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Tait TM8000 Series, Service Manual

The Tait TM8000 Series boasts exceptional performance and versatility, making it a top choice for professional communication needs. To ensure seamless operation and service, download our comprehensive Operation and Service Manual. Obtain this manual free of charge from manualshive.com, empowering you with detailed instructions and insights for optimal product usage.

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General Information

TM8100 Mobile Radio 

Service Manual

May 2004 © Tait Electronics Limited

Important

The components of the circuit boards in the radios are 
susceptible to damage from electrostatic discharges.  
Observe anti-static precautions when handling the 
boards or their components.  Follow the procedures 
given in the manufacturers’ data books.

Storage and Transport
of Items

Always observe anti-static precautions when storing, shipping or 
carrying the circuit boards and their components.  Use anti-static bags 
for circuit boards and anti-static bags or tubes for components that are to 
be stored or shipped.  Use anti-static bags or trays for carrying circuit 
boards, and foil or anti-static bags, trays, or tubes for carrying 
components.

Anti-static 
Workbenches

Use an anti-static workbench installed and tested according to the 
manufacturer’s instructions.  A typical installation is shown in 

Figure 4.1

.  

These benches have a dissipative rubber bench top, a conductive wrist 
strap, and a connection to the building earth.  The material of the bench 
top must satisfy not only anti-static requirements but also the non-scratch 
requirements mentioned above.

Figure 4.1

Typical installation of an anti-static workbench

TO BUILDING
EARTH

METAL FRAME

DISSIPATIVE RUBBER
BENCH MAT

CONDUCTIVE WRIST STRAP

Summary of Contents for TM8000 Series

Page 1: ...TM8000 mobiles TM8100 Mobile Radio Service Manual MM8100 02 00 812 Version 3 00 May 2004 Tait Electronics Limited ...

Page 2: ...dom Tait Mobile Radio Ltd E mail teusales tait co uk Latin America Tait Latin America E mail latinamerica taitworld com Tait North America Regional Head Office United States of America Tait North America Inc E mail usa taitworld com Canada Tait North America Inc E mail canada taitworld com Tait North Asia Regional Head Office Hong Kong Tait Mobile Radio Hong Kong Ltd E mail hongkong taitworld com ...

Page 3: ...TWARE OR FIRMWARE IN WHOLE OR PART Title to Software THIS AGREEMENT DOES NOT CONSTITUTE A CONTRACT OF SALE IN RELATION TO THE SOFTWARE OR FIRMWARE SUPPLIED TO THE LICENSEE NOT WITHSTANDING THE LICENSEE MAY OWN THE MAGNETIC OR OTHER PHYSICAL MEDIA ON WHICH THE SOFTWARE OR FIRMWARE WAS ORIGINALLY SUPPLIED OR HAS SUBSEQUENTLY BEEN RECORDED OR FIXED IT IS A FUNDAMENTAL TERM OF THIS AGREEMENT THAT AT A...

Page 4: ... SHALL BE DETERMINED BY THE NEW ZEALAND COURTS OF LAW PROVIDED HOWEVER TAIT MAY AT ITS ELECTION BRING PROCEEDINGS FOR BREACH OF THE TERMS HEREOF OR FOR THE ENFORCEMENT OF ANY JUDGEMENT IN RELATION TO A BREACH OF THE TERMS HEREOF IN ANY JURISDICTION TAIT CONSIDERS FIT FOR THE PURPOSE OF ENSURING COMPLIANCE WITH THE TERMS HEREOF OR OBTAINING RELIEF FOR BREACH OF THE TERMS HEREOF No Dealings THE LICE...

Page 5: ... Typographical Conventions 8 Associated Documentation 10 Publication Record 11 List of Acronyms 12 Chapter 1 Description of Radio 13 1 Introduction 15 2 General Description 33 3 Circuit Descriptions 63 Chapter 2 Servicing of Radio 79 4 General Information 81 5 Servicing Procedure 107 6 Disassembly and Re assembly of Radio 125 7 Servicing of Control Head 151 8 Servicing of Main Board 165 9 Diagnosi...

Page 6: ...ll accessories associated with the radio is covered in the accessories manual Summary of Service Manual The service manual is divided into two chapters A description of the radio is given in Chapter 1 After an introductory section an illustrated parts breakdown is given for the radio This is followed by a description of the principles of operation of the radio and the functioning of the circuitry ...

Page 7: ...thout prior notice Copyright All information contained in this manual is the property of Tait Electronics Limited All rights are reserved This manual may not in whole or in part be copied photocopied reproduced translated stored or reduced to any electronic medium or machine readable form without prior written permission from Tait Electronics Limited All trade names referenced are the service mark...

Page 8: ...the Start menu then select the Programs option from the list that appears then the Tait Programming Applications option from the second list and finally the TM8100 Programming Application option from the third list that appears Hardware related elements Convention Usage Examples SMALL CAPS QUOTES Labelled hardware items and settings Connect the cable to the NODE port Set the switch to the TX PTT p...

Page 9: ...ith the ANSI definitions Warning This alert notice is used when there is a potential risk of death or serious injury Caution This alert notice is used when there is a risk of minor to moderate injury to people Important This alert notice is used to warn about the risk of equipment damage or malfunction Note This alert notice is used to highlight information that is required to ensure that procedur...

Page 10: ...rid reference indexes PCB layouts and circuit diagrams MMAB12 B1 00 814 Main board B1 PCB information package MMAB12 D1 00 814 Main board D1 PCB information package MMAB12 H5 00 814 Main board H5 H6 PCB information package MMAC20 00 00 814 Control head board two digit display PCB information package MMAC50 00 00 814 Control head board one digit display PCB information package 3DK manuals The follo...

Page 11: ...n Record Version Publication date Amended sections and pages 1 00 September 2003 First release includes information for level 1 repairs only 2 00 March 2004 Second release information for level 2 repairs added 3 00 May 2004 Third release information for TM8110 radio and D1 band added ...

Page 12: ...ncy Control Loop FE Front end FPGA Field programmable Gate Array GPS Global Positioning System GUI Graphical User Interface IPN Internal Part Number IF Intermediate Frequency IQ In phase and Quadrature ISC International Service Centre LCD Liguid crystal Display LED Light emitting Diode LNA Low noise Amplifier LO Local Oscillator LPF Low pass Filter PA Power Amplifier PLL Phase locked Loop PTT Pres...

Page 13: ...TM8100 Mobile Radio Service Manual Description of Radio 13 May 2004 Tait Electronics Limited TM8000 mobiles Chapter 1 Description of Radio ...

Page 14: ...1 6 Specifications 29 2 General Description 33 2 1 Illustrated Parts Breakdown 33 2 2 Architecture of Radio 51 2 3 Operation of Control head Circuitry 53 2 4 Operation in Receive Mode 54 2 5 Operation in Transmit Mode 57 3 Circuit Descriptions 63 3 1 Control head board 63 3 2 Transmitter 64 3 3 Receiver 65 3 4 Frequency Synthesizer 67 3 5 Frequency Control Loop 70 3 6 CODEC and Audio Circuitry 71 ...

Page 15: ...signed primarily for installation in vehicles but can also be used in desktop remote monitoring and similar applications The system consists of the following items radio body control head audio accessories mounting for radio desktop power supply optional Separate calibration and programming applications are used to calibrate and program the radio The service manual covers the servicing of the radi...

Page 16: ...16 Introduction TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 1 1 Illustrations of the TM8115 radio showing both the front and rear ...

Page 17: ...may be connected to the control head and radio body A microphone is the accessory usually required other accessories that are available are a handset high power remote speaker and hands free kit Various external devices may also be connected The user s guide and accessories manual describe the audio accessories Installation Kits and Desktop Power Supply The mounting hardware for the radio is in th...

Page 18: ...18 Introduction TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 1 2 Illustration of the front of the TM8105 and TM8110 radios ...

Page 19: ...mple installation in a vehicle of a radio with a user interface MICROPHONE CONNECTOR MICRO PHONE HANGER PLATE MOUNTING CONTROL HEAD RADIO BODY RADIO SYSTEM HANDS FREE KIT HIGH POWER REMOTE SPEAKER POWER CONNECTOR AUXILIARY CONNECTOR EXTERNAL OPTIONS CONNECTOR RF CONNECTOR EXTERNAL DEVICE VEHICLE BATTERY FUSES RF ANTENNA ...

Page 20: ...am of an example desktop installation of a radio with a user interface MICROPHONE CONNECTOR HANDSET OR DESKTOP MICRO PHONE RADIO SYSTEM DESKTOP POWER SUPPLY CONTROL HEAD RADIO BODY POWER CONNECTOR AUXILIARY CONNECTOR EXTERNAL OPTIONS CONNECTOR RF CONNECTOR RF ANTENNA EXTERNAL DEVICE BACK UP BATTERY AC MAINS ...

Page 21: ...ase is ridged to augment the dissipation of heat The RF auxiliary and power connectors are fixed to the rear of the main board They project through apertures in the heat transfer block and the rear of the case The main board digital board and heat transfer block constitute a separate unit called the main board assembly Internal Options Boards Either Tait designed or custom internal options boards ...

Page 22: ...m of an example installation in a vehicle of a radio with a blank control head EXTERNAL DEVICE PROGRAMMING CONNECTOR MOUNTING BLANK CONTROL HEAD RADIO BODY RADIO SYSTEM VEHICLE BATTERY POWER CONNECTOR AUXILIARY CONNECTOR EXTERNAL OPTIONS CONNECTOR RF CONNECTOR EXTERNAL DEVICE EXTERNAL DEVICE FUSES RF ANTENNA ...

Page 23: ...itted behind the front panel The volume control potentiometer is fixed to the board so is a control head connector which is used for the control head loom between the control head and radio body Options for Control Heads with UI The control heads with UI allow for an optional concealed microphone or the use of a dynamic microphone A concealed microphone is fitted behind the front panel next to the...

Page 24: ...SPEAKER CONCEALED MICROPHONE OPTIONAL CONTROL HEAD CONTROL HEAD BOARD CIRCUIT BOARD FOR OPTIONAL MICROPHONES SPEAKER LEADS MICROPHONE LEADS CONNECTORS FOR OPTIONAL BOARD PADS SPEAKER CONNECTOR CONTROL HEAD CONNECTOR FACTORY CONNECTOR FACTORY ONLY CONTROL HEAD CONNECTOR CONTROL HEAD LOOM RADIO BODY MAIN BOARD DIGITAL BOARD MOUNTED ON MAIN BOARD OPTIONS BOARD OPTIONAL EXTERNAL OPTIONS CONNECTOR POWE...

Page 25: ...assembly excluding special items These repairs entail the replacement of faulty SMT surface mount technology components on the boards as well as the connectors on the main board The special items are the digital board and certain components on the main board the details are given in Chapter 2 Repairs of the special items are level 3 repairs Service Centres The service centres that carry out repair...

