Tait TM9100 Service Manual Download

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TM9100 Service Manual

August 2005

Chapter 2 – Servicing the Radio

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.1 Repair Levels and Website Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.2 Tools, Equipment and Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.3 Servicing Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.4 Test Equipment Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

4.5 Replacing Board Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.6 Shielding Cans and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.7 SMT Repair Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4.8 Computer-Controlled Test Mode (CCTM) . . . . . . . . . . . . . . . . . . . . . . 112

4.9 Visual and Audible Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

5.1 Removing and Mounting the Control Head . . . . . . . . . . . . . . . . . . . . . 124

5.2 Disassembling the Radio Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5.3 Reassembling the Radio Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

5.4 Disassembling and Reassembling the Control Head . . . . . . . . . . . . . . . . 135

Servicing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

6.1 Initial Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6.2 Final Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Power Supply Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

Interface Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163

Frequency Synthesizer Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . .169

9.1 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

9.2 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

9.3 Phase-locked Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

9.4 Loop Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

9.5 Receive VCO and Related Circuitry (UHF Radios) . . . . . . . . . . . . . . . 192

9.6 Transmit VCO and Related Circuitry (UHF Radios) . . . . . . . . . . . . . . . 201

9.7 VCO and Related Circuitry (VHF Radios) . . . . . . . . . . . . . . . . . . . . . . 206

9.8 Power Supply for FCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

9.9 VCXO and TCXO Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

9.10 Signals at TP501 and TP502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

9.11 VCXO and CODEC Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Summary of Contents for TM9100

Page 1: ...TM9100 mobiles Service Manual MMA 00017 01 Issue 1 August 2005 ...

Page 2: ...echnical Support E mail support taitworld com Website http support taitworld com 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 servi...

Page 3: ...icing Procedures 139 7 Power Supply Fault Finding 153 8 Interface Fault Finding 163 9 Frequency Synthesizer Fault Finding 169 10 Receiver Fault Finding 227 11 Transmitter Fault Finding 50W 40W Radios 245 12 Transmitter Fault Finding 25W Radios 315 13 CODEC and Audio Fault Finding 371 14 Fault Finding of Control Head 397 15 Spare Parts 421 Chapter 3 Accessories 427 16 TMAA02 08 Keypad Microphone 43...

Page 4: ...4 TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 5: ... numbers of the boards are listed below the last two digits in the IPN represent the issue of the board Main board B1 band 50W 220 01723 02 Main board H5 and H7 bands 50W 40W 220 01722 02 Main board B1 band 25W 220 01700 10 Main board H5 and H6 bands 25W 220 01697 10 Control head board 220 01718 01 Programming application version 1 1 0 1 Calibration application version 1 0 0 0 Enquiries and Commen...

Page 6: ... such information equipment and software complies with the laws rules and regulations of the applicable jurisdictions Associated Documentation The following associated documentation is available for this product MMA 00009 xx TM9100 Product Safety and Compliance Information MMA 00007 xx TM9100 User s Guide MMA 00018 xx TM9100 Installation Guide MMA 00022 xx TM9100 Main Board H5 H6 25W PCB Informati...

Page 7: ...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 Abbreviations Issue Publication Date Description 01 August 2005 first release Abbreviation Description ACP Adjacent Channel Power ADC Analog to Digital Converter AGC Automatic Gain Control ...

Page 8: ...ward 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 Center LCD Liquid Crystal Display LED Light Emitting Diode LNA Low Noise Amplifier LO Local Oscillator LPF Low Pass Filter N...

Page 9: ...ngth 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 VCO Voltage Controlled Oscillator VCXO Voltage Controlled Crystal Oscillator Abbreviation Description ...

Page 10: ...10 TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 11: ...TM9100 Service Manual 11 Tait Electronics Limited August 2005 TM9100mobiles Chapter 1 Description of the Radio ...

Page 12: ... 2 1 Mechanical Design 23 2 3 Connectors 34 2 4 Hardware and Software Architecture 42 2 5 Operation in Receive Mode 47 2 6 Operation in Transmit Mode 54 3 Circuit Descriptions 63 3 1 Transmitter Circuitry 65 3 2 Receiver Circuitry 68 3 3 Frequency Synthesizer Circuitry 71 3 4 Frequency Control Loop 75 3 5 CODEC and Audio Circuitry 76 3 6 Power Supply Circuitry 80 3 7 Interface Circuitry 86 3 8 Dig...

Page 13: ... and mixed operation for 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 Figure 1 1 ...

Page 14: ...rent 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 50W 40W 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...

Page 15: ...power remote speaker remote PTT kit Installation Kits The radio is delivered with a vehicle installation kit with U cradle Installation of the radio is described in 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 Internal Options Boards The radio provides space for a...

Page 16: ... and 2 identify the digital boards of the analog TM8000 product line c identifies the RF output power 2 25W 4 30 to 59W 5 30 to 59W trigger base dd identifies the frequency band B1 136 to 174MHz H5 400 to 470MHz H6 450 to 530MHz H7 450 to 520MHz Other characters identify frequency bands of the analog TM8000 product line ee identifies any radio options 00 BNC RF connector 01 mini UHF RF connector C...

Page 17: ...mber and product code hot surface safety warning RF exposure safety warning Figure 1 2 Labels of the TM9100 product line S N 19061964 TMAB32 H600 450 530 MHz Tait Electronics Ltd NZ 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 TAITMade in New Zealand TMAH6C ...

Page 18: ...nel spacing B1 band H5 H6 H7 bands 12 5kHz 25kHz 30kHz 12 5kHz 25kHz Channels talkgroups simplex or semi duplex 512 Frequency stability 1 5ppm Zones 26 Supply current receive mode squelched full audio transmit mode 100mA 500mA 10A 110mA 525mA 5 5A RF connector 50Ω miniature UHF or BNC optional Power connector Power supply External speaker between 10 8 and 16 V DC maximum power 10 W into 4 Ω balanc...

Page 19: ... humidity salt fog dust vibration shock Receiver Analog sensitivity 12dB SINAD 0 25µV 119dBm Digital sensitivity TIA EIA 5 BER 0 20µV 121dBm Intermodulation rejection 75dB Adjacent channel selectivity 20kHz 30kHz channel 12 5kHz channel 75dB 65dB Spurious responses rejection 75dB FM hum and noise 20kHz 30kHz channel 12 5kHz channel 43dB 40dB Audio distortion at rated audio 3 Audio bandwidth 300Hz ...

Page 20: ...annel 12 5kHz channel 41dB 37dB Conducted and radiated emissions up to 1GHz between 1 and 4GHz for radio operating frequencies below 500 MHz between 1 and 12 75GHz for radio operating frequencies above 500MHz 36dBm 30dBm 30dBm Audio bandwidth 300Hz to 3kHz flat or with pre emphasis Audio response 1 3dB Audio distortion 3 at 1kHz 60 modulation Transmit rise time from the time the external PTT line ...

Page 21: ...e not scanning receiver active mute on receiver active 3W audio into 16Ω receiver active 10W audio into 4Ω 104mA 158mA 585mA 1 6A Current consumptions by control head only no back lighting no LEDs maximum back lighting no LEDs maximum back lighting and LEDs on additional current with LCD heating on 13 3mA 99 9mA 102mA 220mA Table 1 3 Typical current consumptions by radio body while transmitting an...

Page 22: ...22 Introduction TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 23: ...esign 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 th...

Page 24: ...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 ...

Page 25: ...ust 2005 Figure 2 2 Components of the radio body B cover G chassis C screw M4x16 x4 H auxiliary connector bung D lid assembly I screws M4x16 x2 E screw M3x10 x5 J seal F main board assembly 1 gap pad 50W 40W radio only B Cx4 D Ex5 F G Ix2 H J 3630z_01 1 thermal paste ...

Page 26: ...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 50W 40W radio are longer than those of the 25W radio The grooves at the bo...

Page 27: ...r of the radio body Figure 2 3 Components of the main board assembly B M3x10 screw x3 J D range screwlock fastener x2 C 50W 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 D digital board 1 hexagonal nut E internal options connector 1 lock washer F auxiliary connector 1 RF connector G inner foam D range seal 1 main b...

Page 28: ...o 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 50W 40W 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 34 For heat dissipation one of the screw bosses inside the chassis is in contact with the underside of the main...

Page 29: ...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 potentio...

Page 30: ...on the top side of the control head board Space Frame The aluminum 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...

Page 31: ...l head loom assembly with female female adapter E 3 x 10 PT screw x4 F control head board G space frame seal x2 H short light pipe I long light pipe J space frame 1 speaker clamp 1 speaker 1 LCD assembly 1 main keypad 1 power keypad 1 concealed microphone 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 ...

Page 32: ...of the 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 40 Adapter ...

Page 33: ...9100 User s Guide 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 6 User interface 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 ...

Page 34: ...nector 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 7 Connectors 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 Auxilia...

Page 35: ...ugust 2005 Figure 2 8 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 ...

Page 36: ... UHF connector or a BNC connector with an impedance of 50Ω Important The maximum RF input level is 27dBm Higher levels may damage the radio Figure 2 9 Connectors of the control head front view rear view without adapter flange microphone connector control head connector Table 2 1 RF connector pins and signals Pinout Pin Signal Name Signal Type 1 RF RF analog 2 GND RF ground B C rear view ...

Page 37: ...oad 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 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 Extern...

Page 38: ...se 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...

Page 39: ... options connector pins and signals Pinout Pin Signal Description Signal type 1 13V8_SWa Switched 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 supp...

Page 40: ...g 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 not used connected to AGND 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...

Page 41: ...name Description Signal type 1 MIC_RX_AUD Receive audio output Analog 2 13V8a Power 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 Re...

Page 42: ... 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 39 For a basic block diagram of the main board refer to Figure 2 10 on page 43 For a more detailed block diagram of the transceiver refer to Figure 2 12 on page 48 analog mode and Figure 2 13 on ...

