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TP9100 Service Manual

Introduction

May 2005

Single Battery

Charger and

Batteries

The single battery charger is used to charge the following Tait batteries:

■

6-cell NiMH

■

6-cell NiCd

1.4

Product Codes

This section describes the product codes used to identify products of the
TP9100 portable radio product line.

Radios

The product codes of the TP9100 portable radios have the format:

TPA1

–

bbcc

where:

■

identifies the keypad option:

1 = 4-button keypad, 2 = 16-button keypad

■

identifies the frequency band:

B1= 136 to 174 MHz, H5 =400 to 470 MHz, H6= 450 to 530MHz

■

identifies any radio options.

Accessories

The product code of the accessories specific to the TP9100 portable radios
have the format:

TPA–xx-xxx

1.5

Labels

The following external labels are attached to the back of the radio (covered
by the battery):

■

compliance information and RF exposure safety warning

■

serial number and product code

Figure 1.2

Labels of the TP9100 series

TPAB12-B100

136-174 MHz

S/N

19061964

102104337

Contains intellectual property licenced by

Digital Voice Systems Inc, Motorola Inc

and Tait Electronics Ltd.

Details in user documentation.

N46

TPAB1A

FCC ID: CASTPAB1A

Made in New Zealand by Tait Electronics Ltd.

IC: 737A-TPAB1A

ATTENTION!

Restricted to

occupational use to satisfy

FCC RF exposure limits. See user's

guide for operating instructions.

Summary of Contents for TP9100

Page 1: ...TP9100 portables Service Manual MPA 00005 01 Issue 1 00 May 2005 ...

Page 2: ...hnical Support E mail support taitworld com Website http support taitworld com To our European customers Tait Electronics Limited is an environmentally responsible company which supports waste minimization and material recovery The European Union s Waste Electrical and Electronic Equipment Directive requires that this product be disposed of separately from the general waste stream when its service...

Page 3: ...Servicing the Radio 75 4 General Information 79 5 Disassembly and Reassembly 101 6 Servicing Procedures 127 7 Interface Fault Finding 139 8 Power Supply Fault Finding 149 9 Frequency Synthesizer Fault Finding 159 10 Transmitter Fault Finding 217 11 Receiver Fault Finding 251 12 CODEC and Audio Fault Finding 269 13 Spare Parts 289 Chapter 3 Accessories 295 14 Antenna Identification Chart 297 15 TPA...

Page 4: ...4 TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 5: ... last two digits in the IPN represent the issue of the board Main board B1 band 220 01734 03 Main board H5 band 220 01735 03 Main board H6 band 220 01736 03 Front panel interface board 220 02073 03 Accessory flex board 220 01728 02 UI flex board 220 01731 01 Single charger main board 220 01724 03 Single charger contact board 220 01725 03 Programming application version 1 1 0 1 Calibration applicat...

Page 6: ...ity of the user to ensure that use of such information equipment and software complies with the laws rules and regulations of the applicable jurisdictions Associated Documentation The following associated documentation is available for this product MPA 00004 xx TP9100 Product Safety and Compliance Information MPA 00001 xx TP9100 User s Guide MPA 00006 xx TP9100 Main Board B1 PCB Information MPA 00...

Page 7: ...people Important This alert is used to warn about the risk of equipment dam age or malfunction Note This alert is used to highlight information that is required to ensure that procedures are performed correctly Abbreviations Issue Publication Date Description 01 May 2005 first release Abbreviation Description ACP Adjacent Channel Power ADC Analog to Digital Converter AGC Automatic Gain Control ALC...

Page 8: ...ard Error Correction FPGA Field Programmable Gate Array GPIO General Purpose Input Output GPS Global Positioning System GUI Graphical User Interface IC Integrated Circuit IPN Internal Part Number IF Intermediate Frequency IQ In Phase and Quadrature ISC International Service Center LCD Liquid Crystal Display LED Light Emitting Diode LNA Low Noise Amplifier LO Local Oscillator LPF Low Pass Filter NP...

Page 9: ...th Indication SFE Software Feature Enabler SMA Sub Miniature Version A SMD Surface Mount Device SMT Surface Mount Technology SMPS Switch Mode Power Supply SPI Serial Peripheral Interface TCXO Temperature compensated Crystal Oscillator TEL Tait Electronics Limited VCO Voltage Controlled Oscillator VCXO Voltage Controlled Crystal Oscillator Abbreviation Description ...

Page 10: ...10 TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 11: ...TP9100 Service Manual 11 Tait Electronics Limited May 2005 TP9100 portables Chapter 1 Description of the Radio ...

Page 12: ...n 19 2 3 Connectors and Contacts 27 2 4 Hardware and Software Architecture 30 2 5 Operation in Receive Mode 34 2 6 Operation in Transmit Mode 41 3 Circuit Descriptions 49 3 1 Transmitter Circuitry 51 3 2 Receiver Circuitry 53 3 3 Frequency Synthesizer Circuitry 56 3 4 Frequency Control Loop 60 3 5 CODEC and Audio Circuitry 61 3 6 Power Supply Circuitry 65 3 7 Interfaces Circuitry 68 3 8 Digital Ci...

Page 13: ... compatible analog and mixed operation for voice and data communication This manual includes the information required for servicing the radio and its accessories This section describes the different options available for keypads frequency bands accessories product codes This section also gives an overview of the labels on the product and the specifications Figure 1 1 TP9100 portable radios TP9160 ...

Page 14: ...Tait offers a large variety of audio accessories antennas a single battery charger batteries and other accessories such as carry cases For more information on the serviceable accessories refer to Chapter 3 Accessories on page 295 of this service manual Audio Accessories The radios allow for the connection of a comprehensive range of audio accessories Evolution speaker microphone light duty headset...

Page 15: ...530MHz cc identifies any radio options Accessories The product code of the accessories specific to the TP9100 portable radios have the format TPA xx xxx 1 5 Labels The following external labels are attached to the back of the radio covered by the battery compliance information and RF exposure safety warning serial number and product code Figure 1 2 Labels of the TP9100 series TPAB12 B100 136 174 M...

Page 16: ...00 to 470MHz 450 to 530MHz Frequency stability 1 5ppm Channel capacity simplex or semi duplex 512 Channel spacing narrow medium wide 12 5kHz 20kHz 25kHz Supply voltage 7 5 1 5V DC Antenna connector SMA Accessory connector Ports 1 serial 2I O 1 audio tap in 1 audio tap out PTT speaker microphone Physical characteristics Weight with battery and antenna as stated no belt clip with TPA BA 201 NiCd and...

Page 17: ...ation rain humidity salt fog dust vibration shock Receiver Sensitivity 118dBm for 12dB SINAD Intermodulation 66dB Spurious responses 72dB Selectivity narrow channel spacing medium channel spacing wide channel spacing 65dB 70dB 75dB Hum and noise narrow channel spacing medium channel spacing wide channel spacing 40dBm 41dBm 43dBm Audio bandwidth 300Hz to3 kHz flat or with de emphasis Audio distorti...

Page 18: ...channel spacing medium channel spacing wide channel spacing 2 5kHz 4kHz 5kHz FM hum and noise narrow channel spacing medium channel spacing wide channel spacing 136 to 500MHz above 500MHz 34dB 31dB 48dB 35dB 40dB 37dB Conducted and radiated emissions up to 1GHz between 1 and 4GHz for radio operating frequencies below 500 MHz between 1 and 12 75GHz for radio operating frequencies above 500MHz 36dBm...

Page 19: ...ry radio 2 1 1 Antenna The antenna screws into the antenna SMA connector at the top of the radio For an overview of the available antennas refer to Antenna Identification Chart on page 297 2 1 2 Battery The battery is held in place by two lugs at the bottom of the battery which fit into two holes at the bottom of the radio and a catch mechanism at the top of the radio which is released by squeezin...

Page 20: ... refer to User Interface on page 26 At the top of the front panel assembly three holes are provided for the antenna SMA connector the 16 way 3 way selector switch and the power volume potentiometer of the main board 2 An orange emergency key presses down on a metal lever on the inside of the front panel assembly operating a tact switch on the main board 2 A light pipe fitted to the inside of the f...

Page 21: ...TP9100 Service Manual Description 21 Tait Electronics Limited May 2005 Figure 2 1 Components of the radio 3598z_01 ...

Page 22: ...ating the PTT and two function keys blue and black The PTT keypad consists of the plastic PTT frame C the silicone PTT keypad D one bigger blue PTT pressel E two smaller red function key pressels F the metal PTT lock spring G The PTT lock spring which fits over a T shaped protrusion of the PTT frame secures the PTT keypad to the front panel assembly The pressels operate tact switches on the main b...

Page 23: ...itted to the back of the LCD assembly to protect the LCD assembly against mechanical shock Main Shield Assembly The main shield assembly 2 consists of the metal main shield the conductive mylar the front panel interface board and the polydome Note The individual parts of the main shield assembly are not service able items In case of damage the entire main shield assembly must be replaced For more ...

Page 24: ...e non SMT components at the top of the main board For more information refer to Fitting the Non SMT Components on page 118 An emergency key tact switch and a status LED are located at the top of the main board Tact switches for the PTT and function keys are located at the side of the main board The front panel interface connector which is located at the bottom of the main board connects to the fro...

Page 25: ...ard The rear panel provides the mechanical and electrical interface to the accessories If no accessory is used the rear panel is covered by a dummy cover 3 The plastic rear panel 3 has a central catch for the lock of the dummy cover or accessory and smaller holes for the 13 contacts of the flexible accessory board 3 For more information on the contacts refer to Connectors and Contacts on page 27 T...

Page 26: ...me keys have functions assigned to both short and long key presses A short key press is less than one second and a long key press is more than one second Figure 2 2 User interface display PTT key press to talk function keys scroll keys alphanumeric keys 16 key radio only speaker microphone power volume control 16 way selector status LED right selection key left selection key emergency key 3 way se...

Page 27: ...inouts of the external connectors and contacts Figure 2 3 provides an overview of the connectors and contacts Figure 2 3 Connectors and contacts 3680z_01 antenna SMA connector LCD connector front panel loom connector front panel interface connector speaker pins main board battery pins LCD assembly front panel interface board accessory connector pins accessory connector flexible accessory board fro...

Page 28: ...nt The speaker load configuration is balanced the speaker output lines must not be connected to ground Connecting a speaker output line to ground will cause audio power amplifier shutdown Table 2 1 Antenna SMA connector pins and signals Pinout Pin Signal Name Signal Type 1 RF RF analog 2 GND RF ground B C top view of radio Table 2 2 Battery pins and signals Pinout Pin Signal Name Signal Type 1 BAT...

Page 29: ...s switched off Power 3 ACC RXD Asynchronous serial port Receive data Digital 3V3 CMOS 4 AUD TAP OUT Programmable tap point out of the Rx or Tx audio chain DC coupled Analog 5 ACC TXD Asynchronous serial port Transmit data Digital 3V3 CMOS 6 ACC MIC Accessory microphone input Electret microphone biasing provided Dynamic microphones are not supported Analog 7 ACC GPIO2 Programmable function and dire...

Page 30: ...board inside the radio body includes the following circuitry transmitter receiver frequency synthesizer digital board with a RISC processor and custom logic implemented on an FPGA memory and a DSP CODEC and audio interface power supply For a basic block diagram of the hardware architecture refer to Figure 2 4 on page 31 For a more detailed block diagram of the transceiver refer to Figure 2 6 on pa...

Page 31: ...ont Panel Interface Connector Battery Pins Main Board FPGA RISC Proc Serial Flash SRAM Flash Memory part of transmitter circuitry analog to digital converter 2 digital to analog converter 2 part of CODEC and audio circuitry 2 1 digital RF analog asynchronous serial data synchronous serial data Custom Logic On Off Switch Volume Pot 16 Posn Switch 3 Posn Switch PTT Switch Emergency Key Function Keys...

Page 32: ...owing software modules are stored on the digital section of the main board FPGA image which includes the software implemented RISC processor and the custom logic the custom logic executes additional digital signal processing boot code radio application code digital signal processing radio application database and radio calibration database Hardware and interface drivers are part of the boot code t...

Page 33: ...de for processing of digital signals in analog and digital mode the custom logic executing addition digital signal processing Software Shutdown On shutdown the programming and calibration data is stored in the database and power is removed from the radio Important On power loss any changes made to the programming or calibration data may be lost Programming and Calibration Files One of the servicin...

Page 34: ...GA of the digital circuitry DSP on the digital circuitry Note The block diagrams for the analog and digital modes only differ in the operation of the DSP The receive path consists of three major functional parts RF hardware digital baseband processing audio processing and signaling Note The information flow on a digital radio can be categorized in two forms signaling including user data and voice ...

Page 35: ...emphasis Optional Processing Data and Signaling Encoders ALC Current Sensing PA Drv Ex Pwr Ctrl Ramp Control TCXO 13 000 MHz VCO VCXO Bias Custom Logic Hardware Hardware DSP Mic FGA Loop Filter Volume Control Mic PGA Channel LPF Loop Filter IF UHF 45 1 MHz VHF 21 4 MHz 2nd IF 64 kHz Rx Interface RISC Processor RISC Processor Analog to digital conversion Digital to analog conversion System interfac...

Page 36: ...MHz VHF 21 4 MHz 2nd IF 64 kHz RISC Processor Analog to digital conversion Digital to analog conversion System interface Key Notes 1 2 VHF configuration shown For UHF there are separate VCOs for Rx and Tx External Microphone Speaker Microphone Buffer Accessory Connector External Speaker Accessory Connector RSSI Voice FEC DSP Voice Packets Rx Signaling FEC Rx Burst Builder Vocoder Signaling Packets...

Page 37: ...s then down converted using an image reject mixer to a low IF of 64kHz Quadrature Demodulator The LO for the image reject mixer quadrature demodulator is synthesized and uses the TCXO as a reference This ensures good centring of the IF filters and more consistent group delay performance The quadrature demodulator device has an internal frequency division of 2 so the second LO operates at 2 x IF1 6...

Page 38: ... fed via a single synchronous serial port to the DSP The stream is demultiplexed and the demodulation data used as an input for further audio processing Noise Squelch The noise squelch process resides in the DSP The noise content above and adjacent to the voice band is measured and compared with a preset threshold When a wanted signal is present out of band noise content is reduced and if below th...

Page 39: ...M demodulated it enters the C4FM de modulator Once synchronization has been acquired the received signals should exist as four possible frequencies These frequencies are translated directly into received symbols ready to be passed to the burst builder Rx Burst Builder Digital Mode The job of the burst builder is to dismantle the received burst The burst builder can only receive an incoming burst o...

Page 40: ...es are supervised by various timers Normally these procedures must be applied before transitioning from receive mode to transmit mode However they may be overridden under emergency conditions CODEC The combined audio and side tone signal is converted to analogue form by a 16 bit DAC with integral anti alias filtering This is followed by a programmable gain amplifier with 45dB range in 1 5dB steps ...

Page 41: ...the FPGA of the digital circuitry DSP on the digital circuitry Note The block diagrams for the analog and digital modes only differ in the operation of the DSP The transmit path consists of three major functional parts audio processing and signaling frequency synthesizer RF transmitter Note The information flow on a digital radio can be categorized in two forms signaling including user data and vo...