Page 26: ... repairs to any service centres other than the ISC 1 5 Product Codes Introduction This subsection describes the product codes used to identify different products of the mobile radio product line The product code scheme in general is first explained and then the product codes for the radio body and control head in particular The purpose is solely to enable service technicians to identify the radio ...

Page 27: ...ode might not even exist General Scheme for Product Codes Individual products of the mobile radio product line are identified by product codes with the format TMabcc ddee where a and b are uppercase letters representing the product family and category of product respectively and cc dd and ee are characters that identify the specific product The characters ee are applicable to the radio body only a...

Page 28: ...identifies the architecture of the digital board b identifies the RF performance cc is the letter digit combination identifying the frequency band and dd identifies any options selected The characters dd are set to 00 for the default radio with no options added For universal options available to all Customers the digits 01 to 99 are used for dd For custom options implemented for particular Custome...

Page 29: ...et to 0 when no options are added Both letters and digits may be used for cc The default for cc is 0T on one and two digit display control heads the Tait logo is then displayed next to the LCD screen the product model code TM8110 and TM8115 respectively is displayed above the speaker grille Figure 1 9 illustrates the product codes in use at the time of publication 1 6 Specifications Introduction G...

Page 30: ...miniature UHF Interface connectors Microphone connector Auxiliary connector Internal options connector Ports 1 serial 1 I O 1 serial 3 input 4 I O 1 audio tap in 1 audio tap out 1 serial 7 I O 1 audio tap in 1 audio tap out Physcial characteristics Weight 1 43 kg 50 44 ounces Dimensions Length Width Height 175 mm 6 88 inches 160 mm 6 29 inches 50 mm 1 97 inches Environmental conditions Operating t...

Page 31: ... 75 GHz for radio operating frequencies above 500 MHz 36 dBm 30 dBm 30 dBm Audio response 300 Hz to 3 kHz flat or with pre emphasis Audio distortion 3 at 1 kHz 60 modulation Transmit rise time From the time the external PTT line is asserted to the time when the RF output power reaches 90 of its final value 10 ms Receiver Sensitivity 118 dBm for 12 dB SINAD Intermodulation 66 dB Spurious responses ...

Page 32: ...32 Introduction TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited ...

Page 33: ...f figures covering respectively the control heads with UI the blank control head and the radio body The figures are exploded view illustrations showing how the parts and circuit boards are assembled to build the complete radio Accompanying the figures are tables in which the parts identified in the figures are listed and their details given Labels on Radio Before the different parts of the radio a...

Page 34: ...and connectors on the radio body SERIAL NUMBER AND PRODUCT CODE CONTROL HEAD POWER CONNECTOR BUNG FOR AUXILIARY CONNECTOR COMPLIANCE INFORMATION RF CONNECTOR RADIO BODY SAFETY LABEL HOT SURFACE SAFETY LABEL RF EXPOSURE CONTROL HEAD SEAL LEVER POINT MOUNTING POINTS COVER SEAL FOR EXTERNAL OPTIONS CONNECTOR BUNG IS FITTED IF THERE IS NO CONNECTOR ...

Page 35: ...nstalled a cover seal is supplied instead Whenever the connector is not in use the cover seal is fitted over the connector as shown in the figure The bungs and seals ensure that the radio is sealed to IP54 standards Separation of Control Head and Radio Body Figure 2 2 shows the control head detached from the radio body the control head loom between them and the control head seal The seal is fitted...

Page 36: ...control head Illustrated are the front panel with the various keys and indicator LEDs and the lens covering the display There is a rectangular aperture in the lens through which the display is viewed Depending on the type of control head the aperture is sized to fit either the one or the two characters displayed An identifying label distinguishes the control heads Externally the control heads diff...

Page 37: ...he control head board when a dynamic or concealed microphone is used Space frame Keypad and Display The space frame fits over the speaker a keypad and the LCD for the display The keypad is designed so that pressing any key results in contact being made with the control head board There are four light pipes in the keypad for the LEDs associated with the function keys Light pipes for the three STATU...

Page 38: ...Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 2 4 Interior of a control head with UI showing the space frame and associated parts 5 7 7 6 8 9 9 10 1 CIRCUIT BOARD FOR CONCEALED AND DYNAMIC MICROPHONES OPTIONAL ...

Page 39: ...le 2 1 Parts of the control heads with UI Index Reference IPN Description Quantity 1 Figure 2 3 316 06786 xx Front panel 1 2 Figure 2 3 311 01054 xx Knob for volume control potentiometer 1 3 Figure 2 3 312 01095 xx Lens with Tait logo two digit display 1 312 01106 xx Lens with Tait logo one digit display 4 Figure 2 3 365 01717 xx Label for TM8115 1 365 01745 xx Label for TM8110 5 Figure 2 4 219 02...

Page 40: ...ait Electronics Limited Figure 2 5 Interior of a control head with UI showing the parts remaining after the removal of the space frame 1 16 13 11 12 14 15 CAPSULE OF CONCEALED MICROPHONE OPTIONAL RUBBER SEAL FOR CONCEALED MICROPHONE OPTIONAL LIGHT PIPES FOR STATUS LEDs ...

Page 41: ...connector is not in use the seal is fitted to ensure that the control head is sealed to IP54 standards Figure 2 7 shows the interior of the control head There is provision in the blank control head for the fitting of a custom circuit board Otherwise as shown in the figure only the control head loom is fitted The programming connector at one end of the loom is screwed to the front panel The female ...

Page 42: ...42 General Description TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 2 7 Interior of the blank control head 7 6 1 ...

Page 43: ...nector is indicated in Figure 2 12 Chassis Assembly Figure 2 11 and Figure 2 12 show the parts of the chassis assembly Illustrated in Figure 2 11 are the chassis and the main board digital board and heat transfer block of the main board assembly Also shown are the bung for the auxiliary connector and the seal needed for the RF connector The screws secure the main board assembly in the chassis Figu...

Page 44: ...al Description TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 2 8 Cover control head seal lid assembly and chassis assembly of the radio body CHASSIS ASSEMBLY LID ASSEMBLY 4 1 2 3 3 ...

Page 45: ...t is conducted away in each case are described below Dissipation of Heat from Radio Interior Heat from the radio interior is conducted via the heat transfer block to the cooling fins at the rear where it is radiated away The ridged underside of the chassis augments the dissipation of heat The rear face of the block is in contact with the chassis where the fins are situated A coating of thermal pas...

Page 46: ...y 2004 Tait Electronics Limited Figure 2 10 Parts of the lid assembly with an internal options board 6 TYPICAL LARGE INTERNAL OPTIONS BOARD 5 SCREWS FOR SECURING INTERNAL OPTIONS BOARD OPTIONS LOOM FOAM SEAL COVER SEAL LOCK NUTS SCREWS EXTERNAL OPTIONS CONNECTOR ...

Page 47: ...ence IPN Description Quantity 1 Figure 2 8 303 23166 xx Cover 1 2 Figure 2 8 365 01712 xx Label for cover 1 3 Figure 2 8 349 02067 xx M4 x 16 screw for lid of radio body 4 4 Figure 2 8 362 01115 xx Control head seal 1 5 Figure 2 9 312 01091 xx Lid of radio body 1 6 Figure 2 9 362 01109 xx Main seal in lid 1 7 Figure 2 9 302 50000 xx Bung for aperture for external options connector 1 8 Figure 2 11 ...

Page 48: ...ption TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 2 11 Parts of the chassis assembly 10 11 8 12 9 DIGITAL BOARD HEAT TRANSFER BLOCK MAIN BOARD MAIN BOARD ASSEMBLY THERMAL PASTE SCREW BOSS ...

Page 49: ...t Electronics Limited Figure 2 12 Parts of the main board assembly 13 17 14 18 16 15 THERMAL PASTE THERMAL PASTE DIGITAL BOARD LOCK WASHER OF RF CONNECTOR HEXAGONAL NUT OF RF CONNECTOR RF CONNECTOR POWER CONNECTOR MAIN BOARD INTERNAL OPTIONS CONNECTOR AUXILIARY CONNECTOR ...

Page 50: ...BOARD RECEIVER FRE QUENCY SYNTHE SIZER TRANS MITTER CODEC AND AUDIO CIRCUITRY INTERFACE CIRCUITRY CONTROL HEAD CONNECTOR POWER CONNECTOR AUXILIARY CONNECTOR INTERNAL OPTIONS CONNECTOR FACTORY CONNECTOR FACTORY ONLY RF CONNECTOR DIG TX INH SYN TX LO SYN LOCK SYN RX OSC SYN RX LO1 TX RX RF DIG RX EN DIG SYN SPI DIG SYN SPI TX RX RF DIG SYN EN DIG RX EN DIG RX EN DIG RX EN PSU SYS RST 3V3 ...

Page 51: ... blank control head is discussed in the application manual for 3DK hardware developers Radio Body The radio body houses a main board with the transmitter receiver and associated circuitry and a digital board with the microprocessor and associated circuitry The digital board is reflow soldered to the main board There is also provision for an internal options board to be connected to the main board ...

Page 52: ...ocessing Data and signalling decoders Side tones Volume control Audio PA Phase locked to TCXO LPF ANT Control Head PWR Mag PLL Loop filter Loop filter Frequency control Triple point Equalisation Audio filtering Pre emphasis Optional processing Data and signalling encoders ALC Mic PGA Mic FGA Dir Coup Fin Drv Ex Pwr Crtl Ramp control TCXO 13 000 MHz VCO Control Auxiliary Head VCXO Bias CUSTOM LOGIC...

Page 53: ...provide a user interface consisting of seven segment LCD up and down channel selection keys four programmable function keys ON OFF push button key LED indicators volume control internal speaker microphone connector The LCD displays one or two characters depending on the type of control head The microphone connector may also be used for the connection of a handset or programming lead If required a ...

Page 54: ...arts are described in detail below RF Hardware Front end Circuitry and First IF The front end hardware amplifies and image filters the received RF spectrum then down converts the desired channel frequency to a first intermediate frequency IF1 of 45 1 MHz UHF or 21 4 MHz VHF where coarse channel filtering is performed The first LO local oscillator signal is obtained from the frequency synthesizer a...

Page 55: ...ly disconnecting the first LO for the duration of the impulse The response time of the noise blanker is very fast tens of nanoseconds and is shorter than the time taken for the RF signal to pass through the front end hardware so that the LO is disabled before the impulse reaches the IF stage where it could cause crystal filter ring Digital Base band Processing Custom Logic The remainder of the rec...

Page 56: ...e sample rate is decimated to 8 kHz and bandpass audio filtering 0 3 to 3 kHz is applied De emphasis is then applied to cancel out the receive signals pre emphasised response and improve signal to noise performance Optional processing such as decryption or companding is then applied if applicable Data and Signalling Decoders The data and signalling decoders obtain their signals from various points...