Page 43: ...nterface 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 circuitry 2 1 digital RF analog asynchronous serial data synchronous serial data Custom ...

Page 44: ...les 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...

Page 45: ...ontrol head 3 Normal radio operation starts with the RISC processor executing the radio application code including application software for the analog and or digital modes the DSP executing the DSP code for processing of digital signals in analog and digital mode the custom logic executing additional digital signal processing Figure 2 11 Software architecture FPGA SRAM Dynamic Memory FPGA Image RI...

Page 46: ...io 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 ...

Page 47: ...digital board DSP on digital board Note The block diagrams for the analog and digital modes only differ in the operation of the DSP The receive path consists of three major functional parts RF hardware digital baseband processing audio processing and signaling Note The information flow on a digital radio can be categorized in two forms signaling including user data and voice Whilst setting up a ca...

Page 48: ...iple 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 R...

Page 49: ...trol Head VCXO Bias Hardware Hardware Auxiliary Mic FGA Loop Filter Primary Volume Control Secondary Volume Control Mic PGA Channel LPF Loop Filter Antenna RSSI FM Demod Voice FEC DSP Voice Packets Rx Signaling FEC Rx Burst Builder Vocoder Signaling Packets C4FM Demod Voice Packets Tx Burst Builder C4FM Modulator Tx Signaling FEC Signaling Packets Rx Interface Tx Interface Voice FEC Vocoder ALC Ar...

Page 50: ...es 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 p...

Page 51: ...d 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 t...

Page 52: ...signal is FM demodulated it enters the C4FM de modulator Once synchronization has been acquired the received signals should exist as four possible frequencies These frequencies are translated directly into received symbols ready to be passed to the burst builder Rx Burst Builder Digital Mode The job of the burst builder is to dismantle the received burst The burst builder can only receive an incom...

Page 53: ...i 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 and to the control head via a buffer amplifier The output configurat...

Page 54: ...igital board DSP block on digital board Note The block diagrams for the analog and digital modes only differ in the operation of the DSP The transmit path consists of three major functional parts audio processing and signaling frequency synthesizer RF transmitter Note The information flow on a digital radio can be categorized in two forms signaling including user data and voice Whilst setting up a...

Page 55: ...e 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 Analog Mode The output of the automatic level control provides the input to the DSP audio processing chain at a sample rate of 8kHz Op...

Page 56: ... burst For a voice burst it comprises a fixed number of voice packets with control signaling and low speed data interspersed For a data or control burst it comprises a variable number of data blocks Additionally every air interface burst is expanded with a status symbol after every 70 bits of information These status symbols are used for channel access procedures It is the job of the burst builder...

Page 57: ...t 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 ...

Page 58: ...ference modulation is usually applied directly to the TCXO In the system employed in the TM9100 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 ...

Page 59: ...3 RF Transmitter RF Power Amplifier and Switching 50W 40W Radio The RF power amplifier and exciter of the 50W 40W 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 dr...

Page 60: ...ieve the correct overall wave shape and meet transient ACP specifications A typical ramping waveform is shown in Figure 2 14 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 Bias Ramp Up The steady state final stage bias level is supplied by an 8 bit DAC programmed prior to ramp u...

Page 61: ... reverse order respectively For a given power level the look up table values are scaled by a steady state 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 att...

Page 62: ...62 Description TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 63: ... the control head board The main board is decided 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 ...

Page 64: ...nterface 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 circuitry 2 1 digital RF analog asynchronous serial data synchronous serial data Custom ...

Page 65: ...he synthesizer Power Amplifier The power amplifier comprises the driver amplifier Q306 and two paralleled final devices Q309 and Q310 With the 50W 40W 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 155M...

Page 66: ...r 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 as...

Page 67: ...ower 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 50W 40W radio the directional coupler actively senses the forward power an...

Page 68: ...r 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 f...

Page 69: ...DEC and Audio Digital Board PLL Noise Blanker VHF only Switch VHF 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 se...

Page 70: ...annel 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 ...

Page 71: ... 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 ...

Page 72: ...r LPF Mixer VCXO TCXO Modulator Buffer Amplifier PLL MOD VCO 2 VCO 1 Buffer Amplifiers and Coupler 5 V Switch TR 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 ...

Page 73: ...mpares the 25kHz reference 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 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 cha...

Page 74: ...s 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 ...

Page 75: ...nce frequency Circuit Operation The VCXO output is mixed with the TCXO output to create a nominal difference or offset frequency SYN CDC FCL of 12 0kHz 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 MO...

Page 76: ...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 ...

Page 77: ...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 ...

Page 78: ...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 d...

Page 79: ...ter 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 op...

Page 80: ... 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 nine internal power supplies one SMPS five linear regulators 9V0 6V0 3V3 3V0 AN 2V5 CDC three switched supplies 9V0 ...

Page 81: ...ch 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...

Page 82: ...o 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 7 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 o...

Page 83: ...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 ...

Page 84: ...allation 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 ...

Page 85: ... 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 switched current dra...

Page 86: ...aximum 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 inve...

Page 87: ... 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 5 V Regulator I O Combine and Pul...

Page 88: ...ike 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 capa...

Page 89: ...PI 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 S...

Page 90: ...tion 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 concealed microphone control head options connector for optional circuit bo...

Page 91: ...3 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 Cont...

Page 92: ...ata 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 lev...

Page 93: ...TM9100 Service Manual 93 Tait Electronics Limited August 2005 TM9100mobiles Chapter 2 Servicing the Radio ...

Page 94: ...the Control Head 124 5 2 Disassembling the Radio Body 125 5 3 Reassembling the Radio Body 131 5 4 Disassembling and Reassembling the Control Head 135 6 Servicing Procedures 139 6 1 Initial Tasks 139 6 2 Final Tasks 147 7 Power Supply Fault Finding 153 8 Interface Fault Finding 163 9 Frequency Synthesizer Fault Finding 169 9 1 Initial Checks 170 9 2 Power Supplies 173 9 3 Phase locked Loop 181 9 4 ...

Page 95: ...ter RF Power 324 12 3 Biasing of PA Driver and PAs 335 12 4 RF Signal Path 354 13 CODEC and Audio Fault Finding 371 13 1 Power Supplies 372 13 2 Faulty Speaker Audio 375 13 3 No Speaker Audio at Auxiliary Connector 382 13 4 Faulty Receiver 387 13 5 Faulty Modulation 390 13 6 Faulty Modulation Using Auxiliary Connector 394 14 Fault Finding of Control Head 397 14 1 CCTM Commands 398 14 2 Power Suppl...

Page 96: ...96 TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 97: ...e disassembly of the main board assembly Important The circuit boards in the TM9100 radio are complex They should be serviced only by accredited service centers ASC Repairs attempted without the necessary equipment and tools or by untrained personnel might result in permanent damage to the radio Accreditation of Service Centers Service centers that wish to achieve ASC status should contact Technic...

Page 98: ...pplies service centers 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 Assoc...

Page 99: ... layout of the board All PCB informations are published on the Technical Support website Tait FOCUS Database An additional source of information to service centers 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 s...

Page 100: ... 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 servicin...

Page 101: ...rs 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 TMAA24 00 Product code Item TMAA21 01 Cable DB15 socket to RJ45 plug plus speaker connector TMAA23 02 Cable 50W 40W power connector to banana plugs plus speaker connector TMAA20 03 Cable 25W power connector to banana plugs plus speaker ...

Page 102: ...h 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 Note The radio is designed to satisfy the applicable compliance reg ulations Do not make modifications or changes to the radio n...

Page 103: ... 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 Workben...

Page 104: ...ult 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 com...

Page 105: ...bed in TOPA SV 024 Test Unit on page 477 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 s...

Page 106: ...HF 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 TM91...

Page 107: ... information for the board consult the BOM for the board Identify the component in question in the BOM 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 pr...

Page 108: ... 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 ...

Page 109: ...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 centers Figure 4 4 Shielding cans and connectors bottom side of main board assembly DIGITAL BOARD SYN BOT LO2 BOT VCO BOT VCXO BOT CDC BOT NB BOT VHF ONLY SK103 RF CO...

Page 110: ...d 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 componen...

Page 111: ...ited August 2005 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 ...

Page 112: ...ied 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 HyperTermi nal 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 pari...

Page 113: ...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...

Page 114: ...haracter 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 Sel...

Page 115: ...ge 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 th...

Page 116: ...rom 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 th...

Page 117: ... 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 DA...

Page 118: ...nsity 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 wher...

Page 119: ...e 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 ...

Page 120: ...n 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 incor...

Page 121: ...6 1 on page 144 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 12 on page 122 Table 4 11 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 st...

Page 122: ...n 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...

Page 123: ...dy disassemble and reassemble the control head 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 ...

Page 124: ...tant 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 he...

Page 125: ...ions refer to Reassembling the Radio Body on page 131 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 ...

Page 126: ...ng 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 chass...

Page 127: ...he radio body B cover G chassis C screw M4x16 x4 H auxiliary connector bung D lid assembly I screws M4x16 x2 E screw M3x10 x5 J RF connector seal F main 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 ...

Page 128: ...crews 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 131 5 Separate the main board 1 from the heat transfer block F 6 Inspect the inner foam D ran...

Page 129: ...s K30x8 PT screw x2 I power connector seal J power connector 1 gap pad 50W 40W radio only D auxiliary connector 1 RF connector nut E inner foam D range seal 1 RF connector lock washer F heat transfer block 1 RF connector G outer foam seal 1 main board H 1 E G F I 1 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 ...

Page 130: ...ap 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 boar...

Page 131: ...ws 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 50W 40W 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 o...

Page 132: ... Figure 5 6 on page 131 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...

Page 133: ...e 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 fro...

Page 134: ...onnector 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 127 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 a...

Page 135: ...connect 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 Rel...

Page 136: ...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 G and 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 speak...

