0603 100p 50v NPO ±5%
C420 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C421 018-13100-00 Cap 0603 100p 50v NPO ±5%
C422 015-07220-08 Cap Cer 1206 2u2 16v X7r
C423 015-07220-08 Cap Cer 1206 2u2 16v X7r
C430 015-07220-08 Cap Cer 1206 2u2 16v X7r
C500 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C600 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C601 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C610 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C611 015-07220-08 Cap Cer 1206 2u2 16v X7r
C612 015-07220-08 Cap Cer 1206 2u2 16v X7r
C700 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C701 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C702 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C703 015-06470-01 Cap Cer 1206 470n X7r 20% 50v
C704 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C705 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C706 018-13220-00 Cap 0603 220p 50v NPO±5%
C707 015-06470-01 Cap Cer 1206 470n X7r 20% 50v
C708 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C710 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C711 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C712 015-07220-35 Cap Cer 1210 2u2 X5R 35v
C730 015-26220-18 CAP CER 0805 220N 10% X7R 50V
C731 015-26220-18 CAP CER 0805 220N 10% X7R 50V
C732 018-14100-00 Cap 0603 1n 50v X7r ±10%
C733 018-14100-00 Cap 0603 1n 50v X7r ±10%
C734 015-07220-08 Cap Cer 1206 2u2 16v X7r
C735 015-07220-08 Cap Cer 1206 2u2 16v X7r
D100 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D101 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D102 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D103 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D104 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D110 001-10084-91 Diode SMD BZX84C9V1 Zen SOT23
D201 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D211 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D300 001-10000-99 Diode SMD BAV99 D-Sw SOT23
D720 001-10841-10 Diode SMD BZX84C11v ZEN SOT23
D730 001-10014-03 Diode SMD MBRS140T3 Sch
D731 001-10014-03 Diode SMD MBRS140T3 Sch
E100 057-10081-06 Ind 1806 Blm41p750s Emi Supr
E101 057-10081-06 Ind 1806 Blm41p750s Emi Supr
E102 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E103 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E105 057-10081-06 Ind 1806 Blm41p750s Emi Supr
E710 057-10600-05 Ind 0603 Blm11p600s .5a F/Bead
E711 057-10081-06 Ind 1806 Blm41p750s Emi Supr
E730 057-10081-06 Ind 1806 Blm41p750s Emi Supr
E731 057-10081-06 Ind 1806 Blm41p750s Emi Supr
J100 240-00016-00 Conn RJ45 Shld 8P8C LP RA TH
J200 240-10000-11 Conn SMD 18w Skt M/Match
J201 240-10000-11 Conn SMD 18w Skt M/Match
L712 057-10100-65 Ind SMD Pwr Cdrh6D38 100UH .65
L730 057-10470-10 Ind SMD Pwr CDRH104R 47uH 1A
L731 057-10470-10 Ind SMD Pwr CDRH104R 47uH 1A
Q610 000-10084-71 Xstr BC847BW NPN SOT323
Q720 000-10084-71 Xstr BC847BW NPN SOT323
Q721 000-10442-71 Xstr SI4427BDY PCH MOSFET SO8
R100 038-13100-10 RES 0603 100R 1% 1/10W
R110 038-15100-10 RES 0603 10k 1% 1/10W
R200 038-13100-10 RES 0603 100R 1% 1/10W
R201 038-13100-10 RES 0603 100R 1% 1/10W
R202 038-13100-10 RES 0603 100R 1% 1/10W
R210 038-13100-10 RES 0603 100R 1% 1/10W
R211 038-13100-10 RES 0603 100R 1% 1/10W
R212 038-13100-10 RES 0603 100R 1% 1/10W
R320 036-00000-01 RES 1206 0R 5% 0.25W
R401 038-15820-10 RES 0603 82k 1% 1/10W
R402 038-15820-10 RES 0603 82k 1% 1/10W
R410 038-15150-10 RES 0603 15k 1% 1/10W
R411 038-16150-10 RES 0603 150k 1% 1/10W
R412 038-13100-10 RES 0603 100R 1% 1/10W
R420 038-15330-10 RES 0603 33k 1% 1/10W
R421 038-15220-10 RES 0603 22k 1% 1/10W
R422 038-12470-00 RES 0603 47R 5% 1/10W
R430 038-14220-00 RES 0603 2k2 5% 1/10W
R431 038-14220-00 RES 0603 2k2 5% 1/10W
R441 038-14470-10 Res 0603 4k7 1% 100ppm
R442 038-14470-10 Res 0603 4k7 1% 100ppm
R501 038-15100-10 RES 0603 10k 1% 1/10W
R510 038-13120-00 RES 0603 120R 5% 1/10W
R511 038-10000-00 RES 0603 0R
R600 038-15100-10 RES 0603 10k 1% 1/10W
R601 038-16470-00 RES 0603 470k 5% 1/10W
R602 038-10000-00 RES 0603 0R
R603 038-10000-00 RES 0603 0R
R604 038-10000-00 RES 0603 0R
R605 038-10000-00 RES 0603 0R
R606 038-15100-10 RES 0603 10k 1% 1/10W
R607 038-15100-10 RES 0603 10k 1% 1/10W
R608 038-15100-10 RES 0603 10k 1% 1/10W
R609 038-15100-10 RES 0603 10k 1% 1/10W
R611 038-15100-10 RES 0603 10k 1% 1/10W
R612 038-14470-10 Res 0603 4k7 1% 100ppm
Ref. IPN Description Ref. IPN Description
Ref. PCB Circuit Ref. PCB Circuit Ref. PCB Circuit
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 537
© Tait Electronics Limited June 2006
R701 038-16120-10 RES 0603 120k 1% 1/10W
R710 036-13100-10 RES 0805 100R 1% 1/8W
R720 038-15100-10 RES 0603 10k 1% 1/10W
R721 038-14220-00 RES 0603 2k2 5% 1/10W
R722 038-14470-10 Res 0603 4k7 1% 100ppm
R730 038-12470-00 RES 0603 47R 5% 1/10W
R731 038-12470-00 RES 0603 47R 5% 1/10W
U300 002-10800-00 IC LDO REG LF80C 8V@1A PPAKT/R
U310 002-14931-00 IC L4931CD33 3.3v 250Ma Regso8
U400 002-19120-00 IC TS912ID Cmos R2R Opamp
U500 002-13483-00 IC XCVR RS485 LTD SLEW RATE 3V
U600 002-15595-00 IC 74AHC595 8bit Shiftreg Tsop