Page 42: ...d slow decay up to 2s gain characteristic This characteristic ensures that the peak signal level is regulated near full scale to maximize dynamic range DSP Audio Processing Analog Mode The output of the automatic level control provides the input to the DSP audio processing chain at a sample rate of 8kHz Optional processing such as encryption or companding is done first if applicable Pre emphasis i...

Page 43: ... that the information is structured into bursts An air interface burst can take several forms Every burst consists of a frame synchronization sequence and Network identifier followed by the main body of the burst the content of which depends upon the type of burst For a voice burst it comprises a fixed number of voice packets with control signaling and low speed data interspersed For a data or con...

Page 44: ...patents are pending for several aspects of the synthesizer design Operation of Control Loop The RF PLL is a conventional integer N type design with frequency resolution of 25kHz In transmit mode the loop locks to the transmit frequency whereas in receive mode it locks to the receive frequency minus the first IF frequency Initially the VCO generates an unregulated frequency in the required range Th...

Page 45: ...e VCO in the RF PLL combining to produce a flat modulation response down to DC Reference modulation is usually applied directly to the TCXO The frequency reference is generated by the FCL which itself requires dual point modulation injection to allow modulation down to DC With another modulation point required in the RF PLL this system therefore requires triple point modulation The modulation sign...

Page 46: ...frequency synthesizer nominal frequency KVCO KVCXO VCO deviation Calibration of the nominal frequency is achieved by adding a fixed offset to the FCL nominal frequency the TCXO frequency itself is not adjusted The items KVCO and KVCXO are the control sensitivities of the RF VCO in MHz V and VCXO in kHz V respectively The latter has temperature compensation 2 6 3 RF Transmitter RF Power Amplifier a...

Page 47: ...nce voltage for the loop is supplied by a 13 bit DAC The system driving the DAC supplies the steady state voltage for a given power level as determined by factory calibration The bandwidth of the loop is high to ensure that the loop does not limit the ramping slope and has approx 25dB power control range Under load mismatch at the antenna predetermined VSWR the current drawn by the PA is maintaine...

Page 48: ...amp Up The power ramp signal is supplied by a 13 bit DAC that is controlled by custom logic The ramp is generated using a look up table in custom logic memory that is played back at the correct rate to the DAC to produce the desired waveform The ramp up and ramp down waveforms are produced by playing back the look up table in forward and reverse order respectively For a given power level the look ...

Page 49: ...ce board The main board is divided into the following circuitry modules transmitter receiver frequency synthesizer including FCL CODEC and audio power supply interfaces digital front panel interface Figure 3 1 gives an overview of the of the circuitry modules of the main board and the front panel interface board and shows how they are interconnected For up to date schematics refer to the relevant ...

Page 50: ...itch 1 Front Panel Interface Connector Battery Pins Main Board FPGA RISC Proc Serial Flash SRAM Flash Memory part of transmitter circuitry analog to digital converter 2 digital to analog converter 2 part of CODEC and audio circuitry 2 1 digital RF analog asynchronous serial data synchronous serial data Custom Logic On Off Switch Volume Pot 16 Posn Switch 3 Posn Switch PTT Switch Emergency Key Func...

Page 51: ... of the bias signal is performed by one of the operational amplifiers of IC101 In addition the bias signal can be inhibited by an out of lock signal from the synthesizer Power Control Loop Calibration is used to adjust the power control loop thus setting the output of the transmitter to one of four preferred power levels 1 2 3 and 5W for B1 and 1 2 2 5 and 4W for H5 and H6 The control mechanism fo...

Page 52: ...evel Shifter Crowbar Shaping Filter TX RX RF Transmitter OR Gate TX INH 5V TX 7V5 LINK DIG TX INH SYN LOCK SYN TX LO Power Supply Digital Frequency Synthesizer CDC TXFIN RXAGC CDC TXPWR RXFE Thermal Coupling Codec and Audio Signal Types RF analog clock digital asynchronous serial data synchronous serial data Interfaces AGND Shaper and Level Shifter Buffer Current Sensing PA Difference Amplifier Pr...

Page 53: ...rive First IF Stage and Second Mixer The first IF stage consists of a crystal channel filter BPF1 followed by an IF amplifier and then another crystal filter BPF2 The second mixer is an IC quadrature mixer with an internal AGC amplifier This IC has a divide by two function on the LO input in order to provide the quadrature LO frequencies required internally The second LO frequency is synthesized b...

Page 54: ...CODEC and Audio Digital PLL Transmitter Frequency Synthesizer Mixer Receiver VCO CDC TXPWR RXFE CDC TXFIN RXAGC RX CDC QN RX CDC QP RX CDC IN RX CDC IP 3V0 RX 3V0 AN CDC RX VREF DIG RX EN DIG RX LE RX DIG LD DIG SYN SPI DO DIG VCO LOPWR SYN RX OSC SYN RX LO1 TX RX RF Loop Filter AGND Interfaces DIG RX ATTEN DIG RX ATTEN DIG VCO LOPWR DIG SYN SPI CLK Buffer Attenuator Signal Types RF analog clock d...

Page 55: ...he second a 3dB bandwidth of 15kHz Most of the channel filtering however is implemented in the FPGA and the DSP When the radio is programmed the different filters are selected as assigned by the channel programming The selectable filters plus the fixed crystal filters result in the following total IF 3dB bandwidths wide channel spacing 12 6kHz medium channel spacing 12 0kHz narrow channel spacing ...

Page 56: ...ation Good regulation of the power supply line and load is essential for meeting the transient ACP requirements The regulator output voltage is electrically noisy however and filtering is essential Filtering of the power supply is achieved with a capacitance multiplier Q508 and C585 for the VCO supply Effect of Tuning Range For reasons of noise performance the VCOs are designed to be tuned within ...

Page 57: ...V DEC Frequency Synthesizer LPF Mixer VCXO TCXO Modulator Buffer Amplifier PLL VCO 1 5 V Switch TR Switch VCO UHF only 5V0 AN AGND Power Supply CDC VCXO MOD SYN CDC FCL SYN CDC LFV CDC VCO MOD CODEC and Audio SYN TX LO SYN RX LO1 Trans mitter SYN RX OSC Receiver Digital DIG SYN SPI DO DIG SYN SPI CLK DIG SYN TR SW DIG SYN EN DIG SYN FAST DIG SYN LATCH SYN LOCK SYN DIG FREF 14 V SMPS Buffer Amplifi...

Page 58: ...pares the 25kHz reference and the divided VCO signal and the error is used to control the internal charge pump The charge pump is a current source that can sink or source current in proportion to the frequency or phase error The output is a series of 25kHz pulses with a width that is dependent on the phase error When the output frequency of the synthesizer is correct there is no error and the char...

Page 59: ... in hardware under software control in conjunction with use of the synthesized reference input The result is a transmit receive settling time of less than 4 5ms The switching time is measured for a frequency change equal to the first IF plus 10MHz or 1MHz depending on the repeater offsets used for the band This implies a synthesizer transmit receive change over plus an offset of 1MHz or 10MHz in l...

Page 60: ...CXO reference frequency Circuit Operation The VCXO output is mixed with the TCXO output to create a nominal difference or offset frequency SYN CDC FCL of 12 0 kHz The signal SYN CDC FCL is fed via the CODEC IC502 in the CODEC circuitry to the FPGA The FPGA detects the offset frequency compares it with the programmed offset frequency and outputs a corresponding feedback signal CDC VCXO MOD via IC20...

Page 61: ...wire synchronous serial interface BSDO and BSOFS balls The digital to analog conversion section of the base band CODEC is not used Device IC204 Voice band CODEC The voice band CODEC handles the microphone and speaker signals The digital section communicates with this CODEC via a three wire synchronous serial interface VSFS VSDO and VSDI balls IC204 also contains voice band filtering pre amplificat...

Page 62: ...C AUD TAP IN digital RF analog clock Signal Types asynchronous serial data synchronous serial data CDC2 DIG SDTO DIG RX EN DIG CDC2 SDTI DIG CDC2 SCLK DIG CDC2 LRCK DIG SYS CLK DIG CDC ARSM CDC DIG VSFS CDC DIG VSDO DIG CDC VSDI CDC DIG BSDO CDC DIG BSOFS DIG CDC ASFS DIG CDC ASDI CDC DIG ASDO DIG CDC RST DIG RX EN 3V0 FIL AGND Interfaces Power Supply Receiver Trans mitter Frequency Synthesizer AC...

Page 63: ...ential signal to the internal speaker can be disconnected by dual MOSFET IC207 under control of the digital signal DIG INT SPK INH The external speaker audio signal is permanently connected to the output of IC200 Microphone Signals There are two microphone source signals ACC MIC AUD from accessory connector internal speaker as a microphone The biasing for electret microphones is provided by a filt...

Page 64: ...e low pass filter formed by IC201 pins 1 to 3 R219 R221 R224 C206 C208 and C210 is a third order Butterworth type with a cut frequency of approximately 12 kHz The output of the low pass filter is buffered by IC201 pins 5 to 7 and fed via R207 and R208 to drive the CDC AUD TAP OUT interface line The DC bias for this signal path is provided by IC204 and is approximately 1 2V when operational The off...

Page 65: ...35ms is generated via C634 on the base of the NPN transistor Q606 turning it on This turns on the PNP transistor and charges C620 After the short pulse C610 can hold the 3V3 SMPS IC610 for a further approximately 2 5s a voltage higher than approximately 1V on pin 1 turns this regulator on This regulator supplies the digital circuitry and the software asserts the DIG PSU LATCH signal This signal ho...

Page 66: ...s The 3V3 SMPS and the 2V5 1V8 and 1V5 linear regulators are always on Table 3 1 Radio modes and internal power supplies Internal Power Supply Radio Mode Tx RX Audioa RX Standbyb Economy Modec 5V TX on off off off 5V AN on on on off on cycling 3V AN on on on off on cycling 3V RX off on on off on cycling Audio PA off on off off on cycling a Receiving and audio PA on b Receiving and audio PA off c O...

Page 67: ...tor 3V3 1V8 Regulator 3 V RX Switch PSU Supervisor 7V5 LINK 5V AN 3V3 3V0 AN 3V0 AN 3V3 1V8 3V0 AN 3V0 RX DIG RX EN DIG 5V TX EN DIG 5V AN EN 3V3 DIG WD KICK PSU SYS RST 3V3 AGND 7V5 LINK 7V5 BATT 1V5 SMPS Signal Types analog clock digital asynchronous serial data synchronous serial data 3V3 7V5 SW DIG PSU LATCH 2V5 Regulator 5 V Regulator 5 V Regulator 5 V Regulator 5V TX 7V5 LINK 2V5 CDC 5V TX 7...

Page 68: ... approximately 18mA the inverse of the value of R933 The output configuration is open collector with a pull up to 3 3V Input Signals ACC GPIO1 An input signal applied to ACC GPIO1 is coupled via R908 to ACC DIG GPI1 and fed to the digital section As the input signal may exceed the maximum allowed by the digital section it is clamped by D906 and a shunt regulator The shunt regulator consists of Q90...

Page 69: ...anel Interface Connector BATT DATA 7V5 BATT 3V3 7V5 LINK Current Limited Supply CDC SUI SPK CDC SUI SPK Internal Speaker Pins CDC ACC SPK CDC ACC SPK ACC SPKR ACC SPKR PTT Key Emergency Key Function Key 1 SUI DIG FUNC2 16 Posn Switch 3 Posn Switch ACC PWR ESD Filters EMC ESD Filters AUD TAP IN AUD TAP OUT ACC MIC ACC PTT ESD Filters ACC DIG GPI1 2 DIG ACC GPO1 2 I O Combine ACC GPIO1 2 ACC RXD ACC...

Page 70: ...FPGA 3 3V Accessory A current limited 3 3V Accessory supply is provided on ACC_PWR output Current is limited to approx 50mA by IC900 The current limit setpoint is determined by the value of R954 Above the current setpoint the output voltage folds back to protect the radio and accessory from over current Battery Data A dedicated bidirectional data signal is provided on BATT DATA to allow the radio ...

Page 71: ...d Temperature Sensors on the front panel interface board provide analog levels to indicate the status of X axis tilt Y axis tilt and front panel temperature The tilt signals from the man down sensor are multiplexed onto one output from the interface FPI CDC MANDOWN Whether this signal has X or Y sense selected is determined by DIG MUX ADC 3 8 Digital Circuitry Introduction For a block diagram of t...

Page 72: ...C DIG RXD ACC DIG GPI1 2 DIG ACC GPO1 2 SWI DIG 16POSN1 4 SWI DIG 3POSN1 2 SWI DIG PTT SWI DIG EMERG SWI DIG FUNC1 2 DIG BATT DATA DIG PSU LATCH DIG WD KICK DIG 5V TX EN 3V3 DIG RX EN PSU SYS RST Interfaces Power Supply FPGA DSP McBSP0 McBSP1 DGND 3V3 DSP JTAG Signals Signal Types analog clock digital asynchronous serial data synchronous serial data FPGA JTAG Signals JTAG TCK FPGA JTAG TMS FPGA FP...

Page 73: ...l interface board circuitry Front Panel Interface Connector PL2 FPI CDC MANDOWN FPI CDC TEMP DIG FPI SPI CLK DIG FPI SPI DO DIG FPI LE DIG FPI CD FPI COL1 4 DIG DIG FPI ROW1 4 DIG MUX ADC FPI BL DIG DSP SYS RST Accele rometer 3V3 16 Button Keypad LCD Connector PL1 Back Lighting AGND Temp Sensor Front Panel Interface Board ...

Page 74: ...74 Circuit Descriptions TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 75: ...TP9100 Service Manual 75 Tait Electronics Limited May 2005 TP9100 portables Chapter 2 Servicing the Radio ...

Page 76: ...zer Fault Finding 159 9 1 Initial Checks 160 9 2 Power Supplies 163 9 3 Phase Locked Loop 170 9 4 Loop Filter 176 9 5 Receive VCO and Related Circuitry UHF Radios 183 9 6 Transmit VCO and Related Circuitry UHF Radios 191 9 7 VCO and Related Circuitry VHF Radios 196 9 8 Power Supply for FCL 205 9 9 VCXO and VCTCXO Outputs 208 9 10 Signals at TP501 and TP502 210 9 11 VCXO and CODEC Circuitry 214 11 ...

Page 77: ...iver and PA 230 10 4 RF Signal Path 239 12 CODEC and Audio ault Finding 269 12 1 Power Supplies 270 12 2 Faulty Speaker Audio 272 12 3 No Audio Tap Out at Accessory Connector 278 12 4 Faulty Receiver 282 12 5 Faulty Modulation 284 12 6 Faulty Modulation Using Accessory Audio Tap In 287 13 Spare Parts 289 13 1 Illustrated Spare Parts Catalogue 289 13 2 Spares Kits 293 ...

Page 78: ...78 TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 79: ...ly by accredited service centers ASC Repairs attempted without the necessary equipment and tools or by untrained personnel might result in permanent damage to the radio Accreditation of Service Centers Service centers that wish to achieve ASC status should contact Technical Support They will need to provide evidence that they meet the criteria required for accreditation Technical Support will supp...

Page 80: ...bsite The information available at the different access levels is summarized in Table 4 1 The technical notes mentioned are of different types Associate technical notes relate to the repair of the radio but not the downloading of firmware Tait only technical notes relate to the firmware The PCB information packs are discussed in more detail below PCB Information PCB information for a particular ci...