Page 57: ...o microphone sources a fist microphone connected to the control head and an auxiliary microphone connected via the auxiliary or external options connector Only electret type microphones are supported Support for optional dynamic fist microphones is facilitated by a hardware amplifier and filter this circuitry is mounted on a separate board that needs to be installed in the control head Analogue Pr...

Page 58: ...s is required Frequency Synthesizer Main Parts of Synthesizer As shown in Figure 2 14 the frequency synthesizer consists of two main parts FCL frequency control loop RF PLL phase locked loop The FCL and RF PLL are described briefly below Detailed descriptions of the circuitry are given in Section 3 on page 63 Note that patents are pending for several aspects of the synthesizer design Frequency Con...

Page 59: ...ces a nominal frequency of 12 kHz This is converted to digital form and transported to the frequency control block in custom logic The frequency control block compares the mixer output frequency with a reference generated by the digital clock and creates a DC error signal A programmed offset is also added This error signal is converted to analogue form and used to control the VCXO frequency and re...

Page 60: ...isition of RF PLL In the RF PLL the loop bandwidth is initially set high by increasing the charge pump current and reducing time constants in the loop filter As a result settling to within 1 kHz of the final value occurs in under 4 ms In order to meet noise performance requirements the loop parameters are then switched to reduce the loop bandwidth There is a small frequency kick as the loop bandwi...

Page 61: ...tput of the RF PA passes through a dual directional coupler used for power control and monitoring to the PIN switch The PIN switch toggles the antenna path between the receiver and transmitter in receive and transmit modes respectively Finally the output is low pass filtered to bring harmonic levels within specification Power Control The steady state power output of the transmitter is regulated us...

Page 62: ...egins upon release by the TX INHIBIT signal with the ramping shape being determined by a low pass filter Owing to power leakage through the PA chain ramping the bias takes the PA output power from less than 10 dBm to approximately 25 dB below steady state power Power Ramp up The power ramp signal is supplied by a 13 bit DAC that is controlled by custom logic The ramp is generated using a look up t...

Page 63: ...18 LEDs and the LCD device of the control head Also mounted on the board are the volume control potentiometer and the following five connectors control head connector microphone connector speaker connector two connectors for optional circuit board Protection circuitry is provided for the microphone connector The optional circuit board is installed when a dynamic microphone is used or a concealed m...

Page 64: ...gly LCD Driver An oscillator is used to run the LCD It oscillates at about 60 Hz and employs a Schmitt trigger and D flip flop to ensure a 50 duty cycle to the LCD A reset circuit is required because the reset from the main board is not routed to the control head The reset circuit also employs a Schmitt trigger Volume Control The volume control potentiometer is linear and passes the DC voltage sig...

Page 65: ...nhibited if for any reason an out of lock signal is detected from the synthesizer This ensures that no erroneous signals are transmitted at any time The power control loop senses the forward power by means of the diode D304 This signal is fed to the buffer and a band limited operational amplifier back to the gate of Q306 A voltage clamp one of the operational amplifiers of IC301 for Q306 limits th...

Page 66: ...e by two function on the LO input in order to provide the quadrature LO frequencies required internally The second LO frequency is synthesized by an integer PLL IC403 which uses the TCXO frequency SYN RX OSC 13 0000 MHz as its reference Frequencies of IF Stages The frequency of the first IF stage depends as follows on the frequency band of the radio B1 band 21 400 029 MHz D1 band 21 400 029 MHz H5...

Page 67: ...ium channel spacing 12 0 kHz narrow channel spacing 7 8 kHz The FPGA runs from the DIG SYS CLK signal which has a frequency of 12 288 MHz The receiver requires the TCXO calibration to be completed to ensure that the channel filtering is centred thereby minimising distortion Received Signal Strength Indication The RSSI is calculated in the FPGA and DSP and can be passed as an analogue voltage to th...

Page 68: ...or reasons of noise performance the VCOs are designed to be tuned within a range of 2 to 12 V Active tuning circuitry is required An active loop filter incorporating an IC operational amplifier achieves this range with a suitable power supply voltage Normal synthesizer switching behaviour involves overshoot which dictates that the tuning voltage range must extend above and below the range of 2 to ...

Page 69: ...the frequency or phase error The output is a series of 25 kHz 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 charge pump output will become open circuit Active Loop Filter The loop filter continuously integrates the current pulses from the charge pump and produces a steady DC output voltage that tunes the V...

Page 70: ...izer The FCL circuitry is given on sheet 5 of the circuit diagram for the main board and is described below Elements of FCL Circuitry The FCL is a simple frequency locked loop The circuitry consists of the following elements VCXO XL501 Q501 Q503 TCXO XL500 buffer amplifier IC500 mixer IC501 low pass filter IC502 pins 5 to 7 modulator buffer amplifier IC502 pins 1 to 3 The TCXO supplies a reference...

Page 71: ...C channels are not used Device IC205 IC205 contains two CODECs One is used by the FCL The second is used for auxiliary audio input and VCO modulation output The digital section communicates with this device via a four wire synchronous serial interface Device IC204 IC204 contains base band voice band and auxiliary CODECs and some analogue signal conditioning The reference voltage nominally 1 2 V fo...

Page 72: ...sponse and reduce the signal level to that required by the audio power amplifier Summing Circuit The top of C205 is where side tones are summed in and the CDC RX AUD signal is obtained C201 and R211 pre emphasize and attenuate the side tone signal to give a flat side tone frequency response and reduce the input to an appropriate level Buffer Amplifier IC201 pins 8 to 10 amplifies the signal at the...

Page 73: ...r the ADC input IC205 provides the input biasing of approximately 1 5 V Auxiliary Audio Output The source for the auxiliary audio output signal CDC AUD TAP OUT is provided by IC204 RAMPDAC ball The DAC output of IC204 is low pass filtered to remove high frequency artefacts The low pass filter formed by IC201 pins 1 to 3 R219 R220 R221 R224 C206 C208 and C210 is a third order Butterworth type with ...

Page 74: ...he external supply 13V8 BATT The four lower voltages required are then further stepped down with linear regulators These all take advantage of the efficiency gain of the SMPS The 9 V regulator and the 13 8 V switched supply are connected to 13V8 BATT The two remaining switched supplies 9 V and 3 V use P channel MOSFETs Control of Internal Power Supplies The radio can be turned on using the ON OFF ...

Page 75: ... installation this avoids flattening the battery when the ignition key is off Internal options Power Sense The internal options power sense option is similar to the auxiliary power sense option except that the IOP GPIO7 line of the internal options connector is used The link LK4 is required to connect the line to the power up circuitry This line is also active high it is on when the level exceeds ...

Page 76: ...own to 1 6 V by R746 and R753 to drive the base of Q703 pins 1 2 and 6 When the latter s collector current is low the base current is a maximum and creates a small voltage drop across R761 causing the collector emitter to saturate As the collector current increases the base current decreases proportionally until the voltage across R761 reaches 1 V At this point the base emitter begins to turn off ...

Page 77: ...removing the link LK2 in the power supply area and fitting the 33 kΩ resistor R775 ESD Protection On exposed inputs of the auxiliary and control head connectors ESD electrostatic discharge protection is provided by a 470 pF capacitor and by clamping diodes to ground and to 13 8 V For example on AUX GPIO4 this would consist of D713 and C725 The lines IOP GPIO1 to IOP GPIO7 are intended for connecti...

Page 78: ...78 Circuit Descriptions TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited ...

Page 79: ...TM8100 Mobile Radio Service Manual Servicing of Radio 79 May 2004 Tait Electronics Limited TM8000 mobiles Chapter 2 Servicing of Radio ...

Page 80: ...rol Head 131 6 3 Disassembly of Radio Body 137 6 4 Re assembly of Radio Body 144 6 5 Re assembly and Attachment of Control Head 148 7 Servicing of Control Head 151 7 1 Faults not Involving Control head Board 151 7 2 Faults Involving Control head Board 157 7 3 Replacement of Faulty Component 160 7 4 Replacement of Faulty Control head Board 163 8 Servicing of Main Board 165 8 1 Fault Diagnosis and R...

Page 81: ...irs Replacements of the connectors on the main board assembly however are level 2 repairs because these repairs entail the disassembly of the main board assembly Important The circuit boards in the TM8100 radio are complex They should be serviced only by accredited service centres Repairs attempted without the necessary equipment and tools or by untrained personnel might result in permanent damage...

Page 82: ...ol is strongly recommended but not mandatory Replacement SMT components are supplied by TEL in two separate spares kits one for the control head boards and one for the main board Spare special items are not supplied Further details are given in Subsection 4 2 Website Access To carry out level 1 and level 2 repairs service centres need access to the secured portion of the Technical Support website ...

Page 83: ...s is the Tait FOCUS call logging database This is accessible on the Technical Support website also All Customer related technical issues regarding the radios are recorded on this database These issues may be raised by both Customers and service centres Technical Support resolves the issues and informs the Customer or service centre concerned of the outcome All issues and their solutions are availa...

Page 84: ...for SMT Repairs In general only the standard tools for SMT work are required for level 2 repairs of the circuit boards In addition a can removal tool is recommended but if none is available a hot air tool may be used instead However it should be borne in mind 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 rise...

Page 85: ...for connecting the radio to the test equipment The setting up of the equipment is described in Subsection 4 5 on page 93 The service kit also includes a product support CD and a folder with the necessary service documentation including this manual The CD contains the programming application calibration application and soft copies of the service and related documentation The contents of the service...

Page 86: ...pares kits 4 and 5 are supplied with the kits Table 4 4 Spares kits Kit number Product code Description Repair level 1 TMAA22 01 Parts of two digit display control head excluding control head board 1 2 TMAA22 02 Mechanical parts of radio body 1 3 TMAA22 03 Control head boards two digit display 1 4 TMAA22 04 Selected components of control head boards 2 5 TMAA22 05 Selected components of main board ...

Page 87: ...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 regulations Do not make modifications or changes to the radio not expressly approved by TEL Failure to do ...

Page 88: ...tic bags or tubes for components that are to be stored or shipped Use anti static bags or trays for carrying circuit boards and foil or anti static bags trays or tubes for carrying components Anti static Workbenches Use an anti static workbench installed and tested according to the manufacturer s instructions A typical installation is shown in Figure 4 1 These benches have a dissipative rubber ben...

Page 89: ... do so might result in damage to the power output stage of the transmitter Important While servicing the main board avoid overheating the radio during test transmissions The following is good practice Secure the main board assembly in the chassis with the two external screws and one of the internal screws The screws are labelled 9 and 11 in Figure 2 11 The heat transfer block must be secured to th...

Page 90: ...M8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 4 2 Locations of the capacitors C548 and C565 and the inductors L601 and L602 on the main board VHF BOARD UHF BOARD SIMILAR UHF BOARD VHF BOARD SIMILAR ...

Page 91: ... standard soldering iron with a number 6 iron tip The capacitors are part of the frequency synthesizer circuitry under the SYN TOP can The inductors are part of the SMPS of the power supply circuitry on the bottom side of the board Figure 4 2 shows the locations of the components Can Removal and Installation Cans are best removed and installed using a can removal tool If this tool is available tec...

