Tait Orca 5000 Service Manual Download Page 51

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June 2003 IPN: M5000-00-105

Fault finding charts C - 11

Figure C-3: No serial communication

YES

Is the PTT jammed on?

YES

Make sure PTT is released.

Ensure loom is properly fitted

into the socket on the PCB.

Is the flexible loom

inserted correctly?

YES

Is the Tx/Rx

switch on the calibration

test unit set to Rx?

Set Tx/Rx switch to Rx.

Leads OK?

Replace or repair leads.

YES

No serial communication

Is the flexible loom

end damaged?

YES

Replace flexible loom.

Make sure physical

connections are intact.

YES

Are the physical connections

correct, e.g. battery charged,

comms lead inserted correctly

into the correct port on the PC,

flexible loom contacts clean, etc.?

Is the software using the

correct serial port?

Change the ‘COMM Port’ using

Edit|Preferences or

Tools|Options.

YES

Return to nearest

Tait Dealer

Summary of Contents for Orca 5000

Page 1: ...Tait Orca 5000 Portable Radios Service Manual June 2003 IPN M5000 00 105 ...

Page 2: ...ranties extended or granted by this manual Tait Electronics Ltd accepts no responsibility for damage arising from use of the information contained in the manual or of the equipment and software it describes It is the responsibility of the user to ensure that use of such information equipmentand software complies with the laws rules andregulations of the applica ble jurisdictions Updating equipment...

Page 3: ...N M5000 00 105 iii Publication history Publication Date Product Code May 2001 M5000 00 100 June 2001 M5000 00 101 September 2001 M5000 00 102 May 2002 M5000 00 103 September 2002 M5000 00 104 June 2003 M5000 00 105 ...

Page 4: ...iv June 2003 IPN M5000 00 105 ...

Page 5: ...9 Basic servicing precautions A 9 Programming A 9 Calibrating A 10 Test facilities A 10 Basic maintenance A 10 Servicing Intrinsically Safe radios Servicing Intrinsically Safe radios Servicing Intrinsically Safe radios Servicing Intrinsically Safe radios A 11 A 11 A 11 A 11 Intrinsically Safe radios A 11 IS PCB servicing requirements A 11 FM approval A 11 FM approved products A 11 FM approved acce...

Page 6: ...rts Fault finding charts C 8 C 8 C 8 C 8 Radio cannot be switched on C 9 Cannot change channel C 10 No serial communication C 11 Receive faults C 12 Cannot transmit C 13 No transmit audio C 14 Part D Servicing the radio Servicing the radio Servicing the radio Servicing the radio Servicing the radio D 3 D 3 D 3 D 3 Screw head types D 3 Disassembling the radio Disassembling the radio Disassembling t...

Page 7: ...es D 17 Orca 5010 11 30 spares kit TOPA SP 401G D 18 Orca 5035 spares kit TOPA SP 402G D 19 Orca 5015 2x 40 spares kit TOPA SP 403G D 20 Orca 5010 11 30 re skinning kit TOPA SP 404 D 21 Orca 5035 Re skinning kit TOPA SP 405 D 21 Orca 5020 40 Re skinning kit TOPA SP 406 D 21 Orca 5015 2x 35 40 User Interface PCB and Shield TOPA SP 407 D 22 Orca 5015 21 Re skinning kit TOPA SP 408 D 22 Part E Batter...

Page 8: ...adaptor 7 5 mm Accessory adaptor 7 5 mm Accessory adaptor F 8 F 8 F 8 F 8 Tait Orca vehicle kit Tait Orca vehicle kit Tait Orca vehicle kit Tait Orca vehicle kit F 10 F 10 F 10 F 10 Product codes F 10 Update to the vehicle kit F 10 Installing a vehicle kit F 10 Vehicle kit operation F 10 Vehicle kit specifications F 12 Servicing the vehicle kit F 13 Spares kits F 14 Vehicle kit spares kit TOPA SP ...

Page 9: ...does this manual contain A 3 Calibration service kit A 3 Programming kit A 4 Conventions A 4 The Tait Orca 5000 series of portable radios The Tait Orca 5000 series of portable radios The Tait Orca 5000 series of portable radios The Tait Orca 5000 series of portable radios A 5 A 5 A 5 A 5 The Tait Orca product code A 5 Operating instructions A 5 Accessories A 5 Important information Important infor...

Page 10: ...A 2 June 2003 IPN M5000 00 105 IS PCB servicing requirements A 11 FM approval A 11 FM approved products A 11 FM approved accessories A 11 ...

Page 11: ...td Detailed schematics and component location information for the main PCB may also be obtained from Technical Support ContactyourTaitdealerformoreinformation WWW technical support Tait Electronics Ltd provides product support at the following address http www taitworld com support What does this manual contain ThismanualissuppliedaspartoftheTaitOrca 5000 service kit TOPA SV 117G and provides the ...

Page 12: ...ble of measur ing current up to 3 A accurate to two decimal places DC power supply 7 5 V 3 A for portable radios and TOPA SV A07 if calibrating TOP Axxxx xx 66 88MHz product Programming kit The TOPA SV 116 kit for programming Tait Orca 5000 radios contains accessory connector to modular phone socket programming cable for connecting the radio to the programming lead TOPA SV 003G and 9 pin RS232 to ...

Page 13: ... Operating instructions A user s guide is available for each radio Copies can be obtained through Technical Support Accessories Table A 1 shows the accessories available for Tait Orca 5000 portable radios Of these acces sories only the chargers are serviceable For more information on chargers see Part E Battery packs and chargers The battery packs available for Tait Orca 5000 portable radios are a...

Page 14: ... cover When attaching or removing an accessory ensure that the lever is in the upright position Keepingtheaccessoryconnectorparalleltothe radio engage the two posts at the base of the connector with the rear panel Once the acces sory is in position rotate the lever 90 degrees counterclockwise to lock it in place See Figure A 3 Removing an accessory When removing an accessory press the lock spring ...