Page 81: ... on page 101 for the corresponding torque values Tools for SMT Repairs In general only the standard tools for SMT work are required for level 2 repairs of the circuit boards In addition a can removal tool is recommended but if none is available a hot air tool may be used instead However it should be noted that a hot air tool affords little control Even in skilled hands use of a hot air tool to rem...

Page 82: ...4 00 Product code Item TOPA SV 006 RF cable TPA SV 005 Battery eliminator power supply adaptor TPA SV 007 Programming cable adapter RJ12 socket to TP9100 TPA SV 011 Calibration cable DB15 socket to TP9100 TPA SV 006 Programming cable DB9 socket to RJ12 plug T950 001 USB to serial adapter USB1 1 to serial DB9 pin TOPA SV 024 Test unit TOPA SV 011 Service tools including the modified 3 16 inch 8 mm ...

Page 83: ...adio The illustrations in Reassembling the Radio on page 112 show the correct torque values for the different screws and nuts Non Scratch Bench Tops Use workbenches with non scratch bench tops so that the mechanical parts of the radio are not damaged during disassembly and re assembly The workbench must also satisfy the anti static requirements specified below In addition use a clear area of the b...

Page 84: ...nd 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 Workbench...

Page 85: ...ile servicing the main board avoid overheating the radio during test transmissions The following is good practice Secure the main board assembly in the chassis with the two external screws and one of the internal screws The heat transfer block must be secured to the main board The lid of the radio body may be left off After completing any measurement or test requiring activation of the transmitter...

Page 86: ...programming or calibrating radios the switches have no effect although it is good practice to set the MODE switch to RX Settings for Receive Tests For receive tests set the switches on the test unit as follows HOOK switch OFF HOOK MODE switch RX AUDIO IN switch OFF AUDIO OUT switch SPEAKER or LOAD In the last named case with the switch in the SPEAKER position the received audio is output from the ...

Page 87: ...onnector BNC computer connector RJ12 serial port DB9 banana plugs AC input BNC audio monitor out BNC AUDIO IN HI BNC AUDIO OUT BNC RF in out N type TOPA SV 024 TPA SV 006 cable T950 001 USB1 1 to serial DB9 adapter optional RF comms set Test PC Oscilloscope DC power supply antenna connector SMA TPA SV 005 battery eliminator TPA SV 011 cable TP9100 radio TOPA SV 006 cable ...

Page 88: ...CB information for the board consult the BOM for the board Identify the component in question in the BOM Note however that a new PCB information is published only whenever there is a major change in the design of the board A major change normally involves a change in the layout of the PCB which requires that the issue number in the IPN be incremented Any minor changes following a major change and ...

Page 89: ...figures also show the locations of the connectors on the board Figure 4 3 Shielding cans and connectors DIG BOT REG 1V8 TOP FCL TOP SYN TOP DIG TOP CDC TOP VCO TOP REG 5V TOP PA EX TOP LO2 TOP RX FE TOP MIXER TOP VCXO BOT SYN BOT VCO BOT CDC BOT REG 3V3 BOT PA BOT PA LPF BOT TX CONTROL BOT IF IQ BOT accessory connector PL1 front panel interface connector PL2 battery pins speaker pins antenna SMA c...

Page 90: ...epair Techniques Standard Procedures Service centers carrying out level 2 repairs are expected to be familiar with the standard techniques for the replacement of SMT components However certain components on the main board require non standard techniques and these are discussed below Another issue of concern is the procedure for removing and installing cans A discussion of the issue concludes this ...

Page 91: ...st select the settings for the communications port as follows 1 Open the terminal program In the case of HyperTerminal click Start Programs Accessories Communications HyperTerminal 2 In the terminal program first select the COM port to which the radio is connected Then select the following settings for the port bits per second 19 200 data bits 8 parity none stop bits 1 flow control none 3 Click th...

Page 92: ...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 internal speaker microphone 1 accessory microphone None 323 Audio tap in Generates the audio tone AUD TAP IN at the specified tap point 323 x y where x specifies the tap...

Page 93: ...ee character identifier and y is the version number 133 Hardware version Reads the product code of the radio body and the hardware version number 133 TPAB1x y_z where y is the last four characters of the product code and z is the version number 134 FLASH serial number Reads the serial number of the FLASH memory 134 x where x is the serial number a 16 digit hexadecimal number Radio control category...

Page 94: ... 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 x is the ...

Page 95: ... 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 326 Transmitter power Sets the power level of the transmitter 326 x where x specifies the level 0 off 1 very low 2 low 3 medium 4 high None 331 Final bias 1 Sets or reads the bias voltage for the PA 331 to read value x where...

Page 96: ...ch as voltage and temperature 820 1 start log of battery information returned every ten seconds 820 0 stop log Charging Temp PackV SubPackV Current PackT Cap DisT EndOfChargeT LastCapM CapCorrection LastChargeT StatusMsg 855 LCD Alters or resets the radio s LCD 855 x where x is the command for the LCD 0 to 255 for example 165 turns all pixels on 164 reverts to normal pixel display 167 inverts disp...

Page 97: ...nd up again and place the radio in CCTM again C05 The radio has not responded within the specified time Re enter the CCTM command X04 The DSP is not responding Check the DSP pin connections If the error persists replace the DSP X05 The version of the DSP is incompatible with the version of the radio firmware Replace the DSP with a later version X06 The internal configuration of the MCU is incorrec...

Page 98: ...ndications are provided in the form of different tones emitted from the speaker The information conveyed by the tones is given in Table 4 11 on page 99 Table 4 10 Visual indications provided by the status LED LED color LED name Indications Meanings Red Transmit LED is on The radio is transmitting LED flashes 1 The transmit timer is about to expire 2 The radio cannot transmit because the channel is...

Page 99: ...hed beep Repeated beep every ten seconds while powered up Battery level is low One long low pitched beep 1 On pressing key Key press is invalid 2 On pressing PTT switch Transmission is inhibited 3 While powered up Battery is flat Two short beeps On power up Radio is ready to use Three short beeps While powered up Previously busy channel is now free Three beeps During transmission Transmit time out...

Page 100: ...100 General Information TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 101: ...y catch disassemble and reassemble the radio General Important Before disassembling the radio disconnect the radio from any test equipment or power supply Disassemble only as much as necessary to replace the defective parts Inspect all disassembled parts for damage and replace them if necessary Observe the torque settings indicated in the relevant figures For information on spare parts refer to Sp...

Page 102: ...to release the catch mechanism 2 Tilt the top of the battery outwards and lift the lugs at the bottom of the battery out of the holes at the bottom of the radio Fitting the Battery 1 Insert the lugs at the bottom of the battery into the holes at the bot tom of the radio 2 Push the top of the battery towards the radio until the catch mechanism snaps in Figure 5 1 Removing the battery from the radio...

Page 103: ...o the two screws B and remove the battery catch support bracket C Note The left battery catch D and the right battery catch E are sym metrical but different parts 2 Remove the left battery catch D the right battery catch E and the two springs F Figure 5 2 Components of the battery catch B Torx T6 screw K1 8x5 PT x2 C batter catch support bracket D left battery catch E right battery catch F battery...

Page 104: ...12 Removing the Knobs and the 3 way Actuator The circled numbers in this section refer to the items in Figure 5 3 1 With your fingers pull off the volume knob D 2 Inspect the volume knob seal E and replace it if necessary 3 With your fingers pull off the channel knob B 4 With your fingers pull off the 3 way actuator C Figure 5 3 Removing the knobs and the 3 way actuator B channel knob D volume kno...

Page 105: ...river to remove the two screws B 3 While holding the radio with the chassis facing down tap the bottom end of the radio on the workbench Remove the chassis assembly C from the front panel assembly G 4 Remove the top seal D 5 Inspect the main seal E and replace it if necessary 6 Remove the keypad F Figure 5 4 Removing the chassis from the front panel B Torx T6 screw M2x8 x2 E main seal C chassis as...

Page 106: ...board F and unplug the front panel loom Removing the Main Board The circled numbers in this section refer to the items in Figure 5 5 on page 107 1 Use a Torx T6 screwdriver to remove the screw E fastening the main board F to the chassis I 2 Use a screwdriver with the modified 5 16 inch 8mm long reach socket to remove the SMA nut J and the two knob nuts 1 3 Hold the main board at the bottom break o...

Page 107: ... pin seal C speaker pin frame x2 H chassis plug seal D main shield assembly I chassis E Torx T6 screw M2x5 J SMA nut F main board 1 knob nut x2 c x2 d e f g h i J 1 thermal paste screw boss 3653z_01 front panel interface connector front panel loom recess point main shield assembly chassis break off points b locating holes speaker pins flexibleaccessory board locating pins ...

Page 108: ...ock of the LCD connector on the back of the main shield assembly C and unplug the loom of the LCD assembly D 2 Remove the LCD assembly D 3 Release the lock of the front panel loom connector and disconnect the front panel loom B Figure 5 6 Removing the LCD assembly and the front panel loom B front panel loom C main shield assembly D LCD assembly 3654z_01 C D LCD connector loom of LCD assembly front...

Page 109: ...wo thumbs push the top of the rear panel C off the chassis F and unclip the rear panel If necessary carefully insert a flat bladed screwdriver at the top between the rear panel and the chassis 3 Remove the rear panel seal D The rear panel seal is self adhesive and must be replaced each time it is removed 4 Remove the flexible accessory board E Figure 5 7 Removing the rear panel and the flexible ac...

Page 110: ...hile pushing on the ridge B between the PTT key and the lower function key use pliers to remove the PTT lock spring B 2 Place a small screwdriver on the T shaped protrusion C on the inside of the PTT frame E and push the PTT frame off the front panel C 3 Remove the PTT keypad D from the PTT frame E 4 Remove the blue PTT pressel F and the two red function key pressels G Figure 5 8 Removing the PTT ...

Page 111: ...6 screwdriver to unscrew the screw B and remove the speaker clamp C 2 Use a small flat bladed screwdriver to remove the speaker D The speaker adhesive ring E must be replaced each time the speaker is removed 3 If necessary remove the speaker cloth F Figure 5 9 Removing the speaker B Torx T6 screw K1 8x5 PT E speaker adhesive ring C speaker clamp F speaker cloth D speaker B 3656z_01 C D E F ...

Page 112: ...w adhesive speaker ring is provided on a sheet with backing on both sides and pre cut on one side To fit the adhesive speaker ring to the speaker a Remove and discard the inside part by pushing it through the adhesive speaker ring b Peel off the backing of the adhe sive speaker ring on the pre cut side c Press the speaker onto the adhe sive speaker ring d Push the speaker and the adhe sive speaker...

Page 113: ...Limited May 2005 Figure 5 10 Fitting the speaker B Torx T6 screw K1 8x5 PT E speaker adhesive ring C speaker clamp F speaker cloth D speaker B 3656z_01 Torx T6 2lb in 0 26N m Alignment feature Recess for speaker clamp Screw boss for speaker clamp C D E F Alignment feature ...

Page 114: ... panel C 2 Insert the PTT keypad E into the PTT frame D 3 Fit the PTT frame D and the PTT keypad E to the front panel C by first inserting the bottom tab then bending the PTT frame slightly to allow the top tab to slide in 4 While pushing on the ridge between the PTT key and the lower function key B use pliers to fit the PTT lock spring B over the PTT keypad s T shaped protrusion on the inside of ...

Page 115: ...sassembly and Reassembly 115 Tait Electronics Limited May 2005 Figure 5 11 Fitting the PTT keypad B PTT lock spring E PTT keypad C front panel assembly F PTT pressel D PTT frame G function key pressel x2 C B 3655z_01 D E G F B ...

Page 116: ...ed 3 Peel off the backing of a new rear panel seal D and place the rear panel seal over the flexible accessory board and chassis To achieve proper sealing use a blunt instrument to press down the rear panel seal inside the perimeter of the rear panel seal and around all holes 4 At an inclined angle B slide the rear panel onto the chassis until the two lugs of the rear panel are positioned under th...

Page 117: ...y and Reassembly 117 Tait Electronics Limited May 2005 Figure 5 12 Fitting the flexible accessory board and the rear panel B dummy cover C rear panel D rear panel seal E flexible accessory board F chassis C B D E F slot loom 3657z_01 ...

Page 118: ...rt the potentio meter into the vector plate E 2 Tack solder the component s to the main board at two diagonally opposite legs 3 Fit the main board to the chassis as described in Fitting the Main Board on page 120 but do not fit the two knob nuts and the SMA nut 4 De solder the legs tack soldered in step 2 5 Fit and tighten the two knob nuts and the SMA nut as described in Fitting the Main Board on...

Page 119: ...r 4 Make sure that the loom is correctly seated and lock the connector 5 Open the lock of the front panel loom connector on the back of the main shield assembly Important Make sure that the side of the front panel loom B labelled OUTSIDE faces to the closest side of the chassis 6 Use rubber nose pliers to carefully insert the side of the front panel loom B labelled KEYPAD into the connector 7 Make...

Page 120: ...the screw boss of the chassis 4 Use rubber nose pliers to carefully insert the loom of the flexible accessory board into the accessory connector PL1 on the underside of the main board 5 Insert the main board F into the chassis I 6 Check that the battery pin seal G is positioned correctly Important If the power volume potentiometer the 16 way 3 way selector switch and or the antenna SMA connector w...

Page 121: ...ttery pin seal C speaker pin frame x2 H chassis plug seal D main shield assembly I chassis E screw M2x5 J SMA nut F main board 1 knob nut x2 B c Torx T6 2lb in 0 23N m x2 d e f g h i J 1 thermal paste screw boss flexibleaccessory board 3653z_02 front panel interface connector 5 16 inch 8mm 10lb in 1 13N m front panel loom b locating pins speaker pins locating holes ...

Page 122: ... panel loom labelled RADIO into the connector 3 Make sure that the loom is correctly seated and lock the connector 4 To fit the main shield assembly D to the chassis I a Start at the top by sliding the two locating holes of the main shield assembly over the two locating pins of the chassis b Snap fit the bottom of the main shield assembly into place 5 Fit the two speaker pin frames C over the spea...

Page 123: ... particular around the bends near the top corners b Insert the top two corners of the main seal and hold them in place c Insert the bottom two corners of the main seal d Lift the main seal into place around the bends near the top of the chassis Important Do not stretch the main seal by pulling it or rubbing into place with your fingers e With your fingers tap the main seal into the groove of the c...

Page 124: ...e front panel assembly check by looking through the battery lug holes that the main seal E is not displaced at the base near the battery lugs a Insert the top components of the chassis assembly through the holes of the front panel assembly b Push and hold the chassis assembly towards the top B and carefully push the chassis into the bottom of the front panel assembly C 5 Look through the holes in ...

Page 125: ... numbers in this section refer to the items in Figure 5 17 1 Fit the blue 3 way actuator C 2 Fit the channel knob B 3 Fit the volume knob seal E over the shaft off the volume knob D 4 Fit the volume knob D Figure 5 17 Fitting the 3 way actuator and the knobs B channel knob D volume knob C 3 way actuator E volume knob seal D E C B 3651z_01 ...