Page 92: ...TOR DB15 SOCKET RJ45 PLUG MICROPHONE CONNECTOR IN LINE CONNECTOR AUXILIARY CONNECTOR BANANA PLUGS BNC PLUG TEST UNIT OSCILLOSCOPE RX AUDIO SINAD CONNECTOR AUDIO IN HI RF COMMUNI CATIONS TEST SET AUDIO OUT TX AUDIO CONNECTOR RADIO BODY CONTROL HEAD RF CONNECTOR BNC PLUG BNC PLUG BNC PLUG AUDIO MONITOR OUTPUT RF IN OUT N TYPE CONNECTOR DC POWER SUPPLY PROGRAMMING CONNECTOR RJ45 PLUG DB9 SOCKET ADAPT...

Page 93: ...and service kit The face of the test unit is fitted with a speaker five switches and the following connectors RADIO connector DB15 plug COMPUTER connector RJ12 socket TX AUDIO connector BNC socket RX AUDIO SINAD connector BNC socket These connectors are all required for connecting the test equipment and radio Figure 4 4 illustrates the face of the test unit Use of Test Unit The test unit facilitat...

Page 94: ...ics Limited Figure 4 4 Illustration of the face of the test unit Radio Rx Tx PTT Speaker Radio Load TOP Mod Audio Mic Audio Rx Audio SINAD Tx Audio Computer TOP Off Hook On Hook Off TM8000 only TM8000 AUDIO OUT SWITCH AUDIO IN SWITCH SPEAKER SELECTOR SWITCH HOOK SWITCH MODE SWITCH ...

Page 95: ...h RX initially AUDIO IN switch MIC AUDIO AUDIO OUT switch immaterial When ready to transmit set the MODE switch to the TX PTT position This switch functions in the same way as the PTT switch on the microphone Product Support CD After setting up the test equipment for the first time install the programming and calibration applications on the test PC These applications are included on the product su...

Page 96: ...atically Follow the instructions on the screen to complete the installation 2 Click the Calibration button Installation of the calibration application begins automatically Follow the instructions on the screen to complete the installation 3 The Contents window remains open following installation of the above applications Investigate the remaining features of the product support CD as described bel...

Page 97: ...tWorld button opens the default browser installed on the test PC and accesses the TaitWorld website Programming Application The programming application is typically used to read the programming file of a radio change settings in the various forms constituting the file and reprogram the radio Alternatively the application can be used to open a new file select the required settings and program one o...

Page 98: ...TM commands can be entered at the test PC These commands are then relayed via the test unit to the radio Certain CCTM commands cause the radio to carry out particular functions others read particular settings and parameter values in the radio The CCTM commands of use in servicing radios are listed in Table 4 5 to Table 4 9 grouped according to category Terminal Program for CCTM To place a radio in...

Page 99: ...the speaker 74 x where x is the required state 0 stand by 1 on 2 mute None 110 Audio volume Sets the level of the audio volume 110 x where x defines the required level any integer from 0 to 255 None 138 Select microphone Selects the microphone required 138 x where x is the required microphone 0 control head microphone 1 auxiliary microphone None 323 Audio tap in Generates the audio tone AUD TAP IN...

Page 100: ...sion number of the FPGA 98 QMA1G_x_y where x is a three character identifier and y is an eight digit version number 133 Hardware version Reads the product code of the radio body and the hardware version number 133 x y where x is the product code and y is the version number a four digit number 134 FLASH serial number Reads the serial number of the FLASH memory 134 x where x is the serial number a 1...

Page 101: ...izer 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 Receiver category 32 Receive mode Sets the radio in the receive mode 32 None 63 RSSI level Reads the averaged RSSI level 63 x where...

Page 102: ...tting an integer from 0 to 1023 114 x to set value where x is the required power setting an integer from 0 to 1023 None 304 Driver bias Sets or reads the clamp current at the gate of the PA driver 304 to read value x where x is the DAC value of the clamp current an integer from 0 to 255 304 x to set value where x is the required DAC value of the clamp current an integer from 0 to 255 None 318 Forw...

Page 103: ...ror Codes Once the radio is in CCTM the CCTM commands may be entered as shown in Table 4 5 to Table 4 9 Depending on the command a response might or might not be displayed If an error occurs an error code will be displayed Possible error codes are listed in Table 4 10 Table 4 9 CCTM commands in the transmitter category part 2 Command Usage Entry at keyboard Response on screen Transmitter category ...

Page 104: ...een received Re enter the CCTM command with valid parameters C03 A valid CCTM command has been received but cannot be processed at this time Enter the CCTM command again If the error persists power the radio down and up again and re enter the CCTM command C04 An error occurred on entry into CCTM Power the radio down and up again and place the radio in CCTM again C05 The radio has not responded wit...

Page 105: ...s been initiated One short low pitched beep On pressing function key again Function has been terminated One short high pitched beep While powered up Radio has been stunned One long low pitched beep 1 On pressing key Key press is invalid 2 On entry of PIN PIN is invalid 3 On pressing PTT switch Transmission is inhibited Two short beeps 1 On power up Radio is ready to use 2 On entry of PIN PIN has b...

Page 106: ...106 General Information TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited ...

Page 107: ...oth Whatever the case first check the radio for mechanical loss or damage This is advisable even if the fault concerns a function failure only Inspect the radio as follows Check for Minor Damage or Loss Check for damage or loss of parts that can be replaced without disassembling the radio These parts are knob for volume control potentiometer microphone grommet rubber seal for RF connector bung for...

Page 108: ...ed to have a functional fault continue with the tasks given in Subsection 5 2 on page 109 any additional mechanical damage will be repaired during the course of rectifying the functional fault If the radio has no functional fault repair any additional damage as described below conclude with the tasks of Subsection 5 3 on page 121 Replace Damaged Cover Assembly Remove a damaged cover assembly as de...

Page 109: ...must be done If the fault is not confirmed when the relevant task is done obtain more information from the Customer in particular determine whether the radio is properly configured for the Customer s system Task 1 Power up Radio With the radio connected to the test equipment as described in Subsection 4 5 on page 93 attempt to power up the radio 1 Apply power to the radio If the radio doesn t powe...

Page 110: ...Task 1 5 Check the control head connector on the control head board 6 If the connector is faulty remove the control head board as in Subsection 6 2 on page 131 and replace the connector If the connector is not faulty replace the control head board as in Subsection 7 4 on page 163 7 Check if the radio powers up 8 If the radio powers up return to Step 3 of Task 1 If the radio does not power up the r...

Page 111: ...he main board assembly continue with Step 5 Otherwise continue with Step 8 5 If the programming file can be read now store a copy on the test PC and proceed to Task 3 If the file still cannot be read set up a default programming file 6 Attempt to upload the default programming file to the radio 7 If the upload succeeds proceed to Task 4 If the upload fails continue with Step 8 8 If the main board ...

Page 112: ...om 2 Check if the programming file can be read 3 If the file can be read the original loom is faulty go to 4 If the file still cannot be read reconnect the original loom and go to 5 4 Replace the faulty control head loom and return to Step 4 of Task 2 5 Check the control head connector and microphone connector on the control head board and the path between them 6 If either connector is faulty remo...

Page 113: ...ecting this task should have been rectified in Task 2 Remaining Tasks Further action depends on the nature of the reported fault There are five possibilities 1 If the reported fault concerns powering up the radio and this has now been addressed servicing of the radio is complete Re assemble the radio if necessary and conclude with the tasks of Subsection 5 3 on page 121 2 If the reported fault con...

Page 114: ...tinue with Step 6 If there is a fault continue with Step 3 3 Attempt to rectify the fault as described in Section 7 on page 151 The final test in Section 7 will indicate whether the repair succeeded or failed 4 If the repair succeeded continue with Step 5 If the repair failed conclude with the tasks of Subsection 5 3 on page 121 5 If the reported fault is unspecific proceed to Task 6 If the report...

Page 115: ...oard assembly continue with Step 6 Otherwise continue with Step 5 5 If the main board assembly was replaced or if the repair failed re assemble the radio as described in Subsection 6 4 on page 144 and Subsection 6 5 on page 148 Conclude with the tasks of Subsection 5 3 on page 121 6 If the reported fault concerns the receive function and this has now been rectified re assemble the radio if necessa...

Page 116: ... to Step 4 of Task 6 5 If the speaker and volume control have already been checked go to 8 If they have not check if either is faulty If there is no fault go to 8 If there is a fault repair it as in Subsection 7 1 on page 151 6 If the repair succeeded go to 7 If the repair failed return to Step 4 of Task 6 7 Check if the radio receives If it does return to Step 4 of Task 6 If it does not go to 8 8...

Page 117: ...it is not recalibrate the radio 8 Check if the radio receives If it does return to Step 4 of Task 6 If it does not go to 9 9 Remove the lid of the radio body as in Subsection 6 3 on page 137 and check the RF connector 10 If the connector is OK go to 13 If it is faulty go to 11 11 At level 1 service centres go to 13 and replace the main board assembly At level 2 service centres remove and disassemb...

Page 118: ...ue with Step 3 3 Attempt to rectify the fault as described in the charts of Figure 5 5 and Figure 5 6 4 Re assemble the radio if necessary Conclude with the tasks of Subsection 5 3 on page 121 5 If the reported fault concerns the transmit function and this has not been confirmed obtain more information from the Customer If the reported fault is unspecific and no fault could be found with the radio...

Page 119: ... 6 2 Control head faulty 1 If the control head loom has already been checked go to 5 If it has not exchange the loom for a serviceable spare loom 2 Check if the radio transmits 3 If the radio transmits the original loom is faulty go to 4 If the radio still fails to transmit reconnect the original loom and go to 5 4 Replace the faulty control head loom and return to Step 4 of Task 7 5 Check the con...

Page 120: ...f it does not go to 7 7 Remove the lid of the radio body as in Subsection 6 3 on page 137 and check the RF connector 8 If the connector is OK go to 11 If it is faulty go to 9 9 At level 1 service centres go to 11 and replace the main board assembly At level 2 service centres remove and disassemble the main board assembly as in Subsection 6 3 replace the connector and re assemble the main board ass...

Page 121: ... 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 Final Administration The administration tasks following a successful repair of the radio are discussed in the next paragraph There will be cases on the other hand where the radio could not be repaired for one of the following reasons fault not located repair of fault fa...

Page 122: ...gramming file needs to be obtained and uploaded or the data obtained to create the file If the radio is to be returned to a Dealer or direct to a Customer who does have programming facilities the Dealer or Customer respectively need to be informed so that they can program the radio appropriately Table 5 1 Final tests of transmitter function Test Limits Error in transmit frequency 100 Hz to 100 Hz ...