Page 15: ...e and earphone 30 to 75 C TOPA AA 010 3 wire lapel microphone and earphone 30 to 75 C TOPA AA 011 Light weight single speaker headset with in line PTT 30 to 75 C TOPA AA 012 Over the head headset with noise cancelling boom microphone 30 to 75 C TOPA AA 013 Behind the head headset with noise cancelling boom microphone 30 to 75 C TOPA AA 101G Speaker microphone 10 to 60 C two function buttons with D...

Page 16: ...0 Hz input plug configuration T952 042 USA and Canada 115 V 60 Hz input plug configuration T952 052 UK and Hong Kong 230 V 50 Hz input plug configuration Carrying accessories TOPA CA 001 Heavy duty carry case TOPA CA 002 Heavy duty holster TOPA CA 003 38 mm belt clip x 10 TOPA CA 004 Accessory port cover x 10 TOPA CA 005 55 mm belt clip TOPA CA 006 55 mm belt clip x 10 TOPA CA 101 Heavy duty carry...

Page 17: ...Screw head types Torx recess head screws and Pozidriv recess head screws require the correct sized driver to achieve best performance Most of the screws in Tait Orca 5000 portable radios are Torx head screws and so a Torx T6 driver bit is supplied aspart ofthe servicekit Some earlier radios have Pozidriv screws Torx head 1 8x5 mm screws should be removed using the supplied Torx T6 driver When repl...

Page 18: ...ge has occurred to the antenna or the battery pack General care Wipe the battery contacts accessory connector contacts andradiodisplay with a dry lint free cloth to remove any dirt oil or grease Use a cloth dampened with clean water to cleantheradio scase anddisplaylens but do not immerse the radio in fluids Do not allow the radio to come into contact with detergents alcohol aerosol sprays or petr...

Page 19: ...oved by Factory Mutual Corpora tion FM to the following ratings IS I 1 CD T3C Ta 40 C NI I 2 ABCD T3C Ta 40 C See Table A 3 on page A 12 for more detail on these ratings FM approved products Radios with the following product code have FM IS approval TOP x24x0 B2 TOP x24x0 T2 TOP x25x0 B2 TOP x25x0 T2 TOP x26x0 B2 TOP x26x0 T2 For more information about the Tait Orca product code refer to page page...

Page 20: ...rmal operating conditions Class I Gas or petroleum type environment Division 1 Hazardous mixtures are normally present Groups C D Ethylene and pro pane gases T3C 160 C Incentive The unit is unable to cause ignition under normal operating con ditions Class I Gas or petroleum type environment Division 2 Hazardous mixtures are present abnor mally Groups A B C D Acetylene hydrogen ethylene and propane...

Page 21: ...pecifications B 6 TOP Cxxxx 174 225MHz radio specifications B 7 TOP Gxxxx 336 400MHz radio specifications B 8 TOP Hxxxx 400 470MHz radio specifications B 9 TOP Ixxxx 450 530MHz radio specifications B 10 TOP Jxxxx 806 870MHz radio specifications B 11 TOP Kxxxx 896 941MHz radio specifications B 12 Circuit descriptions Circuit descriptions Circuit descriptions Circuit descriptions B 13 B 13 B 13 B 13...

Page 22: ...B 2 June 2003 IPN M5000 00 105 ...

Page 23: ... please check with your nearest Tait office or authorised dealer who can confirm that the radio meets applicable regulatory requirements Tait Orca products have an intermediate universal IF bandwidth and can be programmed per channel for 2 5 4 0 or 5 0 kHz deviation to cover any channel spacing See Universal band versus wideband IF filtering on page B 15 TOPB600batteriesarerecommendedforuse with c...

Page 24: ...udio out put 300 3000 Hz Trunking data devia tion as per MPT1327 narrowband mediumband wideband 1 5 kHz 2 4 kHz 3 kHz Audio response below limiting in limiting above 3 kHz input for 60 deviation distortion 6 dB oct 1 3 dB relative to 1 kHz 300 3000 Hz 0 dB 0 4 dB relative to maximum sys tem deviation 450 2550 Hz 35 dB oct min 5 mVrms 5 at 1 kHz Ruggedness 2 minutes into infinite VSWR Stability 5 1...

Page 25: ...Ah NiCd 525g 545g 550g With TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per ETS 300 086 Intermediate frequencies 21 4MHz and 455kHz Sensitivity 12dB SINAD 119dBm Sensitivity 20dB SINAD 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 70dB NB 75dB WB Spurious Response 70dB Intermodulation 65dB Blocking 94dB Ultim...

Page 26: ...d 525g 545g 550g With TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per ETS 300 086 Intermediate frequencies 21 4MHz and 455kHz Sensitivity 12dB SINAD 119dBm Sensitivity 20dB SINAD 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 70dB NB 75dB WB Spurious Response 70dB Intermodulation 65dB Blocking 94dB Ultimate Si...

Page 27: ...d 525g 545g 550g With TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per ETS 300 086 Intermediate frequencies 21 4MHz and 455kHz Sensitivity 12dB SINAD 119dBm Sensitivity 20dB SINAD 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 70dB NB 75dB WB Spurious Response 70dB Intermodulation 65dB Blocking 94dB Ultimate Si...

Page 28: ...h TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per ETS 300 086 Intermediate frequencies 45 1MHz and 455kHz Sensitivity 12dB SINAD 119dBm Sensitivity 20dB SINAD 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 66dB NB 72dB WB Spurious Response 70dB Intermodulation 65dB Blocking 94dB Ultimate Signal to Noise Ratio ...

Page 29: ...d 525g 545g 550g With TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per ETS 300 086 Intermediate Frequencies 45 1MHz and 455kHz Sensitivity 12dB SINAD 119dBm Sensitivity 20dB SINAD 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 66dB NB 72dB WB Spurious Response 70dB Intermodulation 65dB Blocking 94dB Ultimate Si...

Page 30: ...iCd 525g 545g 550g With TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per ETS 300 086 Intermediate frequencies 45 1MHz and 455kHz Sensitivity 12dB SINAD 119dBm Sensitivity 20dB SINAD 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 66dB NB 72dB WB Spurious Response 70dB Intermodulation 65dB Blocking 94dB Ultimate ...