Page 126: ...126 Disassembly and Reassembly TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 127: ...ration visual inspection powering up the radio reading the programming file obtaining the details of the Software Feature Enabler SFE reading the calibration file checking the user interface checking any error messages The following tasks only need to be carried out if they relate to the fault reported checking the transmit and transmit audio functions checking the receive and receive audio functi...

Page 128: ...ty If the chassis has been engraved it must be replaced Task 3 Power Up the Radio With the radio connected to the test equipment as described in Test Equipment Setup on page 86 attempt to power up the radio 1 Apply power to the radio and turn on the power volume control 2 If the radio powers up successfully go to Task 4 If it does not repair the radio as described in On Off Switch Faulty on page 1...

Page 129: ...e need for replacing the main board go to Step 6 Otherwise continue with Step 7 6 If the programming file can be read now save a copy on the test PC and go to Task 5 If the file still cannot be read go to step 7 7 Set up a suitable default programming file and attempt to upload it to the radio 8 If the upload succeeds go to Task 6 If the upload fails continue with Step 9 9 If the main board was re...

Page 130: ... The returned value should be between 340 and 800 zone channel control Scroll through all settings and observe the radio display LCD Check visually or use CCTM command 855 165 to switch on all LCD elements CCTM command 855 164 resets the LCD to its original state PTT key While pressing the PTT key the transmit symbol or should appear on the radio display unless transmit is inhibited on the selecte...

Page 131: ...0xabcdefgh Turn the radio off and then back on If the system error persists download new radio firmware To capture details of the system error use CCTM command 204 Error E0015 Battery error Replace the battery Error E0016 Battery error Replace the battery Temperature threshold exceeded Wait until the radio has cooled down Cannot tx Go to Task 9 on page 132 Battery is flat Recharge the battery Unsa...

Page 132: ...ot in lock one or both of the first two values returned are 0 repair the radio as described in Frequency Synthesizer Fault Finding on page 159 5 Repeat Step 1 to Step 4 with the transmit frequency set to the top of the band 6 Use CCTM command 326 1 to set the power level to very low 7 Connect a power meter and measure the transmit power 8 If the carrier power is correct go to Step 10 If the carrie...

Page 133: ... the synthesizer is in lock go to Step 5 If the synthesizer is not in lock repair the radio as described in Frequency Synthesizer Fault Finding on page 159 4 Repeat Step 1 to Step 3 with the receive frequency set to the top of the band 5 Feed a signal without modulation on the receive channel at 47dBm Check for maximum RSSI using the indicator on the radio display the green status LED CCTM command...

Page 134: ...for all radios repair enable software features if applicable final inspection final test final administration Task 1 Repair The fault diagnosis will have resulted in the repair or replacement of the main board This section describes the steps after completion of the fault diagnosis 1 Use the programming and calibration applications to load the pro gramming and calibration files read or set up in I...

Page 135: ...bration application Task 2 Enable Software Features SFE If the main board has been replaced ensure that the correct software features if any are enabled for the Customer If software features need to be enabled a special licence file is required for the replacement main board The file must allow for the enabling of the same software features as in the original assembly Proceed as follows 1 If it wa...

Page 136: ... no mechanical parts were damaged during the repair Repeat the inspection given in Visual Inspection on page 128 Rectify any damage Task 4 Final Test Test the radio to confirm that it is fully functional again The recommended tests are listed in Table 6 2 to Table 6 4 The calibration application can be used for many of these tests It is good practice to record the test results on a separate test s...

Page 137: ...band Wide band 2 5 kHz 4 0 kHz 5 0 kHz Distortion 1 kHz at 1 5 kHz deviation narrow band 1 kHz at 3 0 kHz deviation wide band 3 3 CTCSS continuous tone controlled subaudible signaling deviation Narrow band Medium band Wide band 250 to 350 Hz 500 to 560 Hz 580 to 680 Hz Table 6 3 Final tests of receiver functions analog mode Test Limits Receive sensitivity 118dBm for 12dB SINAD Mute opening Country...

Page 138: ... operation of microphone Speaker Check operation of speaker Function and keypad keys Check operation of all function and keypad keys LCD display Check operation of LCD display shows all pixels Backlighting Check operation of keypad and LCD backlighting Volume control Check operation of volume control and ON OFF switch 16 way and 3 way selectors Check operation of 16 way selector and 3 way selector...

Page 139: ... on page 134 The main shield assembly and LCD assembly are non serviceable items and must be replaced in their entirety if faulty For more information refer to Spare Parts on page 289 Task 1 Front Panel Keypad Faulty Use this procedure for faults with numeric keys scroll keys selection keys or keypad backlighting Before proceeding make sure the fault is not an issue with programming For backlighti...

Page 140: ...sembly and fold the assembly open leaving the loom connected between the front panel and the main board 3 Check the integrity of the front panel loom and confirm it is seated correctly at both ends RADIO and KEYPAD 4 Check the integrity of the LCD assembly loom and its connection to the LCD connector on the main shield assembly 5 Reassemble and power up the radio Check the functionality of the LCD...

Page 141: ...e is missing or corrupt If the ON OFF switch is faulty 1 Remove the front panel and main shield assembly 2 Remove power from the radio 3 Connect a resistance meter such as a multimeter across the test points TP900 and TP7V5SW See Figure 7 1 4 Measure the resistance with the switch in the on and off positions The correct ranges are below 5 If the switch resistances are outside these limits replace ...

Page 142: ... Audio ault Finding on page 269 Task 5 16 Way or 3 Way Selectors Faulty Use this procedure if the radio fails to change the channel when the 16 way selector is turned or the zone when the 3 way selector is turned Before proceeding make sure there is more than one channel and zone programmed for the radio and those channels and zones have been assigned to different positions on the 16 way and 3 way...

Page 143: ... Finding 143 Tait Electronics Limited May 2005 Figure 7 2 PCB layout of pins for RSW1 and DS900 bottom side Pins for 16 way selector R923 indicating non 3V3 end A B 4 1 8 2 Pins for 3 way selector DS900pinA1 green LED DS900 pin A2 red LED ...

Page 144: ... red LED of DS900 See Figure 7 2 3 Activate the relevant LED For the green LED feed a signal without modulation on the receive channel For the red LED ensure the antenna port is terminated with a 50Ω load or antenna and temporarily place the radio in transmit mode Important Do not transmit for more than five seconds with the main board removed from the chassis 4 As the LED is activated monitor the...

Page 145: ...main shield assembly 2 Remove the main board and apply power using an open radio test lead 3 Connect a multimeter or oscilloscope to the non 3V3 end of R922 PTT see Figure 7 3 R923 function key 1 see Figure 7 2 or R924 or R295 function key 2 or 3 see Figure 7 4 4 As each key is pressed monitor the voltage on the appropriate resistor The signal voltages should be as follows 5 If the logic levels ar...

Page 146: ... a front panel that has a known good speaker 2 Reassemble and power up the radio Check the functionality of the speaker microphone 3 If the speaker microphone operates as expected the speaker was faulty Discard and replace with a new one see Spare Parts on page 289 If the speaker microphone is still faulty proceed to Step 4 4 Check the integrity and soldering of speaker pins SPKR_POS and SPKR_NEG ...

Page 147: ...m in CODEC and Audio ault Finding on page 269 If the accessories interface is faulty 1 Remove the front panel main shield assembly and rear panel 2 Replace the flexible accessory board with a known good one 3 Reassemble and check the functionality of the accessories interface 4 If the accessory interface operates as expected the flexible accessory board was faulty Discard and use a new one see Spa...

Page 148: ...148 Interface Fault Finding TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 149: ...ge at TP3V3 test point see Figure 8 1 If it is continuously 3 3V or turns on for a short time approximately 2s go to Step 3 If it never reaches 3 3V go to Task 2 3 While turning the power volume control on use a multimeter to measure the voltage at C721 see Figure 8 1 To do this probe the positive side of the C721 through the DIG BOT can If it is continuously 1 8V or turns on for a short time appr...

Page 150: ...t confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed or no fault could be found replace the main board and go to Final Tasks on page 134 7 Check for shorts to ground and continuity of the DIG PSU LATCH signal from D602 see Figure 8 2 to the FPGA If a fault is found repair it confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed...

Page 151: ...t least one second go to Step 7 If it does not go to Step 5 5 When the power volume control is turned on 7V5_SW should go from 0V to 7 5V This generates a pulse through C634 which turns both Q606 transistors on for approximately 30ms and charges C610 to approximately 7 5V see Figure 8 2 Check for continuity and shorts to ground or power in this path Locate and repair the fault 6 Re measure the vol...

Page 152: ...re 8 2 reconnect the external 7 5V power supply and turn on the radio If the radio powers up go to Final Tasks on page 134 If the radio fails to power up the repair failed replace the main board and go to Final Tasks on page 134 10 Disconnect the 7 5V external supply Check for continuity and faults around IC610 D601 L600 R626 R627 R628 and C630 see Figure 8 2 and repair any faults 11 Repair LINK60...

Page 153: ...TP9100 Service Manual Power Supply Fault Finding 153 Tait Electronics Limited May 2005 Figure 8 2 Measurement points for the checking the 3V3 SMPS top side bottom side ...

Page 154: ...22 see Figure 8 3 If it is correct go to Step 5 If it is not go to Step 7 5 There is a fault on the 1V5 rail Disconnect the 7 5V external supply To isolate further short LINK600 out with solder and cut the track joining LINK601 Again measure the resistance to ensure that the link is cut Measure the voltage across C622 see Figure 8 3 If it is correct the fault is somewhere on the rail after LINK601...

Page 155: ...TP9100 Service Manual Power Supply Fault Finding 155 Tait Electronics Limited May 2005 Figure 8 3 Measurement points for the checking the 1V5 SMPS top side bottom side ...

Page 156: ...lator is active Repair any fault 3 Check the output for shorts to ground Repair any fault 4 Reconnect the 7 5V external supply and turn the power volume control on If the radio powers up or the correct regulator voltage is restored go to Final Tasks on page 134 If the repair failed go to Step 5 5 Disconnect the 7 5V external supply Replace the regulator IC with a spare Reconnect the 7 5V external ...

Page 157: ...TP9100 Service Manual Power Supply Fault Finding 157 Tait Electronics Limited May 2005 Figure 8 4 Measurement points for the checking the linear regulators top side bottom side DIG BOT can ...

Page 158: ...158 Power Supply Fault Finding TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 159: ... Use an oscilloscope with a x10 probe for all voltage measurements required The signals should appear stable and clean Consider any noise or unidentified oscillations as evidence of a fault requiring investigation Use a frequency counter for all measurements of high frequencies The RF power output from the frequency synthesizer will not exceed 10mW If a probe is used for frequency measurements use...

Page 160: ...ve fault will be implied by one of the following consequences radio fails to receive or receive performance is degraded radio fails to enter transmit mode radio exits transmit mode unexpectedly radio enters transmit mode but fails to transmit radio enters transmit mode but transmit performance is degraded With a fault of this kind neither of the initial tasks is required Fault diagnosis should beg...

Page 161: ...ter CCTM 5 If the calibration succeeded but the system error persists replace the main board and go to Final Tasks on page 134 In the case of the second message failed sanity check go to Step 6 In the case of the third message calibration failed go to Step 8 UHF radios or Power Supplies on page 163 VHF radios 6 Enter the CCTM command 205 to reset the calibration values to the default values Then e...

Page 162: ...escribed in the following steps 4 If the lock status is x0x where x is 0 or 1 the FCL is suspect go to Power Supply for FCL on page 205 5 If the lock status is 011 the synthesizer is suspect although the power supplies are functioning correctly go to Loop Filter on page 176 6 If the lock status is 010 the synthesizer and second LO are both out of lock First investigate the synthesizer excluding th...

Page 163: ...0 AN The measurement points for diagnosing faults in the power supplies are summarized in Figure 9 1 Figure 9 1 Measurement points for the synthesizer power supply circuitry PIN 4 OF IC601 PIN 4 OF IC601 R533 PINS 7 AND 15 OF IC503 PINS 7 AND 15 OF IC503 SIGNAL TYPES RF ANALOG CLOCK DIGITAL PLL SMPS LOOP FILTER AND SUMMER FILTERING OF SUPPLY FOR PLL AND LOOP FILTER FILTERING OF SUPPLY FOR VCO CIRC...

Page 164: ...e resistance to ground at the junction of C531 and R530 It should be approx 117kΩ 4 If the SMPS output is correct go to Task 4 If it is not go to Step 5 5 Check the 7V5 LINK supply at R533 and 3VO AN at E2 of Q500 see Figure 9 2 6 If the voltages are correct go to Step 7 If it is not the 7 5V supply is faulty Go to Power Supply Fault Finding on page 149 7 Check the SMPS circuit based on Q500 and L...

Page 165: ...TP9100 Service Manual Frequency Synthesizer Fault Finding 165 Tait Electronics Limited May 2005 Figure 9 2 Synthesizer 14V power supply circuitry top side Measurement point for 14V ...

Page 166: ... 4 If it is not the 7 5V supply is faulty Go to Power Supply Fault Finding on page 149 4 If the input to the regulator IC601 is correct but not the output check IC601 see Figure 9 3 and the associated circuitry if necessary replace IC601 Remove the SYN TOP can and check the C multipliers Q508 pins 3 4 5 see Figure 9 3 5 If a fault is found repair the circuit confirm the removal of the fault and go...

Page 167: ...167 Tait Electronics Limited May 2005 Figure 9 3 Synthesizer components under the SYN TOP and VCO TOP cans top side Measuring point for 3V AN B1 band H5 band Measuring point for 4V3 DEC Measuring point for 3V AN Measuring point for 7V5 Measuring point for 5V0 ...

Page 168: ...check for faults in the C multiplier Q508 pins 3 4 5 and the 5V and transmit receive switches based on Q513 Q507 and Q508 pins 1 2 6 see Figure 9 3 Replace any suspect transistor Conclude with Step 6 5 With a VHF radio check for faults in the C multiplier and 5V switch based on Q508 and Q513 see Figure 9 3 Check the operation of Q517 and Q513 Conclude with Step 6 6 If a fault is found repair the c...

Page 169: ...e is correct go to Step 7 If it is not the 3V regulator IC604 is suspect see Figure 9 4 5 Measure the voltage DIG 3V AN EN at pin 3 of IC604 see Figure 9 4 6 If it is correct go to Step 7 If it is not correct go to Power Supply Fault Finding on page 149 7 Check the components in the path from L506 to IC503 Also check IC503 if necessary replace IC503 see Figure 9 3 8 If a fault is found repair the ...

Page 170: ...o Task 8 If it is not go to Step 3 3 Check IC503 if necessary replace the IC 4 If there is a fault repair the circuit confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed or no fault could be found replace the main board and go to Final Tasks on page 134 Task 8 Reference Frequency If the supply for the charge pump is correct check the reference frequency input fr...

Page 171: ...PUT OF LOOP FILTER AT C565 OUTPUT OF LOOP FILTER AT C565 TP503 JUNCTION OF R566 AND R570 TP503 JUNCTION OF R566 AND R570 SIGNAL TYPES RF ANALOG CLOCK DIGITAL PLL LOOP FILTER AND SUMMER FILTERING OF SUPPLY FOR PLL AND LOOP FILTER FCL VCO CIRCUITRY FREQUENCY SYNTHESIZER PLL FEEDBACK DIGITAL CIRCUITRY DIG SYN EN SYN LOCK DIG SYN FAST INVERTER JUNCTION OF C541 AND R547 JUNCTION OF C541 AND R547 R549 R...