Page 123: ...ith volume set to give 3 W into 16 Ω load 3 00 Table 5 3 Final tests of general radio functions Test Description PTT switch Check that PTT switch functions Microphone Check operation of microphone Check operation of hook switch Data communications Test 1200 baud data transmission standard Test Tait high speed data transmission if feature is enabled Direct connect GPS global positioning system Chec...

Page 124: ...124 Servicing Procedure TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited ...

Page 125: ...procedures are detailed in Subsection 6 1 to Subsection 6 5 respectively References to Disassembly and Re assembly Procedures The full sequence of tasks entailed in servicing the radio is given in Subsection 5 2 on page 109 During the course of servicing a particular radio some or all of the above disassembly and re assembly procedures will be required In Subsection 5 2 there are instructions at t...

Page 126: ...100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 6 1 Lever points for detaching the control head from the radio body LEVER POINT DETAILS OF LEVER POINT INDICATION OF LEVER POINT UNDERSIDE OF CHASSIS CONTROL HEAD RADIO BODY ...

Page 127: ...will need to be returned to the Customer with the same configuration 2 Disconnect the radio from any test equipment or power supply 3 Note the two points where the control head should be levered off the radio body As shown in Figure 6 1 these points are indicated by dot dash dot marks on the underside of the radio body The lever point is between the rubber control head seal and the front panel of ...

Page 128: ... Service Manual May 2004 Tait Electronics Limited Figure 6 2 Details of the control head seal between the radio body and control head CONTROL HEAD LOOM CONTROL HEAD CONTROL HEAD SEAL RADIO BODY SEAL SEAL LIPS FRONT FACE OF RADIO BODY DETAILS OF CONTROL HEAD SEAL ...

Page 129: ... seal Check for any sign of deformation cuts or tears Pay particular attention to the two lips of the seal 3 If the seal is damaged replace it with a spare seal from Spares kit 7 This kit contains a set of these seals 4 Inspect the interior of the control head for signs of damage Check for cracked broken or burnt parts In a control head with UI the parts to inspect are the space frame speaker and ...

Page 130: ...control head showing the control head board CONCEALED MICROPHONE IF FITTED GUIDE 3 CLIP 3 SCREW 1 CLIP 1 CLIP 2 PADS FOR LEADS TO CONCEALED MICROPHONE SPEAKER CONNECTOR CONTROL HEAD BOARD SPEAKER CONTROL HEAD CONNECTOR SCREW 3 GUIDE 4 SCREW 2 GUIDE 1 GUIDE 2 POSITION OF CIRCUIT BOARD FOR OPTIONAL MICROPHONES CONNECTORS FOR OPTIONAL BOARD ...

Page 131: ...crophone is fitted unsolder the microphone leads from the control head board The leads are soldered to pads on the board as shown in Figure 6 3 4 Note whether the speaker leads are connected to the control head board If so disconnect the leads The radio will need to be returned to the Customer in its original state 5 Use a Torx T10 screwdriver to remove the screws securing the control head board T...

Page 132: ...l 1 Figure 2 3 312 01095 xx Lens with Tait logo two digit display 1 Figure 2 3 312 01106 xx Lens with Tait logo one digit display 365 01717 xx Label for TM8115 1 Figure 2 3 365 01745 xx Label for TM8110 209 00011 xx Elastomeric strip 2 Figure 2 4 319 30073 xx Space frame 1 Figure 2 4 008 00031 xx LCD 1 Figure 2 5 252 00011 xx Speaker 1 Figure 2 5 307 01024 xx Speaker membrane 1 Figure 2 5 311 0311...

Page 133: ... panel Assembly There are two methods of repairing a damaged front panel assembly replace complete front panel assembly replace damaged parts of front panel assembly Generally either method may be used However the latter method must be used if a concealed microphone is fitted or custom labels have been added to the front panel The two methods are described separately below Replace Front panel Asse...

Page 134: ...Figure 6 4 Plan view of the control head with the control head board removed CLIP 6 CLIP 4 CLIP 2 CLIP 5 CLIP 3 CLIP 1 SPEAKER LCD ELASTOMERIC STRIPS SPACE FRAME APERTURE FOR MICROPHONE CONNECTOR KEYPAD CONCEALED MICROPHONE IF FITTED APERTURE FOR SHAFT OF VOLUME CONTROL POTENTIOMETER LIGHT PIPES FOR STATUS LEDs ...

Page 135: ...clip out of its recess Pulling on the space frame helps release the clips 3 Pull the space frame out when all six clips have been released 4 Remove the elastomeric strips speaker LCD keypad and if fitted concealed microphone Replace Damaged Parts Replacement Task Replace any of the following parts that external and internal inspection have shown to be damaged Refer to the accessories manual regard...

Page 136: ...e assembly of Radio TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 6 5 Lever points for removing the cover of the radio body LEVER POINT UPPER SCREW BOSS DETAILS OF LEVER POINT LOWER SCREW BOSS ...

Page 137: ...o points where the cover should be levered off the radio body As shown in Figure 6 5 each lever point is a slot above the lower screw boss 2 Insert the blade of a small about 3 mm flat bladed screwdriver in each of the above slots in turn In each case push the screwdriver under the cover towards the upper screw boss This will release the cover from the upper boss Remove the cover 3 Use a Torx T20 ...

Page 138: ...Radio TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 6 6 The four screws that secure the lid to the chassis of the radio body CHASSIS LID BUNG FOR AUXILIARY CONNECTOR COVER SEAL FOR EXTERNAL OPTIONS CONNECTOR ...

Page 139: ... Electronics Limited Figure 6 7 Illustration of the lid removed from the chassis of the radio body with an options board installed in the lid SLOT IN HEAT TRANSFER BLOCK FOR SCREWDRIVER MAIN SEAL CHASSIS LID MAIN BOARD INTERNAL OPTIONS BOARD MAIN SEAL OPTIONS LOOM INTERNAL OPTIONS CONNECTOR ...

Page 140: ...cs Limited Figure 6 8 Illustration of the chassis showing the screws that secure the main board assembly BUNG FOR AUXILIARY CONNECTOR SCREW 2 SCREW 3 SCREW 4 SCREW 5 SCREW 1 SCREW 6 SCREW 7 PLAN VIEW REAR VIEW PAD TOP CAN DIGITAL BOARD SEAL FOR RF CONNECTOR HEAT TRANSFER BLOCK MAIN BOARD PAF TOP CAN ...

Page 141: ...e are labelled screw 1 to screw 5 in Figure 6 8 Use a Torx T10 screwdriver to remove the screws The order of removal is immaterial but good practice would be to follow the order from screw 1 to screw 5 4 Note the two exterior screws securing the main board assembly these are labelled screw 6 and screw 7 in Figure 6 8 Use a Torx T20 screwdriver to remove the screws 5 The main board assembly is now ...

Page 142: ...the auxiliary connector 3 Use a torque driver with a 14 mm long reach socket to remove the hexagonal nut of the RF connector Also remove the lock washer 4 Use a Torx T10 screwdriver to remove the three screws securing the copper plate on the main board to the heat transfer block Access to the screws is via the holes in the PAD TOP and PAF TOP cans shown in Figure 6 8 Figure 6 9 Features of the mai...

Page 143: ...screw for lid of radio body 4 Figure 2 8 362 01115 xx Control head seal 1 Figure 2 8 362 01109 xx Main seal in lid 1 Figure 2 9 302 50000 xx Bung for external options connector 1 Figure 2 9 302 50001 xx Bung for auxiliary connector 1 Figure 2 11 362 01113 xx Seal for RF connector 1 Figure 2 11 349 02067 xx External M4 x 16 screw for main board assembly 2 Figure 2 11 349 02066 xx Internal M3 x 10 s...

Page 144: ...fer block If the residual paste has been contaminated with dirt clean off the paste 3 Obtain 0 1 cm3 of thermal paste Use Dow Corning 340 silicone heat sink compound IPN 937 00000 55 or the equivalent 4 Use a stiff brush to apply the paste in a thin film to the required area on the copper plate Ensure that no bristles from the brush come loose and remain embedded in the paste The paste needs to be...

Page 145: ...nsure that no bristles from the brush come loose and remain embedded in the paste The paste needs to be completely free of contaminants 5 Thermal paste is also required on the screw boss in contact with the PCB The area is shown in Figure 2 11 Inspect the area as well as the corresponding area on the PCB If the residual paste has been contaminated with dirt clean off the paste 6 Replenish the past...

Page 146: ...to tighten the screws to 2 5 N m 22 lbf in If the screws are not tightened properly the radio will overheat The reason for pressing down on the can is to ensure that the circuit board is seated correctly on the bosses for the five internal screws 5 Clean off any excess thermal paste on the heat transfer block 6 Screw in the five internal screws by hand as far as possible The screws are labelled sc...

Page 147: ... on the main board This is best done with the lid placed next to the chassis as shown in Figure 6 7 2 Place the lid in position on the chassis Ensure that the main seal in the lid is properly seated 3 Screw in by hand the four screws that secure the lid Ensure that the screws start easily and are not cross threaded Then use a Torx T20 torque driver to tighten the screws to 2 5 N m 22 lbf in 4 Fit ...

Page 148: ... 10 it will have a protective film covering the screen Peel off the film before continuing 2 Ensure that the LCD is free of dirt and fingerprints Use isopropyl alcohol and a soft lens cleaning cloth to clean the LCD including the electrical contact points Take care not to scratch the soft polariser material on both sides of the LCD 3 Place the LCD in its recess in the cover as shown in Figure 6 4 ...

Page 149: ...meric strips causing failure in the operation of the LCD 3 Screw in by hand the three screws that secure the control head board The screws are labelled screw 1 to screw 3 in Figure 6 3 Ensure that the screws start easily and are not cross threaded Then beginning with screw 1 use a Torx T10 torque driver to tighten the screws to 0 6 N m 5 lbf in 4 If an optional microphone board is included attach ...

Page 150: ... radio body as noted in Subsection 6 1 on page 127 2 Reconnect the control head loom to the connector on the radio body Refer to Figure 6 2 3 Align the control head with the inner face of the radio body Ensure that the control head loom folds properly into the space between the control head and the radio body 4 Press the control head against the radio body until it clips into position Ensure that ...

Page 151: ...d faults involving control head board Subsection 7 1 below and Subsection 7 2 on page 157 cover the repair procedures for these two cases respectively Repair of the control head board however is a level 2 repair Level 1 service centres should instead replace the board as described in Subsection 7 4 on page 163 For level 2 service centres Subsection 7 3 on page 160 describes how to find the correct...

Page 152: ...152 Servicing of Control Head TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 7 1 Primary side of the control head board PADS FOR LCD PADS FOR LCD PADS FOR LCD PAD FOR KEY ...

Page 153: ...s described in Subsection 6 5 on page 148 7 Reconnect the control head loom to the control head and test the user interface If the fault has been removed return to Subsection 5 2 on page 109 If it has not go to Task 2 Task 2 Display Faulty but not LEDs Replace LCD If the elastomeric strips are not the cause of the fault replace the LCD as follows 1 Disconnect the control head loom Remove the contr...