Page 31: ...0 With TOPB600 1100mAh NiCd 490g 510g 515g With TOPB200 1500mAh NiCd 525g 545g 550g With TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per EIA Intermediate frequencies 45 1MHz and 455kHz Sensitivity 12dB SINAD 0 25µV 119dBm Sensitivity 20dB SINAD 0 40 µV 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 60dB NB 65d...

Page 32: ...0 With TOPB600 1100mAh NiCd 490g 510g 515g With TOPB200 1500mAh NiCd 525g 545g 550g With TOPB700 1500mAh NiMH 510g 530g 535g With TOPB500 2000mAh NiMH 550g 570g 575g Receiver Measurements as per EIA Intermediate frequencies 45 1MHz and 455kHz Sensitivity 12dB SINAD 0 25µV 119dBm Sensitivity 20dB SINAD 0 40µV 114dBm Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal Selectivity 60dB NB 65dB...

Page 33: ...re controlled by calibration Maximum Deviation and Modulation Balance tests Receiver RF fromthe antennaisfedviatheLPFandPIN switchintothereceiver TheRFpassesthrough the front end tuning circuit which rejects unwanted frequencies The front end is electronically tuned and the front end tuning voltage that sets the centre of the bandpass filter is determined during calibration Front End Tuning test T...

Page 34: ... transmitter from operating and informs the control microproc essor The reference frequency for the synthesiser is provided by the TCXO temperature compen satedcrystaloscillator whichisinitiallyseton frequency using a DC voltage at calibration TCXO Calibration test Power supplies 5V DIG The 5V DIG supply provides a regulated 5 V to the microprocessor and its associated circuitry It is controlled b...

Page 35: ...rence in the synthesiser Accessory connector interface The accessory connector interface is described in Part F Accessories Universal band versus wideband IF filtering The IF filtering for the universal band is designed in such a way that it functionally meets specifications for both narrowband and wideband systems The Deviation and Receive Audio Processing are selectable per channel which enables...

Page 36: ...B 16 Circuit descriptions June 2003 IPN M5000 00 105 ...

Page 37: ...K 47K 22K Q3 DTC144W 1 2 3 R12 47K R15 2K2 TP1 TP2 C15 1N0 C16 150P TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 SK3 SMA 90DEG SKT SWITCH 1P1W 1 2 R5 2K2 R6 10 R7 10 MIC MICORPHONE 1 V 2 GND GREEN D1 DUAL LED 1 2 RED D1 DUAL LED 3 4 RV1 10K LOG POT 4 5 CW RV1 10K LOG POT 1 3 2 TP15 TP17 TP16 R20 2K2 R17 180 R8 330 LK3 LK4 7V5 BATT 7V5 ACC PL1 7V5 ACC 2 PL1 RXD 3 PL1 TXD 5 PL1 EXT PTT 12 PL...

Page 38: ...B 18 Circuit diagrams June 2003 IPN M5000 00 105 ...

Page 39: ... SW 1 2 4 8 C C Q1 BC847W Q2 BC847W R1 470 R2 470 C1 100N C11 10N C2 47N R4 1K0 R3 1K0 C5 10N C6 10N C7 10N C8 10N C9 10N C10 10N C4 1N0 C3 100N LK1 LK2 Q5 BC857W Q4 BC857W R16 33 R14 4K7 R13 47K 47K 22K Q3 DTC144W 1 2 3 R15 2K2 TP1 TP2 C15 1N0 C16 150P TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 SK3 SMA 90DEG SKT SWITCH 1P1W 1 2 R5 2K2 R6 10 R7 10 MIC MICORPHONE 1 V 2 GND GREEN D1 DUAL L...

Page 40: ...B 20 Circuit diagrams June 2003 IPN M5000 00 105 ...

Page 41: ...he programming system for Tait Orca 5000 conventional or trunked radios Contents Test facilities Test facilities Test facilities Test facilities C 3 C 3 C 3 C 3 Error codes C 3 Test commands C 5 Calculating the parameters required for test command 101 C 7 Fault finding charts Fault finding charts Fault finding charts Fault finding charts C 8 C 8 C 8 C 8 Radio cannot be switched on C 9 Cannot chang...

Page 42: ...C 2 June 2003 IPN M5000 00 105 ...

Page 43: ...quency value entered Error codes Theerrorsyoumayreceivewhiletheradioisin testmodeareoutlinedbelow Iftheradiomust bereturnedforrepair e g theDSPneedstobe replaced contact your Tait dealer for more information C01 An invalid command code has been received Try sending the command again C02 A valid commandcodehasbeenreceivedbut withinvalidparameters Checktheparameters and try sending the command again...

Page 44: ...r This error indicates that the radio s model configu ration checksum is incorrect Contact your Tait dealer X32 Database checksumerror This error indicates that the radio s database checksum is incor rect Contact your Tait dealer X33 ESN error The radio s electronic serial number is incorrect Contact your Tait dealer X35 Temperature is above the T1 threshold and turn down of transmit power is impe...

Page 45: ...io to Rx 32 None Set radio to Tx 33 None Set transmit to low power 34 None Set transmit to mid power 135 None Set transmit to high power 35 None Set transmit to max power 36 None Set transmit to no power 137 None Activate economy mode 42 None Deactivate economy mode 43 None Read battery level 46 Returns 0 to 255 Read temperature level 47 Returns 0 to 255 Set keypad test on 50 None Set keypad test ...

Page 46: ...TCXO mod 112 0 to 255 Set VCO mod 113 0 to 255 Set Tx power level 114 0 to 255 Set TCXO coarse frequency 115 0 to 255 Set TCXO fine frequency 116 0 to 255 Set Rx front end tuning 117 0 to 255 Set squelch threshold 118 0 to 255 Set CTCSS modulation 120 0 to 32767 Set DCS modulation 121 0 to 32767 Set FFSK modulation 122 0 to 32767 Set Selcall modulation 123 0 to 32767 Set DTMF modulation 124 0 to 3...