U610 002-10126-71 IC SMD DS1868 Dgtl Pot Tsop20
U700 002-13001-00 IC TPA3001 20W Mono PA TSSOP24
220-01721-04 PCB MFX Head Remote
219-02914-00 LOOM MFX Remote Head
302-05263-00 Brkt U Thumb Scrw TMA
302-10062-00 Brkt Remote Head TM8200
316-06842-00 Pnl Rear TM8200 MF2
346-10030-08 Scrw P/T Wn1412 Kc30x08 Zbc
349-00060-00 Scrw 10G*20 SLFDRL Hex/Poz TMA
353-05007-00 Wshr Rubber M4*19*1.0 S/A
354-01052-00 Fsnr Bush PSM SHK-B-M4 Ins
402-00015-00 MANL f/instr TMAA03-05
410-01183-02 Pkg Box 220x82x65 TMA
410-01197-01 Pkg Ins Lg Ctrl Hd TMA
TMAA04-01 Remote Cable Parts
219-02918-00 Cbl Rmt Ctrl Hd Kit, comprising:
219-00025-00 loom 6m shld Bonded+Drain
240-02158-00 Conn Shld RJ45 Shortbody Plg
360-02022-00 Grommet Mic TMA
Grid Reference List
C1 D1 D7
C100 J3 E3
C101 L4 E3
C102 J4 E3
C103 J4 E3
C110 L4 F4
C300 M5 G2
C301 N5 G3
C310 M2 G4
C311 N2 G4
C312 M2 G5
C320 P4 D8
C400 L3 G10
C401 L3 G10
C410 M3 G8
C411 M3 G8
C420 L3 G5
C421 L3 G6
C422 K3 F7
C423 K3 F7
C430 M2 G9
C500 L4 F6
C600 L2 C3
C601 L2 B2
C610 K1 C5
C611 K1 C4
C612 J2 C5
C700 F2 C6
C701 G3 C7
C702 E3 C7
C703 E2 C6
C704 G2 C6
C705 F2 B6
C706 E3 B6
C707 E2 B6
C708 G2 A6
C710 E2 D6
C711 F2 D7
C712 E2 D7
C720 F1 D2
C721 G1 D2
C730 E3 B8
C731 G3 A8
C732 F4 B9
C733 G4 B9
C734 F4 B10
C735 F4 B9
D100 K3 F4
E4
D101 K4 E4
F4
D102 K4 F4
E4
D103 K4 E5
F5
D104 K5 E5
D110 L5 F3
D201 K5 E8
D211 K5 C9
D300 N5 G3
D301 M5 G2
D720 G1 D2
D730 F3 B7
D731 G3 B7
E100 J5 E2
E101 H5 E2
E102 K4 F3
E103 K4 E4
E105 H5 F2
E710 F2 D7
E711 E2 D7
E730 E4 B8
E731 G4 B8
J100 H4 E1
J200 P3 E10
J201 B4 C10
L712 D2 D8
L730 E4 B9
L731 G4 B9
MT800 D3 B5
MT801 M3 B5
Q610 K1 D4
Q720 F1 D2
Q721 G2 D3
R100 J3 F2
R110 L4 F3
R200 N4 F8
R201 R3 E8
R202 R2 E8
R203 J5 E1
R210 C3 D9
R211 B3 C9
R212 B4 C9
R213 J5 D1
R320 N4 E8
R321 M4 E8
R401 L3 G10
R402 L3 G10
R410 M3 G8
R411 M3 G7
R412 L4 G7
R420 L3 G6
R421 L3 G6
R422 K3 F7
R430 M2 G9
R431 M2 G9
R440 K3 E5
R441 K3 D5
R442 J3 D5
R501 M4 E7
R510 K4 F6
R511 K4 F6
R600 L2 B1
R601 L2 B2
R602 L1 C1
R603 L2 C1
R604 L2 B1
R605 L2 B3
R606 M2 B3
R607 M2 B3
R608 M2 B3
R609 M2 B4
R610 J2 B5
R611 K1 C4
R612 K1 D4
R701 E3 B6
R710 F2 D6
R720 F1 D1
R721 F1 D2
R722 G1 D2
R730 E3 B7
R731 G3 A7
U300 P5 G3
U310 N2 G4
U400 L3 F6
G7
1G9
U500 L4 F7
U600 L2 B2
U610 K2 B4
U700 F3 B7
538 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Board Layout
IPN 220-01721-04
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 539
© Tait Electronics Limited June 2006
Circuit Diagram
Ref. IPN Description Ref. IPN Description
Ref. PCB Circuit Ref. PCB Circuit Ref. PCB Circuit
540 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
C1 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C2 015-07470-20 CAP Cer 1206 4u7 10% 25V X7R
C3 015-06470-01 Cap Cer 1206 470n X7r 20% 50v
C4 018-13100-00 Cap 0603 100p 50v NPO ±5%
C7 015-27100-08 Cap Cer 0805 X7R 1uF 16V 10%
C9 018-13100-00 Cap 0603 100p 50v NPO ±5%
C10 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C13 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C15 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C17 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C101 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C102 015-07470-20 CAP Cer 1206 4u7 10% 25V X7R
C103 015-07470-20 CAP Cer 1206 4u7 10% 25V X7R
C203 018-13270-00 Cap 0603 270p 50v NPO±5%
C207 018-13270-00 Cap 0603 270p 50v NPO±5%
C209 018-13270-00 Cap 0603 270p 50v NPO±5%
C213 018-13270-00 Cap 0603 270p 50v NPO±5%
DS1 008-00014-73 LED Hp Grn Rang PCB Mtg
J1 240-10000-11 Conn SMD 18w Skt M/Match
J2 240-00016-00 Conn RJ45 Shld 8P8C LP RA TH
J3 240-00016-00 Conn RJ45 Shld 8P8C LP RA TH
R1 038-13120-00 RES 0603 120R 5% 1/10W
R2 038-10000-00 RES 0603 0R
R3 038-15820-10 RES 0603 82k 1% 1/10W
R4 038-15820-10 RES 0603 82k 1% 1/10W
R6 038-15220-10 RES 0603 22k 1% 1/10W
R7 038-15100-10 RES 0603 10k 1% 1/10W
R8 038-15820-10 RES 0603 82k 1% 1/10W
R9 038-13100-10 RES 0603 100R 1% 1/10W
R10 038-15100-10 RES 0603 10k 1% 1/10W
R12 038-16100-10 RES 0603 100k 1% 1/10W
R13 038-16100-10 RES 0603 100k 1% 1/10W
R14 036-13560-10 RES 0805 560R 1% 1/8W
R15 038-15820-10 RES 0603 82k 1% 1/10W
R16 038-15100-10 RES 0603 10k 1% 1/10W
R17 038-15220-10 RES 0603 22k 1% 1/10W
R18 038-13220-10 RES 0603 220R 1% 1/10W
R19 038-14120-10 RES 0603 1k2 1% 1/10W
R20 038-10000-00 RES 0603 0R
R21 038-10000-00 RES 0603 0R
R30 038-13390-10 RES 0603 390R 1% 1/10W
R31 038-13390-10 RES 0603 390R 1% 1/10W
R40 036-00000-01 RES 1206 0R 5% 0.25W
R103 038-12100-10 RES 0603 10R 1% 1/10W
R104 038-15100-10 RES 0603 10k 1% 1/10W
R203 038-13100-10 RES 0603 100R 1% 1/10W
R207 038-13100-10 RES 0603 100R 1% 1/10W
R209 038-13100-10 RES 0603 100R 1% 1/10W
R213 038-13100-10 RES 0603 100R 1% 1/10W
R911 036-00000-01 RES 1206 0R 5% 0.25W
R915 036-00000-01 RES 1206 0R 5% 0.25W
R917 038-10000-00 RES 0603 0R
U1 002-19120-00 IC TS912ID Cmos R2R Opamp
U2 002-12523-17 IC LM317l Reg T0252 0.5a
U3 002-13483-00 IC XCVR RS485 LTD SLEW RATE 3V
219-02882-00 Loom Control Head TMA
219-02950-00 CBL MFX Remote Kit Gnd Lead
220-01720-05 PCB MFX Radio Remote
302-10063-01 Brkt PCB Remote TM8200 Body
302-50002-01 Bung RJ45 MFO
316-06843-00 Pnl Frt Remote TM8200 MF0