Page 172: ...CTM command 334 0 to switch off the synthesizer and measure the voltage on both sides of R716 see Figure 9 6 6 Enter the CCTM command 334 1 to switch on the synthesizer and measure the voltage on both sides of R716 see Figure 9 6 7 If the voltages measured in Step 5 and Step 6 are still not correct check whether the IO port D2 of IC701 is faulty or shorted by solder If the voltages are correct go ...

Page 173: ...TP9100 Service Manual Frequency Synthesizer Fault Finding 173 Tait Electronics Limited May 2005 Figure 9 6 Synthesizer components under the DIG BOT can bottom side DIG BOT can ...

Page 174: ...rrect go to Loop Filter on page 176 If it is not go to Step 4 4 Check for continuity between pin 14 of IC503 and the digital input R742 to D1 of IC701 DIG TOP can Figure 9 7 5 If there is a fault go to Step 6 If there is no fault the digital circuitry is faulty replace the main board and go to Final Tasks on page 134 6 Repair the fault Confirm the removal of the fault and go to Final Tasks on page...

Page 175: ...TP9100 Service Manual Frequency Synthesizer Fault Finding 175 Tait Electronics Limited May 2005 Figure 9 7 Synthesizer components under the DIG TOP can top side DIG TOP can ...

Page 176: ... the radio in CCTM 2 Remove R542 see Figure 9 8 3 Using an oscilloscope proceed as follows to observe the voltage at C565 before and after grounding the junction between C541 and R547 see Figure 9 8 While holding the oscilloscope probe at C565 use a pair of tweezers to momentarily ground the junction The voltage should change to the following value if it is not already at this value 4 If the loop ...

Page 177: ...ual Frequency Synthesizer Fault Finding 177 Tait Electronics Limited May 2005 Figure 9 8 Synthesizer components under the SYN TOP can top side B1 band H5 band Junction between C541 and R547 Junction between C541 and R547 ...

Page 178: ...Frequency Synthesizer Fault Finding TP9100 Service Manual Tait Electronics Limited May 2005 Figure 9 9 Synthesizer components under the SYN BOT can bottom side Test point TP504 for synthesizer loop voltage ...

Page 179: ...83 If it exhibits a system error or a transmit fault the transmit VCO is suspect go to Transmit VCO and Related Circuitry UHF Radios on page 191 Task 13 Check Reference Voltage If the loop filter circuitry is suspect first check the reference voltage for the filter 1 Remove the SYN BOT can 2 Measure the reference voltage at pin 5 of IC505 see Figure 9 9 The result should be 3 If the voltage is cor...

Page 180: ...loop filter is faulty go to Step 3 If the voltage is correct resolder R542 in position see Figure 9 8 and go to Task 15 3 Check IC504 IC505 Q511 see Figure 9 9 C548 see Figure 9 8 and associated components 4 If a fault is found repair the circuit repeat the measurement of the feedback voltage in Step 1 and resolder R542 in position see Figure 9 8 5 If the feedback voltage is now correct go to Fina...

Page 181: ...717 see Figure 9 6 and the digital circuitry The result should be 9 Enter the CCTM command 389 0 to set the mode to slow 10 Measure the voltage at the via between R717 see Figure 9 6 and the digital circuitry The result should be 11 If the voltages measured in Step 8 and Step 10 are correct go to Step 12 If they are not the digital circuitry is faulty replace the main board and go to Final Tasks o...

Page 182: ...548 see Figure 9 8 and associated components Conclude with Step 9 4 Remove R566 and R570 see Figure 9 8 which provide a modulation path to the VCO s 5 Repeat the measurement of Step 1 6 If the correct result is now obtained go to Step 7 If the correct result is still not obtained the CODEC and audio circuitry is suspect resolder R566 and R570 in position see Figure 9 8 and go to CODEC and Audio Fa...

Page 183: ...related circuitry The minimum and maximum receive frequencies for the different UHF frequency bands are defined in Table 9 2 There are six aspects Task 17 check receive VCO Task 18 repair PLL feedback Task 19 repair receive VCO Task 20 check switching to receive mode Task 21 repair switching network Task 22 check receive buffer amplifier The measurement points for diagnosing faults in the VCO and ...

Page 184: ...OF Q514 COLLECTOR OF Q514 TX PORT RX PORT SIGNAL TYPES RF ANALOG CLOCK DIGITAL PLL LOOP FILTER AND SUMMER FILTERING OF SUPPLY FOR VCO CIRCUITRY FREQUENCY SYNTHESIZER PLL FEEDBACK LOOP VOLTAGE RECEIVE VCO TRANSMIT VCO TRANSMIT BUFFER AMPLIFIER AND COUPLER 5 V SWITCH TR SWITCH SYN TX LO SYN RX LO1 TRANS MITTER RECEIVER DIGITAL CIRCUITRY DIG SYN TR SW DIG SYN EN 14 V INVERTER RECEIVE BUFFER AMPLIFIER...

Page 185: ...to the maximum given in Table 9 2 3 If the receive frequency measured in Step 2 is correct go to Step 4 If it is incorrect go to Task 19 If no frequency is detected go to Task 20 4 Proceed as follows to observe the receive frequency at the RX port before and after applying 3V DC to the junction of C541 and R547 see Figure 9 11 there is a convenient 3V level at R544 see Figure 9 11 While holding th...

Page 186: ... Service Manual Tait Electronics Limited May 2005 Figure 9 11 Synthesizer components under the SYN TOP and VCO TOP cans UHF radio top side Figure 9 12 Synthesizer components under the MIXER TOP can UHF radio top side Measuring point for SYN RX LO1 ...

Page 187: ...11 2 Remove the VCO BOT can 3 Replace the components C567 R574 see Figure 9 13 and IC503 see Figure 9 11 4 Also check the second stage of the receive buffer amplifier based on IC404 see Figure 9 12 Repair any fault 5 Confirm that the fault in the radio has been removed If it has go to Final Tasks on page 134 If it has not replace the main board and go to Final Tasks on page 134 Figure 9 13 Synthes...

Page 188: ...Resolder R542 in position see Figure 9 11 Replace the main board and go to Final Tasks on page 134 Task 20 Check Switching to Receive Mode If no receive frequency is detected in the check of the receive VCO first check that the transmit receive switch is functioning correctly 1 Resolder R542 in position see Figure 9 11 2 Enter the CCTM command 335 0 to switch on the supply to the receive VCO 3 Mea...

Page 189: ...e via between R720 and the digital circuitry 6 If the voltages measured in Step 4 and Step 5 are correct go to Step 7 If they are not the digital circuitry is faulty resolder R720 in position see Figure 9 7 replace the main board and go to Final Tasks on page 134 7 Check and resolder R720 in position see Figure 9 7 and check for continuity between Q508 and the digital circuitry via R593 see Figure...

Page 190: ... the CCTM command 335 1 to set the transmit receive switch on 5 Again measure the voltage at Q514 and IC404 6 If the voltages are correct the receive VCO is suspect go to Step 7 If they are not the receive buffer amplifier is suspect go to Step 9 7 Remove the VCO TOP can 8 Check the receive VCO circuitry based on Q504 see Figure 9 11 Conclude with Step 10 9 Check the first buffer stage based on Q5...

Page 191: ...ansmit VCO and related circuitry The minimum and maximum transmit frequencies for the different UHF frequency bands are defined in Table 9 3 There are five aspects Task 23 check transmit VCO Task 24 repair PLL feedback Task 25 repair transmit VCO Task 26 check switching to transmit mode Task 27 check transmit buffer amplifier The measurement points for diagnosing faults in the VCO and related circ...

Page 192: ...e maximum given in Table 9 3 3 If the transmit frequency measured in Step 2 is correct go to Step 4 If it is incorrect go to Task 25 If no frequency is detected go to Task 26 4 Proceed as follows to observe the transmit frequency at the TX port before and after applying 3V DC to the junction of C541 and R547 there is a convenient 3V level at R544 see Figure 9 11 While holding the probe on the TX p...

Page 193: ...n board and go to Final Tasks on page 134 Task 25 Repair Transmit VCO If either or both the minimum and maximum transmit frequencies are incorrect the transmit VCO circuitry is faulty 1 Remove the VCO TOP can 2 Check the transmit VCO The circuitry is based on Q510 see Figure 9 11 3 If a fault is found repair it and go to Step 4 If no fault is found go to Step 6 4 Repeat the frequency measurements ...

Page 194: ...2 Enter the CCTM command 335 1 to switch on the supply to the transmit VCO 3 Measure the voltage at the second collector pin 3 of Q506 see Figure 9 11 The voltage should be 4 Enter the CCTM command 335 0 to switch off the supply 5 Again measure the voltage at the second collector of Q506 6 If the voltages measured in Step 2 and Step 4 are correct go to Task 27 If they are not the switching network...

Page 195: ... the transmit buffer amplifier in transmit mode Enter the CCTM command 335 1 to set the transmit receive switch on 5 Again measure the voltage at IC506 6 If the voltages are correct the transmit VCO is suspect go to Step 7 If they are not the transmit buffer amplifier is suspect go to Step 9 7 Remove the VCO TOP can 8 Check the transmit VCO circuitry based on Q510 see Figure 9 11 Conclude with Ste...

Page 196: ...ion apply only to VHF radios the VHF frequency bands are defined in Table 9 4 There are six aspects Task 28 check VCO Task 29 repair PLL feedback Task 30 repair VCO Task 31 check transmit receive switch Task 32 repair switching network Task 33 check buffer amplifier The measurement points for diagnosing faults in the VCO and related circuitry are summarized in Figure 9 14 Table 9 4 Minimum and max...

Page 197: ... SIGNAL TYPES RF ANALOG CLOCK DIGITAL PLL LOOP FILTER AND SUMMER FILTERING OF SUPPLY FOR VCO CIRCUITRY FREQUENCY SYNTHESIZER PLL FEEDBACK VCO BUFFER AMPLIFIER Q5000 D510 5 V SWITCH TR SWITCH SYN TX LO SYN RX LO1 TRANS MITTER RECEIVER DIGITAL CIRCUITRY DIG SYN TR SW DIG SYN EN 14 V INVERTER R544 JUNCTION OF C541 AND R547 JUNCTION OF C541 AND R547 3V0 AN L506 3 V SUPPLY D510 IC506 L525 D515 D510 L50...

Page 198: ...to the maximum given in Table 9 4 3 If the maximum frequency measured in Step 2 is correct go to Step 4 If it is incorrect go to Task 30 but if no frequency at all is detected go to Task 31 4 Enter the CCTM command 335 0 to set the transmit receive switch off receive mode 5 Proceed as follows to observe the receive frequency at the RX port before and after applying 3V DC to the junction of C541 an...

Page 199: ...ncy Synthesizer Fault Finding 199 Tait Electronics Limited May 2005 Figure 9 15 Synthesizer components under the SYN TOP can VHF radio top side Figure 9 16 Synthesizer components under the PA EX TOP can VHF radio top side TX port ...

Page 200: ...suspect 1 Resolder R542 in position see Figure 9 15 2 Remove the VCO BOT can 3 Check the components R567 C589 C590 and L5000 see Figure 9 17 and IC503 see Figure 9 15 4 Confirm that the fault in the radio has been removed If it has go to Final Tasks on page 134 If it has not replace the main board and go to Final Tasks on page 134 Figure 9 17 Synthesizer circuitry under the VCO BOT can VHF radio b...

Page 201: ... 9 17 3 If a fault is found repair it and go to Step 4 If no fault is found go to Step 7 4 Repeat Step 1 and Step 2 of Task 28 to measure the maximum VCO frequency 5 Repeat Step 4 and Step 5 of Task 28 to measure the minimum VCO frequency 6 If the frequencies are now correct resolder R542 in position see Figure 9 15 and go to Final Tasks on page 134 If they are still not correct go to Step 7 7 Res...

Page 202: ... C594 7 If the voltages measured in Step 4 and Step 6 are correct go to Step 8 If they are not the switching network is suspect go to Task 32 8 Enter the CCTM command 335 1 to switch on the supply to the TX port 9 Measure the voltage at the junction of L5001 and C596 see Figure 9 17 Some RF noise might be observed The voltage should be 10 Enter the CCTM command 335 0 to switch off the supply 11 Ag...

Page 203: ...command 335 1 and again measure the voltage at the left side of R720 6 If the voltages measured in Step 4 and Step 5 are correct go to Step 7 If they are not the digital circuitry is faulty replace the main board and go to Final Tasks on page 134 7 Check for continuity between R576 see Figure 9 17 and R720 8 If no fault is found go to Step 9 If a fault is found repair the circuit confirm that the ...

Page 204: ... 9 17 Some RF noise might be observed 3 Measure the voltage at the collector of Q5000 see Figure 9 17 4 If the voltages measured in Step 2 and Step 3 are not correct go to Step 5 If they are check the VCO circuitry based on Q504 see Figure 9 17 Conclude with Step 6 5 The buffer amplifier is suspect Check the buffer circuitry based on Q5000 IC506 see Figure 9 17 6 If a fault is found repair the cir...

Page 205: ... reference frequency input from the FCL to the PLL will imply that the FCL is suspect Fault diagnosis of the FCL is divided into four stages check power supply check VCXO and VCTCXO outputs check signals at TP501 and TP502 check VCXO and CODEC circuitry The checking of the power supply is given in this section in Task 34 below The remaining three stages are covered in VCXO and VCTCXO Outputs to VC...

Page 206: ...TOR BUFFER AMPLIFIER AGND DIGITAL CIRCUITRY CDC VCXO MOD SYN CDC FCL BUFFER AMPLIFIER INTERFACE CIRCUITRY RECEIVER FCL CIRCUITRY 3V0 AN SUPPLY C536 R541 VCXO OUTPUT AT C536 VCXO OUTPUT AT C536 PLL SYN RX OSC C510 TP504 FEEDBACK SIGNAL SYN DIG FREF TCXO OUTPUT VCXO OUTPUT AT R522 PIN 1 OF IC501 VCXO OUTPUT AT R522 PIN 1 OF IC501 LO INPUT AT R521 PIN 4 OF IC501 LO INPUT AT R521 PIN 4 OF IC501 TP502 ...

Page 207: ...remove the FCL TOP can and place the radio in CCTM 2 Measure the supply 3V0 AN at the via shown in Figure 9 19 3 If the voltage is correct go to VCXO and VCTCXO Outputs on page 208 If it is not the 3V regulator IC604 is suspect go to Task 4 of Power Supply Fault Finding on page 156 via adjacent R536 3 0 0 06V DC Figure 9 19 FCL circuitry under the FCL TOP can top side 3V0 AN VCTCXO output VCXO out...

Page 208: ...9 The signal should be 2 If the signal is correct go to Task 36 If it is not go to Step 3 3 The VCXO circuitry under the VCXO BOT can is faulty Remove the VCXO BOT can 4 Locate and repair the fault in the VCXO Q501 Q503 XL501 and associated components see Figure 9 20 5 Confirm the removal of the fault and go to Task 36 If the repair failed replace the main board and go to Final Tasks on page 134 V...