Page 47: ...equencies Note tttttt and rrrrrr may be up to 6 digits long Example 1 Calculating tttttt for an H band radio Example 2 Calculating rrrrrr for an H band radio Note IF depends on the radio s switching band For A B C and D bands radios the IF is 21 4 MHz For A band add the IF MHz in the formula radio uses high side injection For E F G H I J and K band radios the IF is 45 1 MHz transmit frequency MHz ...

Page 48: ...in Figures C 1 to C 6 address the faults you are most likely to find They are Radio cannot be switched on Cannot change channel No serial communication Receive faults Cannot transmit and No transmit audio If you experience other faults that do not fall into these categories contact your Tait dealer ...

Page 49: ... Tait Dealer YES NO Check on off volume control switch Function for pins 1 to 4 OK NO Battery contacts clean and unobstructed Clean battery contacts using the graphite tip of a 4H 4 or harder pencil Radio cannot be switched on NO Is the battery charged YES Charge the battery NO After charging battery can radio be switched on Replace battery contacts ...

Page 50: ...rest Tait Dealer Replace channel selector switch Using the truth table below is channel selector operation OK Cannot change channel NO 6 3 4 1 2 0 0 0 1 3 0 0 1 0 5 0 1 0 0 9 1 0 0 0 PINS CHANNELS 1 S C to GND 0 O C to GND Bottom of PCB Antenna connector 16 way selector On off volume control 1 2 3 6 5 4 ...

Page 51: ...t to Rx Set Tx Rx switch to Rx NO Leads OK Replace or repair leads NO YES No serial communication NO Is the flexible loom end damaged YES Replace flexible loom Make sure physical connections are intact NO YES Are the physical connections correct e g battery charged comms lead inserted correctly into the correct port on the PC flexible loom contacts clean etc Is the software using the correct seria...

Page 52: ... and GND and between pin 2 and GND YES Return to nearest Tait dealer Receive faults YES NO Does speaker Z 16 ohms YES Check programming Are channels programmed correctly YES NO Are the speaker contacts functioning Is the frequency band information correct YES Replace speaker Replace speaker contacts Replace on off volume control switch NO Is receive sense 117 dBm YES NO Is squelch operating normal...

Page 53: ... Is the radio in lock command 72 NO Return to nearest Tait Dealer Cannot transmit YES YES Is current greater than 1 5 A high power or 700 mA low power YES NO YES Is the transmit current less than 400 mA Is RF switch functioning Check PTT switch YES NO Replace RF out assembly YES Check programming Are channels and frequency band information programmed correctly NO ...

Page 54: ...ES YES Is the flexible loom damaged When an external accessory is plugged in is there microphone audio for the accessory YES Return to nearest Tait dealer No transmit audio YES Is the internal microphone working Ensure loom is properly fitted into the socket on the PCB Replace internal microphone NO NO Replace flexible loom NO ...

Page 55: ...hield sub assembly from the chassis D 5 Removing the PCB from the chassis D 6 Removing the rear panel D 7 Replacing key mechanical and ancillary devices Replacing key mechanical and ancillary devices Replacing key mechanical and ancillary devices Replacing key mechanical and ancillary devices D 8 D 8 D 8 D 8 Replacing the lens Orca 5015 2x 35 40 D 8 Replacing the PTT keypad D 8 Replacing the speak...

Page 56: ...t panel to the chassis D 16 Spares kits Spares kits Spares kits Spares kits D 17 D 17 D 17 D 17 Information contained in the tables D 17 PCB Product Codes D 17 Orca 5010 11 30 spares kit TOPA SP 401G D 18 Orca 5035 spares kit TOPA SP 402G D 19 Orca 5015 2x 40 spares kit TOPA SP 403G D 20 Orca 5010 11 30 re skinning kit TOPA SP 404 D 21 Orca 5035 Re skinning kit TOPA SP 405 D 21 Orca 5020 40 Re ski...

Page 57: ...he volume control switch the microphone the speaker contacts the battery contacts the PTT tact switch the RF out assembly the auxiliary flexible PCB the rear panel and the chassis A list of spares kits available for servicing Tait Orca 5000 portable radios is shown in Table D 1onpageD 17 Thesesparescanbeordered from your local Tait dealer Screw head types Most of the screws in Tait Orca 5000 porta...

Page 58: ... the insert using a sharp scalpel blade Remove the two chassis screws at the base of the radio Figure D 1 then reattach the battery and hold the base of the radio in one hand With the other hand pull the chassis from the front panel using the base of the battery as leverage Figure D 3 At this point you can replace the following the front panel assembly thePTTkeypad PTTkeyandfunctionkeys the speake...

Page 59: ...the shield away from the chassis Maintain pressure and insert a flat bladed screwdriver approximately 4 mm in the gap between the shield and the chassis Twist the screwdriver and the shield should rise up over the clip Figure D 4 Removing the shield sub assembly from the chassis battery pack front panel chassis shield 1 2 3 4 microphone grommet protruding from the shield grip battery here gently p...

Page 60: ...e PCB assembly and polyester dome Orca 5015 Orca 502x Orca 5035 and Orca 5040 Removing the PCB from the chassis Remove the knob seal which covers the anten na connector channel selector switch and volume control switch Remove the screw through the PA shield Remove the three nuts for the antenna connec tor and knobs using the supplied 8 mm long reach socket driver then remove the three ribbed lock ...

Page 61: ...y rear cover lugs free of the holes in the rear panel To remove the rear panel insert a small flat bladed screw driver just under the notch in the base and twist Remove the rear panel seal Note that the RF contact pinnormally remainsin therear panel seal Make sure that this is not lost during disassembly Using a calibration pin lift the auxiliary flexi ble PCB contact area from the lower lefthand ...

Page 62: ...s Orca 5015 2x 35 40 You must disassemble the radio before gently prising the lens away from the front panel of the radio Remove any adhesive remaining on the front panel Peel the paper from the back of the new lens and place the lens in position on the front panel Press firmly into position then remove the piece of clear plastic from the front of the lens Figure D 6 Replacing the lens Replacing t...

Page 63: ...rom the front panel and unplug the user interface loom from the main PCB Unplug the LCD display loom from the user interface PCB remove the LCD display from the shield and discard the LCD display Position the new LCD display on the shield pass the LCD loom through the gap in the shield and plug into the connector on the user interface PCB Push down the two connector lugs to secure the loom Plug th...