346-10030-08 Scrw P/T Wn1412 Kc30x08 Zbc
349-02062-00 Scrw M3*8 T/T P/T ContiR
26.4.2 TMAC34-0T Torso Interface (PCB IPN 220-01720-05)
Parts List
Grid Reference List
C1 1:J2 H7
C2 1:K1 J6
C3 1:D2 H3
C4 1:J1 H8
C5 2:J2 G7
C6 1:K1 J7
C7 1:J2 G7
C8 2:K2 J9
C9 1:K2 G8
C10 1:N2 G9
C13 1:N2 G9
C15 2:L2 H10
C17 2:L2 H8
C102 1:D1 H4
C103 1:E2 D7
C203 1:J2 D6
C207 1:H2 D5
C213 1:H1 D6
DS1 1:F2 J5
D1 2:J2 G4
D2 1:H2 E5
D3 2:H2 G3
J1 1:H2 E3
J2 1:N2 E12
J3 1:L2 G12
J4 1:M2 D9
MT1 1:R2 F12
Q1 2:G2 G4
Q2 2:G2 F5
R1 2:N2 E10
R2 2:J2 G7
R3 1:J1 J6
R4 1:J1 J6
R5 2:H2 G4
R6 1:J1 H7
R7 1:G2 E5
R8 1:J1 J8
R9 2:L2 J9
R10 1:K2 G8
R11 2:G2 F4
R12 1:N2 G9
R13 1:N2 G9
R14 1:F2 H5
R15 2:L2 H9
R16 1:H2 D5
R17 2:L2 H9
R18 1:D2 H4
R19 1:E2 H4
R20 2:L2 J10
R21 1:N2 G10
R22 2:H2 G4
R23 2:G2 G5
R24 2:G2 F5
R30 1:F2 D10
R31 1:E2 E9
R40 2:N2 F11
R103 1:G2 E7
R104 1:G2 E7
R203 1:J2 E6
R207 1:J2 E6
R209 1:H2 E6
R213 1:H2 E6
R820 2:L2 H10
R821 1:N2 G10
R900 1:F2 E9
R901 1:E2 E9
R910 2:J2 E10
R911 2:L2 F11
R912 1:H2 E5
R915 2:M2 G12
R916 2:N2 F11
R917 1:N2 F11
R918 2:M2 G11
R920 1:D2 J4
U1 1:K1 G8
J8
J5
U2 1:D2 J4
U3 1:F2 E8
TM8100/TM8200 Service Manual Installing an Enhanced Remote Kit 541
© Tait Electronics Limited June 2006
Board Layout
IPN 220-01720-05
542 Installing an Enhanced Remote Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Circuit Diagram
TM8100/TM8200 Service Manual TMAA04-04 Crossband Linking Cable 543
© Tait Electronics Limited June 2006
27 TMAA04-04 Crossband Linking Cable
The TMAA04-04 crossband linking cable is used to connect
the auxiliary connectors of two radios configured as a
crossband repeater. Components in the TMAA04-04 are
optomized for voice applications.
27.1 Installation
1. Remove the rubber bung that covers the auxiliary connector on each
of the radios.
2. Plug each end of the crossband linking cable into the auxiliary
connector on each radio.
27.2 Radio Programming
After the transmit and receive channels have been programmed for both
radios, settings in the following forms must also be configured:
■PTT form (refer to Table 27.1)
■Programmable I/O form — Digital tab (refer to Table 27.2)
■Programmable I/O form — Audio tab (refer to Table 27.3).
If a repeater transmit tail is required, settings in the following forms must be
configured in both radios:
■PTT form (TM8100 radios only) (refer to Table 27.4)
■Basic Settings form—Subaudible Signalling tab (TM8200 radios and
optional for TM8100 radios) (refer to Table 27.5 and Table 27.6).
Some of the settings shown in the tables are default settings and may not
need to be changed. In all cases, refer to the online help of the programming
application for more information.
Crossband Settings
in the PTT Form The following table shows the crossband linking settings required in the
External PTT (1) tab of the PTT form.
Important The radio does not meet the IP54 protec-
tion standard once the auxiliary connector
rubber bung has been removed and a cross-
band linking cable has been installed. Care
must be taken when the radio is being oper-
ated in an environment where there is
water, dust or other environmental hazards.
Table 27.1 Crossband settings in the PTT form, External PTT (1) tab
Field Setting
Advanced EPTT1 PTT Transmission Type Voice
Audio Source Audio Tap In
544 TMAA04-04 Crossband Linking Cable TM8100/TM8200 Service Manual
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Programmable I/O
Form—Digital Tab The following table shows the crossband linking settings required in the
Digital tab of the Programmable I/O form.
Programmable I/O
Form—Audio Tab The following table shows the crossband linking settings required in the
Audio tab of the Programmable I/O form.
27.2.1 Repeater Transmit Tail Settings
TM8100 Radios If the transmitter requires a “tail”, then this can be set in the External
PTT (1) tab of the PTT form. During the PTT deactivation delay period,
any signalling, such as CTCSS or DCS, is still present.
If a further transmitter tail is required, then this can be configured in the
Subaudible Signalling tab of the Basic Settings form. During the lead-out
delay period, no signalling, such as CTCSS or DCS, is present.
TM8200 Radios If the transmitter requires a “tail”, then this can be configured in the
Subaudible Signalling tab of the Basic Settings form. During the lead-out
delay period, no signalling, such as CTCSS or DCS, is present.
Table 27.2 Crossband settings in the Programmable I/O form, Digital tab
Pin Direction Label Action Active Debounce Signal State Mirrored To
AUX_GPI1 Input PTT_INS External PTT 1 Low 10 None None
AUX_GPIO5 Output BUSY Busy Status1Low None None None
1. To transmit only when the signalling is valid, set this field to Signalling Audio Mute Status.
Table 27.3 Crossband settings in the Programmable I/O form, Audio tab
Pin Tap In Tap In Type Tap In Unmute Tap Out Tap Out Type Tap Out Unmute
Rx None A-Bypass In On PTT R7 D-Split Busy Detect1
EPTT1 T5 A-Bypass In On PTT None C-Bypass 0 On PTT
1. This can be set to Busy Detect + Sub if the mute is to open only when valid subaudible signalling is present with
the transmission.