Page 154: ...of Control Head TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 7 2 Secondary side of the control head board with the LCD driver circuitry and other components indicated 1 2 3 PINS OF RV1 ...

Page 155: ...sembling the spare control head of Spares kit 1 or 10 as described in Subsection 6 2 6 Re assemble the control head as described in Subsection 6 5 Reconnect the control head loom test the keys to confirm the removal of the fault and return to Subsection 5 2 Task 4 Speaker Faulty If the speaker functions only intermittently or the audio level is low repair the control head as follows 1 Disconnect t...

Page 156: ...cing of Control Head TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 7 3 Secondary side of the control head board with IC3 IC5 IC7 and the switching transistors for the LEDs indicated ...

Page 157: ... head loom Confirm the removal of the fault and return to Subsection 5 2 on page 109 6 Remove the control head board as described in Subsection 6 2 7 Replace the potentiometer RV1 See Figure 7 1 8 Re install the control head board as described in Subsection 6 5 Reconnect the control head loom Confirm the removal of the fault and return to Subsection 5 2 7 2 Faults Involving Control head Board Type...

Page 158: ...go to Step 4 4 Test the user interface If the fault has been removed return to Subsection 5 2 If it has not the repair failed replace the control head board as described in Subsection 7 4 on page 163 Task 2 Some LEDs Faulty If the display functions correctly but one or more but not all of the LEDs D1 to D18 are faulty check the control head board as follows 1 Disconnect the control head loom Remov...

Page 159: ...epair any fault and go to Step 8 3 Use the multimeter to check that the RST line at pin 6 at 1E10 of IC7 is high The level should be 3 3 V If it is go to Step 5 If it is not go to Step 4 4 Check for continuity in the LCD driver circuitry D22 C12 R27 at 1E9 and 1E10 see Figure 7 2 Repair any fault and go to Step 8 If there is no continuity fault replace IC7 and go to Step 8 5 Use the multimeter to ...

Page 160: ... to board identify replacement component in BOM of PCB information pack consult technical notes obtain replacement component The technical notes will indicate whether there have been any changes affecting the component in question Identify PCB Information Pack First identify which version of PCB information pack applies to the control head board under repair 1 Note the IPN of the PCB The IPN is pr...

Page 161: ...k and click the adjacent view download command The document is displayed View the document print a copy or save a copy in the test PC Alternatively right click the view download command and select the save or print option from the menu that appears Identify Replacement Component After locating the correct PCB information pack for the board consult the BOM for the board Identify the component in qu...

Page 162: ... publication of the PCB information pack in question 5 Identify any of the above technical notes that apply to the control head board 6 For each technical note identified in Step 5 click the adjacent view download command The technical note is displayed View the document print a copy or save a copy in the test PC Alternatively right click the view download command and select the save or print opti...

Page 163: ...s contain replacement control head boards for two and one digit display control heads respectively Check with TEL regarding the availability of the kits Re assemble and Test Control Head Re assemble the control head with the replacement control head board as described in Subsection 6 5 on page 148 Reconnect the control head loom to the radio body and test the user interface as described in Task 5 ...

Page 164: ...164 Servicing of Control Head TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited ...

Page 165: ...ction 8 3 on page 169 For level 2 service centres Subsection 8 2 on page 166 describes how to find the correct replacement for a faulty component on the board 8 1 Fault Diagnosis and Repair Identify Suspect Circuit Module With the information gained from the initial investigation identify which module of the circuitry on the main board is faulty power supply circuitry interface circuitry frequency...

Page 166: ...he complete main board assembly as described in Subsection 8 3 Re install Cans and Retest Finally re install all cans on the main board that have been removed refer to Subsection 4 4 on page 91 for information on can replacement Repeat the above basic tests following the re installation of the cans The tests should again confirm the removal of the fault Re assemble the radio body as described in S...

Page 167: ...al Support website as described in the next paragraph Access Website To locate the correct version of PCB information pack follow the procedure given below It is advisable to print and store a copy of every PCB information pack published on the Technical Support website 1 Access the Technical Support website at support taitworld com 2 Click the Login button The Log in dialogue box appears 3 Enter ...

Page 168: ...cal note published 1 If not already logged on to the Technical Support website do so as described above Associate access is sufficient 2 Click the Mobile Radios TM8000 option A list of facilities for this product family appears 3 Click the Technical Notes facility A list of all technical notes appears 4 From the publication dates of the technical notes identify those that follow publication of the...

Page 169: ...he chassis as described in Subsection 6 4 on page 144 Calibrate and Program Radio Connect the radio to the test equipment Calibrate and program the replacement main board assembly in the same way as the faulty assembly Use the files downloaded as described in Tasks 2 and 4 of Subsection 5 2 on page 109 If a file could not be downloaded use the default file Test Main board Assembly Carry out the ba...

Page 170: ...L 4 Supply the serial number of the radio under repair and the serial number of the replacement main board assembly 5 If it is known from Task 3 above that the radio had software features enabled go to Step 6 Otherwise go to Step 7 6 Ask the CSO or TEL for a licence file for the replacement main board assembly The CSO will supply the required file Go to Step 8 7 Ask the CSO or TEL if the radio und...

Page 171: ... the capacitors C548 and C565 and the inductors L601 and L602 Grid References Throughout this section data in square brackets are grid references giving the locations of the components concerned on the circuit diagram The first reference in square brackets is for the B1 H5 and H6 bands and the second is for the D1 band Using the first reference in the next subsection as an example the format is th...

Page 172: ...ults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 1 Important components of the power supply circuitry on the bottom side of the main board PIN 5 PIN 7 CAN FOR DIGITAL BOARD ...

Page 173: ...the radio powers up return to Subsection 8 1 If it does not go to Step 5 5 Check the digital power up signal at pin 5 at 6G6 6E6 of IC602 see Figure 9 1 the signal is active high namely when the voltage exceeds 2 0 V DC Measure the voltage at pin 5 If it exceeds 2 0 V 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 ...

Page 174: ...ting the supply or preventing the radio from powering up While keeping the ON OFF key depressed measure the supply at the 3V3 test point at 1N0 1B11 near the corner of the digital board see Figure 9 2 The voltage is 3 3 0 1 V when there is no fault If the voltage is correct the digital board is faulty return to Subsection 8 1 and replace the complete main board assembly If the voltage is not corre...

Page 175: ... Step 6 If the fault remains the repair failed return to Subsection 8 1 and replace the complete main board assembly 6 Reconnect the 13 8 V supply Press the ON OFF key If the radio powers up return to Subsection 8 1 If the radio fails to power up disconnect the 13 8 V supply and go to Step 7 7 Measure the resistance of L601 at 6H6 6E7 see Figure 9 1 The resistance should be virtually zero If it is...

Page 176: ...done on the input output and control line of the relevant regulator IC Repair any fault 2 If the regulator IC has been removed resolder it in position 3 Reconnect the 13 8 V supply and press the ON OFF key If the radio powers up or the correct regulator voltage is restored return to Subsection 8 1 If the repair failed go to Step 4 4 Disconnect the 13 8 V supply Replace the regulator IC with a spar...

Page 177: ...ply to the AUX GPI3 line pin 4 of the auxiliary connector SK101 Check that the power up signal is high Remove the 3 3 V supply and ground the AUX GPI3 line to be precise the voltage on the line should be less than 0 6 V If the signal is correct return to Subsection 8 1 If it is not check for continuity and shorts to ground between D601 at 6C6 6E3 see Figure 9 1 and pin 4 of the auxiliary connector...

Page 178: ...the circuit diagram for the internal circuitry dashed lines enclose connector signals Internal signals are all named signals outside these enclosures In Figure 9 4 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 Table 9 1 Implementation of the power up options Power up option Link to insert Factory default Act...

Page 179: ...e replaced to rectify faults refer to Figure 9 5 to Figure 9 7 for the locations of the components These figures show the three areas of the main board where the components of the interface circuitry are situated Figure 9 4 Example illustrating the convention for internal and connector signals 3V3_CL 3V3 D705 BAV70W 2 3 R723 33K R731 1K0 IOP_GPIO7 1B2 6B4 ITF_IOP_GPO7 3V3_CL 3V3 D706 BAV70W 1 3 R7...

Page 180: ...n or to a temperature change This might expose any intermittent contact in which case go to Step 3 3 If the expected signal is not present check whether the expected internal signal is present If it is go to Step 5 If it is not go to Step 4 4 The fault lies with the radio s internal circuitry If the power supply circuitry or the CODEC and audio circuitry is suspect continue with the fault diagnosi...

Page 181: ...go to Step 7 If it is not go to Step 8 4 For the CH ON OFF line apply a short to ground on pin 5 of a connector mated to the control head connector Check that there is 3 9 V DC present on the ITF ON OFF line and that PSU ON OFF is approximately equal to the radio s primary supply voltage nominally 13 8 V DC 5 Remove the short on the connector Check that with CH ON OFF open circuit both ITF ON OFF ...

Page 182: ...agnosis of Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 7 Components of the interface circuitry on the bottom side of the main board CAN FOR DIGITAL BOARD ...

Page 183: ...Configure the suspect line as an input and then carry out the procedure given in Task 2 9 3 Frequency Synthesizer Introduction This subsection covers the diagnosis of faults in the frequency synthesizer The synthesizer is a closed loop control system A fault in one area can cause symptoms to appear elsewhere Locating the fault can therefore be difficult The fault diagnosis procedure is divided int...

Page 184: ... Diagnosis of Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 8 Synthesizer circuitry under the FCL TOP can on the top side of the main board SYN TOP CAN ...

Page 185: ...TM command 72 again and take the action indicated If the repair failed or no fault could be found return to Subsection 8 1 and replace the complete main board assembly 4 Check for 3 V DC on pins 7 15 and 16 of IC503 at 5H7 see Figure 9 9 If there is go to Step 5 If there is not check for faults in the 3V0 AN supply to IC503 from IC603 at 6H5 6D7 If a fault is found repair it and confirm the remova...

Page 186: ... of Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 9 Synthesizer circuitry under the SYN TOP and VCO TOP cans on the top side of the main board VHF BOARD UHF BOARD ...

Page 187: ...s in Step 4 After these checks enter the CCTM command 335 0 to switch off the transmit receive switch 4 Measure the voltage on the collector of Q510 at 5Q3 see Figure 9 9 It should be about 5 V If it is go to Step 5 If it is not check the circuit between Q510 and pin 3 of Q508 at 5Q6 If a fault is found repair it and confirm that the voltage is now correct then enter the CCTM command 72 again and ...

Page 188: ...f Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 10 Synthesizer circuitry under the SYN BOT and VCO BOT cans on the bottom side of the main board VHF BOARD UHF BOARD ...