Page 64: ... 5 6 7 8 9 10 11 13 12 1 5 antenna connector channel selector switch on off volume control switch antenna connector pin placement 5 pins speaker contact pin placement channel selector pin placement 6 pins on off volume control pin placement 5 pins PTT tact switch PA can PA screw microphone placement microphone grommet placement user interface loom connector 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 65: ...le only when the PCB has been removed from the chassis 1 2 3 4 5 6 7 8 9 antenna connector channel selector switch on off volume control switch RF assembly placement auxiliary flex socket PTT tact pin placement 4 pins battery contact placement battery contact seal placement microphone pin placement 2 pins 1 2 3 4 5 6 7 8 9 ...

Page 66: ...phone make sure it isalignedwiththemarksonthePCB sinceitis polarised Refer to Figures D 8 and D 9 for the placement of the microphone The microphone should not hang over the edge of the PCB Solder it in place using a light tip soldering iron e g Weller PTR7 tip Replacing the battery and speaker contacts Following the disassembly instructions disas semble the radio to the PCB level Remove the PCB f...

Page 67: ...re that the orientation is such that the bends follow the groove on the new chassis Locate the tab in the hole at the top of the chassis groove Place top corners Smooth seal into position across the top of the chassis Placethesealinthegrooveatthebottomofthe radio and locate the corners Starting at the corners and moving towards themiddle workthesealintoplacealongboth sidesofthechassis Becarefulnot...

Page 68: ...ible PCB over and fit the contact areaonthechassis itshouldfitsnuglyinplace Replace the rear panel seal by tucking the two tags at the top of the seal under the lip on the chassis and folding it over the flexible PCB Check that the RF contact pin is positioned correctly in the rear panel seal and that the seal is flush with the chassis Slide the rear panel on from the top of the radio Figure D 10 ...

Page 69: ...tsforthe two switches are black Replace the nuts making sure they are thread ed correctly before using an 8 mm long reach socket driver set to 10in lb 1 1Nm Then tighten the PA screw to 2in lb 0 23Nm Using a heavy tip soldering iron e g Weller 2PTCC8 tip solder the antenna connector and two switches in place if required taking care not to damage the surrounding compo nents Replace the knob seal ov...

Page 70: ...g sure that the seal is not pinched using the battery as leverage as in radio disas semblymaybehelpful Replacethetwochassis screwsatthebaseoftheradio tighteningthem to 2in lb 0 23Nm Replace the two knobs on the radio with new knobs Presseachknobonfirmly Thereshould be a small gap between the knob label and the base of the knob 8 9 7 4 5 6 2 1 3 6 6 8 shield chassis antenna connector channel select...

Page 71: ...which the spares item is shown and the number in brackets refers to the numbered legend within each figure PCB Product Codes Tait Orca 5000 main PCBs are available on an exchangebasisfromTechnical SupportatTait Electronics Ltd When ordering use the following naming convention TOP XXXXX KS For example a replacement main PCB for a TOP B2620 T0 is a TOP B2620 KS The Tait Orca product code can be foun...

Page 72: ...00 Antenna SMA Connector Nut 10 D 12 8 353 00010 42 Ribbed Lock Washer M6x10x0 7mm 30 D 12 7 360 01060 00 PTT Function Key Actuator 40 360 02019 00 Microphone Grommet Seal 10 D 5 1 365 01673 00 Insert Front Panel Logo Label 1 362 01035 01 Chassis Plug Seal green 10 D 10 9 362 01106 00 Rear Panel Seal 10 D 10 5 362 01089 01 Aux Flex Seal 10 D 10 2 362 01091 01 Knob Seal 10 D 12 10 362 01092 02 Main...

Page 73: ...tor Nut 10 D 12 8 353 00010 42 Ribbed Lock Washer M6x10x0 7mm 30 D 12 7 360 01060 00 PTT Function Key Actuator 40 360 02019 00 Microphone Grommet Seal 10 D 5 1 362 01035 01 Chassis Plug Seal green 10 D 10 9 362 01087 00 Battery Contact Seal 10 D 9 8 362 01106 00 Rear Panel Seal 10 D 10 5 362 01089 01 Aux Flex Seal 10 D 10 2 362 01091 01 Knob Seal 10 D 12 10 362 01092 02 Main Seal 20 369 01039 00 A...

Page 74: ... Channel volume Control Nut M6x7 9x3mm 20 D 12 9 352 01053 00 Antenna SMA Connector Nut 10 D 12 8 353 00010 42 Ribbed Lock Washer M6x10x0 7mm 30 D 12 7 356 01070 00 Speaker Contact Probe Spring 10 360 01060 00 PTT Function Key Actuator 40 360 02019 00 Microphone Grommet Seal 10 D 5 1 362 01035 01 Chassis Plug Seal green 10 D 10 9 362 01087 00 Battery Contact Seal 10 D 9 8 362 01106 00 Rear Panel S...

Page 75: ...9 01 Channel Knob 1 311 01050 01 Volume Knob 1 311 03110 00 Keypad 1 316 06765 00 Rear Panel 1 345 00020 11 Screw M2x8mm SS Pan Torx Patch 2 362 01106 00 Rear Cover Seal 1 362 01091 01 Knob Seal 1 362 01092 02 Main Seal 1 OPP501 PHA Front Panel Assembly 1 399 00010 69 Plastic Bag 75x100mm Mini Grip 1 399 00010 53 Plastic Bag 150x250mm 1 410 01064 01 Packaging Header Card New Logo 1 316 06765 01 Re...

Page 76: ... 07043 00 LCD Frame Holder 1 220 01501 00 PCB Flexi User Interface 1 369 01044 00 Conductive Adhesive Mylar 365 00011 38 Yellow Label Static Warning IPN Description Quantity 311 01049 01 Channel Knob 1 311 01050 01 Volume Knob 1 311 03113 00 Keypad 1 316 06765 00 Rear Panel 1 345 00020 11 Screw M2x8mm SS Pan Torx Patch 2 362 01106 00 Rear Cover Seal 1 362 01091 01 Knob Seal 1 362 01092 02 Main Sea...