Table 27.4 Transmit tail settings in the PTT form, External PTT (1) tab
Field Setting
Advanced EPTT1 PTT Deactivation Delay up to 1000ms
Table 27.5 Additional Transmit tail in the Basic Settings form, Subaudible
Signalling tab
Field Setting
CTCSS Settings Lead-Out Delay any duration, up to 1000ms
DCS Settings Lead-Out Delay any duration, up to 1000ms
Table 27.6 Transmit tail in the Basic Settings form, Subaudible Signalling tab
Field Setting
CTCSS Settings Lead-Out Delay any duration, up to 1000ms
DCS Settings Lead-Out Delay any duration, up to 1000ms
TM8100/TM8200 Service Manual TMAA04-04 Crossband Linking Cable 545
© Tait Electronics Limited June 2006
27.3 Operational Testing
1. On the receiving radio, inject an on-channel RF signal at a level of
-70dBm, modulated to ±3kHz deviation (wide bandwidth channel)
or ±1.5kHz (narrow bandwidth channel), at 1kHz AF.
2. On the transmitting radio, the resulting deviation should be:
■±3kHz (with a tolerance of ±200Hz) on a 25kHz wide
bandwidth channel.
■±1.5kHz (with a tolerance of ±200Hz) on a 12.5kHz narrow
bandwidth channel.
27.4 Interface Specification
The following table and diagram summarizes the signals used for the crossband
linking cable on the radios’ auxiliary connectors and shows the interface
between the cable and the radios.
Figure 27.1 TMAA04-04 crossband linking cable
auxiliary connector
radio 1
auxiliary connector
radio 2
crossband linking board
Table 27.7 Auxiliary connectors—pins and signals
Pin Signal name Description
2 AUX_GPIO5
busy (output)
7 AUD_TAP_IN
audio tap input
12 AUX_GPI1
PTT (input)
13 AUD_TAP_OUT
audio tap output
15 AGND
analogue ground
J
B
C
D
E
F
G
H
I
1)
1!
1@
1#
1$
1%
rear view
546 TMAA04-04 Crossband Linking Cable TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Ref. IPN Description Ref. IPN Description
27.5 PCB Information
27.5.1 TMAA04-04 Parts List (PCB IPN 220-02127-01)
C2 018-16100-00 Cap 0603 100n 16v x7r + - 10%
C10 018-16100-00 Cap 0603 100n 16v x7r + - 10%
J1 240-00031-00 Plg 15w Drng UL-CSA Pnl Mtg
R1 038-13560-10 RES 0603 560R 1% 1/10W
R6 038-13560-10 RES 0603 560R 1% 1/10W
205-00110-50 CBL 8wy Oval Std Telecom
219-03005-00 CBL TMA X-Band
220-02127-01 PCB MFX Programming cable
240-00031-00 Plg 15w Drng UL-CSA Pnl Mtg
240-06010-18 Conn 15w Hood/Cvr Drng MDJ15
402-00030-0X MANL f/instr TMAA04-04 XB
TM8100/TM8200 Service Manual TMAA04-04 Crossband Linking Cable 547
© Tait Electronics Limited June 2006
27.5.2 Crossband Linking Board Layouts
IPN 220-02127-01
548 TMAA04-04 Crossband Linking Cable TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
27.5.3 Crossband Linking Board Circuit Diagram
TM8100/TM8200 Service Manual TMAA04-05 Ignition Sense Kit 549
© Tait Electronics Limited June 2006
28 TMAA04-05 Ignition Sense Kit
The TMAA04-05 ignition sense kit provides a
mating plug for the radio’s auxiliary connector.
The four metre length of cable from pin 4 of the
plug connects to the vehicle’s ignition signal.
Once the kit is installed, the ignition signal is used
to power up and power down the radio, so that the
radio turns off when the vehicle ignition is off.
This avoids any possibility that the radio may
flatten the vehicle’s battery. When the vehicle
ignition is turned on, the radio either turns on, or
returns to the state that it was in when the vehicle
ignition was turned off.
Important The radio does not meet the IP54 protection standard once
the bung for the auxiliary connector is removed. Therefore,
once the
TMAA04-05 ignition sense kit is installed,
mount
the radio in areas where it is not exposed to water, dust or
other environmental hazards
.
28.1 Installation
1. Connect the auxiliary connector plug to the radio’s
auxiliary connector
2. Connect the ignition sense cable to the 13.8 V signal controlled by the
vehicle’s ignition key.
28.2 Radio Programming
Program the AUX GPI3 line to ‘Power Sense (Ignition)’ and active
to ‘High’.
Refer to the online help of the programming application for
more information.
ignition sense cable
plug into the
radio’s auxiliary
connector
auxiliary connector plug
550 TMAA04-05 Ignition Sense Kit TM8100/TM8200 Service Manual
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TM8100/TM8200 Service Manual TMAA10-01 Desktop Microphone 551
© Tait Electronics Limited June 2006
29 TMAA10-01 Desktop Microphone
The TMAA10-01 desktop microphone is an omnidirectional
dynamic microphone which can be used in dispatch
situations, where the microphone is positioned on a flat
surface. The desktop microphone plugs into the microphone
socket on the radio control head.
The desktop microphone has an internal pre-amplifier and an
adjustable sensitivity control on the underside of the desktop
microphone base.
29.1 Operation
Hold down the monitor key and check whether the channel is clear.
If the channel is clear, press the PTT key to transmit. Speak clearly into the
microphone and release the PTT key when you have finished talking.
Note The monitor key can be locked in the ‘on’ position. To do this,
hold the monitor key down and slide the monitor key towards
you. The monitor key should now be locked on.
29.2 Installation
Important The desktop microphone grommet must be installed
whenever the desktop microphone is plugged into the
microphone socket. When installed, the grommet has two
functions:
■to prevent damage to the microphone socket when
there is movement of the microphone cord, and
■to ensure that the control head is sealed against water,
dust and other environmental hazards.
1. Plug the microphone cord into the microphone socket on the radio
control head.
2. Slide the grommet along the cord and push two adjacent corners of the
grommet into the microphone socket cavity.
PTT key monitor key
grommet
microphone
base
grille
TRANSMIT
MONITOR
552 TMAA10-01 Desktop Microphone TM8100/TM8200 Service Manual
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3. Squeeze the grommet and push the remaining corners into position.
4. Check that the grommet is seated correctly in the cavity.
29.3 Adjustment
Adjust the output sensitivity of the desktop
microphone using R5. R5 is accessible from the
underside of the desktop microphone, as shown.
The microphone sensitivity is set to maximum by
rotating R5 counterclockwise.
29.4 Interface Specification
The following table and diagram summarizes the signals used for the desktop
microphone on the radio’s microphone connector and shows the interface
between the desktop microphone and the radio.
Figure 29.1 Correct desktop microphone grommet seating
microphone
grommet
control head
adjust R5 here
Table 29.1 Desktop microphone connector—pins and signals
Pin Signal Colour Description
1 — — not connected
2 — — not connected
3 — — not connected
4 MIC_PTT yellow PTT
5 MIC_AUD red audio from the microphone
6 AGND bare analogue ground
7 — — not connected
8 — — not connected
TM8100/TM8200 Service Manual TMAA10-01 Desktop Microphone 553
© Tait Electronics Limited June 2006
.
29.5 Circuit Description
The desktop microphone uses a dynamic microphone capsule and contains
a pre-amplifier (Q1) to boost the microphone level to that required by the
radio. Power for the pre-amplifier is provided by the electret microphone
bias circuit within the radio. R5 is used to adjust the gain.
PTT and hookswitch signals are combined onto one line and fed to the
control head PTT input of the radio.
