Professional Digital Two-Way Radio System MOTOTRBO™ Repeater Basic Service Manual DR 3000 Repeater
Title Page M DR 3000 UHF Range 1 MOTOTRBO™ Repeater Basic Service Manual 6866576D03-A
Foreword This manual covers all models of the MOTOTRBO Repeater, unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level and is typical of some local service centers, Motorola Authorized Dealers, self-maintained customers, and distributors.
iii Document History The following major changes have been implemented in this manual since the previous edition: Edition 6866576D03-A 6866576D03-A Description Initial Release Date Feb.
iv Notes February 21, 2007 6866576D03-A
Table of Contents v Table of Contents Foreword .........................................................................................................ii Product Safety and RF Exposure Compliance ............................................................................................ii Computer Software Copyrights ...................................................................................................................ii Document Copyrights ...................................................
vi Table of Contents 5.6 5.7 5.8 5.9 5.10 Disassembly Procedures — Detailed .......................................................................................... 5-4 5.6.1 Disassembly of Cover...................................................................................................... 5-4 5.6.2 Disassembly of Repeater Indicator Board ....................................................................... 5-5 5.6.3 Disassembly of Fan ........................................................
viii List of Figures List of Figures Figure 1-1. Figure 2-1. Figure 2-2. Figure 4-1. Figure 4-2. Figure 5-1. Figure 5-2. Figure 5-3. Figure 5-4. Figure 5-5. Figure 5-6. Figure 5-7. Figure 5-8. Figure 5-9. Figure 5-10. Figure 5-11. Figure 5-12. Figure 5-13. Figure 5-14. Figure 5-15. Figure 5-16. Figure 5-17. Figure 5-18. Figure 5-19. Figure 5-20. Figure 5-21. Figure 5-22. Figure 5-23. Figure 5-24. Figure 5-25. Figure 5-26. Figure 5-27. Repeater Model Numbering Scheme.......................................
List of Tables ix List of Tables Table 1-1. Table 2-1. Table 2-2. Table 3-1. Table 3-2. Table 4-1. Table 5-1. Table 5-2. Table 5-3. Table 5-4. Table 6-1. 6866576D03-A Frequency Ranges and Power Levels ................................................................................. 1-1 Recommended Test Equipment ........................................................................................... 2-1 Service Aids .....................................................................................
x February 21, 2007 Related Publications 6866576D03-A
Chapter 1 1.1 Introduction Notations Used in This Manual Throughout the text in this publication, you will notice the use of note and caution notations. These notations are used to emphasize that safety hazards exist, and due care must be taken and observed. NOTE: An operational procedure, practice, or condition that is essential to emphasize. ! Caution 1.2 CAUTION indicates a potentially hazardous situation which, if not avoided, might result in equipment damage.
1-2 1.3 Introduction: MOTOTRBO Repeater Model Numbering Scheme MOTOTRBO Repeater Model Numbering Scheme Model No.
Introduction: UHF1 High Power MOTOTRBO Repeater (403-470 MHz) Model Chart 1.
1-4 1.5 Introduction: Specifications Specifications General Specification UHF1 Channel Capacity 1 Technical RF Output 25-40W Frequency 403-470 MHz Dimensions (HxWxL) 132.6 mm x 482.6 mm x 296.5 mm Weight 14 kg Voltage Requirements 100-240 V AC 47-63 Hz (13.6 V DC) Current Drain: Standby Transmit 0.5 A (1 A DC typical) 1.
Introduction: Specifications 1-5 Transmitter Specification UHF1 Frequency 403-470 MHz Channel Spacing 12.5 kHz/25 kHz Frequency Stability (-30°C to +60°C) ±0.5 ppm Power Output 25-40 W Modulation Limiting ±2.5 kHz @ 12.5 kHz ±5.0 kHz @ 25 kHz FM Hum and Noise -40 dB @ 12.5 kHz -45 dB @ 25 kHz Conducted/Radiated Emission -36 dBm < 1 GHz -30 dBm > 1 GHz Adjacent Channel Power 60 dB @ 12.
1-6 Introduction: Specifications Notes February 21, 2007 6866576D03-A
Chapter 2 2.1 Test Equipment and Service Aids Recommended Test Equipment The list of equipment contained in Table 2-1 includes most of the standard test equipment required for servicing Motorola repeaters. Table 2-1. Recommended Test Equipment Equipment Characteristic Example Application Service Monitor Can be used as a substitute for items marked with an asterisk (*) Aeroflex 2975 (www.aeroflex.
2-2 2.2 Test Equipment and Service Aids: Service Aids Service Aids Table 2-2 lists the service aids recommended for working on the repeater. While all of these items are available from Motorola, most are standard workshop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. Table 2-2. Service Aids Motorola Part Number Description Application RLN4460_ Test Set Enables connection to audio/accessory jack. Allows switching for radio testing.