Page 137: ...ead loom assembly E 3 x 10 PT screw x4 F control head board G space frame seal x2 H short light pipe I long light pipe J space frame 1 speaker clamp 1 speaker 1 LCD assembly 1 main keypad 1 power keypad 1 concealed microphone 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 ...

Page 138: ...138 Disassembly and Reassembly TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 139: ...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 97 Task 1 Initial Administration When a radio is received for repair details of the Customer and the fau...

Page 140: ...o 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 additio...

Page 141: ...he radio powers up successfully go to Task 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 th...

Page 142: ...ting section of the online help 5 If the programming file can be read now save a copy on the test PC and go to Task 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 con...

Page 143: ...peaker 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 for the following elements of the user interface volume control Use CCTM command 1010 to read the volume potentiometer The returned value should be between 0 and 255 LCD Check visually or use CCTM command 1006 1 to switch on all LCD elements Power...

Page 144: ...0003 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 145 Out of lock Go to Frequency Synthesizer Fault Finding on pa...

Page 145: ...uency 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 147 If it does not repair the radio as described in Transmitter Fault ...

Page 146: ...age 169 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 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 7 ...

Page 147: ...fter 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 programmi...

Page 148: ... 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 143 go to Step 2 If it was not possible go to Step 3 2 Reading the software features will have revealed if any software features were enabled for the radio under repair If there were go to Step 3 If there were no...

Page 149: ... 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 pro...

Page 150: ... 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 S...

Page 151: ...ata 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 operatio...

Page 152: ...152 Servicing Procedures TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 153: ...asks are applicable depends on the nature of the fault radio fails to power up power up option has failed external power at connector has failed With the first fault either 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 In this case carry out Task 1 to Task 3 With the second fault the radio powers up when th...

Page 154: ...tial Tasks on page 139 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 Task 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...

Page 155: ...9100 Service Manual Power Supply Fault Finding 155 Tait Electronics Limited August 2005 Figure 7 1 Important components of the power supply circuitry bottom side including 3 3V regulator IC602 pin 7 pin 5 ...

Page 156: ...rd is affecting the supply or preventing the radio from powering up While keeping the ON OFF key depressed measure the supply at the 3V3 test 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 main board assembly and go to Final Tasks on page 147 If the voltage is not correct go to S...

Page 157: ...ault remains the repair failed replace the main board assembly and go to Final Tasks on page 147 6 Reconnect the 13 8V supply Press the ON OFF key If the radio powers up return to Initial Tasks on page 139 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...

Page 158: ...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 139 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 pres...

Page 159: ...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...

Page 160: ... 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 volt...

Page 161: ...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 ...

Page 162: ...irst 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...

Page 163: ... 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...

Page 164: ...Service Manual Tait Electronics Limited August 2005 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 CAN IF TOP CAN ...

Page 165: ...ock 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...

Page 166: ...166 Interface Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 8 4 Components of the interface circuitry bottom side ...

Page 167: ...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 153 and CODEC and Audio Fault Finding on page 371 respectively If the digital board is suspect replace the main board assembly and go to Final Tasks on page 147 8 The fault lies in the fil...

Page 168: ...168 Interface Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 169: ...12 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 u...

Page 170: ...ult 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 wi...

Page 171: ...smit 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 main board assembly and go to Final Tasks on page 147 In the case of the second message failed sanity check go to Step 6 In the case of the third messag...

Page 172: ...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 215 5 If the lock status is 011 the synthesizer is suspect although the power supplies are...

Page 173: ... 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 PIN 4 OF Q508 PIN 4 OF Q508 PIN 4 OF IC606 PIN 4 OF IC606 PIN 5 OF IC606 PIN 5 OF IC606 Q500 AND R533 Q500 AND R533 PINS 7 AND 15 OF IC503 PINS 7 AND 15 OF IC503 SIGNAL T...

Page 174: ...t 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 Task 3 of Power Supply Fault Finding on page 158 7 Remove the FCL TOP can and check the SMPS circuit based on Q500 Q502 and L502 see Figure 9 3 Remove the SYN BOT can and check IC504 and IC505 for shorts see Figure 9 4 replace any suspe...

Page 175: ...inding 175 Tait Electronics Limited August 2005 Figure 9 2 Synthesizer circuitry under the SYN TOP can and the 6 V regulator IC606 top side B1 band H5 H6 bands Measurement point on L506 pin not used Pin 5 5 pin device Q5004 Q508 Q512 Q507 Q506 Q508 Q512 ...

Page 176: ...176 Frequency Synthesizer Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 9 3 Synthesizer circuitry under the FCL TOP can top side SYN TOP CAN ...

Page 177: ...01 is suspect go to Task 3 of Power Supply Fault Finding on page 158 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 confir...

Page 178: ... Frequency Synthesizer Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 9 4 Synthesizer circuitry under the SYN BOT and VCO BOT cans bottom side B1 band H5 H6 bands Q511 Q505 ...

Page 179: ...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 VCO BOT can and check the transmit receive switch based on Q5002 and Q5003 see Figure 9 4 Replace any suspect transistor Conclude wit...

Page 180: ...pply 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 Task 3 of Power Supply Fault Finding on page 158 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 o...

Page 181: ...and output are summarized in Figure 9 5 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 re...

Page 182: ...ER 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...

Page 183: ...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 147 If it has not the FCL is suspect go to Power Supply for FCL on page 215 Figure 9 6 Components between the digital board and the frequency synthesizer VIAS FOR MEA...

Page 184: ...d 6 Enter the CCTM command 334 1 to switch on the synthesizer and measure the voltage at the via between R104 see Figure 9 6 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 main board assembly and go to Final Tasks on page 147 If the voltages are correct go to Step 8 8 There is a fault between the digital board and...

Page 185: ...to Loop Filter on page 187 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 6 5 If there is a fault go to Step 6 If there is no fault the digital board is faulty replace the main board assembly and go to Final Tasks on page 147 6 Repair the fault Confirm the removal of the fault and go to Final Tasks on pag...

Page 186: ...izer Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 9 7 Synthesizer circuitry under the SYN TOP can top side B1 band H5 H6 bands Q512 Q512 Junction of C541 and R547 Junction of C541 and R547 ...

Page 187: ... R542 see Figure 9 7 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 7 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 St...

Page 188: ... error or a transmit fault the transmit VCO is suspect go to Transmit VCO and Related Circuitry UHF Radios on page 201 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 14 If it i...

Page 189: ...If the voltage is correct resolder R542 in position see Figure 9 7 and go to Task 15 3 Check IC504 IC505 Q511 see Figure 9 4 C5085 to C5089 B1 band see Figure 9 7 or C5085 and C5086 H5 H6 bands see Figure 9 7 and associated components 4 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 7 5 If the feedback volt...

Page 190: ...d the digital board see Figure 9 6 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 6 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 main board assembly and go to Final Tasks on page 14...

Page 191: ...C5085 and C5086 H5 H6 bands see Figure 9 7 and associated components Conclude with Step 9 4 Remove R566 and R570 see Figure 9 7 which provide a modulation path to the VCO s 5 Repeat the measurement of Step 1 6 If the correct result is now obtained go to Step 7 If the correct result is still not obtained the CODEC and audio circuitry is suspect resolder R566 and R570 in position see Figure 9 7 and ...

Page 192: ...d related circuitry The minimum and maximum receive frequencies for the different UHF frequency bands are defined in Table 9 2 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 an...

Page 193: ...N 4 OF 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 C...

Page 194: ... maximum given in Table 9 2 3 If the receive frequency measured in Step 2 is correct go to Step 4 If it is incorrect go to Task 19 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 9 While holding the probe on the RX...

Page 195: ...l Frequency Synthesizer Fault Finding 195 Tait Electronics Limited August 2005 Figure 9 9 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 ...

Page 196: ...emove the VCO BOT can 3 Replace the components C567 R574 see Figure 9 10 and IC503 see Figure 9 9 4 Also check the second stage of the receive buffer amplifier based on IC5100 see Figure 9 10 Repair any fault 5 Confirm that the fault in the radio has been removed If it has go to Final Tasks on page 147 If it has not replace the main board assembly and go to Final Tasks on page 147 Figure 9 10 Synt...

Page 197: ...e receive VCO The circuitry is based on Q504 see Figure 9 9 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 Task 17 5 If the frequencies are now correct resolder R542 in position see Figure 9 9 and go to Final Tasks on page 147 If they are still not correct go to Step 6 6 Resolder R542 in position see Fi...

Page 198: ...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 9 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 ...

Page 199: ...n 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 6 replace the main board assembly and go to Final Tasks on page 147 7 Check and resolder R103 in position see Figure 9 6 and check for continuity between Q508 and the digital board via R593 see Figure 9 9 and R103 8...

Page 200: ...he 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 9 Conclude with Step 10 9 Check the first buffer stage based on Q5...

Page 201: ...transmit VCO and related circuitry The minimum and maximum transmit frequencies for the different UHF frequency bands are defined in Table 9 3 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 ci...

Page 202: ...e maximum given in Table 9 3 3 If the transmit frequency measured in Step 2 is correct go to Step 4 If it is incorrect go to Task 25 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 9 While holding the probe on the TX ...

Page 203: ... assembly and go to Final Tasks on page 147 Task 25 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 9 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...

Page 204: ...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 9 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 ...

Page 205: ...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 9 Conclude with Step 10 9...

Page 206: ...apply only to VHF radios the VHF frequency bands are defined in Table 9 4 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 11 Table 9 4 Minimum and maximum...

Page 207: ...1 PIN 2 OF D5004 PIN 2 OF D5004 TX 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 ...

Page 208: ... maximum given in Table 9 4 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 Task 31 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 R54...

Page 209: ...Service Manual Frequency Synthesizer Fault Finding 209 Tait Electronics Limited August 2005 Figure 9 12 Synthesizer circuitry under the SYN TOP can VHF radio top side Tx port Junction of C541 and R547 Rx port ...