Figure 29.2 Desktop microphone to radio interface
554 TMAA10-01 Desktop Microphone TM8100/TM8200 Service Manual
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TM8100/TM8200 Service Manual TMAA10-02 Handset 555
© Tait Electronics Limited June 2006
30 TMAA10-02 Handset
The TMAA10-02 handset provides the user with privacy and also
improves the audio quality in noisy environments. The handset
uses a dynamic microphone capsule, therefore the radio control
head must support dynamic microphone operation. For example,
a TMAA02-06 (support kit for dynamic microphones) must be
fitted to control head TMAC20-0T.
When your radio receives a call and the handset is mounted in
its locking cradle, the radio unmutes and you can hear the call
from your radio’s internal speaker and from any connected
remote speaker.
If you remove the handset from its cradle when you receive a call,
the radio unmutes and you can hear the call from your radio’s
internal speaker, from any connected remote speaker and from the
handset earpiece.
Using private handset mode, the radios internal and external speakers
are muted and the call can only be heard from the handset earpiece.
30.1 Installation
30.1.1 Handset Wiring
The circled numbers in the following instructions refer to items in the
diagram in Table 30.1.
1. Drill a hole in the chosen mounting surface for the radio to handset
cord and pass the cord through the hole.
2. Prepare the radio to handset cord, as follows.
■Cut the radio to handset cord to the required length.
■Strip away about 60mm (2 inches) of the cable outer sheath on the
end without a connector.
■Cut off the exposed orange, red, black and bare wires.
■Strip about 6mm (0.2 inches) of the coating off each of the five
remaining wires.
3. Secure the radio to handset cord in the handset PCB P-clip b, as
shown in the diagram.
4. Connect the five wires to the handset PCB connector c.
locking
cradle
push-
button
handset
grommet
radio to
handset cord
mounting
plate
556 TMAA10-02 Handset TM8100/TM8200 Service Manual
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30.1.2 Handset Installation
1. Press the pushbutton and remove the handset from the locking cradle.
2. Disassemble the locking cradle by removing the four locking cradle
screws.
3. Screw the handset mounting plate to the required mounting surface.
Note that mounting screws are not provided in this kit.
4. Clamp the top part of the locking cradle onto the mounting plate,
and secure it with the four locking cradle screws.
30.1.3 Connecting the Handset to the Radio
Important The handset microphone grommet must be installed when-
ever the handset to radio cord is plugged into the microphone
socket. When installed, the grommet has two functions:
■to prevent damage to the microphone socket when there
is movement of the microphone cord, and
■to ensure that the control head is sealed against water,
dust and other environmental hazards.
1. Plug the radio to microphone cord into the microphone socket on
the radio control head.
2. Slide the grommet along the cord and push two adjacent corners of the
grommet into the microphone socket cavity.
3. Squeeze the grommet and push the remaining corners into position.
4. Check that the grommet is seated correctly in the cavity.
Table 30.1 Handset PCB connector wiring
Handset PCB
Connector
Colour Reference
2white
or violet
d
3blue e
8brown
f
9 yellow g
10 green h
b
c
de f g h
TM8100/TM8200 Service Manual TMAA10-02 Handset 557
© Tait Electronics Limited June 2006
30.2 Radio Programming
Dynamic
Microphone
Support
Dynamic microphone support must be enabled in the UI Preferences form
of the radio’s programming application, so that audio is optomized for
dynamic microphones. Refer to the online help of the programming
application for more information.
Private Handset
Mode If private handset mode is required, the radio needs to be programmed to
mute the audio power amplifier when the handset is out of the cradle. The
audio path is then only through the RX AUDIO line to the handset earpiece.
The following table shows the settings required in the Programmable I/O
form of the radio’s programming application. Refer to the online help of the
programming application for more information.
Note If private handset mode is programmed, then no audio will be
heard from the speakers if the handset is unplugged.
Figure 30.1 Correct handset microphone grommet seating
microphone
grommet
control head
Table 30.2 Handset settings in the UI Preferences form
(TM8100 Programming Application)
Field Setting Selected/Cleared
Audio Setup Enable Options Board Preamp selected
Table 30.3 Handset settings in the UI Preferences form
(TM8200, TM9000/TP9000 Programming Application)
Field Setting Selected/Cleared
Audio>Audio Setup Dynamic Mic Support selected
Table 30.4 Handset settings in the Programmable I/O form, Digital tab
Pin Direction Label Action Active Debounce Signal State Mirrored To
CH_GPIO1 Input None Force Audio PA Off High 25 None None
558 TMAA10-02 Handset TM8100/TM8200 Service Manual
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30.3 Interface Specification
The following table and diagram summarizes the signals used for the handset
on the radio’s microphone connector and shows the interface between the
handset and the radio.
.
Table 30.5 Handset microphone connector—pins and signals
Pin Signal Handset PCB
Connector Colour Description
1 RX_AUD 8 brown receive audio to handset
2 — — — not connected
3 — — — not connected
4 PTT 2 white PTT and hookswitch
5 MIC 9 yellow audio from the handset to dynamic-mic
support board
6 GND 10 green analogue ground
7 — — — not connected
8 CH_GPIO1 3 blue programmable line controlling private mode
Figure 30.2 Handset to radio interface
TM8100/TM8200 Service Manual TMAA10-03 and TMAA10-06 High-Power Remote Speakers 559
© Tait Electronics Limited June 2006
31 TMAA10-03 and TMAA10-06
High-Power Remote Speakers
The TMAA10-03 remote speaker (for the 25W radio) and
the TMAA10-06 remote speaker (for the 40W/50W
radio) are installed in parallel with the radio’s existing
internal speaker. The remote speaker can then be installed
at some distance from the radio, or it can be used to
increase the volume of the audio from the radio’s existing
internal speaker.
The remote speaker is supplied with a socket housing
(already installed) and a flying lead connector. This
connector enables the speaker to be easily removed and
reconnected as required.
The flying lead connector is terminated with two
receptacles. The receptacles supplied with the
TMAA10-03 (for 25W radios) are different to those
supplied with the TMAA10-06 (40W/50W radios). Two spare receptacles are included with each
kit, along with four mounting screws and washers.
31.1 Installation
Remote Speaker
Mounting 1. Choose a mounting position for the remote speaker where it will not
interfere with the operation of any of the vehicle controls.
2. Remove the remote speaker from the mounting bracket and use the
screws and washers provided to fix the mounting bracket securely in
the chosen location.
Important Check before drilling that the drill will not damage any
components or wiring behind the mounting location.
■If mounting the bracket onto a metal surface, drill two 3.5mm
(0.14 inch) holes in the appropriate locations and secure the
bracket with the supplied self tapping screws.
■If mounting the bracket to any other material, such as plastic, drill
two 4.5mm (0.18 inch) holes and attach the bracket with screws
and captive nuts, or similar.
3. Attach the speaker to the mounting bracket using the thumbscrews.
Important Check that the speaker cable is protected from engine heat,
sharp edges and from being pinched or crushed.
mounting
bracket
receptacles
flying lead
connector
socket
housing
remote
speaker
cable
560 TMAA10-03 and TMAA10-06 High-Power Remote Speakers TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
4. Run the free end of the speaker cable to the radio power cable and
install the two receptacles in the power connector, as described in the
“Power Connector Wiring” procedure.