Test Equipment and Service Aids: Programming Cables DB 25 CONNECTOR 1 13 14 25 2-3 USB CONNECTOR 4 1455 24 CABLE 915 15 CABLE TABLE 2: WIRE DIAGRAM 26 PIN ACCESSORY PORT CONNECTOR TO MOBILE RADIO ACCESSORY CONNECTOR 25 26 1 2 VIEWED FROM FRONT (PIN END) OF CONNECTOR USB PIN No. DESCRIPTION 3 VCC (5v) 1 2 DATA - 2 3 1 DATA + 4 GND DB25P 9 SPEAKER - 7 11 EXT MIC 17 17 DIGI IN 1 (EXT PTT) 20 16 GND 16 10 SPEAKER + 1 Figure 2-2.
2-4 Test Equipment and Service Aids: Programming Cables Notes February 21, 2007 6866576D03-A
Chapter 3 3.1 Transceiver Performance Testing General The MOTOTRBO Repeater meets published specifications through their manufacturing process by utilizing high-accuracy laboratory-quality test equipment. The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule.
3-2 Transceiver Performance Testing: Setup Table 3-2. Receiver Performance Checks Test Name Communications Analyzer Radio Test Set Comment Rated Audio Mode: GEN Output level: 1.0 mV RF 4th channel test frequency* Mod: 1kHz tone at 3 kHz deviation Monitor: DVM: AC Volts Use tuner tool to program repeater to an appropriate test frequency with carrier squelch. PTT to OFF (center), meter selector to Audio PA Set volume to 7.75 Vrms via tuner tool.
Chapter 4 4.1 Repeater Tuning and Programming Introduction This chapter provides an overview of the MOTOTRBO Customer Programming Software (CPS), as well as the Tuner application, which are all designed for use on Windows 2000/XP operating system. These programs are available in one kit as listed in the Table 4-1. An Installation Guide is also included with the kit. NOTE: Refer to the appropriate program on-line help files for the programming procedures. Table 4-1. Repeater Software Program Kits 4.
4-2 4.3 Repeater Tuning and Programming: Repeater Tuning Setup Repeater Tuning Setup A personal computer (PC), Windows 2000/XP and a tuner program (which is available as part of the MOTOTRBO CPS kit) are required to tune the repeater. To perform the tuning procedures, the repeater must be connected to the PC and test equipment setup as shown in Figure 4-2.
Chapter 5 5.1 Disassembly/Reassembly Procedures Introduction This chapter provides details about the following: • Preventive maintenance (inspection and cleaning). • Safe handling of CMOS and LDMOS devices. • Disassembly and reassembly of the repeater. • Disassembly and reassembly of the Transmit and Receive radios. • Repair procedures and techniques. 5.2 Preventive Maintenance Periodic visual inspection and cleaning is recommended. 5.2.
5-2 5.3 Disassembly/Reassembly Procedures: Safe Handling of CMOS and LDMOS Devices Safe Handling of CMOS and LDMOS Devices Complementary metal-oxide semiconductor (CMOS) devices are used in this family of repeaters, and are susceptible to damage by electrostatic or high voltage charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair.
Disassembly/Reassembly Procedures: Repair Procedures and Techniques — General 5.
5-4 5.
Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 5.6.2 5-5 Disassembly of Repeater Indicator Board (Refer to Figure 5-2 and Figure 5-3) 1. Disconnect the blue ethernet cable from the ethernet connector on the Repeater Indicator Board. 2. Disconnect flex cable from 30-position connector on Repeater Indicator Board, noting orientation of cable which is identified with a solid black line. This is important for reassembly.
5-6 Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 7. Store Repeater Indicator Board in an anti-static bag when it is not being serviced. Front Panel M6 Screws (4) Repeater Indicator Board Light Guide M3 Screws (4) Figure 5-3. Repeater Indicator Board Disassembly 5.6.3 Disassembly of Fan 1. Unplug the fan cable from the mating connector on the connector board assembly. 2.
Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 5.6.4 5-7 Removing Transmit Radio (Refer to Figure 5-5) 1. Disconnect flex cable from 30-position connector on Transmit radio, noting orientation of cable which is identified with a solid blue line. This is important for reassembly. 2. Disconnect SSI flex cable from the connector on the Transmit radio, noting orientation of cable which is identified with a solid black line. This is important for reassembly. 3.
5-8 Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 5.6.4.1 Removing Thermal Pad and Heatsink (Refer to Figure 5-5) 1. Remove all of the seven screws which secure the heatsink to the Transmit radio using a T10 TORX™ driver. 2. Remove the heatsink from the Transmit radio. 3. Peel off and discard the thermal pad. 4. Replace all worn parts. 5.6.5 Removing Receive Radio, Power Supply and Connector Board Assembly (Refer to Figure 5-6) 1.
Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 5-9 9. Take precaution not to damage the power supply or the connector board assembly and place assembly on a flat surface. Receive Bracket Connector Board Assembly Receive Radio M5 Screws M3 Screws (5) Power Supply Washer Figure 5-6.
5-10 Disassembly/Reassembly Procedures: Disassembly Procedures — Detailed 5.6.5.1 Disassembly of Receive Radio (after Receive radio assembly is removed from repeater) 1. With assembly on a flat surface, loosen and remove the two M5 screws and washers that secure the Receive radio to the bracket using a T25 TORX™ driver. 2. Slide the Receive radio out of the bracket. 5.6.5.2 Disassembly of Connector Board Assembly (after Receive radio assembly is removed from repeater) 1.
Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly — Detailed 5.7 5-11 Transmit and Receive Radio Disassembly — Detailed To remove Transmit and Receive radios from the repeater, refer to Sections 5.6.4 and 5.6.5 accordingly. 5.7.1 Transceiver Board and Receiver Board Removal 1. Remove the seven screws from the die cast cover using the T20 TORX™ driver as shown in Figure 5-7. NOTE: Do not remove the O-rings from the screws. 2. Lift the die cast cover from the chassis.
5-12 Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly — Detailed 3. Remove the accessory connector from the radio assembly by inserting a flat-blade screwdriver into the slot on the side of the connector as shown in Figure 5-8. ! Caution The accessory connector should never be removed when the cover is still assembled to the radio. Flat-blade Screwdriver Slot Accessory Connector Figure 5-8. Accessory Connector Removal 4.
Disassembly/Reassembly Procedures: Transmit and Receive Radio Disassembly — Detailed 5-13 5. Remove the transceiver board by sliding a finger into the opening provided at the front of the radio and gently press up on the 30-pin connector, lifting up the front of the board, as shown in Figure 5-10. Then, slide the transceiver board towards the front of the radio to allow the RF/DC connectors to clear the chassis. Handle the transceiver board by the edges only and store it in an antistatic bag.
5-14 5.8 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed Transmit and Receive Radio Reassembly — Detailed The following reassembly procedures are applicable to both the Transmit and Receive radios. 1. Prior to reassembling the radio, inspect all seals and sealing surfaces for damage (nicks, cuts, etc.) or debris. Refer to the exploded view and bill of materials for the correct part numbers and replace parts, as necessary. Reseat all new seals on their respective parts.
Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5-15 3. Assembly of the GPS Plug Push the GPS plug into the chassis opening until it is fully seated. Refer to Figure 5-13. GPS Plug GPS Plug Figure 5-13. Replacing GPS Plug 5.8.1 Transceiver Board and Receiver Board Reassembly 1.
5-16 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 2. Insert the RF/DC retention clips and fully seat them. The DC clip should be inserted first to properly locate the transceiver board. Refer to Figure 5-15. RF/DC Retention Clips Figure 5-15. Inserting RF/DC Retention Clips 3. Insert the accessory connector into the radio assembly and press into place until the connector is flushed with the chassis. Refer to Figure 5-16. Accessory Connector Figure 5-16.
Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5-17 4. Place the PA pad on to the die cast cover by aligning the two holes in the PA pad with the alignment pins on the die cast cover. 5. Fit the O-ring onto the die cast cover securely. Refer to Figure 5-17. O-ring PA Pad Die Cast Cover Figure 5-17.
5-18 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 6. Place the die cast cover onto the chassis orienting the die cast cover so that screw holes 6 and 7 align with the bosses on the chassis as shown in Figure 5-18. Screws (7) Die Cast Cover Radio Chassis Figure 5-18.
Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5-19 7. Using a T20 TORX™ driver, tighten the seven screws between 2.94 N-m (26 lbs-in) in the order shown in Figure 5-19. 8. Repeat tightening the seven screws in the order shown otherwise the first three screws will likely be loose. Figure 5-19. Screw Sequence to Tighten Die Cast Cover 5.8.2 Thermal Pad Replacement Procedure A. Chassis Thermal Pad Replacement Procedure Harmonic Filter Thermal Pad Replacement 1.
5-20 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed Driver Thermal pad Replacement 1. Use a plastic flat-edge tool to lift the pad from the chassis surface. Discard the old pad. 2. Use a soft cloth to remove any remaining residue. Alcohol can also be used, if necessary. Care should be taken to minimize any cleaning-agent contact with the surrounding shield gasket. 3.
Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5.8.3 5-21 Reassembly of Receive Radio, Power Supply and Connector Board Assembly (Refer to Figure 5-6) Visually inspect repeater enclosure to ensure that no metal shavings or debris are found. 5.8.3.1 Reassembly of Power Supply 1. Align the two mounting holes on each side of the bracket with the mounting holes on the power supply. 2. Secure the power supply and the bracket with four M5 screws and washers. 3.
5-22 Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 12. Insert the solder terminal end of the SSI cable into the 11-position connector at the front face of Receive radio. A dashed black line is visible from the top view. 5.8.4 Reassembly of Transmit Radio (Refer to Figure 5-5) 5.8.4.1 Replacing the Thermal Pad and Heatsink 1. Make sure that mating surfaces of Heatsink and Transmit radio are cleaned and free from any debris. 2.
Disassembly/Reassembly Procedures: Transmit and Receive Radio Reassembly — Detailed 5.8.5 5-23 Reassembly of Fan 1. Position the fan in the enclosure with arrow pointing outward and the wires on the fan at the bottom right corner of the fan. Screws Position of arrow Fan Back of Enclosure Figure 5-23. Fan Orientation 2. Position the fan grill outside of the enclosure aligning with the screw holes. 3. Install four 3.5 mm screws through the fan grill, the rear panel of the enclosure and onto the fan clip.
5-24 Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists 5.9 Repeater Exploded Mechanical Views and Parts Lists Transmit Bracket & Radio Assembly See following pages for breakdown. 32 7 13 12 4 15 10 11 17 5 9 14 16 1 33 8 6 Receive Bracket & Radio assembly See following pages for breakdown. 3 16 2 Front Panel complete assembly See following pages for breakdown. Figure 5-24.
Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists 5-25 23 20 31 18 19 22 21 Figure 5-25. Receive Bracket and Radio Assembly Exploded View 27 26 25 24 28 19 31 Figure 5-26.
5-26 Disassembly/Reassembly Procedures: Repeater Exploded Mechanical Views and Parts Lists 29 22 30 2 Figure 5-27. Front Panel Complete Assembly Exploded View Table 5-3. Repeater Exploded View Parts List Item No. Description Part Number 1 Screw, TT6x1.
Disassembly/Reassembly Procedures: Torque Chart 5-27 Table 5-3. Repeater Exploded View Parts List Item No. Description Part Number 17 Lock Nut M4 0285854Y02 18 Power Supply PMPN4001_ 19 Screw, M5x0.8x8.0, Starpan STLZNC 0310909A74 20 Receive Radio Brick Assembly PMTE4004_ 21 Connector Board Assembly PMLN4815_ 22 Screw, M3x0.
5-28 Disassembly/Reassembly Procedures: Torque Chart Notes February 21, 2007 6866576D03-A
Chapter 6 6.1 Basic Troubleshooting Introduction This chapter contains error codes and board replacement procedures. If the repeater does not pass all the performance checks in Chapter 3, then please send the repeater to a Motorola Service Center listed in Appendix A. NOTE: To access the various connector pins, use the housing eliminator/test fixture along with the diagrams found in this section of the manual.
6-2 6.3 Basic Troubleshooting: LED Indicator Descriptions LED Indicator Descriptions Table 6-1.
Appendix A 1.0 EMEA Regional Warranty, Service and Technical Support Warranty and Service Support Motorola offers long term support for its products. This support includes full exchange and/or repair of the product during the warranty period, and service/ repair or spare parts support out of warranty. Any "return for exchange" or "return for repair" by an authorized Motorola Dealer must be accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer.
A-2 2.
EMEA Regional Warranty, Service and Technical Support: 4.0 A-3 Technical Support Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions which may be encountered. 5.0 North Europe - Stephen Woodrow Telephone: +44 (0) 1256 488 082 Fax: +44 01256 488 080 Email: CSW066@motorola.com Central and East Europe - Siggy Punzenberger Telephone: +49 (0) 6128 70 2342 Fax: +49 (0) 6128 95 1096 Email: TFG003@email.mot.
A-4 February 21, 2007 EMEA Regional Warranty, Service and Technical Support: 6866576D03-A
Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to portable and mobile subscriber radio products. All terms do not necessarily apply to all radios, and some terms are merely generic in nature. Term Definition Analog Refers to a continuously variable signal or a circuit or device designed to handle such signals. Band Frequencies allowed for a specific purpose.
Glossary-2 Term Definition PC Board Printed Circuit Board. Also referred to as a PCB. PL Private-Line Tone Squelch: A continuous sub-audible tone that is transmitted along with the carrier. Programming Cable A cable that allows the CPS to communicate directly with the radio using RS232. Receiver Electronic device that amplifies RF signals. A receiver separates the audio signal from the RF carrier, amplifies it, and converts it back to the original sound waves.
MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners. © 2007 Motorola, Inc. All rights reserved. March 2007. www.motorola.