Page 209: ...he signal should be 2 If the signal is correct go to Signals at TP501 and TP502 on page 210 If it is not go to Step 3 3 The VCTCXO module XL500 or its supply voltage is faulty 4 Locate and repair the fault of XL500 and associated components see Figure 9 21 5 Confirm the removal of the fault and go to Signals at TP501 and TP502 on page 210 If the repair failed replace the main board and go to Final...

Page 210: ...signals at the TP501 and TP502 test points The procedure is divided into three tasks Task 37 check signal at TP502 Task 38 check signal at TP501 and ground TP501 if loop is oscillating Task 39 check signal at TP502 with TP501 grounded These checks will reveal any faults in the mixer and LPF low pass filter circuitry and any additional fault in the VCXO circuitry Figure 9 21 Test points TP501 and T...

Page 211: ...ult in the mixer IC501 and associated components or LPF circuitry IC502 pins 5 to 7 and associated components see Figure 9 19 5 Repair the circuitry Note that the TCXO input to the mixer at R521 pin 4 of IC501 see Figure 9 19 should be Also the VCXO input to the mixer at R522 pin 1 of IC501 see Figure 9 19 although noisy and difficult to measure should be 6 Confirm the removal of the fault and go ...

Page 212: ... it is not there is a fault in the modulator buffer amplifier IC502 pins 1 to 3 and associated components see Figure 9 19 Rectify the fault and return to Step 1 5 Connect the TP501 test point to ground by resoldering R527 in the position shown in Figure 9 19 This forces the VCXO loop voltage high 6 Use the oscilloscope probe to check the VCXO output at C536 probe the via next to C536 see Figure 9 ...

Page 213: ...n 4 of IC501 see Figure 9 19 should be Also the VCXO input to the mixer at R522 pin 1 of IC501 see Figure 9 19 although noisy and difficult to measure should be 5 Confirm the removal of the fault and go to Step 6 If the repair failed resolder R527 in its original position as shown in Figure 9 19 replace the main board and go to Final Tasks on page 134 6 Resolder R527 in its original position as sh...

Page 214: ...lts were rectified perform the following CCTM checks 1 Enter the CCTM command 393 1 1900 Measure the voltage level at the TP501 test point see Figure 9 21 2 Enter the CCTM command 72 and note the lock status 3 Enter the CCTM command 393 1 1900 Again measure the voltage level at the TP501 test point 4 Enter the CCTM command 72 and note the lock status 5 If the above voltage levels are not correct o...

Page 215: ...done remove the CDC TOP can 2 Check the following digital signals at IC205 see Figure 9 22 pin 10 DIG CDC2 LRCK pin 12 DIG CDC2 SCLK pin 8 CDC2 DIG SDTO pin 9 DIG CDC2 SDTI These signals to and from the digital circuitry should all be active 3 If the digital signals are correct the CODEC 2 circuitry is suspect go to Step 6 If they are not go to Step 4 4 If any or all digital signals are missing ch...

Page 216: ... the fault and go to Step 9 If the repair failed replace the main board and go to Final Tasks on page 134 9 Replace all cans 10 Repeat Task 40 to confirm the removal of the fault If the repair failed replace the main board and go to Final Tasks on page 134 Figure 9 22 Synthesizer components under the CDC TOP can top side ...

Page 217: ...commands frequency bands can removal and replacement and transmit tests CCTM Commands The CCTM commands required in this section are listed in Table 10 1 Full details of the commands are given in Computer Controlled Test Mode CCTM on page 91 Table 10 1 CCTM commands required for the diagnosis of faults in the transmitter Command Description 32 33 803 101 x y 0 114 x 326 x 331 331 x 334 x 335 x Set...

Page 218: ... frequency in the above ranges Can Removal There are four cans shielding the bulk of the transmitter circuitry PA BOT can PA LPF BOT can TX CONTROL BOT can PA EX TOP can To remove any can first remove the main board from the chassis Follow the procedures given in Disassembly and Reassembly on page 101 Can Replacement Replace all cans that have been removed only after repairing the board This appli...

Page 219: ...ary a 50Ω load may be used instead Do not operate the transmitter without such a load or without a connection to the test set Failure to do so might result in damage to the power output stage of the transmitter Limit Duration of Transmit Tests After setting the frequency and power level if necessary enter the CCTM command 33 to perform a transmit test This command places the radio in transmit mode...

Page 220: ...le 5V0 TX The power supplies distribution is summarized in Figure 10 1 Figure 10 1 Measurement and test points for diagnosing faults involving the power supplies for the transmitter RF Connector Receiver LPF PA Power Control PIN Switch Driver Exciter TX RX RF Transmitter 5V TX 7V5 LINK SYN TX LO Power Supply Frequency Synthesizer Signal Types RF analog clock digital Interfaces AGND Buffer R150 Cur...

Page 221: ...radio to high power Note Using the CCTM command 326 5 will set the radio to maximum power and the driver stage will be under current limiting 6 Attempt to place the radio in transmit mode Enter the CCTM command 33 7 If the radio enters the transmit mode continue with Step 8 If instead a C03 error is displayed in response to the command 33 go to Task 5 on page 227 8 Measure the voltage at the point...

Page 222: ...l Tait Electronics Limited May 2005 Figure 10 2 Measuring points under the PA bot can bottom side for measuring the power supply B1 band H5 band H6 similar Measuring point on L115 Measuring point on L111 Measuring point on L111 Measuring point on L115 ...

Page 223: ...e the 5V TX supply voltage under the TX CONTROL BOT can see Figure 10 3 4 Enter the CCTM command 32 to place the radio in receive mode 5 If the supply measured in Step 3 is correct go to Task 3 If it is not the 5V regulator IC600 and the associated switching circuitry are suspect go to Task 4 of Power Supply Fault Finding on page 156 supply 5V TX 5 0V DC Figure 10 3 Measuring points under TX CONTR...

Page 224: ...program the radio with the highest frequency in the radio s frequency band Enter the CCTM command 101 x x 0 where x is the frequency in hertz The required values for the different frequency bands are given in Table 10 2 on page 218 3 Enter the CCTM command 33 to place the radio in transmit mode 4 Note the RF output power measured by the test set and note the current reading on the DC power supply ...

Page 225: ...aping Filter TX RX RF Transmitter OR Gate TX INH 5V TX 7V5 LINK DIG TX INH SYN LOCK SYN TX LO Power Supply Digital Frequency Synthesizer CDC TXFIN RXAGC CDC TXPWR RXFE Thermal Coupling Codec and Audio Signal Types RF analog clock digital asynchronous serial data synchronous serial data Interfaces AGND Shaper and Level Shifter Buffer Current Sensing PA Difference Amplifier Pre Driver 7V5 BATT Lead ...

Page 226: ...r the following CCTM commands in turn and measure the RF output power in each case 326 3 mid power 326 2 low power 326 1 very low power 2 The above measurements should confirm that the power remains unchanged at all settings Carry out Task 9 and then Task 12 Table 10 3 Tasks to be performed according to the results of the power and current measurements of Task 3 Power Current Task Correct Correct ...

Page 227: ...signal at the D TX INH test point see Figure 10 3 The signal should be 6 If the signal is inactive as required go to Step 8 If it is active about 2 8V the temperature sensor is suspect go to Step 7 7 Enter the CCTM command 32 to place the radio in receive mode and go to Task 6 8 The lock status is possibly no longer normal Enter the CCTM command 72 and check the lock status 9 Enter the CCTM comman...

Page 228: ...r converting to degrees celsius use the formula on page 217 should be about 23 to 25 C If it is go to Biasing of PA Driver and PA on page 230 If it is not go to Step 3 3 Check D201 and the surrounding components see Figure 10 5 The temperature sensor is located on the top side of the main board 4 If there is no fault go to CODEC and Audio ault Finding on page 269 If a fault is found repair it conf...

Page 229: ...uspect or the input to the PA is reduced Check the circuitry of the PA Q106 and the PA driver Q103 1 Enter the CCTM command 331 to check the DAC value of final bias 1 CDC TX FIN RXAGC Record the value x returned 2 Enter CCTM command 114 0 to turn off power control Note the current reading on the DC power supply This is the bias current Table 10 4 shows the bias currents for each power setting 3 En...

Page 230: ...Important The PA BOT can must not be removed while the radio is in transmit mode To access the measurement and test points remove the TX CONTROL BOT and PA BOT cans Task 9 Prepare to Check Biasing If the transmitter is not being inhibited check the biasing of the PA First make the following preparations 1 Set the current limit on the DC power supply to 2 A 2 Enter the CCTM command 331 to check the...

Page 231: ...Gate TX INH 5V TX 7V5 LINK DIG TX INH SYN LOCK SYN TX LO Power Supply Digital Frequency Synthesizer CDC TXFIN RXAGC CDC TXPWR RXFE Thermal Coupling Codec and Audio Signal Types RF analog clock digital asynchronous serial data synchronous serial data Interfaces AGND Shaper and Level Shifter Buffer Current Sensing PA Difference Amplifier Pre Driver 7V5 BATT VGATE Pin 15 of IC101 Pin 15 of IC101 Pin ...

Page 232: ...mentioned in Step 5 of Task 9 this will be less than 550mA 3 Enter the CCTM command 331 x where x was recorded in Task 9 4 Check that the voltage changes to 5 Also note the current reading This should increase by an amount approximately equal to the offset given in Table 10 5 6 If the voltage and current are both correct go to Step 7 If the voltage is correct but not the current go to Task 11 If n...

Page 233: ... Figure 10 7 PA circuitry under the TX CONTROL BOT can bottom side TXPWR RXFE test point VGATE test point PA BIAS test point pin 14 of IC101 via of CDC TXFIN RXAGC TXPWR RXFE test point PA BIAS test point pin 14 of IC101 via of CDC TXFIN RXAGC VGATE test point B1 band H5 band H6 similar ...

Page 234: ...and 33 to place the radio in transmit mode 2 Enter the CCTM command 331 x where x was recorded in Task 9 3 Check that the voltage at the gate of Q106 see Figure 10 8 is 4 Enter the CCTM command 32 to place the radio in receive mode 5 If the voltage measured above is correct Q106 is faulty replace the main board and go to Final Tasks on page 134 If it is not correct go to Step 6 6 Check the circuit...

Page 235: ...onics Limited May 2005 Figure 10 8 PA driver circuitry under the PA BOT can B1 band SYN TX LO measuring point Driver output Exciter output H5 band SYN TX LO measuring point Driver output Exciter output H6 band SYN TX LO measuring point Driver output Exciter output ...

Page 236: ...it is not go to CODEC and Audio ault Finding on page 269 6 Check IC101 and the surrounding shaping filter circuitry see Figure 10 7 If a fault is found repair it confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed replace the main board and go to Final Tasks on page 134 Task 13 Biasing of PA Driver voltage clamp If the PA biasing and power control are correct th...

Page 237: ...nd go to Final Tasks on page 134 If it is not go to Task 15 Task 15 Check Power Control Check the power control circuitry if the voltage at the VGATE test point is incorrect Important Ensure that the current limit on the DC supply is 2A 1 Enter the CCTM command 114 0 to switch off the power 2 Note the current reading on the DC power supply 3 Check that the voltage from the DAC is changing Measure ...

Page 238: ...ill be located 1 Enter the CCTM command 32 and then check C115 C175 R123 and R132 see Figure 10 7 in the power control circuit 2 Repair any fault revealed by the checks in Step 1 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed or a fault cannot be found go to Step 3 3 Measure the voltage at pin 1 of IC101 see Figure 10 7 in the shaping filter circuit The vol...

Page 239: ...grouped as follows Task 18 to Task 20 initial RF signal path Task 21 and Task 22 PIN switch Task 23 LPF The initial signal path includes the exciter and PA driver The PIN switch and LPF make up the final signal path The measurement points for diagnosing faults in the signal path are summarised in Figure 10 9 Figure 10 9 Measurement points for diagnosing faults in the RF signal path RF Connector Re...

Page 240: ...B1 band or C125 H5 H6 at the SYN TX LO measuring via see Figure 10 8 The required voltage should be as given in Table 10 6 B1 Table 10 7 H5 or Table 10 8 H6 6 Enter the CCTM command 32 to place the radio in receive mode 7 If the voltage measured above is correct go to Task 19 If it is not go to Step 8 8 Check C138 B1 band or C125 H5 H6 see Figure 10 10 If the capacitor is not faulty go to Frequenc...

Page 241: ...3 0 68 0 3 2 5 400 435 470 0 45 0 1 0 46 0 1 0 55 0 1 1 3 0 3 1 5 0 3 1 4 0 3 0 95 0 3 0 91 0 3 0 82 0 3 4 400 435 470 0 45 0 1 0 53 0 1 0 65 0 1 1 4 0 3 1 8 0 3 1 6 0 3 1 4 0 3 1 6 0 3 1 4 0 3 Table 10 8 RF voltages along the initial RF signal path H6 band Power level W Frequency MHz RF voltages V Synthesizer output Exciter output Driver output 1 450 490 530 0 35 0 1 0 51 0 1 0 46 0 1 0 85 0 3 1 ...

Page 242: ... transmit mode 5 Use an RFP5401A RF probe or the equivalent to measure the RF voltage after C146 B1 band or C110 H5 H6 at the exciter output measuring point in Figure 10 8 The required voltage should be as given in Table 10 6 B1 Table 10 7 H5 or Table 10 8 H6 6 Enter the CCTM command 32 to place the radio in receive mode 7 If the voltage measured above is correct go to Task 19 If it is not go to S...

Page 243: ...TP9100 Service Manual Transmitter Fault Finding 243 Tait Electronics Limited May 2005 Figure 10 10 Components under the PA EX TOP can top side B1 band H5 band H6 similar ...

Page 244: ... checks reveal a fault go to Step 6 If they do not go to Task 9 6 Repair the fault Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed replace the main board and go to Final Tasks on page 134 7 Enter the CCTM command 326 5 to set the power level to the maximum and then the command 33 to place the radio in transmit mode 8 Measure the RF voltage at the gates of th...

Page 245: ...est lead to the test set 6 Enter the CCTM command 326 5 to set the transmitter power level to the maximum 7 Enter the CCTM command 101 x x 0 where x is the lowest frequency in hertz for maximum power as given in Table 10 6 B1 Table 10 7 H5 or Table 10 8 H6 8 Enter the CCTM command 33 to place the radio in transmit mode 9 Measure the RF output power This should exceed 6W B1 band or 5W H5 H6 10 Ente...

Page 246: ...ual Tait Electronics Limited May 2005 Figure 10 11 Circuitry under the PA LPF BOT can bottom side and points for attaching the test lead and test capacitor Mounting point for test capacitor Mounting point for test capacitor H5 band H6 similar B1 band ...

Page 247: ...wer level to the maximum 4 Enter the CCTM command 101 x x 0 where x is the lowest frequency in hertz for maximum power as given in Table 10 6 B1 Table 10 7 H5 or Table 10 8 H6 5 Enter the CCTM command 33 to place the radio in transmit mode 6 Again measure the RF output power This should exceed 5W 7 Enter the CCTM command 32 to place the radio in receive mode 8 Enter the CCTM command 101 x x 0 wher...