Power Connector
Wiring Insert the flying lead receptacles into the power connector socket, as shown
in the diagrams below.
Note The positive remote speaker wire has a white stripe.
1. TMAA10-03 remote speaker (25W radios)
For the TMAA10-03 remote speaker (25W radios), insert the flying
lead receptacles:
■the positive wire and receptacle into the position nearest to the red
wire, and
■the negative wire and receptacle into the position nearest to the
black wire.
2. TMAA10-06 remote speaker (40W/50W radios)
For the TMAA10-06 remote speaker (40W/50W radios), insert the
flying lead receptacles:
■the positive wire and receptacle into position 3, and
■the negative wire and receptacle into position 2.
Connecting the
Remote Speaker To connect the remote speaker, plug the flying lead into the housing socket.
To disconnect the speaker, release the locking mechanism and unplug the
flying lead.
power
connector
flying lead
connector
speaker +
speaker –
+13.8V
(red)
ground
(black)
power connector
flying lead
connector
speaker – (to pin 2)
speaker + (to pin 3)
+13.8V
(red)
ground
(black) power connector
rear view
b
e
d
c
SPKR +
SPKR –
+
TM8100/TM8200 Service Manual TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit 561
© Tait Electronics Limited June 2006
32 TMAA10-04 Remote PTT Kit and
TMAA10-05 Hands-Free Kit
The TMAA10-04 remote PTT kit and the TMAA10-05
hands-free kit plug into the radio’s auxiliary connector.
Both kits use the remote electret microphone to replace
communication through the usual rugged microphone.
The rugged microphone can still provide hookswitch
operation, if this is required.
The TMAA10-04 kit uses a conveniently mounted remote
PTT key for PTT operation. When the remote PTT is
activated, the remote microphone is used for communication.
There are three mounting options for the remote microphone
and an extension lead is provided for the remote PTT in the
TMAA10-04 kit.
32.1 VOX Operation (TMAA10-05 Hands-Free Kit)
Your radio may able to detect the sound of your voice, so that you can make
calls without using the PTT key. Voice-operated transmit (VOX) is turned
on and off either by using a function key programmed for VOX or by
using the radio’s Main menu.
Changing to VOX
Using a Function
Key
The function key programmed for VOX toggles VOX between on and off.
When VOX is turned on, it remains on until the function key is pressed again.
While VOX is on, the VOX indication may be
programmed to appear below the channel infor-
mation on your display.
Changing to VOX by
using the Main
Menu
1. Select Menu>Radio Settings>
Function Settings>VOX.
Important These kits do not meet the IP54 pro-
tection standard. Care must be taken
when a radio with a TMAA10-04 or
TMAA10-05 kit installed is being
operated in an environment where
there is water, dust or other
environmental hazards.
auxiliary
connector plug
extension lead for
remote PTT
remote microphone
remote PTT (TMAA10-04)
remote microphone
mounting options
562 TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit TM8100/TM8200 Service Manual
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2. In the VOX menu, choose On.
3. Press Select.
While VOX is on, the VOX indication may be
programmed to appear below the channel infor-
mation on your display.
Changing the
Sensitivity of VOX You may need to change the threshold at which the radio detects your voice
and makes a call. To do this, you use the VOX Sensitivity menu.
1. Select Menu>Radio Settings>
Function Settings>VOX Sensitivity.
2. In the VOX Sensitivity menu, use the scroll keys
or to adjust the VOX sensitivity to the
desired level.
3. Press Done to save this setting.
32.2 Installation
Important Care should be taken to avoid routing any cables near vehi-
cle pedal controls, steering column and other moving parts.
Installing the
Remote
Microphone
1. Choose one of the three mounting options provided for the remote
microphone and determine its most appropriate location.
The mounting position of the microphone should be no more than
50cm (20 inches) from the user’s mouth.
2. Route the remote microphone cable so as not to distract the driver.
3. Mount the remote microphone in the chosen location and check
that the microphone and cable are clear of all the usual movements
performed by the user.
Installing the
Remote PTT
(TMAA10-04)
Important The remote PTT must be operable from a normal
driving position.
1. Secure the remote PTT in position using the velcro strap and plug the
remote PTT cord into the remote PTT extension lead.
A common position for the remote PTT is on the gear lever of
the vehicle.
TM8100/TM8200 Service Manual TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit 563
© Tait Electronics Limited June 2006
2. Check that the cord and lead do not interfere with the safe operation
of the vehicle.
32.3
Radio Programming for the
TMAA10-04 Remote PTT Kit
Remote PTT
Settings in the PTT
Form
The following table shows the settings required in the PTT form of the
programming application. Some of these settings are default settings and
may not need to be changed. Refer to the online help of the programming
application for more information.
Note The handsfree remote PTT cannot transmit when the rugged
microphone is on the microphone clip (microphone hookswitch
is closed) if:
■hookswitch operation is programmed for the rugged microphone,
and
■the Inhibit PTT Transmission When Mic On Hook field is
selected in the PTT tab of the PTT form.
Remote PTT
Settings in the
Programmable I/O
Form
The following table shows the settings required in the Programmable I/O
form of the programming application. Some of these settings are default
settings and may not need to be changed. Refer to the online help of the
programming application for more information.
Note The Programmable I/O form setting for AUX_GPIO4 must have
the default programming settings and the AUX_GPIO4 pullup
resistor on the radio main PCB must be set for the factory default
of 3.3V (R769 fitted).
Table 32.1 Remote PTT settings in the PTT form, External PTT (1) tab
Field Setting
Advanced EPTT1 PTT Transmission Type Voice
Audio Source AUX MIC
Table 32.2 Remote PTT settings in the Programmable I/O form, Digital tab
Pin Direction Label Action Active Debounce Signal State Mirrored To
AUX_GPI1 Input None External PTT 1 Low 25 None None
AUX_GPIO4 None None No Action None None None None
564 TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit TM8100/TM8200 Service Manual
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32.4 Radio Programming for the TMAA10-05 Hands-Free Kit
VOX Settings in the
PTT Form The following table shows the settings required in the PTT form of the
programming application. For detailed instructions on how to configure a
radio for VOX operation, refer to the section “Configuring VOX” in the
online help of the programming application.
VOX Settings in the
Key Settings Form In the Key Settings form of the programming application, one of the
function keys on the control head can be programmed to activate VOX.
32.5 Interface Specification
The following table and diagram summarizes the signals used for the remote
PTT and hands-free kits on the radio’s auxiliary connector and shows the
interface between the kits and the radio.
Table 32.3 VOX settings in the PTT form, External PTT (2) or VOX tab
Field Setting
EPTT2 or VOX Inhibit Inhibit PTT When Emergency Active select1
1. These are recommended settings only.
Inhibit PTT Transmission When Mic on Hook cleara
Indicate PTT Inhibit to User cleara
Advanced EPTT2 or VOX PTT Transmission Type Voice
Audio Source AUX MIC
PTT Priority Highesta
Table 32.4 VOX settings in the Key Settings form
Field Setting
Function Key Actions Key 11
1. Select the required function key.
VOX Activation
Table 32.5 Auxiliary connector—pins and signals
Pin Signal name Description
8 +13V8_SW
power to hands-free microphone pre-
amplifier
10 AUX_GPIO4
reference voltage to pre-amplifier
regulator
12 AUX_GPI1
PTT signal from hands-free kit
14 AUX_MIC_AUD
microphone audio to the radio
15 AGND
analogue ground
J
B
C
D
E
F
G
H
I
1)
1!