Page 210: ...uspect 1 Resolder R542 in position see Figure 9 12 2 Remove the VCO BOT can 3 Replace the components L510 see Figure 9 13 and IC503 see Figure 9 12 4 Confirm that the fault in the radio has been removed If it has go to Final Tasks on page 147 If it has not replace the main board assembly and go to Final Tasks on page 147 Figure 9 13 Synthesizer circuitry under the VCO BOT can VHF radio bottom side...

Page 211: ...13 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 Task 28 to measure the maximum VCO frequency 5 Repeat Step 4 and Step 5 of Task 28 to measure the minimum VCO frequency 6 If the frequencies are now correct resolder R542 in position see Figure 9 12 and go to Final Tasks on page 147 If they are still not correct go to Step 7 7 Resold...

Page 212: ...age 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 Task 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 13 Some RF noise might be observed The voltage should be 10 Enter the CCTM command 335 0 to switch off the supply 11 Ag...

Page 213: ... 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 6 replace the main board assembly and go to Final Tasks on page 147 7 Check and resolder R103 in position see Figure 9 6 and check for continuity between Q5003 see Figure 9 13 and the digital board via R103 8 If no fault ...

Page 214: ...9 13 Some RF noise might be observed 3 Measure the voltage at pin 1 of Q5001 see Figure 9 13 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 13 Conclude with Step 6 5 The buffer amplifier is suspect Check the buffer circuitry based on Q5001 see Figure 9 13 6 If a fault is found repair the circuit and confi...

Page 215: ...t 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 Task 34 below The remaining three stages are covered in VCXO and TCXO Outputs...

Page 216: ...FIER 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...

Page 217: ...assembly from the chassis and place the radio in CCTM 2 Measure the supply 3V0 AN at the via shown in Figure 9 15 The via is adjacent to the CDC TOP can 3 If the voltage is correct go to VCXO and TCXO Outputs on page 218 If it is not the 3V regulator IC603 is suspect go to Task 3 of Power Supply Fault Finding on page 158 via adjacent to CDC TOP can 3 0 0 3 V DC Figure 9 15 TCXO circuitry under the...

Page 218: ...xt to C536 see Figure 9 16 The signal should be 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 17 5 Confirm the removal of the fault and go to Task 36 If the repair failed replace the main board assembly a...

Page 219: ...thesizer Fault Finding 219 Tait Electronics Limited August 2005 Figure 9 16 FCL circuitry under and adjacent the FCL TOP can VIA FOR MEASURING VCXO OUTPUT POSITION IN WHICH TO PLACE R527 FOR FAULT DIAGNOSIS PURPOSES WHEN LOOP OSCILLATES ...

Page 220: ...s at TP501 and TP502 on page 221 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 15 5 Confirm the removal of the fault and go to Signals at TP501 and TP502 on page 221 If the repair failed replace the main board assembly and go to Final Tasks on page 147 TCXO...

Page 221: ...ifference frequency at the TP502 test point see Figure 9 16 The signal is SYN CDC FCL and should be 2 If the signal is correct go to Task 38 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 16 5 Repair...

Page 222: ...not there is a fault in the modulator buffer amplifier IC502 pins 1 to 3 and associated components see Figure 9 16 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 16 This forces the VCXO loop voltage high 6 Use the oscilloscope probe to check the VCXO output at C536 probe the via next to C536 see Figure 9 16 The ...

Page 223: ...f IC501 see Figure 9 16 should be Also the VCXO input to the mixer at R522 pin 1 of IC501 see Figure 9 16 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 16 replace the main board assembly and go to Final Tasks on page 147 6 Resolder R527 in its original position a...

Page 224: ...aults 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 16 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...

Page 225: ...e 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 17 3 Confirm the removal of the fault and go to Step 4 If the repair failed replace the main board assembly and go to Final Tasks on page 147 4 Replace all cans 5 Repeat Task 40 to confirm the removal of the fault If the repair failed replace the main board a...

Page 226: ...If there are faults such as open circuits in the connections repair the circuitry and repeat Task 40 If the connections are not faulty then the digital board is faulty Replace the main board assembly and go to Final Tasks on page 147 6 The CODEC 2 circuitry comprises IC205 and associated components under the CDC TOP can see Figure 9 15 as well as R246 under the CDC BOT can see Figure 7 3 on page 1...

Page 227: ...f the receiver sensitivity is low begin with Faulty Receiver Sensitivity on page 228 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 112 Table 10 1 CCTM commands required for the diagnosis of faults in the receiver Command Description 72 101 x y ...

Page 228: ...ult 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 10mdB should result in a ten fold chan...

Page 229: ...0 Service Manual Receiver Fault Finding 229 Tait Electronics Limited August 2005 Figure 10 1 Receiver circuitry under the IF TOP can top side Q404 H5 H6 bands Measurement point B1 band Q404 Measurement point ...

Page 230: ...lies First check the two power supplies 3V0 AN and 3V0 RX for the receiver circuitry 1 Remove the main board assembly from the chassis 2 Check for 3 0V DC 3V0 AN at the TP601 test point near the LO2 BOT 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 Task 3 of Power Supply Fault Finding on page 158 4 Remove the LO2 BOT can 5 Check f...

Page 231: ...iver Fault Finding 231 Tait Electronics Limited August 2005 Figure 10 2 Receiver circuitry under the LO2 BOT can bottom side H5 H6 bands B1 band Figure 10 3 Receiver circuitry under the FE TOP can top side Measurement point Q401 ...

Page 232: ...age 147 4 Recalibrate the receiver using the calibration application 5 Confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed go to Task 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 stat...

Page 233: ...t 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 147 If the repair failed go to Task 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 c...

Page 234: ...uning 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...

Page 235: ... 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 215 8 Recalibrate the receiver using the calibration application 9 Confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed go to Task 9 Vc 2 7 0 1V Ic 10 1mA...

Page 236: ...ck 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 Task 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 50W 40W Radios on page 245 or Transmitter Fault Finding 25W Radios ...

Page 237: ...tion 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 3 If the settings are correct go to Task 11 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 Task 1 and check the receiver se...

Page 238: ...etween 0mdB and about 3mdB 2 If the values are as expected go to Task 13 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 Task 1 and check the receiver sensitivity 5 Check if the RSSI fault has been removed If it has go to Final Tasks on page 147 If it has not go to Task 13 Task 13 AGC Delta Gain I...

Page 239: ...libration 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 Channel Profiles heading 2 Click the General Settings tab 3 Check the setting in the Squelch Detect Type field Ensure that the setting is what the Customer expe...

Page 240: ...e 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 147 If it has not go to T...

Page 241: ...ning 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 Task 10 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...

Page 242: ...tion 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 XL...

Page 243: ...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 147 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 s...

Page 244: ...244 Receiver Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 245: ...mputer Controlled Test Mode CCTM on page 112 Table 11 1 CCTM commands required for the diagnosis of faults in the transmitter Command Description 32 33 47 101 x y 0 114 x 304 304 x 318 319 326 x 331 331 x 332 332 x 334 x 335 x Set radio in receive mode Set radio in transmit mode Read temperature near PAs displays temperature x in degrees celsius and voltage y Set transmit frequency x in hertz and ...

Page 246: ...e 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 main board assembly 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 123 Can Repla...

Page 247: ...n board assembly will be connected to the RF communications test set as shown in Figure 4 2 on page 106 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 Tes...

Page 248: ...ulator 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 T...

Page 249: ...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 Task 7 in Transmitter RF Power on page 262 7 Measure the voltage at the point on L310 shown in Figure 11 2 B1 band or Figure 11 3 H5 H7 bands This is the supply ...

Page 250: ...er Fault Finding 50W 40W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 11 2 Point for measuring the power supply to the PAs B1 band Q310 B1 BAND Q309 L310 PAF TOP MEASUREMENT POINT ON L310 ...

Page 251: ...al Transmitter Fault Finding 50W 40W Radios 251 Tait Electronics Limited August 2005 Figure 11 3 Point for measuring the power supply to the PAs H5 and H7 bands PAF TOP H5 H7 BANDS Q310 Q309 L310 MEASUREMENT POINT ON L310 ...

Page 252: ...0 Service Manual Tait Electronics Limited August 2005 Figure 11 4 Point for measuring the power supply to the PA driver B1 band B1 BAND L306 Q308 R339 R350 Q306 PADTOP MEASUREMENT POINT ON L306 POINT 1 ON R350 MEASUREMENT POINT ON R339 POINT 2 ON R350 ...

Page 253: ...Radios 253 Tait Electronics Limited August 2005 Figure 11 5 Point for measuring the power supply to the PA driver H5 and H7 bands R339 Q308 H5 H7 BANDS L306 R350 Q306 PADTOP MEASUREMENT POINT ON L306 POINT 1 ON R350 MEASUREMENT POINT ON R339 POINT 2 ON R 350 ...

Page 254: ...uld be 4 If the voltage measured in Step 3 is correct go to Step 5 If it is not go to Task 3 and check the 9V power supply 5 Measure the voltage at the point 2 on R350 shown in Figure 11 4 B1 band or Figure 11 5 H5 H7 bands 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 4 B1 band or Figure 11 5 H5 H7 bands and conclude with...

Page 255: ...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 6 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 259 If it is not the 9V regulator IC601 and the associated switching circuitry Q603 are susp...

Page 256: ...e 9V supply the forward and reverse RF power and the inhibiting of the transmitter B1 BAND H5 H7 BANDS 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 ...

Page 257: ... 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 7 Data required for the first task checking the forward and reverse powers are supplied in Table 11 3 Ta...

Page 258: ...POINT 50 TEST LEAD TO TEST SET Ω 50 TEST LEAD TO TEST SET Ω D TX INH TEST POINT D TX INH 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 PW...

Page 259: ...oltage 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 6 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 ...

Page 260: ...red 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 proc...

Page 261: ...r 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 Task 19 ...