Page 189: ... R566 and go to Step 3 3 The PLL is probably receiving insufficient RF power from the VCO s Check for faults in the circuitry of the VCO s and related buffer amplifier s If a fault is found repair it confirm the removal of the fault and return to Subsection 8 1 If the repair failed or the fault could not be found return to Subsection 8 1 and replace the complete main board assembly Table 9 2 Nomin...

Page 190: ... to Subsection 8 1 and replace the complete main board assembly 4 Check for open circuits short circuits and faulty components in the circuitry in the feedback path for the operational amplifier IC505 at 5J5 5F8 Q511 IC504 R554 R556 C548 C555 see Figure 9 9 and Figure 9 10 If no fault is found go to Step 5 If a fault is found repair it confirm the removal of the fault and return to Subsection 8 1 ...

Page 191: ...scope probe to check the VCXO output at C536 at 5G8 5H6 probe the via situated between C536 and R537 see Figure 9 11 The signal should be a sine wave of about 1 1 Vpp on 1 45 V DC If it is go to Step 3 If it is not go to Step 2 2 The VCXO circuitry Q501 Q503 XL501 and associated components under the VCXO BOT can is faulty If not already done remove the main board assembly from the chassis and remo...

Page 192: ... TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 11 FCL circuitry under and adjacent the FCL TOP can VIA BETWEEN C536 AND R357 POSITION IN WHICH TO PLACE R527 FOR FAULT DIAGNOSIS PURPOSES WHEN LOOP OSCILLATES ...

Page 193: ...5 to 7 at 5F7 5H5 and associated components under the FCL TOP can is faulty Remove the FCL TOP can 3 Locate the fault in the mixer or LPF circuitry see Figure 9 11 Note that the TCXO input to the mixer at R521 at 5D7 5H3 pin 4 of IC501 should be a square wave with a frequency of 13000 000 Hz and an amplitude of 3 Vpp Also the VCXO input to the mixer at R522 at 5D6 5G3 pin 1 of IC501 should be a si...

Page 194: ...d 72 and note the lock status 2 Enter the CCTM command 393 1 1900 Note the voltage level this should be about 2 1 V DC Then enter the CCTM command 72 and note the lock status 3 If the above voltage levels are not correct or if the FCL is out of lock in either or both of the above cases go to Step 4 If the voltage level remains fixed at about 1 5 V DC go to Step 5 If the voltage levels are all corr...

Page 195: ...pin 8 and DIG CDC2 SDTI at pin 9 at 2Q2 The signals should be active 3 3 V digital signals to and from the digital board If the signals are correct go to Step 8 If they are not go to Step 7 7 If any or all digital signals are missing check the connections between IC205 and the digital board Repair any faults such as open circuits and return to Step 1 If the connections are not faulty then the digi...

Page 196: ...omplete main board assembly 4 Use the oscilloscope probe to check the difference frequency at the TP502 test point at 5F8 5J6 see Figure 9 11 The signal is SYN CDC FCL and should be a sine wave with a frequency of about 17 kHz and an amplitude of about 1 3 Vpp on 1 5 V DC If the signal is correct go to Step 6 If it is not go to Step 5 5 The mixer circuitry IC501 at 5D7 5H4 and associated component...

Page 197: ...e gain loss rather than sensitivity loss Consequently if the receiver sensitivity is too low first check the receiver gain as follows 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 Note the value x returned A change in the input level of 10 dB should result in a tenfo...

Page 198: ...Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 13 Receiver circuitry under the IF TOP can FCL TOP CAN DIRC TOP CAN SYN TOP CAN FE TOP CAN CDC TOP CAN MEASUREMENT POINT ...

Page 199: ...atus is active about 3 0 V If it is go to Step 4 If it is not check the signal continuity from the digital board to the receiver Repair any fault and go to Step 7 If the digital board itself appears faulty return to Subsection 8 1 and replace the complete main board assembly An alternative measurement point to the above is pin 24 at 4L2 4D10 of IC400 under the IF TOP can see Figure 9 13 4 Enter th...

Page 200: ... Diagnosis of Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 14 Receiver circuitry under the LO2 BOT can CDC BOT CAN VCXO BOT CAN SYN BOT CAN VCO BOT CAN ...

Page 201: ...1 a a 0 where a is the frequency in hertz Enter the CCTM command 376 and record the value returned this is the front end tuning voltage in millivolts 3 Compare the values measured in Steps 1 and 2 with the nominal DAC and voltage values listed in Table 9 3 If the values are correct go to Step 4 If they are not recalibrate the receiver using the calibration application and check the DAC and voltage...

Page 202: ...4 0 24 145 1 88 15 1 04 0 18 155 1 136 15 1 60 0 18 164 1 174 15 2 04 0 18 174 1 210 15 2 57 0 18 D1 band Frequency MHz DAC value Voltage V 215 9 42 20 0 5 0 2 228 1 103 15 1 2 0 18 241 1 151 15 1 7 0 18 253 1 187 15 2 2 0 18 266 1 224 10 2 6 0 12 H5 band Frequency MHz DAC value Voltage V 399 9 0 to 36 0 to 0 43 417 1 94 15 1 11 0 18 435 1 106 15 1 25 0 18 452 1 156 15 1 84 0 18 470 1 191 15 2 25 ...

Page 203: ...t go to Step 4 If they are not recalibrate the receiver using the calibration application and check the DAC and voltage values again If the values are now correct the fault has been rectified return to Subsection 8 1 If they are not go to Step 4 4 Remove the FE TOP and IF TOP cans Check the soldering of all the components of the front end tuning circuitry from C400 at 4B6 4G1 to T401 at 4L6 4G10 s...

Page 204: ...y are now correct go to Step 4 If they are not go to Task 1 and check the receiver sensitivity 4 Check if the RSSI fault has been removed If it has return to Subsection 8 1 If it has not go to Step 5 5 Note the values listed in the RSSI Delta Gain Values field The values should run gradually from 0 dB to about 3 dB If they do go to Step 7 If they do not recalibrate the receiver and check the value...

Page 205: ...the Country City and Hard fields are what the Customer expects 5 Open the Raw Data page and click the Mute tab Compare the values in the Mute Noise Readings field with the required minimum and maximum values listed in Table 9 5 If the values 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 remo...

Page 206: ...Tait Electronics Limited Figure 9 16 TCXO circuitry under the CDC TOP can Table 9 5 Mute data Channel spacing SINAD dB Minimum noise value Maximum noise value Narrow 12 5 kHz 8 1900 2300 20 250 500 Medium 20 kHz 8 3700 4200 20 1000 1500 Wide 25 kHz 8 5500 7300 20 2200 3700 IF TOP CAN ...

Page 207: ...on fault has been removed If it has return to Subsection 8 1 If it has not go to Step 4 4 Input a large unmodulated RF input signal exceeding 90 dBm at the RF connector Use a needle probe to measure the frequency of the signal at the QN test point at 4P1 4C12 access is through the hole in the IF TOP can see Figure 9 13 The frequency is the second IF and should be 64 000 kHz If it is go to Step 6 I...

Page 208: ...n first remove the main board assembly from the chassis In the case of the PAD TOP and PAF TOP cans also remove the screws securing the heat transfer block to the PCB then separate the block slightly from the PCB the RF connector limits the amount of movement Secure the block again before any transmit tests Replace all cans that have been removed only after repairing the board This applies to the ...

Page 209: ...3J1 see Figure 9 17 If the supply is correct go to Task 2 If it is not go to Subsection 9 1 Task 2 Check Forward and Reverse Powers Next check the forward and reverse power for an indication of which part of the circuitry is suspect 1 Enter the CCTM command 318 to check the forward power The value returned is the voltage in millivolts corresponding to the power level and should be as shown in Tabl...

Page 210: ... filter Table 9 6 Voltages in millivolts corresponding to nominal forward and reverse powers Frequency band Forward power 318 command Reverse power 319 command B1 1200 to 1900 500 D1 1700 to 2400 700 H5 2600 to 3400 1000 H6 2900 to 3800 1000 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 ...

Page 211: ...pply The power should exceed 32 W The current should exceed 5 A UHF or 4 A VHF 2 If the RF output power measured in Step 1 is correct go to Step 3 If there is no power at all go to Step 5 If the power is wrong or too low go to Task 14 3 If the current measured in Step 1 is correct go to Step 4 If it is not go to Task 11 4 Enter the following CCTM commands in turn and measure the RF output power in...

Page 212: ... The normal status is 110 If it is not proceed to the relevant subsection If it is go to Step 4 4 Check for short circuits on the DIG TX INH line from the D TX INH test point Repair any fault confirm the removal of the fault and return to Subsection 8 1 If the repair failed or no fault could be found return to Subsection 8 1 and replace the complete main board assembly 5 Suspect the temperature se...

Page 213: ...inal Gate Bias 2 page 4 Also find the offset current for the PA driver Open the Tx Driver Bias Limit page click the Set button and note the offset current in mA in the Target Current field 5 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 a returned 6 Enter the CCTM command 332 to check the DAC value of final bias 2 CDC TX FIN B...

Page 214: ... Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 18 PA circuitry under the PAF TOP can B1 H5 and H6 bands H5 H6 BANDS B1 BAND MEASUREMENT POINT ON L310 B1 BAND SIMILAR ...

Page 215: ...t the voltage at the gate of Q310 at 3F2 3D5 is between 2 and 5 V If it is Q310 is faulty return to Subsection 8 1 and replace the complete main board assembly If it is not go to Step 4 4 Check the circuitry between pin 14 of IC301 and the gate of Q310 see Figure 9 17 to Figure 9 21 If a fault is found repair it confirm the removal of the fault and return to Subsection 8 1 If the repair failed or ...

Page 216: ...nosis of Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 19 PA circuitry under the PAF TOP can D1 band PAF TOP D301 MEASUREMENT POINT ON L310 Q310 Q309 D1 BAND ...

Page 217: ...y under the PAD TOP can B1 H5 and H6 bands 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 COMPONENTS C310 R324 R327 COMPONENTS C310 R324 R327 MEASUREMENT POINT ON L306 MEASUREMENT POINT ON L306 ...

Page 218: ...ctronics Limited Figure 9 21 PA driver circuitry under the PAD TOP can D1 band R308 R324 C310 R327 C301 Q303 C313 Q300 C300 C317 C389 Q306 PAD TOP SYNTHESIZER OUTPUT AT C300 BUFFER OUTPUT AT C313 MEASUREMENT POINT ON L306 DRIVER OUTPUT EXCITER OUTPUT AT C301 D1 BAND COMPONENTS C310 R324 R327 ...

Page 219: ...d in Task 5 and check that the voltage at the gate of Q309 at 3F3 3E5 is between 2 and 5 V If it is Q309 is faulty return to Subsection 8 1 and replace the complete main board assembly If it is not go to Step 4 4 Check the circuitry between pin 8 of IC301 and the gate of Q309 see Figure 9 17 to Figure 9 21 If a fault is found repair it confirm the removal of the fault and return to Subsection 8 1 ...