1@
1#
1$
1%
rear view
TM8100/TM8200 Service Manual TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit 565
© Tait Electronics Limited June 2006
.
32.6 Circuit Description
The remote microphone signal is amplified by a pre-amplifier in the
auxiliary connector plug. The power supply to this amplifier is provided by
the +13.8V supply on the auxiliary connector. This supply is filtered and
regulated down to approximately 3.3V. The reference voltage for the
regulator is provided by AUX_GPIO4 line.
The remote microphone signal is fed via AUX_MIC_AUD and an input
selector to the radio’s internal microphone amplifier. The microphone input
selected depends on the PTT source used to make the call. If the remote PTT
is used, then AUX_MIC_AUD is selected. If the control head microphone
PTT is used, then CH_MIC_AUD is selected. Test points for all other
auxiliary connections are provided on the auxiliary connector plug PCB to
facilitate the connection of other devices or signals e.g ignition switch signal.
Figure 32.1 TMAA10-04/TMAA10-05 to radio interface
566 TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Ref. IPN Description Ref. IPN Description
32.7 PCB Information
32.7.1 TMAA10-04/TMAA10-05 Parts List (PCB IPN 220-01711-01)
C2 015-26330-08 Cap Cer 0805 330n 5% 10v X7r
C3 018-15100-00 Cap 0603 10n 50v X7r +-10%
C4 015-26330-08 Cap Cer 0805 330n 5% 10v X7r
C6 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
C7 015-26100-08 Cap Cer 0805 100n 10% X7r 50v
Q1 000-10084-71 Xstr BC847BW NPN SOT323
Q2 000-10085-71 Xstr SMD BC857BW PNP SOT323
Q3 000-10084-71 Xstr BC847BW NPN SOT323
Q4 000-10084-71 Xstr BC847BW NPN SOT323
R1 038-14220-00 Res 0603 2k2 1/16w +-5%
R3 038-14390-10 Res 0603 3k9 1%
R4 038-15470-10 Res 0603 47k 1/16w+-1%
R6 038-15330-10 Res 0603 33k 1%
R13 038-15100-10 Res 0603 10k 1/16w +-1%
R16 038-15470-10 Res 0603 47k 1/16w+-1%
R17 038-15150-00 Res 0603 15k 1/16w +-5%
R18 038-15100-10 Res 0603 10k 1/16w +-1%
R19 038-15100-10 Res 0603 10k 1/16w +-1%
219-00305-00 cable
220-01711-01 Pcb HFree
240-06010-18 Conn 15w Hood/Cvr Drng MDJ15
252-00010-72 Mic Electret Unidir 2.5mm Plg
402-00006-01 F/Inst TMAA10-04/TMAA10-05 Eng
TMAA10-04 Remote PTT only
236-00001-00 Sw Ptt W/Cbl & Strap
TM8100/TM8200 Service Manual TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit 567
© Tait Electronics Limited June 2006
32.7.2 Pre-Amplifier Board Layout
IPN 220-01711-01 IPN 220-01711-01
568 TMAA10-04 Remote PTT Kit and TMAA10-05 Hands-Free Kit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
32.7.3 Pre-Amplifier Board Circuit Diagram
TM8100/TM8200 Service Manual TMAA10-07 Desktop Microphone 569
© Tait Electronics Limited June 2006
33 TMAA10-07 Desktop Microphone
The TMAA10-01 desktop microphone is an
omnidirectional dynamic microphone which can be used
in dispatch situations, where the microphone is positioned
on a flat surface. The desktop microphone plugs into the
microphone socket on the radio control head.
The desktop microphone has an internal pre-amplifier and
an adjustable output control on the underside of the
desktop microphone base.
33.1 Operation
Hold down the MONITOR key and check whether the channel is clear.
If the channel is clear, press the TRANSMIT key (PTT) to transmit. Speak
clearly into the microphone and release the TRANSMIT key when you have
finished talking.
Note The MONITOR key can be locked in the ‘on’ position. To do this,
hold the MONITOR key down and slide the LOCK key towards
you. The MONITOR key should now be locked on.
33.2 Installation
Important The desktop microphone grommet must be installed
whenever the desktop microphone is plugged into the
microphone socket. When installed, the grommet has two
functions:
■to prevent damage to the microphone socket when
there is movement of the microphone cord, and
■to ensure that the control head is sealed against water,
dust and other environmental hazards.
1. Plug the microphone cord into the microphone socket on the radio
control head.
TRANSMIT
key
grommet
TRANSMIT
MONITOR
LOCK
key
MONITOR
key
570 TMAA10-07 Desktop Microphone TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
2. Slide the grommet along the cord and push two adjacent corners of the
grommet into the microphone socket cavity.
3. Squeeze the grommet and push the remaining corners into position.
4. Check that the grommet is seated correctly in the cavity.
33.3 Adjustment
Adjust the output sensitivity of the desktop
microphone using the control accessible from the
underside of the desktop microphone,.
The microphone sensitivity is set to maximum by
turning the control fully clockwise.
33.4 Radio Programming
The desktop microphone has an internal pre-amplifier. Therefore, the
dynamic microphone support in the UI Preferences form of the radio’s
programming application should not be enabled.
33.5 Interface Specification
The following table and diagram summarizes the signals used for the desktop
microphone on the radio’s microphone connector and shows the interface
between the desktop microphone and the radio.
Figure 33.1 Correct desktop microphone grommet seating
microphone
grommet
control head
adjust output level here
Table 33.1 Desktop microphone connector—pins and signals
Pin Signal Description
1 — not connected
2 — not connected
3 — not connected
4 MIC_PTT PTT
5 MIC_AUD audio from the microphone
6 AGND analogue ground
7 — not connected
8 — not connected
TM8100/TM8200 Service Manual TOPA-SV-024 Test Unit 571
© Tait Electronics Limited June 2006
34 TOPA-SV-024 Test Unit
The TOPA-SV-024 test unit is used to test and maintain Tait portable and
mobile radios by providing an interface between the radio, a test PC, and
an RF communications test set.
The diagram below shows the front panel of the test unit.
34.1 Test Equipment Setup
The diagram on the following page shows how the test unit is connected to
the radio, the test PC, and the RF communications test set.
Note The test unit can also be connected to a Tait Orca portable radio
(TOP) using the TOPA-SV-007 cable, or to a T2000 radio using
the T2000-11 cable. Use with Tait Orca and T2000 radios is not
described in this document.