Page 262: ...ic signal at the D TX INH test point see Figure 11 18 on page 288 B1 band or Figure 11 6 H5 H7 bands 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 Task 8 8 The lock status is possibly no longer normal Enter the CCTM command 7...

Page 263: ...urned 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 269 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 8 B1 band and Figure 11 9 H5 and H7 bands 5 If there is no fault go to CODEC and Audio Fault Finding on page 371 If a fault i...

Page 264: ...e Manual Tait Electronics Limited August 2005 Figure 11 8 PA circuitry under the PAF TOP can and part of the directional coupler under the DIRC TOP can B1 band B1 BAND C348 C349 C350 D301 Q309 Q310 TEST PAD MOUNTING POINT FOR TEST CAPACITOR TEMPERATURE SENSOR ...

Page 265: ...65 Tait Electronics Limited August 2005 Figure 11 9 PA circuitry under the PAF TOP can and part of the directional coupler under the DIRC TOP can H5 and H7 bands H5 H7 BANDS C348 C349 C350 D301 Q310 Q309 TEST PAD MOUNTING POINT FOR TEST CAPACITOR TEMPERATURE SENSOR ...

Page 266: ... 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 ...

Page 267: ...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 center 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 E...

Page 268: ...eat 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 12 and then Task 13 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...

Page 269: ...heck 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 ...

Page 270: ...NCY 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 PIN 8 OF IC303 PIN 8 OF IC303 PIN 9 OF IC303 PIN 9 OF IC303 PIN 10 OF IC303 PIN 10 OF IC303 PIN 5 OF IC303 PIN 5 OF IC303 PIN 3 OF IC303 PIN 3 OF IC303 FIN1 TEST POINT FIN1 TEST P...

Page 271: ... Step 7 of Task 12 this will be less than 500mA 3 Enter the CCTM command 331 x where x was recorded in Task 12 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 Task 14 If neither the...

Page 272: ...ited August 2005 Figure 11 11 Test points and components of the shaping filter B1 band 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 ...

Page 273: ...t 2005 Figure 11 12 Test points and components of the shaping filter H5 and H7 bands 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 CAN PWR TEST POINT SET PWR TEST POINT VCO TOP CAN DRV TEST POINT FIN2 TEST POINT FIN1 TEST POINT ...

Page 274: ...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 Task 12 6 Check that the voltage at the gate of Q310 is see Figure 11 13 and Figure 11 14 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 th...

Page 275: ...g 50W 40W Radios 275 Tait Electronics Limited August 2005 Figure 11 13 PA circuitry under the PAF TOP can B1 band B1 BAND 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 ...

Page 276: ...Service Manual Tait Electronics Limited August 2005 Figure 11 14 PA circuitry under the PAF TOP can H5 and H7 bands 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 ...

Page 277: ...ultimeter to measure the voltage at the FIN1 test point see Figure 11 11 and Figure 11 12 The voltage should be 2 Enter the CCTM command 331 x where x was recorded in Task 12 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 371 6 Check I...

Page 278: ...1 and Figure 11 12 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 Task 12 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...

Page 279: ... 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 Task 12 6 Check that the voltage at the gate of Q309 is see Figure 11 13 and Figure 11 14 7 Enter the CCTM command 32 to place the radio in receive mode 8 If the voltage is correct Q309 is faulty replace the m...

Page 280: ...ultimeter to measure the voltage at the FIN2 test point see Figure 11 11 and Figure 11 12 The voltage should be 2 Enter the CCTM command 332 y where y was recorded in Task 12 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 371 6 Check I...

Page 281: ...mp 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 Task 21 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 te...

Page 282: ... go to Task 21 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 15 and Figure 11 16 8 Enter the CCTM command 32 to place the radio in receive mode 9 If the v...

Page 283: ...ansmitter Fault Finding 50W 40W Radios 283 Tait Electronics Limited August 2005 Figure 11 15 PA driver circuitry under the PAD TOP can B1 band PADTOP Q3504 B1 BAND R327 C310 R324 Q306 COMPONENTS C310 R324 AND R327 GATE OF Q306 ...

Page 284: ...ng 50W 40W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 11 16 PA driver circuitry under the PAD TOP can H5 and H7 bands PADTOP H5 H7 BANDS Q306 R324 C310 R327 GATE OF Q306 COMPONENTS C310 R324 AND R327 ...

Page 285: ...ent 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 293 If it does not go to Step 6 6 Check that the voltage from the DAC is chan...

Page 286: ...286 Transmitter Fault Finding 50W 40W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 11 17 Circuitry under the DIRC TOP can B1 BAND H5 H7 BANDS R3035 D305 R383 D305 ...

Page 287: ...ance might 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 17 and go to Step 11 ...

Page 288: ... 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 11 and Figure 11 12 C310 R324 and R327 see Figure 11 15 and Figure 11 16 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 15 and Fig...

Page 289: ...ransmitter Fault Finding 50W 40W Radios 289 Tait Electronics Limited August 2005 Figure 11 19 Components of concern on the bottom side of the main board H5 and H7 bands H5 H7 BANDS C319 R341 R340 R396 COPPER PLATE VCO BOT CAN ...

Page 290: ...asure 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 Task 25 5 Enter the CCTM command 32 to place the radio in receive mode 6 Check C322 C324 R342 R347 see Figure 11 11 and Figure 11 12 and R396 see Figure 11 18 and Figure 11 19 in the power control circuit Repair any fault Replace IC303 if none of the o...

Page 291: ... 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 11 and Figure 11 12 and C319 see Figure 11 18 and Figure 11 19 and go to Step 6 5 Check the components between the PWR test point and pin 1 of IC301 see Figure 11 11 and Figure 11 12 and go to Step 6 6 Repair any fault revealed by the checks in Step 4 and Step 5 Replace ...

Page 292: ...al 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 20 Figure 11 20 Measurement points for diagnosing faults in the RF signal path TEST CAPACITOR TEST CAPACITOR L314 RF CON N...

Page 293: ...nes 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 21 and Figure 11 22 Earth the probe to the FCL TOP can adjacent to the PA driver circuitry The required voltage should be as given in Tab...

Page 294: ... driver circuitry under the PAD TOP can B1 band PADTOP Q306 C3500 C3505 C3509 C307 Q3501 Q3504 Q3502 Q3505 R3525 OUTPUT OF PA DRIVER OUTPUT OF STAGE 3 OF EXCITER AT C307 OUTPUT OF STAGE 1 OF EXCITER AT C3505 JUNCTION OF R3525 AND C3512 OUTPUT OF STAGE 2 OF EXCITER AT C3509 B1 BAND SYNTHESIZER OUTPUT AT C3500 FCL TOP CAN ...

Page 295: ...cuitry under the PAD TOP can H5 and H7 bands PADTOP 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 ...

Page 296: ... 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 ...

Page 297: ... 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 ...

Page 298: ...de 5 Measure the RF voltage after C3505 see Figure 11 21 and Figure 11 22 Use an RFP5401A RF probe or the equivalent The required voltage should be as given in Table 11 8 B1 band 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 Task 29 If it is not go to Step 8 8 Check the components around Q3501 see Fig...

Page 299: ...uivalent The required voltage should be as given in Table 11 8 B1 band Table 11 9 H5 or Table 11 10 H7 2 If the voltage is correct go to Task 30 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 21 and Figure 11 22 5 Repair any fault revealed by the above checks Replace Q3502 see Figure 11 21 and Figure 11 22 ...

Page 300: ...in transmit mode measure the RF voltage at the junction of R3525 and C3512 see Figure 11 21 and Figure 11 22 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 21 and Figure 11 22 Repair any fault Replace Q3504 if none of the othe...

Page 301: ...ep 6 If they do not go to Task 12 in Biasing of PA Driver and PAs on page 269 6 Repair the fault Confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed replace the main board assembly and go to Final Tasks on page 147 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 th...

Page 302: ...0W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 11 23 Components of the interstage matching circuitry between the PA driver Q306 and the PAs Q309 and Q310 B1 band B1 BAND Q310 Q309 Q306 PAF TOP CAN PAD TOP CAN ...

Page 303: ...inding 50W 40W Radios 303 Tait Electronics Limited August 2005 Figure 11 24 Components of the interstage matching circuitry between the PA driver Q306 and the PAs Q309 and Q310 H5 and H7 bands H5 H7 BANDS Q310 Q309 Q306 PAF TOP CAN PAD TOP CAN ...

Page 304: ...ath to the test pad shown in Figure 11 25 and Figure 11 26 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 band Table 11 9 H5 or Table ...

Page 305: ...nding 50W 40W Radios 305 Tait Electronics Limited August 2005 Figure 11 25 Circuitry under the DIRC TOP can and the points for attaching the test lead and test capacitor B1 band B1 BAND C348 C349 C350 TEST PAD MOUNTING POINT FOR TEST CAPACITOR ...

Page 306: ...100 Service Manual Tait Electronics Limited August 2005 Figure 11 26 Circuitry under the DIRC TOP can and the points for attaching the test lead and test capacitor H5 and H7 bands H5 H7 BANDS C348 C349 C350 TEST PAD MOUNTING POINT FOR TEST CAPACITOR ...

Page 307: ... 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 band 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 1...

Page 308: ...e 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 band 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 ou...

Page 309: ...ios 309 Tait Electronics Limited August 2005 Figure 11 27 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 ...

Page 310: ... 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 band 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...

Page 311: ...ual Transmitter Fault Finding 50W 40W Radios 311 Tait Electronics Limited August 2005 Figure 11 28 Components of concern on the bottom side of the main board B1 band B1 BAND R389 R390 NB BOT CAN COPPER PLATE VCO BOT CAN ...

Page 312: ... Finding 50W 40W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 11 29 Components of concern on the bottom side of the main board H5 and H7 bands H5 H7 BANDS R3000 R389 R390 COPPER PLATE VCO BOT CAN ...