Page 77: ...y chargers Battery chargers Battery chargers Battery chargers E 5 E 5 E 5 E 5 Desktop fast charger Desktop fast charger Desktop fast charger Desktop fast charger E 6 E 6 E 6 E 6 Fast charger operation E 6 Using the fast charger E 9 Repairing the fast charger E 10 Desktop trickle charger Desktop trickle charger Desktop trickle charger Desktop trickle charger E 12 E 12 E 12 E 12 Trickle charger oper...

Page 78: ...E 2 June 2003 IPN M5000 00 105 ...

Page 79: ...ves the Low Battery warning Short condition the battery weekly Long condition the battery only for the following reasons on first use of new battery if performance is poor and after more than two weeks of storage Avoid leaving charged batteries in the charger for more than a day Clean electrical contacts of the battery using a fibre glass pencil or the graphite tip of a type 4H 4 or harder pencil ...

Page 80: ...1 5 A at high power transmit 300 mA in receive at rated audio 80 mA on standby no audio 55 mA with low economy cycling enabled 45 mA with medium economy cycling enabled and 40 mA with high economy cycling enabled Economy cycling in conventional radios is programmed in the Power Save Features screen of the Tait Orca Portable Conventional Programming Application TOPCPA Dynamic power control in trunk...

Page 81: ...ntrinsically safe batteries see page A 11 Repair of chargers is limited to replacement of the spring contacts the discharge tact switch and the DC jack The repair information provided for the fast charger also applies to repair of the trickle charger and multi charger A spares kit is available for Tait Orca chargers TOPA SP 202 The contents of the spares kit is shown in Table E 2 and the assembly ...

Page 82: ...ctionwithPolySwitch PS1 Under reverse polarity conditions D1 conducts drawing the available short circuit current until PS1 trips D1 also protects against any voltage spikes that may come through the AC to DC adaptor The unit is designed for 10 5 14 V operation The 5V supply is produced by the regulator IC1 A feature of this regulator is that it provides a RESET output to the microproces sor ThisR...

Page 83: ...324D V GND V V R17 1K0 R20 100K 05 R21 1K0 C17 100N R23 10K 0 5 R39 1K0 R40 10K 0 5 R37 10K 0 5 R38 1M0 R35 100K 05 R36 100K 05 R49 100K 05 R48 100K 05 C20 100N R46 27K 0 5 R45 100K 05 R50 10K 0 5 R41 1E R42 1E R55 10K 0 5 C25 100N R56 47K C26 1N0 C1 1N0 R3 47K C4 1N0 C2 100N R2 1E R1 1E SK1 DC JACK 2 5MM IC1 L4949 VS 1 CT 4 GND 5 RESET 6 SI 2 VOUT 8 VZ 3 SO 7 Q3 BC847W BATT 3 9MM BASE DIA G D S Q...

Page 84: ...sarethemain connections for charging In the battery pack the temperature contact is connected to ground via a thermistor This allows the charg er to monitor the temperature of the battery and if the battery temperature is outside the range 5 C to 40 C the charger will not charge the battery The charger also uses the temperature line for detecting the presence of a battery for example detecting whe...

Page 85: ...this point it is recommended the battery be left in the charger for a further 1 to 2 hours to ensure maximum battery charge Once the batteryis fully charged the indicator will glow green Avoid leaving charged batteries in the charger for more than a day Conditioning the battery with the fast charger Two conditioning functions are available on thefastcharger ashortconditioningcycleand a long condit...

Page 86: ...inserting the battery radio Continue holding the conditioning button until the indicator flashes amber When the indicator flashes amber release the conditioning button The long condition cycle will take approxi mately 24 hours Oncecharged thecharger sindicatorwillglow green if the battery is in good condition The indicator will flash red if the battery is well below optimum capacity consult your T...

Page 87: ...n or solderwick Place the new parton the boardandsolder it in place usinga medium tip soldering iron e g Weller PTA7 tip Replacing the DC jack RemovetheDCjackusingadesolderingstation or solderwick There is a lot of solder on both sides of the board so be sure to remove it all Placethenewpartontheboardandsolderitin place using a heavy tip soldering iron e g Weller 2PTCC8 tip Reassembling the charge...

Page 88: ...ich changes the charge current as desired Themaximumvoltageavailablefromthetrick le charger is limited to less than 10 5 V by R111 in conjunction with Q101 so that the radio can not be damaged if the battery goes open circuit If the battery goes short circuit then Q102 is held off by Q103 and thus Q100 is off and there is negligible charge current Onstartup thestateofthechargerissimilarto thatwhen...

Page 89: ...sert the battery radiointothecharger Makesuretheindicator on the charger glows red If the indicator does not glow red check that the battery radio is seated properly and the charger is plugged in correctly The indicator will remain red until the radio is removed from the charger The battery will be fully charged in about 16 hours Youcan leave the battery in the charger until you next need to use t...

Page 90: ...as soon as the radio is seated in the charger Check that the battery and charger contacts are clean and not obstructed The charger LED glows amber Saferangefor chargingis5 Cto40 C and optimum battery performance will be obtained between 15 C and 25 C The charger will start charging when the battery temperature is within the range 5 C to 40 C The charger LED flashes red Check that the battery and c...

Page 91: ...o not Do not pull the top off the charger using the housing of the individual chargers Instead from the side of the charger lift the top cover up and gently fold back Unplug the red and black wires leading to the faulty charger Remove the three screws holding the faulty charger to the top of the multi charger Gently pull the faulty charger away from the multi charger top Turn the charger upside do...

Page 92: ...ulti charger replacing the 10 screws using a Pozi 1 driver Figure E 8 The Tait Orca Fast Charger PCB The inset shows where to place the diode 1N4001 or similar for using the PCB in a multi charger Fuse replacement Each charger is protected by a 3A fuse To replace a fuse open the multi charger as described previously The fuse must be replaced with a 12V 3A secondary fuse made from material with a C...