Page 248: ...evel to the maximum 5 Enter the CCTM command 101 x x 0 where x is the lowest frequency in hertz for maximum power as given in Table 10 6 B1 Table 10 7 H5 or Table 10 8 H6 6 Enter the CCTM command 33 to place the radio in transmit mode 7 Measure the RF output power This should exceed 5W 8 Enter the CCTM command 32 to place the radio in receive mode 9 Enter the CCTM command 101 x x 0 where x is the ...

Page 249: ...TP9100 Service Manual Transmitter Fault Finding 249 Tait Electronics Limited May 2005 Figure 10 12 Circuitry under the RX FE TOP can top side B1 band H5 band H6 band ...

Page 250: ...250 Transmitter Fault Finding TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 251: ...on If the receiver sensitivity is low begin with Faulty Receiver Sensitivity on page 252 to determine the extent of the loss in sensitivity CCTM Commands The CCTM commands required are listed in Table 11 1 Full details of the commands are given in Computer Controlled Test Mode CCTM on page 91 Table 11 1 CCTM commands required for the diagnosis of faults in the receiver Command Description 72 101 x...

Page 252: ...sitivity on page 258 to rectify the fault 1 Input an RF signal not necessarily modulated of 90dBm at the RF connector 2 Enter the CCTM command 378 to measure the receiver output level 3 Note the value x returned for the receiver output level Depending on the frequency band in which the radio operates the value should be Note that a change in the input level of 10dB should result in a ten fold chan...

Page 253: ...t check the two power supplies 3V0 AN and 3V0 RX for the receiver circuitry 1 Remove the main board from the chassis 2 Check for 3 0V DC 3V0 AN at the TP3V0 AN test point near the speaker pin see Figure 12 3 on page 273 3 If the voltage is correct go to Step 4 If it is not the 3V regulator IC604 is suspect go to Task 4 of Power Supply Fault Finding on page 156 4 Remove the LO2 TOP can 5 Check for ...

Page 254: ...l Tait Electronics Limited May 2005 Figure 11 1 Receiver circuitry under the IF IQ BOT can top side Figure 11 2 Receiver circuitry under the LO2 TOP can bottom side Figure 11 3 Receiver circuitry under the RX FE TOP can bottom side measurement point ...

Page 255: ...e 134 4 Recalibrate the receiver using the calibration application 5 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed go to Task 7 Task 4 Check Lock Status If the logic signal from the digital board is active as required check the lock status of the radio 1 Enter the CCTM command 72 to determine the lock status The status should be normal 2 If the lock status...

Page 256: ...ier bias conditions First measure Vc between the collector of Q404 and ground see Figure 11 1 5 Secondly check Ic To do so unsolder and raise one terminal of L419 tombstone position see Figure 11 1 connect a multimeter between this terminal and the pad for the terminal and measure the current 6 If the checks in Step 2 to Step 5 reveal no fault go to Task 6 If there is a fault repair it and go to S...

Page 257: ... 2 If the above check reveals no fault go to Step 3 If there is a fault repair it and go to Step 6 3 Remove the RX FE TOP and PA LPF BOT cans 4 Make a visual check of the components in the receive path of the PIN switch and LPF circuits 5 If the visual check reveals an obvious fault repair it and go to Step 6 If there is no obvious fault go to Task 7 6 Recalibrate the receiver using the calibratio...

Page 258: ...ing circuitry Open the Raw Data page and click the Receiver tab 2 Record the values listed in the Rx FE Tune BPF Settings field these are the DAC values of the FE front end tuning voltages for the five frequencies FE TUNE0 to FE TUNE4 FE TUNE0 is the lowest frequency and FE TUNE4 the highest fre quency in the radio s frequency band the values are given in Table 11 2 3 For each of the frequencies F...

Page 259: ...cks in Step 2 to Step 5 reveal no fault go to Step 7 If there is a fault repair it and go to Step 8 7 Check the signal level at the output of LO1 and continue the fault diagnosis as in Power Supply for FCL on page 205 8 Recalibrate the receiver using the calibration application 9 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed go to Task 9 Vc 2 7 0 1V Ic 10 ...

Page 260: ... to T401 see Figure 11 3 and Figure 11 4 3 Check the IF amplifier bias conditions as in Step 4 and Step 5 of Task 5 4 Check the LNA bias conditions as in Step 4 and Step 5 of Task 8 5 If the checks of Step 2 to Step 4 reveal no fault go to Step 6 If there is a fault repair it and go to Step 7 6 Check the PIN switch and LPF as in Task 21 to Task 23 of Transmitter Fault Finding 7 Recalibrate the rec...

Page 261: ... calibration application open the Raw Data page and click the Receiver tab 2 Note the settings listed in the AGC Voltage Cal Pts field The nominal settings should be as listed in Table 11 3 3 If the settings are correct go to Task 11 If they are not go to Step 4 4 Recalibrate the receiver and check the settings again 5 If the settings are now correct go to Step 6 If they are not go to Task 1 and c...

Page 262: ...3dB 2 If the values are as expected go to Task 13 If they are not go to Step 3 3 Recalibrate the receiver and check the values again 4 If the values are now correct go to Step 5 If they are not go to Task 1 and check the receiver sensitivity 5 Check if the RSSI fault has been removed If it has go to Final Tasks on page 134 If it has not go to Task 13 Task 13 AGC Delta Gain If the RSSI delta gain v...

Page 263: ...bration application for Task 15 and Task 16 Task 14 Determine Type of Muting Selected First use the programming application to determine the type of muting selected 1 In the programming application click the Basic Settings page under the Channel Profiles heading 2 Click the General Settings tab 3 Check the setting in the Squelch Detect Type field Ensure that the setting is what the Customer expect...

Page 264: ...ab 4 Compare the values in the Mute Noise Readings field with the required minimum and maximum values listed in Table 11 4 5 If the mute noise readings are correct go to Task 1 and check the receiver sensitivity If they are not go to Step 6 6 Recalibrate the mute and then check if the mute fault has been removed 7 If the fault has been removed go to Final Tasks on page 134 If it has not go to Task...

Page 265: ... Opening Pt fields and the Hysteresis fields under the Squelch Thresholds label are what the Customer expects 3 If the calibration values are as expected go to Task 10 and check the RSSI calibration If they are not go to Step 4 4 Adjust the values in the Opening Pt and Hysteresis fields Program the radio with the new values 5 Check if the mute fault has been removed If it has go to Final Tasks on ...

Page 266: ...ibration application to check the TCXO calibration Open the Raw Data page and click the Volt Ref TCXO VCO VCXO tab 2 Note the values listed in the Tx TCXO and Rx TCXO fields of the TCXO group box The values should be 3 If the calibration values are correct go to Step 4 If they are not recalibrate the TCXO and go to Step 8 4 Remove the FCL TOP can 5 Check the components of the TCXO which is based o...

Page 267: ... should be 3 If the second IF is correct go to Step 6 If it is not go to Step 4 4 Recalibrate the TCXO 5 Check if the distortion fault has been removed If it has go to Final Tasks on page 134 If it has not go to Step 6 6 Remove the IF IQ BOT can 7 Check the components between T401 see Figure 11 4 and IC400 see Figure 11 1 these form the matching circuitry for the crystal filters XF400 and XF401 se...

Page 268: ...268 Receiver Fault Finding TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 269: ...correct amount of RF power Fault Diagnosis Procedures The procedures for diagnosing the above faults are given below in the following sections In each case however first carry out the tasks of Power Supplies on page 270 Also note that the conditions concerning the accessory connector can both occur at the same time In this case carry out both No Audio Tap Out at Accessory Connector on page 278 and...

Page 270: ...emove the main board from the chassis 2 Measure the voltage 7V5 SW at pin 6 of IC200 see Figure 12 1 3 If the voltage is correct go to Task 2 If it is not go to Step 4 4 The fault will be at IC200 see Figure 12 1 since any fault with 7V5 LINK in the interfaces circuitry will already have been rectified Therefore check the soldering of IC200 Repair any fault 5 Confirm the removal of the fault and g...

Page 271: ...cuitry in the vicinity of PL1 and IC200 top side Figure 12 2 Test points for the 3V power supply and the volume potentiometer bottom side Measuring point for DIG AUD PA EN Measuring point for DIG INT SPK EN Measuring point for level shifted signal Test point 3V0 AN Test point TP908 for volume potentiometer ...

Page 272: ... to the fault exhibited Faulty Speaker Audio distorted or no speaker audio No Audio Tap Out at Accessory Connector Faulty Receiver receiver does not operate Faulty Modulation distorted or no transmit modulation Faulty Modulation Using Accessory Audio Tap In modulation at accessory connector only Further details are given in the introduction to the section 12 2 Faulty Speaker Audio Introduction Thi...

Page 273: ...TP9100 Service Manual CODEC and Audio Fault Finding 273 Tait Electronics Limited May 2005 Figure 12 3 Circuitry under and next to the CDC TOP can top side ...

Page 274: ...in board is faulty replace the main board and go to Final Tasks on page 134 7 Vary the volume control This should cause the signal level at the C238 see Figure 12 1 to vary If it does go to Step 8 If it does not go to Task 6 8 Check the voltage at pin 1 of IC200 see Figure 12 1 9 If the voltage is correct go to Step 11 If it is not check for and repair any faults in the circuits incorporating Q200...

Page 275: ...ep 5 5 Check for and repair any soldering faults around IC200 see Figure 12 1 or else replace IC200 6 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed replace the main board and go to Final Tasks on page 134 7 Check the positive and negative speaker pins 8 If the speaker outputs are correct go to Step 11 If not go to Step 9 9 Check for and repair any solderin...

Page 276: ...e 12 1 or else replace IC200 6 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed replace the main board and go to Final Tasks on page 134 7 Check accessory speaker connection pins for ACC SPKR and ACC SPKR and accessory flex as described in Accessories Interface Faulty on page 147 8 Confirm the removal of the fault and go to Final Tasks on page 134 If the repa...

Page 277: ... 3 If the volume varies as expected go to Step 6 If it does not go to Step 4 4 Check and repair any soldering faults around R900 see Figure 12 4 Q910 and R953 see Figure 12 3 5 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed replace the main board and go to Final Tasks on page 134 6 Remove the CDC TOP can 7 Check the voltage at the junction of C245 non groun...

Page 278: ...ector In other words there is no signal at pin 4 AUD TAP OUT of the connector The fault diagnosis procedure comprises two tasks Task 7 check signal from CODEC Task 8 check LPF and buffer amplifier in CODEC circuitry These tasks need to be followed by those of Faulty Modulation Using Accessory Audio Tap In on page 287 if there is also a fault with the transmit modulation using the accessory connect...

Page 279: ... 7 If the signal is correct the fault is with PL1 or the accessory flex connector Refer to Accessories Interface Faulty on page 147 for accessory connector service instructions If the signal is not correct go to Step 8 8 Check the received signal is present at the junction of E900 and C909 see Figure 12 1 The signal should be 9 If the signal is correct go to Step 10 If it is not go to Task 8 10 Ch...

Page 280: ... based on IC201 pins 1 to 3 see Figure 12 5 Repair any fault and conclude with Step 10 7 Check the voltage at pin 7 of IC201 see Figure 12 5 8 If the voltage is correct go to Step 9 If it is not check the buffer amplifier based on IC201 pins 5 to 7 see Figure 12 5 Repair any fault and conclude with Step 10 9 Check R207 and R208 see Figure 12 5 Repair any fault and conclude with Step 10 10 Confirm ...

Page 281: ...TP9100 Service Manual CODEC and Audio Fault Finding 281 Tait Electronics Limited May 2005 Figure 12 5 Circuitry under the CDC BOT can bottom side Measuring point at R224 QN measuring point TP444 ...

Page 282: ...h no RF signal applied and in receive mode check the voltage at pin 14 of IC201 see Figure 12 5 3 If the above voltage is correct go to Task 10 If it is not go to Step 4 4 Check the voltage at pin 12 of IC201 see Figure 12 5 5 If the above voltage is correct go to Step 8 If it is not go to Step 6 6 Check for and repair any shorts to ground at the junction of R238 and pin 12 of IC201 see Figure 12 ...

Page 283: ... receiver is at fault 1 Use the programming application to find the frequency selected for channel 1 2 Apply a strong on channel signal 3 Check that a sine wave is present using TP444 see Figure 12 5 4 If there is a sine wave present go to Step 5 If there is not go to Receiver Fault Finding on page 251 5 Either the digital circuitry or CODEC 1 IC204 is faulty Replace the main board and go to Final...

Page 284: ...to the speaker and check that the audio signal appears at the junction of C235 and R261 and also the junction of C236 and R262 see Figure 12 3 4 If the audio signal is not present check and repair the speaker speaker pins components and soldering of C235 and C236 see Figure 12 3 If the signal is present go to Step 6 5 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair...

Page 285: ... the removal of the fault and go to Final Tasks on page 134 If the repair failed the DC bias is suspect go to Task 14 Task 13 Check External Accessory Microphone Audio To check the modulation from the external microphone 1 Apply an AC coupled 1kHz audio signal with level 9 5mVrms to the ACC MIC signal on pin 6 of the connector PL1 2 Check that the audio signal appears at the junction of R229 R232 ...

Page 286: ...ound replace the main board and go to Final Tasks on page 134 4 Check the DC levels at the junction of R226 and C213 also the junction of R229 and C213 see Figure 12 3 5 If either DC level is not present check and repair the components and soldering around R226 R229 R232 and C213 see Figure 12 3 If both DC levels are correct then the fault is between E901 see Figure 12 1 and R226 C213 Replace the ...

Page 287: ...DC offset voltage at pin 8 3 If the offset is correct go to Task 16 If the offset is not correct go to Step 4 4 Check and repair the components and soldering around PL1 E902 and C911 see Figure 12 1 5 Confirm the removal of the fault and go to Final Tasks on page 134 If the repair failed go to Step 6 6 Check for and repair any soldering faults around IC205 and R241 see Figure 12 3 7 Confirm the re...

Page 288: ...gnal of 0 7Vpp at pin 8 AUD TAP IN of the connector PL1 see Figure 12 1 2 Enter CCTM command 33 to place radio in transmit mode 3 Enter CCTM command 323 t5 to select AUD TAP IN as modulation source 4 Check the modulation of the radio If there is no modulation go to Frequency Synthesizer Fault Finding on page 159 If there is modulation the hardware is not faulty Check the setup of the audio tap poi...

Page 289: ...t panel assembly 4 keys a front panel assembly 16 keys not available not available TPA SP 001 TP9155 re skinning kit TPA SP 002 TP9155 general spares kit TPA SP 003 TP9160 re skinning kit TPA SP 004 TP9160 general spares kit C PTT keypad not available TPA SP 101 PTT spares kit TPA SP 001 003 reskinning kits TPA SP 002 004 general spares kits D PTT frame not available TPA SP 101 PTT spares kit TPA ...

Page 290: ... SP 103 main shield assembly spares kit 2 front panel loom not available TPA SP 103 main shield assembly spares kit 2 screw M2x5 345 00020 09 TPA SP 002 004 general spares kits 2 main board B1 band H5 band H6 band TPAA10 B100 TPAA10 H500 TPAA10 H600 TPAA10 B100 TPAA10 H500 TPAA10 H600 2 knob nut 2x 352 00013 00 TPA SP 002 004 general spares kits 2 SMA nut 352 00012 00 TPA SP 002 004 general spares...