Page 220: ...C303 at maximum power 40 W Frequency band Frequency MHz Voltage V Pin 9 Pin 5 FWD PWR B1 136 155 174 2 2 0 1 2 3 0 1 2 5 0 1 1 9 0 1 2 1 0 1 2 3 0 1 D1 216 241 266 2 2 0 1 2 2 0 1 2 3 0 1 4 3 0 1 4 3 0 1 4 7 0 1 H5 400 435 470 3 4 0 1 3 8 0 1 4 0 0 1 3 3 0 1 3 7 0 1 3 9 0 1 H6 450 490 530 3 9 0 1 4 2 0 1 4 7 0 1 3 8 0 1 4 1 0 1 4 6 0 1 DIRC TOP CAN IF TOP CAN VCO TOP CAN UHF ONLY SET_PWR TEST POIN...

Page 221: ... 8 and 2 5 V If it does go to Step 3 If it does not go to Subsection 9 7 on the CODEC and audio circuitry 3 Check that the voltage at the SET PWR test point at 3B5 3G2 see Figure 9 22 is between 2 and 5 V If it is go to Step 4 If it is not go to Step 5 4 Remove the PAD TOP can Check that the voltage on the gate of Q306 at 3C3 3E3 is between 2 and 5 V If it is replace Q306 confirm the removal of th...

Page 222: ...TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 23 Components of concern on the bottom side of the main board B1 H5 and H6 bands B1 BAND COPPER BLOCK VCO BOT CAN NB BOT CAN COPPER BLOCK VCO BOT CAN H5 H6 BANDS ...

Page 223: ...ot go to Step 5 If it is measure the voltage at pin 10 of IC303 The voltage should be 4 8 0 5 V If it is go to Step 4 If it is not go to Step 5 4 Check C322 C324 R342 R347 see Figure 9 22 and R396 see Figure 9 23 and Figure 9 24 in the power control circuit Repair any fault If these components are not faulty replace IC303 Confirm the removal of the fault and return to Subsection 8 1 If the repair ...

Page 224: ...n Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 24 Components of concern on the bottom side of the main board D1 band R390 R389 R3000 C319 R340 C345 R396 R3009 COPPER BLOCK VCO BOT CAN ...

Page 225: ...osis of Faults on Main Board 225 May 2004 Tait Electronics Limited Figure 9 25 Components of the interstage matching circuitry between the PA driver Q306 and the PAs Q309 and Q310 B1 H5 and H6 bands B1 BAND H5 H6 BANDS PAF TOP CAN PAD TOP CAN ...

Page 226: ...output 1 136 155 174 0 3 0 1 0 3 0 1 0 2 0 1 0 2 0 1 0 3 0 1 0 2 0 1 2 4 0 5 2 5 0 5 2 6 0 5 1 8 0 5 1 0 0 5 1 5 0 5 5 136 155 174 0 3 0 1 0 2 0 1 0 2 0 1 0 2 0 1 0 3 0 1 0 2 0 1 2 5 0 5 2 6 0 5 2 6 0 5 3 0 0 5 1 5 0 5 2 6 0 5 12 136 155 174 0 3 0 1 0 2 0 1 0 2 0 1 0 2 0 1 0 3 0 1 0 3 0 1 2 5 0 5 2 6 0 5 2 7 0 5 4 2 0 5 2 0 0 5 3 8 0 5 26 136 155 174 0 3 0 1 0 2 0 1 0 2 0 1 0 2 0 1 0 3 0 1 0 3 0 1...

Page 227: ...5 0 5 3 4 0 5 4 2 5 2 12 5 40 216 241 266 0 3 0 1 0 3 0 1 0 3 0 1 0 3 0 1 0 3 0 1 0 2 0 1 3 3 0 5 3 3 0 5 3 6 0 5 12 5 9 4 20 8 Table 9 10 RF voltages along the initial RF signal path of the UHF radio H5 and H6 bands Power level W Frequency MHz RF voltages V Synthesizer output Buffer output Exciter output Driver output 1 450 490 530 0 2 0 1 0 2 0 1 0 2 0 1 0 3 0 1 0 3 0 1 0 4 0 1 4 5 0 5 4 6 0 5 3...

Page 228: ...00 Confirm the removal of the fault and return to Subsection 8 1 If the repair failed return to Subsection 8 1 and replace the complete main board assembly 5 Measure the RF voltage after C301 at 3A3 3E1 see Figure 9 20 and Figure 9 21 This is the output of the exciter The required voltage should be as given in Table 9 8 B1 band Table 9 9 D1 or Table 9 10 H5 H6 If it is go to Step 7 If it is not go...

Page 229: ...inal of an 82 pF B1 band or 680 pF D1 H5 H6 test capacitor to the PCB at the point shown in Figure 9 27 and Figure 9 28 Mount the capacitor vertically Use a test capacitor of the type GRM111 DLI C17 Murata 1210 or the equivalent 4 Solder a 50 Ω test lead to the PCB Solder the outer sheath to the test pad shown in Figure 9 27 and Figure 9 28 and solder the central wire to the other terminal of the ...

Page 230: ...04 Tait Electronics Limited Figure 9 27 Circuitry under the DIRC TOP can the measurement point on L315 and the points for attaching the test lead and test capacitor B1 H5 and H6 bands MEASUREMENT POINT ON L315 H5 H6 BANDS B1 BAND MOUNTING POINT FOR TEST CAPACITOR TEST PAD TEST PAD ...

Page 231: ...004 Tait Electronics Limited Figure 9 28 Circuitry under the DIRC TOP can the measurement point on L315 and the points for attaching the test lead and test capacitor D1 band DIRC TOP C350 C349 C348 L315 D1 BAND MEASUREMENT POINT ON L315 MOUNTING POINT FOR TEST CAPACITOR TEST PAD ...

Page 232: ...04 Tait Electronics Limited Figure 9 29 Circuitry under the PIN TOP can and points for attaching the test lead and test capacitor H5 H6 BANDS B1 BAND MOUNTING POINT FOR TEST CAPACITOR TEST PAD TEST PAD D307 PIN TOP C361 C362 C363 TEST PAD MOUNTING POINT FOR TEST CAPACITOR D1 BAND ...

Page 233: ... Step 7 If D307 is faulty replace it confirm the removal of the fault and return to Subsection 8 1 If the repair failed return to Subsection 8 1 and replace the complete main board assembly 7 Check the 9V0_TX supply to the PIN switch via R3000 at 3M5 3J10 and R389 and R390 at 3M5 3F10 on the bottom side of the PCB see Figure 9 23 and Figure 9 24 Replace any faulty component and again measure the R...

Page 234: ... power should exceed 32 W and the supply current should be less than 5 2 A VHF or 6 0 A UHF If the power and current are skewed low at one part of the frequency band and high elsewhere go to Task 15 If the power and current are low at all three frequencies go to Task 16 Task 15 Power and Current Are Skewed If the RF output power and the supply current are skewed the output matching is suspect 1 Re...

Page 235: ...1 to check the DAC value of final bias 1 CDC TX FIN BIAS 1 Record the value a returned 2 Note the current reading on the DC power supply Enter the CCTM command 331 1 to turn off final bias 1 3 Enter the CCTM command 33 to place the radio in transmit mode Note the RF output power measured at the test set This should be as shown in Table 9 10 If it is go to Step 4 to repeat the check with the second...

Page 236: ...ively In each case however first carry out Task 1 Also note that the fourth and fifth conditions mentioned above can both occur at the same time In this case carry out both Task 5 and Task 6 Task 1 Check Power Supply Before searching for faults in the CODEC and audio circuitry first check the 2 5 V DC supply The procedure is given in Task 3 of Subsection 9 1 on the power supply circuitry Task 2 Fa...

Page 237: ...ly 6 Check that there is approximately 9 5 Vpp AC on each speaker output at maximum volume If there is the fault is unknown it could be intermittent return to Subsection 8 1 and replace the complete main board assembly If there is no AC check that C204 at 2D2 2D4 and R214 at 2D3 2E4 see Figure 9 30 are not faulty and are correctly soldered Repair any fault Confirm the removal of the fault and retu...

Page 238: ...faulty return to Subsection 8 1 and replace the complete main board assembly 10 Check for continuity between the TP200 test point at 2D2 2D4 see Figure 9 30 and the junction between R218 and IC204 at 2E4 2G10 see Figure 9 32 Repair any fault if necessary replace R214 R215 at 2D3 2E4 see Figure 9 29 or R218 Confirm the removal of the fault and return to Subsection 8 1 If the repair failed or the fa...

Page 239: ...ee Figure 9 32 Confirm the removal of the fault and return to Subsection 8 1 If the repair failed or the fault could not be found return to Subsection 8 1 and replace the complete main board assembly 3 Check the circuitry R238 R239 R240 at 2N4 2F11 around pins 12 13 and 14 of IC201 see Figure 9 32 Repair any fault Confirm the removal of the fault and return to Subsection 8 1 If the repair failed o...

Page 240: ...re 9 31 Circuitry under the CDC TOP can adjacent interface circuitry and the QN and TP503 test points SYN TOP CAN FCL TOP CAN IF TOP CAN JUNCTION OF R234 AND R235 QN TEST POINT JUNCTION OF R708 AND C706 ITF AUD TAP IN JUNCTION OF R237 AND R241 JUNCTION OF R229 AND R232 TP503 TEST POINT JUNCTION OF C708 AND C732 ...

Page 241: ...If it is not go to Step 3 3 Remove the CDC BOT can Check that the voltage across C202 at 2D7 2H3 is 3 V see Figure 9 32 If it is go to Step 4 If it is not check the soldering of R209 at 2D8 2J3 see Figure 9 32 and check for shorts to ground at C202 Repair any fault Confirm the removal of the fault and return to Subsection 8 1 If the repair failed or the fault could not be found return to Subsectio...

Page 242: ... of Faults on Main Board TM8100 Mobile Radio Service Manual May 2004 Tait Electronics Limited Figure 9 32 Circuitry under the CDC BOT can LO2 BOT CAN CAN FOR DIGITAL BOARD JUNCTION OF R218 AND IC204 CDC AUD TAP OUT ...

Page 243: ...ommand 324 r5 Check that the received signal is present with an offset of 2 4 V DC at pin 13 AUD TAP OUT of the auxiliary connector alternatively as CDC AUD TAP OUT at 2B6 2G3 at the junction of R207 and R208 see Figure 9 32 If it is go to Step 6 If it is not return to Subsection 8 1 and replace the complete main board assembly 6 Remove the CDC BOT can Check that the voltage at pin 1 at 2E6 2H4 of...

Page 244: ...e repair failed return to Subsection 8 1 and replace the complete main board assembly 4 Check that there are no shorts at pin 7 of the auxiliary connector If there are none go to Step 5 If there are repair the fault Confirm the removal of the fault and return to Subsection 8 1 If the repair failed return to Subsection 8 1 and replace the complete main board assembly 5 Remove the CDC TOP can Check ...

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