Page 93: ...5000 accessory connector F 3 F 3 F 3 F 3 Screw head types F 3 Connecting an accessory F 3 Connecting a headset F 5 Accessory connector signal descriptions F 6 7 5 mm Accessory adaptor 7 5 mm Accessory adaptor 7 5 mm Accessory adaptor 7 5 mm Accessory adaptor F 8 F 8 F 8 F 8 Tait Orca vehicle kit Tait Orca vehicle kit Tait Orca vehicle kit Tait Orca vehicle kit F 10 F 10 F 10 F 10 Product codes F 1...

Page 94: ...F 2 June 2003 IPN M5000 00 105 ...

Page 95: ...able at the accessory connector and thesignalsaredescribedin more detail in Accessory connector signal descrip tions on page F 6 Screw head types The Tait Orca 5000 Acces sory connector requires a Pozi 1 driver for the green P Clip connector and a Hex 2 driver for the D Clip connector Additionally a Torx T6 driver is required Connecting an accessory Check that your accessory is compatible with the...

Page 96: ...essory connector PCB links if required 6 Crimp the cable at an appropriate distancealongthecable approximatelyin line with the edge of the PCB 7 Use narrow nose pliers to pull out the appropriateplugsinthesealandfititonto the PCB 8 Fit the grommet and PCB seal into the housing and secure it with the supplied screw Torque the screw to 3in lb 0 34Nm 9 Fit the lock to the accessory connector housing ...

Page 97: ...D or to any other signal Table F 2 Accessory connector headset connections Signal Description Type Signal level Output impedance current Input impedance RX DET AF ACC Unmuted receive audio Analogue audio 1 15 1 6 VDC 53 225 mVrms 2 2 kΩ MOD AUDIO Modulator input Analogue audio 0 4 8 Vpp 2 4 VDC 470 Ω 7V5 ACC Accessory power DC supply 7 0 V nominal 20 mA max RXD ACC Serial receive data CMOS high 0 ...

Page 98: ...whichfollows thesquelch detectline On trunked radios SENSE 1 ACCisacurrently unusedinput EXT MIC TheEXT MICsignalisananalogueinputfrom the microphone of an accessory Connecting a microphone to EXT MIC automatically turns off the radio s internal microphone EXT PTT The EXT PTT is an analogue signal from the accessory interface to the control area and indicates an external request for PTT and extern...

Page 99: ...June 2003 IPN M5000 00 105 Tait Orca 5000 accessory connector F 7 Figure F 3 Tait Orca accessory connector circuit diagram ...

Page 100: ... of the 7 5 mm adaptor is to demultiplextheaccessory sMIC PTTlineinto two separate lines for the Tait Orca portable radio The adaptoralso detects thepresence of the accessory speaker and turns off the radio s speaker Figure F 5 shows the circuit diagram for the 7 5 mm accessory adaptor When the accessory PTT switch is pressed it connects the microphone to the adaptor between groundandthebaseofQ3 s...

Page 101: ...June 2003 IPN M5000 00 105 7 5 mm Accessory adaptor F 9 Figure F 5 Tait Orca 7 5 mm accessory adaptor circuit diagram ...

Page 102: ...and will allow radios with both old and new chassis to be located in the vehicle kit For instructions on replacing the quarter turn moulding see Trigger reassembly on page F 14 Installing a vehicle kit Detailedinstallation instructionsareprovided in the Tait Orca vehicle kit installation guide IPN 429 40000 xx This guide is included with each vehicle kit Vehicle kit operation Inserting the radio R...

Page 103: ...s within the safe range for recharging 0ºC to 50ºC If the indicator remains amber consid er turning on your air conditioning Optimum battery charging performance is obtained between 15ºC and 25ºC Charge times when the radio is turned off are up to 1 hours for the 1100 mAh NiCd battery and up to 2 hours for the 1500 mAh NiCd battery Youcanstill usetheradio whilethe batteryis beingcharged butthechar...

Page 104: ...dry lint free cloth to remove any dirt oil or grease Do not allow the vehicle kit to come into contact with detergents alcohols aerosol sprays or petroleum based products as they may permanently damage the case Vehicle kit specifications The following table outlines the vehicle kit specifications Details of test methods can be obtained from Tait Electronics Ltd Table F 5 General specifications Par...

Page 105: ...ssory probe PCB Carefully use narrow nose pliers to unplugtheMCXconnectorfromtheaccessory probe PCB Now remove the two KC22x6 screws on the front of the vehicle kit holding the accessory probe PCB into the front mould ing TheaccessoryprobePCBcannowbetilted upwards and removed from the moulding Fit the seal onto the new accessory probe PCB and reassemble the vehicle kit Read the assembly instructio...

Page 106: ...checkthatthelocatingpegspopout Ifthe triggerassemblydoesnotworkcorrectly check thatthequarter turnmouldingisinthecorrect positionandrepeattheassemblyprocess Tighten the two KC30x10 trigger assembly screws while holding the trigger assembly in place Rear cover reassembly Locatethetopoftherearcoverintothebackof the trigger assembly Press the bottom of the rear cover toclick lockthecover into thefron...

Page 107: ... 83 Visor microphone socket 2 5 mm DC jack 5 F 8 6 240 04021 85 Power ignition sense socket 4 way right angle PCB mounting 5 F 8 7 303 11204 00 Chassis moulding 10 305 00007 00 Trigger moulding 10 305 00008 01 Quarter turn moulding green 10 F 6 5 305 00009 00 Peg moulding 10 F 6 4 305 00010 00 Trigger cap moulding 10 F 6 8 305 00021 00 Trigger spring 10 305 00022 00 Peg spring 20 305 00023 00 Lock...

Page 108: ... Auxiliary seal 4 305 00013 00 Probe seal moulding 4 305 00015 00 Back plate 4 305 00023 00 Lock 4 F 6 7 353 05006 00 Washer 7 16 beryllium 1 365 01610 00 Front warning label 5 365 01611 00 Front operation label 5 365 01612 00 Rear type approval label 5 365 00011 54 White label R1556 2 90 x 24mm 11 399 00010 53 Plastic bag 150 x 250mm 1 399 00010 69 Mini grip plastic bag 75 x 100mm 10 410 01153 00...