Page 313: ...TM9100 Service Manual Transmitter Fault Finding 50W 40W Radios 313 Tait Electronics Limited August 2005 Figure 11 30 Circuitry under the LPF TOP can B1 BAND H5 H7 BANDS ...

Page 314: ...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 band 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 com...

Page 315: ...r Controlled Test Mode CCTM on page 112 Table 12 1 CCTM commands required for the diagnosis of faults in the transmitter Command Description 32 33 47 101 x y 0 114 x 304 304 x 318 319 326 x 331 331 x 332 332 x 334 x 335 x Set radio in receive mode Set radio in transmit mode Read temperature near PAs displays temperature x in degrees celsius and voltage y Set transmit frequency x in hertz and recei...

Page 316: ...shielding the bulk of the transmitter circuitry PAD TOP PAF TOP DIRC TOP PIN TOP LPF TOP To remove any can first remove the main board assembly 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 123 Can Replacement Repla...

Page 317: ...board assembly will be connected to the RF communications test set as shown in Figure 4 2 on page 106 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...

Page 318: ...ator 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 TRA...

Page 319: ... 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 Task 7 in Transmitter RF Power on page 328 7 Measure the voltage at the point on L310 shown in Figure 12 2 This is the supply at ...

Page 320: ...itter Fault Finding 25W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 12 2 Point for measuring the power supply to the PAs H5 H6 BANDS B1 BAND MEASUREMENT POINT ON L310 B1 BAND SIMILAR ...

Page 321: ...ited August 2005 Figure 12 3 Point for measuring the power supply to the PA driver R324 C310 H5 H6 BANDS B1 BAND MEASUREMENT POINT ON L306 MEASUREMENT POINT ON L306 L306 POINT 2 ON R350 POINT 2 ON R350 POINT 1 ON R350 POINT 1 ON R350 MEASUREMENT POINT ON R339 MEASUREMENT POINT ON R339 ...

Page 322: ...p 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 Task 1 to confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed or the fault could not be found replace the main board assembly and go to Final Tasks on pag...

Page 323: ... August 2005 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 ...

Page 324: ...sk 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...

Page 325: ...INT 50 TEST LEAD TO TEST SET Ω 50 TEST LEAD TO TEST SET Ω D TX INH TEST POINT D TX INH 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 ...

Page 326: ...tage 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 En...

Page 327: ...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...

Page 328: ...ignal 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 Task 12 in Biasing of PA Driver and PAs on page 335 5 Check the logic signal at the D TX INH test point see Figure 12 4 The signal ...

Page 329: ... 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 335 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 B1 band and Figure 12 7 ...

Page 330: ...ios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 12 6 PA circuitry under the PAF TOP can and part of the directional coupler under the DIRC TOP can B1 band Mounting point for test capacitor Test pad Temperature sensor ...

Page 331: ...inding 25W Radios 331 Tait Electronics Limited August 2005 Figure 12 7 PA circuitry under the PAF TOP can and part of the directional coupler under the DIRC TOP can H5 and H6 bands Mounting point for test capacitor Test pad Temperature sensor ...

Page 332: ...st 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 1...

Page 333: ... 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 center 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 b...

Page 334: ...t 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 12 and then Task 13 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 r...

Page 335: ...k 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 ...

Page 336: ...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 PIN 8 OF IC303 PIN 8 OF IC303 PIN 9 OF IC303 PIN 9 OF IC303 PIN 10 OF IC303 PIN 10 OF IC303 PIN 5 OF IC303 PIN 5 OF IC303 FIN1 TEST POINT FIN1 TEST POINT FIN2 TEST POINT FI...

Page 337: ... Task 12 this will be less than 500mA 3 Enter the CCTM command 331 x where x was recorded in Task 12 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 14 If neither the current n...

Page 338: ...ice Manual Tait Electronics Limited August 2005 Figure 12 9 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 ...

Page 339: ...TM 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 Task 12 6 Check that the voltage at the gate of Q310 is see Figure 12 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 m...

Page 340: ...l Tait Electronics Limited August 2005 Figure 12 10 PA circuitry under the PAF TOP can H5 H6 BANDS B1 BAND CICUITRY BETWEEN IC301 AND PAs H5 AND H6 BANDS SIMILAR VIA TO GATE OF Q309 VIA TO GATE OF Q310 VIA TO PIN 14 OF IC301 VIA TO PIN 8 OF IC301 PAF TOP PAF TOP ...

Page 341: ... PAs 1 Use the multimeter to measure the voltage at the FIN1 test point see Figure 12 9 The voltage should be 2 Enter the CCTM command 331 x where x was recorded in Task 12 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 371 6 Check IC3...

Page 342: ...re 12 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 Task 12 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 ar...

Page 343: ... 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 Task 12 6 Check that the voltage at the gate of Q309 is see Figure 12 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 mai...

Page 344: ... PAs 1 Use the multimeter to measure the voltage at the FIN2 test point see Figure 12 9 The voltage should be 2 Enter the CCTM command 332 y where y was recorded in Task 12 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 371 6 Check IC3...

Page 345: ...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 Task 21 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...

Page 346: ...o to Task 21 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 11 8 Enter the CCTM command 32 to place the radio in receive mode 9 If the voltage is correct r...

Page 347: ...nsmitter Fault Finding 25W Radios 347 Tait Electronics Limited August 2005 Figure 12 11 PA driver circuitry under the PAD TOP can GATE OF Q306 H5 H6 BANDS B1 BAND COMPONENTS C310 R324 R327 COMPONENTS C310 R324 R327 GATE OF Q306 ...

Page 348: ...he 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 355 If it does not go to Step 6 6 Check that the voltage from the DAC ...

Page 349: ...TM9100 Service Manual Transmitter Fault Finding 25W Radios 349 Tait Electronics Limited August 2005 Figure 12 12 Circuitry under the DIRC TOP can B1 band H5 H6 bands ...

Page 350: ...pin 5 of IC303 or use the FWD PWR test point see Figure 12 9 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 9 Remove the DIRC TOP can 10 Check the components of the directional coupler see Figure 12 12 and go t...

Page 351: ...ontrol 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 9 C310 R324 and R327 see Figure 12 11 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 11 3 Con...

Page 352: ...352 Transmitter Fault Finding 25W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 12 13 Components of concern on the bottom side of the main board B1 band H5 H6 bands ...

Page 353: ...igure 12 9 if none of the other components is faulty Confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed replace the main board assembly and go to Final Tasks on page 147 8 Measure the voltage at pin 1 of IC301 see Figure 12 9 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 meas...

Page 354: ...ask 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 14 Figure 12 14 Measurement points for diagnosing faults in the RF signal path TEST CAPACITOR TEST CAPACIT...

Page 355: ...26 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 15 Earth the probe to the FCL TOP can adjacent to the PA driver circuitry The required voltage should be as given in Tabl...

Page 356: ...tronics Limited August 2005 Figure 12 15 PA driver circuitry under the PAD TOP can H5 H6 BANDS SYNTHESIZER OUTPUT AT C300 BUFFER OUTPUT AT C313 SYNTHESIZER OUTPUT AT C300 BUFFER OUTPUT AT C313 EXCITER OUTPUT AT C301 EXCITER OUTPUT AT C301 B1 BAND DRIVER OUTPUT DRIVER OUTPUT ...

Page 357: ... 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 9 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 ...

Page 358: ...15 9 Repair any fault revealed by the above checks Replace Q300 see Figure 12 15 if none of the other components is faulty 10 Confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed replace the main board assembly and go to Final Tasks on page 147 Task 27 Output of Exciter If the output of the buffer amplifier is correct check that of the exciter at C301 1 With the ...

Page 359: ... they do not go to Task 12 in Biasing of PA Driver and PAs on page 335 6 Repair the fault Confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed replace the main board assembly and go to Final Tasks on page 147 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...

Page 360: ...g 25W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 12 16 Components of the interstage matching circuitry between the PA driver Q306 and the PAs Q309 and Q310 B1 BAND H5 H6 BANDS PAF TOP CAN PAD TOP CAN ...

Page 361: ...B Solder the outer sheath to the test pad 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 B1 band or Table 12 9 H5 H...

Page 362: ...s TM9100 Service Manual Tait Electronics Limited August 2005 Figure 12 17 Circuitry under the DIRC TOP can and the points for attaching the test lead and test capacitor B1 band H5 H6 bands Mounting point for test capacitor Test pad Test pad ...

Page 363: ... 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 B1 band or Table 12 9 H5 H6 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 i...

Page 364: ...r 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 B1 band or Table 12 9 H5 H6 8 Enter the CCTM command 33 to place the radio in transmit mode 9 Measu...

Page 365: ...ult Finding 25W Radios 365 Tait Electronics Limited August 2005 Figure 12 18 Circuitry under the PIN TOP can and points for attaching the test lead and test capacitor B1 band H5 H6 bands Mounting point for test capacitor Test pad Test pad ...

Page 366: ...r 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 B1 band or Table 12 9 H5 H6 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...

Page 367: ...nsmitter Fault Finding 25W Radios 367 Tait Electronics Limited August 2005 Figure 12 19 Components of concern on the bottom side of the main board B1 BAND COPPER PLATE VCO BOT CAN NB BOT CAN COPPER PLATE VCO BOT CAN H5 H6 BANDS ...

Page 368: ...368 Transmitter Fault Finding 25W Radios TM9100 Service Manual Tait Electronics Limited August 2005 Figure 12 20 Circuitry under the LPF TOP can top side B1 band H5 H6 bands ...

Page 369: ...itter 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 B1 band or Table 12 9 H5 H6 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...

Page 370: ...370 Transmitter Fault Finding 25W Radios TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 371: ...e 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 372 Also note that the conditions concerning the auxiliary connector can both occur at the same time In this case carry o...

Page 372: ...emove the main board assembly 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 Task 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 t...