Page 291: ...ometer alignment plate 302 05274 00 TPA SP 002 004 general spares kits TPA SP 103 main shield assembly spares kit 4 battery catch left 303 03077 00 TPA SP 108 battery latch spares kit battery catch right a 303 03075 00 TPA SP 108 battery latch spares kit battery latch beama 302 30045 00 TPA SP 108 battery latch spares kit battery latch coila 319 01043 00 TPA SP 108 battery latch spares kit speaker...

Page 292: ...292 Spare Parts TP9100 Service Manual Tait Electronics Limited May 2005 Figure 13 1 Serviceable parts 3 3 3 4 4 3 4 ...

Page 293: ...on radio TPA SP 003 TP9160 re skinning kit 16 button radio TPA SP 004 TP9160 spares kit 16 button radio TPA SP 100 volume channel knob spares kit TPA SP 101 PTT spares kit TPA SP 102 Speaker spares kit TPA SP 103 main shield assembly spares kit TPA SP 104 LCD spares kit TPA SP 105 chassis assembly spares kit TPA SP 106 accessory flex spares kit TPA SP 107 main seal spares kit TPA SP 108 battery la...

Page 294: ...294 Spare Parts TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 295: ...TP9100 Service Manual 295 Tait Electronics Limited May 2005 TP9100 portables Chapter 3 Accessories ...

Page 296: ...ation 302 15 7 Contact Board XPA CH M02 PCB Information 307 16 TPA AA 201 Accessory Connector Kit 309 16 1 Connecting an Accessory 309 16 2 Disassembly and Reassembly 312 17 TPA AA 202 Accessory Cable Kit 313 17 1 Connecting an Accessory 313 17 2 Disassembly and Reassembly 316 18 TPA AA 210 Hirose Accessory Adapter 317 18 1 Connecting an Accessory 317 18 2 Disassembly and Reassembly 318 19 TOPA SV...

Page 297: ...ed on antenna type and length Figure 14 1 Antenna identification chart TPA AN 013 400 450 MHz 3 27 in 83 mm 3 03 in 77 mm 2 80 in 71 mm TPA AN 014 435 480 MHz TPA AN 015 470 520 MHz TPA AN 002 136 151 MHz 6 50 in 165 mm 5 87 in 149 mm 5 59 in 142 mm TPA AN 003 150 162 MHz TPA AN 004 162 174 MHz VHF and UHF Helical Antennas VHF UHF 5 91 in 150 mm 5 31 in 135 mm TPA AN 011 400 470 MHz TPA AN 012 450...

Page 298: ...298 Antenna Identification Chart TP9100 Service Manual Tait Electronics Limited May 2005 ...

Page 299: ... 12V 3A power adaptor T952 400 and the correct mains cable for your mains volt age 1 Plug the mains cable into the 12V 3A power adaptor T952 400 2 Plug the power adaptor cable into the charger 3 Plug the mains cable into the mains socket When power is first applied to the charger all three LEDs should light up for two seconds and then go out 15 2 Charging the Battery 1 Ensure the charger is connec...

Page 300: ...ssemble the charger as described in Disassembly Reassembly on page 301 and check fuse F1 see Figure 15 1 4 Check the power connector 5 Check the connections of the cable between the two PCBs Table 15 1 Troubleshooting the charger Fault LED Possible causes and solutions Flashing fault The battery is not compatible with the charger use only Tait batteries and chargers There is insufficient voltage t...

Page 301: ... three screws 1 and remove the contact PCB J Figure 15 2 Parts of the single charger Description IPN B rubber bumper x4 369 00010 11 C screw P T 30x10 x6 346 10030 10 D bottom cover 346 10025 06 E main PCB TPA CH M01 F cable 219 02944 00 G light pipe 262 00007 xx H top cover 303 23168 xx I cradle 303 30073 xx J contact PCB TPA CH M02 1 screw P T 25x6 x3 345 10025 06 Note The characters xx in an IP...

Page 302: ...01 10000 70 Diode SMD BAV70 D Sw SOT23 D2 001 10099 01 Diode BAV99w Dual Ss D3 001 10099 01 Diode BAV99w Dual Ss D4 001 10000 70 Diode SMD BAV70 D Sw SOT23 D5 001 10015 50 Diode SMD 1 5SMC22AT3 Tvs Zen D6 001 10084 82 Diode SMD BZX84C8V2 Zen SOT23 D7 001 10084 33 Diode SMD BZX84C3V3 Zen SOT23 D50 001 10008 35 Diode SMD MBRD835 Sch Dpak DS1 008 10002 00 LED SMD 0603 Red U B C190KRKT DS2 008 10001 0...

Page 303: ... 1 D2 C3 1 G9 1 G3 C4 1 G8 1 G3 C5 1 F4 1 D2 C6 1 G4 1 C6 C7 1 F7 1 B8 C8 1 E6 1 C9 C9 1 G9 1 B9 C10 1 F7 1 F10 C11 1 E4 1 D9 C16 1 C7 1 E6 C19 1 A6 1 F4 C28 1 E3 1 E1 C29 1 F7 1 E1 C30 1 E5 1 D1 C31 1 N3 1 F1 C32 1 G7 1 E1 C33 1 G5 1 E1 C34 1 E6 1 D1 C35 1 H4 1 F1 C52 1 A7 1 F5 C53 1 B6 1 F5 C55 1 B6 1 F5 C57 1 B4 1 F7 C58 1 C3 1 F9 C59 1 D4 1 D9 C60 1 E7 1 E8 C61 1 C3 1 F9 C64 1 H5 1 A5 C65 1 D8...

Page 304: ...304 TPA CH 001 Single Battery Charger TP9100 Service Manual Tait Electronics Limited May 2005 15 6 3 PCB Layout top side ...

Page 305: ...TP9100 Service Manual TPA CH 001 Single Battery Charger 305 Tait Electronics Limited May 2005 15 6 4 PCB Layout bottom side ...

Page 306: ...306 TPA CH 001 Single Battery Charger TP9100 Service Manual Tait Electronics Limited May 2005 15 6 5 Circuit Diagram ...

Page 307: ... The following information applies to the contact board with the PCB IPN 220 01725 03 15 7 1 Parts List 15 7 2 PCB Layout top side Ref IPN Description DATA 303 50030 00 Cntct Apco DP1 Chgr MINUS 303 50030 00 Cntct Apco DP1 Chgr PLUS 303 50030 00 Cntct Apco DP1 Chgr TEMP 303 50030 00 Cntct Apco DP1 Chgr 219 02622 01 T700 Interface Cbl 12way ...

Page 308: ...308 TPA CH 001 Single Battery Charger TP9100 Service Manual Tait Electronics Limited May 2005 15 7 3 PCB Layout bottom side 15 7 4 Circuit Diagram ...

Page 309: ... an accessory make sure it meets the following specifications speaker impedance 32Ω 16Ω min speaker power 0 25Wrms min microphone electret approximately 1kΩ PTT switch not in series with microphone Note If your accessory has a PTT switch in series with the microphone the accessory cannot be used The PTT needs to be a separate sig nal and must be made available at the connector separately it must n...

Page 310: ... Output impedance current Input impedance AUD TAP OUT P8 Programmable tap point out of the Rx or Tx audio chain DC coupled Analog audio 0 69Vpp for 60 deviation at 1kHz 10dBm into 600Ω 600Ω AUD TAP IN P9 Programmable tap point into the Rx or Tx audio chain DC coupled Analog audio 0 69Vpp for 60 deviation at 1kHz 10dBm into 600Ω 100kΩ DC to 100kHz ACC PWR P10 Accessory power DC supply 3 3V nominal ...

Page 311: ...re 16 1 Accessory connector PCB and circuit diagram PL4 P8 PL8 P9 PL2 PL3 PL5 PL10 PL7 P10 P11 P12 P13 P14 P16 AUD TAP OUT AUD TAP IN ACC PWR ACC RXD ACC TXD ACC GPIO1 ACC GPIO2 R4 0Ω ACC MIC GND PL6 PL1 P1 P2 PL12 ACC PTT P3 R1 12kΩ P4 P5 BUTTON1 PL9 P6 P7 PL11 C1 4 7µF ACC SPKR ACC SPKR PL13 R3 0Ω ...

Page 312: ... the clamp G and remove the strain relief I and the insert H Important During reassembly make sure that the accessory housing seal C is inserted correctly inside the accessory connector housing F Reassembly is carried out in reverse order of the disassembly Figure 16 2 Components of the accessory connector kit B Torx T6 screw F accessory connector housing C accessory housing seal G clamp D accesso...

Page 313: ...17 1 Connecting an Accessory 1 Verify that your accessory is compatible with the accessory connector refer to Table 17 1 2 When connecting an accessory make sure it meets the following specifications speaker impedance 32Ω 16Ω min speaker power 0 25Wrms min microphone electret approximately 1kΩ PTT switch not in series with microphone Note If your accessory has a PTT switch in series with the micro...

Page 314: ...t impedance AUD TAP OUT white blue stripe Programmable tap point out of the Rx or Tx audio chain DC coupled Analog audio 0 69Vpp for 60 deviation at 1kHz 10dBm into 600Ω 600Ω AUD TAP IN blue Programmable tap point into the Rx or Tx audio chain DC coupled Analog audio 0 69Vpp for 60 deviation at 1kHz 10dBm into 600Ω 100kΩ DC to 100kHz ACC PWR brown Accessory power DC supply 3 3V nominal 100mA max A...

Page 315: ...8 P9 PL2 PL3 PL5 PL10 PL7 P10 P11 P12 P13 P14 P16 AUD TAP OUT AUD TAP IN ACC PWR ACC RXD ACC TXD ACC GPIO1 ACC GPIO2 R4 0Ω ACC MIC GND PL6 PL1 P1 P2 PL12 ACC PTT P3 R1 12kΩ P4 P5 BUTTON1 PL9 P6 P7 PL11 C1 4 7µF ACC SPKR ACC SPKR PL13 R3 0Ω orange gray white red black white red stripe green yellow blue brown white blue stripe violet Accessory Connector PCB ...

Page 316: ... D 2 Fold out the accessory connector PCB E Important During reassembly make sure that the accessory housing seal C is inserted correctly inside the accessory connector housing F Reassembly is carried out in reverse order of the disassembly Figure 17 2 Components of the accessory cable kit B Torx T6 screw E accessory connector PCB C accessory housing seal F accessory connector housing D accessory ...

Page 317: ...ory adapter refer to Table 18 2 2 When connecting an accessory make sure it meets the following specifications speaker impedance 32Ω 16Ω min speaker power 0 25Wrms min speaker configuration single ended microphone electret approximately 1kΩ PTT switch not in series with microphone Table 18 1 Compatible Hirose accessories from Tait and Otto Tait Part No Otto Part No Description TPA AA 211 V4BA1TP1 ...

Page 318: ...r pins and signals Signal name Pin Description Signal type Signal level Output impedance current Input impedance HIROSE MIC 1 External microphone input electret Dynamic microphones are not supported Analog audio 9 5Vrms for 60 modulation at 1kHz DC coupled 2 2kΩ HIROSE PWR 2 Accessory power DC supply 3 3V nominal 100mA max HIROSE SPKR 3 External speaker output Analog audio 6 5Vpp a To drive 16Ω GN...

Page 319: ...tions test set The diagram below shows the front panel of the test unit 19 1 Test Setup The diagram on the following page shows how the test unit is connected to the radio the test PC and the RF communications test set Note The test unit can also be connected to a Tait Orca portable radio TOP using the TOPA SV 007 cable or to a T2000 radio using the T2000 11 cable Use with Tait Orca and T2000 radi...

Page 320: ...er connector banana plugs AC input BNC audio monitor out BNC AUDIO IN HI BNC AUDIO OUT BNC RF in out N type antenna connector SMA power connector TMAA23 02 cable 40W 50W radios TMAA20 03 cable 25W radios TMAA21 01 cable TOPA SV 024 TPA SV 006 cable TPA SV 005 battery eliminator to DC power supply TPA SV 011 cable to radio connector of test unit TM9100 radio TP9100 radio TOPA SV 006 cable to RF in ...

Page 321: ...ed to switch between Mod Audio Audio Tap In Mic Audio and Off no audio signal With the Tait Orca portables this switch can be used for setting up dual point modulation by applying modulation to different parts of the radio For normal transmit deviation tests other portables and mobiles this switch is set to Mic Audio 19 2 3 On Hook Off Hook Switch Important When using the test unit with portables ...

Page 322: ...onnect the radio s internal speaker on mobiles If the switch is set to Speaker or Load this simulates an external speaker being connected in parallel to the radio s internal speaker With all settings a low level audio signal is available for testing through the SINAD port Portable When set to Speaker only the speaker of the test unit is active When set to Radio only the speaker of the portable is ...

Page 323: ...t R1 032 31820 01 Res M F Pwr 17x5 8e2 5 2 5w R2 032 31820 01 Res M F Pwr 17x5 8e2 5 2 5w R3 030 55120 20 Res Flm 4x1 6 12k 5 0 4w R4 030 53560 20 Res Flm 4x1 6 560e 5 0 4w R5 030 54270 20 Res Flm 4x1 6 2k7 5 0 4w R6 030 52560 20 Res Flm 4x1 6 56e 5 0 4w R7 030 55100 20 Res Flm 4x1 6 10k 5 0 4w SW1 230 00010 42 Sw Tgl On Off On Dpdt Ms500hb SW2 230 00010 57 Sw Tgl Dpdt On On Pnl Mtg SW3 230 00010 ...

Page 324: ...fer to the parts list for actual values used SPEAKER 4Ω SPKR 8 2 Ω SHOULD BE DPTT IPN 032 31820 01 IPN 250 00010 19 not part of PCB not fitted not fitted not fitted Portable Mobile Mobile Portable Portable Mobile Portable Mobile Portable Mobile Portable Portable Mobile Mobile Mobile Portable Portable Mobile RADIO RADIO Mobile Portable Mobile Portable MOD AUDIO AUDIO TAP IN ...

Page 325: ...VERSE COMPILE OR REVERSE ASSEMBLE ANY SOFTWARE OR FIRMWARE IN WHOLE OR PART Important Notice THE SOFTWARE OR FIRMWARE MAY CONTAIN OPEN SOURCE SOFTWARE COMPONENTS OPEN SOURCE COMPONENTS OPEN SOURCE COMPONENTS ARE EXCLUDED FROM THE TERMS OF THIS AGREEMENT EXCEPT AS EXPRESSLY STATED IN THIS AGREEMENT AND ARE COVERED BY THE TERMS OF THEIR RESPECTIVE LICENCES WHICH MAY EXCLUDE OR LIMIT ANY WARRANTY FRO...

Page 326: ... AND TOTAL LIABILITY FOR ANY SUCH CLAIM SHALL BE LIMITED AT THE OPTION OF TAIT TO THE REPAIR OR REPLACEMENT OF THE SOFTWARE OR FIRMWARE OR THE REFUND OF THE PURCHASE PRICE OF THE SOFTWARE OR FIRMWARE General THE LICENSEE CONFIRMS THAT IT SHALL COMPLY WITH THE PROVISIONS OF LAW IN RELATION TO THE SOFTWARE OR FIRMWARE Law and Jurisdiction THIS AGREEMENT SHALL BE SUBJECT TO AND CONSTRUED IN ACCORDANC...

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Summary of Contents for TP9100

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