Figure 34.1 TOPA-SV-024 test unit
572 TOPA-SV-024 Test Unit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
Figure 34.2 Test equipment setup
radio connector
(DB15)
RF connector
(mini UHF or
BNC)
auxiliary
connector
(DB15)
microphone
connector (RJ45)
receive audio /
SINAD connector
(BNC)
transmit audio
connector (BNC)
computer
connector
(RJ12)
serial port
(DB9)
speaker
connector
banana plugs
AC input
(BNC)
audio
monitor
out (BNC)
AUDIO
IN HI
(BNC)
AUDIO
OUT
(BNC)
RF in/out
(N-type)
power
connector
TMAA23-02 cable
(50W/40W radios)
TMAA20-03 cable
(25W radios)
TMAA21-01 cable
TOPA-SV-024
T2000-A19
cable
radio with user interface
RF comms set
Test PC
Oscilloscope
DC power supply
microphone
connector (RJ45)
programming
connector (DB9)
TMAA21-01 cable
TMAA20-02 cable
radio with blank control head
TM8100/TM8200 Service Manual TOPA-SV-024 Test Unit 573
© Tait Electronics Limited June 2006
34.2 Operation
This section explains the function of the TOPA-SV-024 test unit controls.
The procedure for using the test unit is described in the relevant section on
test equipment setup.
34.2.1 Portable / Mobile Switch
This 2-way toggle switch is used to switch attenuation resistors (R4, R5, R6)
in and out of the line from the radio’s positive speaker output to the positive
Rx Audio/SINAD
output of the test unit (before the isolating transformer).
■When set to Portable, the attenuation resistors are switched out.
■When set to Mobile, the attenuation resistors are switched in
(attenuation 10:1).
Important Selecting the wrong switch position may result in incorrect
SINAD readings and damage to the test unit.
34.2.2 Mod Audio/Audio Tap In / Off / Mic Audio Switch
This 3-way toggle switch is used to switch between Mod Audio/Audio Tap
In, Mic Audio, and Off (no audio signal).
■With the Tait Orca portables, this switch can be used for setting up dual
point modulation by applying modulation to different parts of the radio.
■For normal transmit deviation tests (other portables and mobiles), this
switch is set to Mic Audio.
34.2.3 On Hook / Off Hook Switch
Important When using the test unit with portables, the On Hook /
Off Hook toggle switch must be set to Off Hook.
Portables do not have a hookswitch, and if the switch is set
to On Hook, the accessory function key of the portable is
activated.
This 2-way toggle switch is used to simulate the microphone hookswitch
opening (“hook off ”) and closing (“hook on”). This is done by switching a
12kΩ resistor (R3) in or out of the MIC_PTT line.
■When set to Off Hook, the 12kΩ resistor (R3) is switched out of the
MIC_PTT line. This simulates the microphone being removed from the
microphone clip.
■When set to On Hook, a 12kΩ resistor (R3) is switched into the
MIC_PTT line. This simulates the microphone being placed on the
microphone clip.
574 TOPA-SV-024 Test Unit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
34.2.4 Rx / Tx/PTT Switch
This 2-way toggle switch is used to switch between receive and transmit mode.
■When set to Rx, the PTT line is switched to high impedance.
■When set to Tx/PTT, the PTT line is pulled to ground.
34.2.5 Speaker / Radio / Load Switch
This 3-way toggle switch is used during receive audio tests to switch the audio
to the test unit speaker (Speaker), to the radio’s internal speaker (Radio) or to
a dummy load consisting of R1 and R2 (Load).
Note This switch does not disconnect the radio’s internal speaker on
mobiles. If the switch is set to Speaker or Load, this simulates an
external speaker being connected in parallel to the radio’s internal
speaker.
With all settings, a low level audio signal is available for testing through
the SINAD port.
Portable ■When set to Speaker, only the speaker of the test unit is active.
■When set to Radio, only the speaker of the portable is active.
■When set to Load, no speaker is active. The audio signal is terminated in
the test unit dummy load.
Mobile ■When set to Speaker, the speakers of the test unit and the mobile are
both active. The speaker of the mobile cannot be disconnected.
■When set to Radio, only the speaker of the mobile is active.
■When set to Load, the speaker of the mobile remains active.
TM8100/TM8200 Service Manual TOPA-SV-024 Test Unit 575
© Tait Electronics Limited June 2006
34.3 PCB Information
34.3.1 Parts List (PCB IPN 220-01418-02A Rev. 4)
34.3.2 PCB Layout
BNC1 240-02100-11 Skt Coax BNC 3.5mm Pnl N/Tag
BNC2 240-02100-11 Skt Coax BNC 3.5mm Pnl N/Tag
C1 011-54100-01 Cap Cer AI 1n 10% T/C B 50v
C2 011-54100-01 Cap Cer AI 1n 10% T/C B 50v
C3 020-59100-06 Cap Elec Rdl 100m 16v 6.3x11
C4 011-54100-01 Cap Cer AI 1n 10% T/C B 50v
PL1 240-00010-55 Plg 15w Drng W-Wrap Pnl Mtg
PL2 240-04021-60 Skt 6w Modr Ph Vrt T-Ent
R1 032-31820-01 Res M/F Pwr 17x5 8e2 5% 2.5w
R2 032-31820-01 Res M/F Pwr 17x5 8e2 5% 2.5w
R3 030-55120-20 Res Flm 4x1.6 12k 5% 0.4w
R4 030-53560-20 Res Flm 4x1.6 560e 5% 0.4w
R5 030-54270-20 Res Flm 4x1.6 2k7 5% 0.4w
R6 030-52560-20 Res Flm 4x1.6 56e 5% 0.4w
R7 030-55100-20 Res Flm 4x1.6 10k 5% 0.4w
SW1 230-00010-42 Sw Tgl On Off On Dpdt Ms500hb
SW2 230-00010-57 Sw Tgl Dpdt On-On Pnl Mtg
SW3 230-00010-03 Sw Tgl Spst Mini Pnl Mtg
SW4 230-00010-16 Sw Tgr Spst 3-Pos Pnl Mtg
SW5 230-00010-03 Sw Tgl Spst Mini Pnl Mtg
TRAN 054-00010-17 Xfmr Line 600 Ohm 1:1
Not part of the PCB:
SPKR 032-31820-01 Res M/F Pwr 17x5 8e2 5% 2.5w
250-00010-19 Spkr C/W Rubber Sealing Ring
R
e
f
.
IPN D
escr
i
pt
i
on
R
e
f
.
IPN D
escr
i
pt
i
on
top side
bottom side
IPN 220-01418-02
576 TOPA-SV-024 Test Unit TM8100/TM8200 Service Manual
© Tait Electronics Limited June 2006
34.3.3 Circuit Diagram
The component values in the schematic diagram are
indicative only. Refer to the parts list for actual values
used.
SPEAKER 4Ω
SPKR 8.2Ω
SHOULD BE DPTT IPN 032-31820-01
IPN 250-00010-19
not part of PCB
not fitted not fitted
not fitted
Portable
Mobile
Mobile
Portable
Portable
Mobile
Portable
Mobile
Portable
Mobile
Portable
Portable
Mobile
Mobile
Mobile
Portable
Portable
Mobile
RADIO
RADIO
Mobile
Portable
Mobile
Portable
MOD AUDIO / AUDIO TAP IN
TM8100/TM8200 Service Manual 577
© Tait Electronics Limited June 2006
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© Tait Electronics Limited June 2006
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