Page 373: ...ervice Manual CODEC and Audio Fault Finding 373 Tait Electronics Limited August 2005 Figure 13 1 Power supply circuitry for the CODEC and audio circuitry under the CDC BOT can LO2 BOT CAN CAN FOR DIGITAL BOARD ...

Page 374: ...r IC604 is suspect see Figure 13 1 Check the regulator as described in Task 3 of Power Supply Fault Finding on page 158 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 modulat...

Page 375: ... 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 vicini...

Page 376: ...Task 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 Task 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...

Page 377: ...d assembly and go to Final Tasks on page 147 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 main board assembly and go to Final Tasks on page 147 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 sol...

Page 378: ...and Audio Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 13 3 Circuitry under the CDC TOP can and adjacent interface circuitry Junction of R234 and R235 Junction of R708 and C706 ...

Page 379: ...asks on page 147 If the repair failed or the fault could not be found replace the main board assembly and go to Final Tasks on page 147 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 main board assembly and go to Final Tasks...

Page 380: ...DEC and Audio Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 13 4 Circuitry under the CDC BOT can LO2 BOT CAN CAN FOR DIGITAL BOARD JUNCTION OF R218 AND IC204 CDC AUD TAP OUT ...

Page 381: ...rect go to Step 4 If it is not either CODEC 1 IC204 or the digital board is faulty replace the main board assembly and go to Final Tasks on page 147 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 147 If the re...

Page 382: ...here 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 394 if there is also a fault with the transmit modulation using the auxiliary connector Figure 13 5 Circuitry...

Page 383: ...ns 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 che...

Page 384: ...384 CODEC and Audio Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 13 6 Circuitry in the vicinity of the auxiliary connector bottom side AUXILIARY CONNECTOR SK101 ...

Page 385: ...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...

Page 386: ...386 CODEC and Audio Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 13 7 Circuitry under the CDC BOT can LO2 BOT CAN CAN FOR DIGITAL BOARD JUNCTION OF R224 AND IC204 ...

Page 387: ...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 Task 11 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 r...

Page 388: ...and Audio Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 Figure 13 8 Circuitry in the vicinity of the CDC TOP can B1 band H5 H6 bands Junction of C708 and C732 Junction of C708 and C732 ...

Page 389: ...se 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 227 5 Either the digital board or CODEC 1 IC204 is faulty replace t...

Page 390: ... 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 ...

Page 391: ...TM9100 Service Manual CODEC and Audio Fault Finding 391 Tait Electronics Limited August 2005 Figure 13 9 Circuitry in under the CDC BOT can LO2 BOT CAN CAN FOR DIGITAL BOARD ...

Page 392: ...oard assembly and go to Final Tasks on page 147 Task 14 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...

Page 393: ...M9100 Service Manual CODEC and Audio Fault Finding 393 Tait Electronics Limited August 2005 Figure 13 10 Circuitry under the CDC TOP can ITF AUD TAP IN JUNCTION OF R237 AND R241 JUNCTION OF R229 AND R232 ...

Page 394: ...mmand 32 to place the radio in receive mode 4 If the modulation is correct go to Step 5 If it is not go to Task 12 of Faulty Modulation on page 390 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 ...

Page 395: ...replace IC205 see Figure 13 10 5 Confirm the removal of the fault and go to Final Tasks on page 147 If the repair failed replace the main board assembly and go to Final Tasks on page 147 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 main board assembly and go to Final Tasks on page 147 9 Check for and re...

Page 396: ...396 CODEC and Audio Fault Finding TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 397: ... 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...

Page 398: ...003 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 ...

Page 399: ...emote 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 ...

Page 400: ...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 su...

Page 401: ...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...

Page 402: ...lighting Faulty on page 404 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...

Page 403: ...and connect it to a good control head 3 Replace 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 R4 to R8...

Page 404: ...f Q102 If the signal is correct continue with step 3 If the signal is not correct refer to Power Supply Faulty on page 400 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 re...

Page 405: ...ature 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 400 4 Check the signal at pin 4 G2 of Q102 If the signal is not correct visually inspect pin 4 for open contact Otherwise ...

Page 406: ...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...

Page 407: ...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 ...

Page 408: ... 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 backligh...

Page 409: ...ust 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 ba...

Page 410: ...nal 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 t...

Page 411: ...TM9100 Service Manual Fault Finding of Control Head 411 Tait Electronics Limited August 2005 Figure 14 10 PCB layout of the power on off key circuitry top side bottom side ...

Page 412: ... 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 tact switch 2 Visually inspect both tact switches A and B of a key for...

Page 413: ...istor 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 P...

Page 414: ...rite 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 416 Figure 14 13 Circuit diagram of the speaker circuitry J103 18 SPKR Cont...

Page 415: ...TM9100 Service Manual Fault Finding of Control Head 415 Tait Electronics Limited August 2005 Figure 14 14 PCB layout of the speaker circuitry top side bottom side ...

Page 416: ...y of the main board refer to xxx on page yyy 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 s...

Page 417: ...TM9100 Service Manual Fault Finding of Control Head 417 Tait Electronics Limited August 2005 Figure 14 16 PCB layout of the volume control circuitry top side bottom side ...

Page 418: ...y 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 I...

Page 419: ...TM9100 Service Manual Fault Finding of Control Head 419 Tait Electronics Limited August 2005 Figure 14 18 PCB layout of PTT circuitry top side bottom side ...

Page 420: ...420 Fault Finding of Control Head TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 421: ... 15 Spare Parts Introduction This section lists all serviceable parts except PCB components of the radio body Figure 15 1 Figure 15 2 and Table 15 1 control head Figure 15 3 and Table 15 2 Figure 15 1 Spare parts of the radio body sheet 1 of 2 B Cx4 D E x2 Gx5 F I C 1 1 1 J H ...

Page 422: ...422 Spare Parts TM9100 Service Manual Tait Electronics Limited August 2005 Figure 15 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 ...

Page 423: ... 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 0...

Page 424: ...424 Spare Parts TM9100 Service Manual Tait Electronics Limited August 2005 Figure 15 3 Spare parts of the control head C E F G G 1 H I J 1 1 1 1 1 1 x2 x4 D 3451z_02 B 1 ...

Page 425: ...ht pipe 1 262 00003 xx TMAA22 97 I Long light pipe 1 262 00004 xx TMAA22 97 J Space frame 1 319 30077 xx TMAA22 97 1 Speaker clamp 1 303 50111 xx TMAA22 97 1 Speaker 1 252 00011 xx TMAA22 97 1 LCD assembly 1 TMAA22 94 x3 1 Main keypad 1 311 03124 xx TMAA22 97 1 Power keypad 1 311 03120 xx TMAA22 97 1 Concealed microphone 1 TMAA02 07 1 Front panel assembly 1 TMAA22 97 1 Knob for volume control pote...

Page 426: ...426 Spare Parts TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 427: ...TM9100 Service Manual 427 Tait Electronics Limited August 2005 TM9100 mobiles Chapter 3 Accessories ...

Page 428: ...440 17 3 Removing a Radio from the Security Bracket 441 17 4 Replacing the Radio in the Security Bracket 441 17 5 Disassembling the Security Bracket 442 17 6 Ordering Extra Parts 442 18 TMAA04 05 Ignition Sense Kit 443 18 1 Installation 443 18 2 Radio Programming 443 19 TMAA10 01 Desktop Microphone 445 19 1 Operation 445 19 2 Installation 445 19 3 Adjustment 446 19 4 Interface Specification 446 19...

Page 429: ...ecification 457 22 4 Circuit Description 457 22 5 PCB Information 458 23 Installing an Enhanced Remote Kit 461 23 1 Installation 461 23 2 Circuit Description 467 23 3 Servicing the Remote Control Head Installation Parts 468 23 4 PCB Information 470 24 TOPA SV 024 Test Unit 477 24 1 Test Setup 477 24 2 Operation 479 24 3 PCB Information PCB IPN 220 01418 02A 481 ...

Page 430: ...430 TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 431: ... Using the Keypad The 12 alphanumeric keys on the keypad microphone are used to dial call strings and enter text The left selection key right selection key and scroll keys or have the same functions as the left and right selection keys and scroll keys on the control head Pressing an alphanumeric key enters the first character on the key into the control head display Subsequent quick presses toggle...

Page 432: ...adio s Main menu or you can use a combination of the two methods as in the following example Example Making a local call to your Dispatcher 1 Select the required channel 2 Select Menu Local Calls 3 Press the key corresponding to the first letter of the name of the person you want to call You will have to use short presses to toggle through the characters on the key until you get the correct one se...

Page 433: ...he 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 micropho...

Page 434: ...ne help of the programming application for more information about these programming options 16 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 16 5 Circuit Description The microphone has a standard 12 key telephone keypad which is c...

Page 435: ...6w 1 R10 038 15100 10 Res 0603 10k 1 16w 1 R11 038 15470 10 Res 0603 47k 1 16w 1 R12 038 15470 10 Res 0603 47k 1 16w 1 R13 038 13180 00 Res 0603 180e 1 16w 5 R14 038 12100 10 Res 0603 10e 1 R15 038 15470 10 Res 0603 47k 1 16w 1 R16 038 13180 00 Res 0603 180e 1 16w 5 R17 038 13470 00 Res 0603 470e 1 16w 5 R18 038 17100 00 Res 0603 1m 1 16w 5 R19 038 15120 00 Res 0603 12k 1 16w 5 R20 038 14120 10 Re...

Page 436: ...B7 R15 G6 1G8 R14 J4 1B6 R12 G5 1G6 R11 G5 1G6 R10 G3 1K6 R1 J5 1D7 Q2 J6 1B8 Q1 J5 1B7 J9 K3 1F5 1E5 1G5 J7 K5 1D5 1B5 J5 J5 1F11 J4 J2 1E12 J3 J5 1F7 J2 G5 1G8 J12 J3 1E5 J11 D3 1E4 J1 G2 1J4 DS6 D2 1C3 DS5 B2 1C3 DS4 C4 1C3 DS3 B4 1C2 DS2 C5 1C2 DS1 B5 1C1 D4 H4 1F8 D3 F3 1K6 1K7 D2 G4 1J7 1H6 D1 J4 1H5 C8 G4 1H6 C7 J3 1H5 C6 F5 1J6 C5 J5 1F8 C4 H4 1J14 C3 H4 1J14 C2 H4 1J12 C1 H5 1H10 Bottom S...