Page 109: ... buttons To do this add two resistors inside the microphone disconnect the speaker and crimp a 6 way phone plug onto the cable Setting up hookswitch functionality for a trunked radio Hook switch functionalitycan be achieved by programmingexternalfunctionBUTTON 1to Clear As long as the microphone clip is grounded then whenever the mobile micro phone is on hook the call will be cleared down Youmustu...

Page 110: ... kΩ for BUTTON 2 R 27 kΩ 4 MOB MIC Dynamic microphone input imped ance 600 Ω 5 GND Ground 6 N C Pin Signal Description 1 GND Signal ground 2 RX IN RS 232 Receive data to radio 3 TX OUT RS 232 Transmit data from radio 4 N C 5 BUSY Radio receiving low busy including beeps 6 AUDIO D25 Single ended audio Zout 3 kΩ AC coupled 7 GND Signal ground 8 EXT MIC D25 Microphone input Zin 1 kΩ 9 MOD AUDIO To mo...

Page 111: ... showing how the four PCBs interconnect and naming the connectors on each PCB is shown in Figure F 9 Thefollowingsubsectionsandtheirassociated diagrams expand on the functionality of each vehicle kit PCB Vehicle kit accessory probe PCB IPN 220 01506 xx This PCB provides the interface to the radio s accessory connector The audio control signals connect to the options PCB via a 16 way MicroMatch rib...

Page 112: ...e The switch mode current source is based around a Maxim MAX1627 100 duty cycle high efficiency step down DC DC controller IC4 The core of the current source is a Buck converter consisting of Q9 L2 C46 C47 and D5 The feedback for the controller IC4 is via current sense resistors R58 R59 and a differ ential amplifier IC5 B In steady state approximately 0 8 A flows through R58 and R59 generating a v...

Page 113: ...input used for general voltage measurements is IC3 pin 16 The expanded voltage input used for fine voltage measurements is IC3 pin 17 Battery tempera ture is measured via IC3 pin 18 This pin is pulled to ground via a 10 kΩ nominal thermistor inside the battery case The battery capacity input used to tell the charger whether the battery is NiCd or NiMH is IC3 pin 19 Thelineto IC3 pin 7 isaninput wh...

Page 114: ...ery voltage triggers IC2 A the vehicle battery must recov er by approximately 1 V above the threshold before the vehicle kit will be powered up NotethattoadjusttheLVSDthreshold voltage dividerR22 R24 R25andR26mustbechanged Vehicle kit options PCB IPN 220 01505 xx This PCB contains the mode switching logic the microphone pre amp the RS 232 conver sion module the audio power amplifier with its assoc...

Page 115: ...s high and the audio PA is held in its mute mode via Q3 The audio PA can alsobe put into standby mode via the SPK CUT control signal being high Q4 will always override Q3 PuttingtheaudioPAintostandbyispartofthe power save feature ofthe vehicle kit LVSD is a control line from the charger PCB which goes high when the vehicle battery is too low 11V If LVSD is high then the audio PA is put into standb...

Page 116: ...s disabled RS 232 Conversion AnRS 232level3wireserialportisprovidedat the DB25 connector TX OUT RX IN GND for use by devices such as data terminals The radio provides CMOS level serial communica tions via the RXD and TXD signals These signals are converted to full RS 232 voltage levels i e 10 V for a logic 0 and 10 V for a logic 1 by IC3 ...

Page 117: ...t provides a glossary of terms Contents Glossary Glossary Glossary Glossary G 3 G 3 G 3 G 3 Accessory connector compatibility Accessory connector compatibility Accessory connector compatibility Accessory connector compatibility G 8 G 8 G 8 G 8 ...

Page 118: ...G 2 June 2003 IPN M5000 00 105 ...

Page 119: ...CTM Computercontrolledtestmode Theoperating mode of the radio whereby computer equip ment can control various radio functions by sending commands down a serial link to the radio channel A receive transmit frequency pair chassis old new See New chassis on page A 5 and Accessory connector compatibility on page G 8 configuration The determination and setup of the configura tion data for a given frequ...

Page 120: ...cial functions dialling Theactofenteringanumberorlabelbytyping in successive characters on the keyboard DSP Digital signal processor DTMF Dual tone multiple frequency Method of encodingdigits 0to9 andcharacters AtoF each as a pair of eight standard tones economy mode When the radio is cycling between the receive mode and standby state Available on Tait Orca conventional radios ECR External call re...

Page 121: ...isplay LED Light emitting diode LPF Low pass filter MCU Micro control unit mute The receive audio gating element When active receive audio is passed to the speaker The decision to activate deactivate the audio signal path is based on an evaluation of signal ling codes CTCSS DCS Selcall contained in the audio information contrast with squelch number A simple string that corresponds to an MPT1343 de...

Page 122: ...coding on the channel for the purpose of selecting an individual or group with which to communi cate selecting The act of picking a label from a displayed list using the arrow keys signalling Non voice coding on the channel for the purposeofidentifyingpartiesand or segregat ing user groups e g CTCSS DCS Selcall SMD Surface mount device SOIC Small outline integrated circuit SOT Small outline transi...

Page 123: ...e radio obeys commands on the control channel and generally operates as proscribed in MPT1343 trunking system The infrastructure comprising repeaters and radios requiredto support a number of control channels and traffic channels Two tone Also known as Type 99 In band two tone sequential signaling used to control the muting of a radio Used for selective calling of individual units or groups of uni...

Page 124: ...ry Connector Elan Excel or Eclipse TOP 5000 01 Chassis TOP 5000 02 Chassis TOP 5000 current chassis Old P Clip Old P Clip Enhanced Hard ened New Green P Clip with green dot Old D Clip New D Clip with green dot Old Vehicle Kit New Vehicle Kit with green quarter turn tip Old Dummy Cover New Dummy Cover The graphic shows the shape of the hole for the accessory connector s quarter turn tip on the back...

Page 125: ...June 2003 IPN M5000 00 105 G 9 Notes ...

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