Page 437: ...TM9100 Service Manual TMAA02 08 Keypad Microphone 437 Tait Electronics Limited August 2005 16 6 3 Keypad Microphone Board Layout IPN 226 00145 04 top side IPN 226 00145 04 bottom side ...

Page 438: ...438 TMAA02 08 Keypad Microphone TM9100 Service Manual Tait Electronics Limited August 2005 16 6 4 Keypad Microphone Board Circuit Diagram ...

Page 439: ...TMAA03 02 security bracket are illustrated in Figure 17 1 Figure 17 1 Parts of the TMAA03 02 security bracket Description Quantity B security bracket cradle base 1 E short mounting rails for TM8100 2 C slide locks 1 left 1 right screws M4x25 T T P T ContiR for attaching short mounting rails to TM8100 radio not pictured 4 D slide lock key 2 F tall mounting rails for TM8200 2 self tapping screws 10G...

Page 440: ... 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 the 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 ha...

Page 441: ...ation replace and do not re use Security Bracket once it has been involved in a crash greater than 50km h 17 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 R...

Page 442: ...s The following parts can be 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 XX 2 Security Crdl Mtg Short TM8 short mounting rails for TM8100 319 60002 XX 2 Scrw M4 25 T T P T ContiR for attaching short m...

Page 443: ...ns 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 18 1 Installation 1 Connect the auxiliary c...

Page 444: ...444 TMAA04 05 Ignition Sense Kit TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 445: ...icrophone 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 19 2 Installation Important The desktop microphone grommet must be installed whenever the desktop microphone is plugged into the microphone socket When installed the ...

Page 446: ...mum by rotating R5 counterclockwise 19 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 19 1 Correct desktop microphone grommet seating microphone grommet control head adjust R5 here Table 19 1 Desktop microphone connector p...

Page 447: ... 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 19 2 Desktop microphone to radio interface ...

Page 448: ...448 TMAA10 01 Desktop Microphone TM9100 Service Manual Tait Electronics Limited August 2005 ...

Page 449: ... 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 20 1 Installation 20 1 1 Handset Wiring 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 f...

Page 450: ...alled 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 ...

Page 451: ...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 20 1 Correct handset microphone grommet seating microphone grommet control head Table 20 2 Handset settings in the UI Preferences form TM8...

Page 452: ...n the handset and the radio Table 20 5 Handset microphone connector pins and signals Pin Signal HandsetPCB 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 analog ground 7 not connected 8 CH_GPIO1 3 blue programmable line controlli...

Page 453: ...t 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 5...

Page 454: ... speaker 25W radio insert the the positive remote speaker wire into the position nearest to the red wire With the TMAA10 06 remote speaker 50W 40W radio insert the positive remote speaker wire into the upper position marked 3 Figure 21 1 Power connector wiring of the TMAA10 03 remote speaker Figure 21 2 Power connector wiring of the TMAA10 06 remote speaker power connector remote speaker cable spe...

Page 455: ... to avoid routing any cables near vehi cle pedal controls steering column and other moving parts 22 1 1 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...

Page 456: ...r more information Note If hookswitch operation is programmed for the rugged micro phone and the Inhibit PTT Transmission When Mic On Hook field is selected in the PTT tab of the PTT form then the hands free remote PTT cannot transmit when the rugged microphone hookswitch is closed the microphone is on the microphone clip 22 2 2 Remote PTT Settings in the Programmable I O Form Note The Programmabl...

Page 457: ...ne 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...

Page 458: ...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...

Page 459: ...TM9100 Service Manual TMAA10 04 Remote PTT Kit 459 Tait Electronics Limited August 2005 22 5 2 Pre Amplifier Board Layout IPN 220 01711 01 bottom side IPN 220 01711 01 top side ...

Page 460: ...460 TMAA10 04 Remote PTT Kit TM9100 Service Manual Tait Electronics Limited August 2005 22 5 3 Pre Amplifier Board Circuit Diagram ...

Page 461: ...ith 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 103 for m...

Page 462: ...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 23 1 2 Parts Required The following diagram identifies the parts for remote control head installation and shows how they fit together Figure 23 1 Parts for remote control head installation b torso inte...

Page 463: ...ol head loom from the radio body The control head is now separate from the radio body 23 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 h...

Page 464: ...talling 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...

Page 465: ...ion using the two thumb screws provided 23 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 W...

Page 466: ...n 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 ...

Page 467: ...s Limited August 2005 23 2 Circuit Description Figure 23 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 23 3 Block diagram of remote control head installation ...

Page 468: ... 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 23 4 Parts of the torso interface Description IPN B control head board C torso interface loom 219 02882 XXa D 3 x 8 PT screw x4 346 10030 XXa E PCB bracket 302 10063 XXa F front panel 316 06843 XX...

Page 469: ...ector 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 23 5 Parts of the control head interface Description IPN B 3 x 8 PT screw x7 346 10030 XXa C control head interface PCB D control head interface 316 06842 XXa control head interface loom219 02914 XXa a Contac...

Page 470: ...OT23 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 Blm11p6...

Page 471: ...J4 1E3 C110 L4 1F4 C300 M5 1G2 C301 N5 1F3 C310 M2 1G4 C311 M2 1G4 C320 P4 1D8 C400 L3 1G10 C401 L3 1G10 C410 M3 1G8 C411 M3 1G8 C420 L3 1G5 C421 L3 1G6 C422 K3 1F7 C423 K3 1F7 C430 M2 1G9 C500 L4 1F6 C600 L2 1C3 C601 L2 1B2 C610 K1 1C5 C611 K1 1C4 C612 J2 1C5 C700 F2 1C6 C701 G3 1C7 C702 F3 1C7 C703 E2 1C6 C704 G2 1C6 C705 G2 1B6 C706 E3 1B6 C707 E2 1B6 C708 G2 1A6 C710 E2 1D6 C711 F2 1D7 C712 E2...

Page 472: ...472 Installing an Enhanced Remote Kit TM9100 Service Manual Tait Electronics Limited August 2005 Board Layout IPN 220 01721 02 ...

Page 473: ...TM9100 Service Manual Installing an Enhanced Remote Kit 473 Tait Electronics Limited August 2005 Circuit Diagram ...

Page 474: ...es M F SMD 0805 560e 5 R16 038 15100 00 Res 0603 10k 1 16w 5 R18 038 13220 00 Res 0603 220e 1 16w 5 R19 038 14120 00 Res 0603 1k2 1 16w 5 R30 038 13390 00 Res 0603 390e 1 16w 5 R31 038 13390 00 Res 0603 390e 1 16w 5 R103 038 12100 00 Res 0603 10e 1 16W 5 R104 038 15100 00 Res 0603 10k 1 16w 5 R203 038 13100 00 Res 0603 100e 1 16w 5 R207 038 13100 00 Res 0603 100e 1 16w 5 R209 038 13100 00 Res 0603...

Page 475: ...TM9100 Service Manual Installing an Enhanced Remote Kit 475 Tait Electronics Limited August 2005 Board Layout IPN 220 01720 01 ...

Page 476: ...476 Installing an Enhanced Remote Kit TM9100 Service Manual Tait Electronics Limited August 2005 Circuit Diagram ...

Page 477: ...ations test set The diagram below shows the front panel of the test unit 24 1 Test 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 rad...

Page 478: ...ker connector banana plugs AC input BNC audio monitor out BNC AUDIO IN HI BNC AUDIO OUT BNC RF in out N type antenna connector SMA power connector TMAA23 02 cable 50W 40W radios TMAA20 03 cable 25W radios TMAA21 01 cable TOPA SV 024 TPA SV 006 cable TPA SV 005 battery eliminator to DC power supply TPA SV 011 cable to radio connector of test unit TM9100 radio TP9100 radio TOPA SV 006 cable to RF in...

Page 479: ...ch 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 24 2 3 On Hook Off Hook Switch Important When using the test unit with po...

Page 480: ...connect 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...

Page 481: ...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 0001...

Page 482: ...efer to the parts list for actual values used SPEAKER 4Ω SPKR 8 2 Ω 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 ...

Page 483: ...REVERSE COMPILE OR REVERSE ASSEMBLE ANY SOFTWARE OR FIRMWARE IN WHOLE OR PART Important Notice THE SOFTWARE OR FIRMWARE MAY CONTAIN OPEN SOURCE SOFTWARE COMPONENTS OPEN SOURCE COMPONENTS OPEN SOURCE COMPONENTS ARE EXCLUDED FROM THE TERMS OF THIS AGREEMENT EXCEPT AS EXPRESSLY STATED IN THIS AGREEMENT AND ARE COVERED BY THE TERMS OF THEIR RESPECTIVE LICENCES WHICH MAY EXCLUDE OR LIMIT ANY WARRANTY F...

Page 484: ...LE AND TOTAL LIABILITY FOR ANY SUCH CLAIM SHALL BE LIMITED AT THE OPTION OF TAIT TO THE REPAIR OR REPLACEMENT OF THE SOFTWARE OR FIRMWARE OR THE REFUND OF THE PURCHASE PRICE OF THE SOFTWARE OR FIRMWARE General THE LICENSEE CONFIRMS THAT IT SHALL COMPLY WITH THE PROVISIONS OF LAW IN RELATION TO THE SOFTWARE OR FIRMWARE Law and Jurisdiction THIS AGREEMENT SHALL BE SUBJECT TO AND CONSTRUED IN ACCORDA...

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