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Motorola ASTRO SPECTRA Service Manual
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Motorola ASTRO SPECTRA Service Manual

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®
ASTRO
Digital Spectra
and Digital Spectra Plus
UHF
VHF
800 MHz
Mobile Radios
Basic Service Manual
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  • Page 1 ® ASTRO ® Digital Spectra and Digital Spectra Plus 800 MHz Mobile Radios Basic Service Manual...

  • Page 3: Motorola, Inc

    ® ® Digital Spectra Title Page and Digital Spectra Plus VHF/UHF/800 MHz Digital Mobile Radios Basic Service Manual Motorola, Inc. 8000 West Sunrise Boulevard 6881076C20-E Fort Lauderdale, Florida 33322...

  • Page 4: Foreword

    No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola.

  • Page 5: Table Of Contents

    Disclaimer..............................ii Trademarks ..............................ii Commercial Warranty ..................xii Limited Warranty ............................xii MOTOROLA COMMUNICATION PRODUCTS ................1-xii I. What This Warranty Covers And For How Long ..............xii II. General Provisions ........................ xii III. State Law Rights ......................... xiii IV. How To Get Warranty Service .................... xiii V.
  • Page 6 Table of Contents Chapter 1 Introduction ................. 1-1 Notations Used in This Manual ...................... 1-1 Radio Descriptions......................... 1-1 1.2.1 FLASHport®........................1-2 Control Head Descriptions ......................1-2 1.3.1 General ..........................1-2 1.3.1.1 Model W3 Control Head................... 1-3 1.3.1.2 Model W3 Controls ....................1-3 1.3.1.3 Models W4, W5, W7, and W9 Controls Head............
  • Page 7 Table of Contents 3.9.1 VHF Radios ........................3-6 3.9.2 UHF and 800 MHz Radios ....................3-6 3.10 Command Board..........................3-6 3.11 VOCON (Vocoder/Controller) Board....................3-7 3.11.1 ASTRO Digital Spectra ..................... 3-7 3.11.2 ASTRO Digital Spectra Plus ..................... 3-7 Chapter 4 Test Equipment, Service Aids, and Tools......
  • Page 8 Table of Contents 6.3.8 Transmitter Test Pattern ....................6-23 Chapter 7 Encryption ................7-1 Universal Crypto Module Kits......................7-1 7.1.1 ASTRO Digital Spectra ..................... 7-1 7.1.2 ASTRO Digital Spectra Plus ..................... 7-1 7.1.3 Secure Dispatch Operation....................7-1 7.1.4 Secure Emergency Operation................... 7-2 Load an Encryption Key.........................
  • Page 9 Table of Contents 8.2.8.1 Low-/Mid-Power Radio ..................8-13 8.2.8.2 High-Power Radio....................8-13 8.2.9 VCO Board ........................8-14 8.2.9.1 Low-/Mid-Power Radio ..................8-14 8.2.9.2 High-Power Radio....................8-15 8.2.10 RF Board ........................8-15 8.2.10.1 Low-/Mid-Power Radio ..................8-15 8.2.10.2 High-Power Radio....................8-16 Final Reassembly ........................
  • Page 10 Table of Contents 11.11 Large Pushbutton Parts ......................11-10 Appendix A Replacement Parts Ordering..........A-1 Basic Ordering Information ......................A-1 Transceiver Board and VOCON Board Ordering Information............A-1 Motorola Online..........................A-1 Mail Orders ............................A-1 Telephone Orders ..........................A-2 Fax Orders .............................A-2 Parts Identification .........................A-2 Product Customer Service ......................A-2 Glossary..................
  • Page 11 List of Figures List of Figures Figure 1-1. Typical W3 Hand-Held Control Head ..................1-3 Figure 1-2. Typical W4 Rotary Control Head................... 1-4 Figure 1-3. Typical W5 Pushbutton Control Head ................... 1-4 Figure 1-4. Typical W7 Pushbutton Control Head ................... 1-4 Figure 1-5.
  • Page 12 List of Figures Figure 11-4. Model W9 Pushbutton Control Head Exploded View............11-5 Figure 11-5. Low-Power (15W) Radio Exploded View ................11-6 Figure 11-6. Mid-Power (20-40/25-50/35W) Radio Exploded View............11-7 Figure 11-7. High-Power (50-110W) Radio Exploded View ..............11-8 Figure 11-8. Motorcycle Interconnect Board and Assembly (HLN6365) Exploded View ......11-9 Figure 11-9.
  • Page 13 Recommended Motorola Test Equipment................4-1 Table 4-2. Wattmeter Plug-In Elements ....................4-2 Table 4-3. Recommended Non-Motorola Test Equipment ..............4-2 Table 4-4. Common Service Aids for Board-Level Troubleshooting ............4-3 Table 4-5. Service Aids for ASTRO Digital Spectra Board-Level Troubleshooting ........ 4-4 Table 4-6.
  • Page 14 ASTRO Digital Spectra and Digital Spectra Plus Mobile Radios Detailed Service Manual ..6881076C25 ASTRO Digital Spectra Mobile Radios Dual Control Head Radio System Service Manual..6881091C78 ASTRO Spectra and Digital Spectra FM Two-Way Mobile Radios Installation Manual ....6881070C85 ASTRO Spectra Motorcycle Radios Supplemental Installation Manual........6880103W01 CPS Programming Installation Guide ..................6881095C44...

  • Page 15: Commercial Warranty

    Product Accessories One (1) Year Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period.

  • Page 16: State Law Rights

    Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada.

  • Page 17: Patent And Software Provisions

    A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such claim; B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its settlement or compromise; and C.

  • Page 18: Model Numbering, Charts, And Specifications

    Model Numbering, Charts, and Specifications Model Numbering, Charts, and Specifications Mobile Radio Model Numbering Scheme Typical Model Number: Position: 12 13 Position 1 - Type of Unit Positions 13 - 16 D = Dash-Mounted Mobile Radio SP Model Suffix M = Motorcycle Mobile Radio T = Trunk-Mounted Mobile Radio Position 12 - Unique Model Variations...

  • Page 19: Astro Digital Spectra Motorcycle 15 Watt (Ranges 1 And 2) Model Chart

    Model Numbering, Charts, and Specifications xvii ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 1 and 2) Model Chart Model Number Description M04JGF9PW4AN Model W4 (136-162 MHz), Range 1, 15 Watt, 128 Channels M04JGF9PW5AN Model W5 (136-162 MHz), Range 1, 15 Watt, 128 Channels M04JGH9PW7AN Model W7 (136-162 MHz), Range 1, 15 Watt, 128 Channels M04KGF9PW4AN...

  • Page 20: Astro Digital Spectra Motorcycle 15 Watt (Ranges 3 And 3.5) Model Chart

    xviii Model Numbering, Charts, and Specifications ASTRO Digital Spectra Motorcycle 15 Watt (Ranges 3 and 3.5) Model Chart Model Number Description M04RGF9PW4ANSP02 Model W4 (450-482 MHz), Range 3, 15 Watt, 128 Channels M04RGF9PW5ANSP02 Model W5 (450-482 MHz), Range 3, 15 Watt, 128 Channels M04RGF9PW4ANSP01 Model W4 (453-488 MHz), Range 3.5, 15 Watt, 128 Channels M04RGF9PW5ANSP01...

  • Page 21: Astro Digital Spectra Vhf 10-25 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO Digital Spectra VHF 10–25 Watt Model Chart Model Number Description D04JHH9PW3AN Model W3 (136-145.9 MHz), 10-25 Watt, 255 Channels D04JHF9PW4AN Model W4 (136-162 MHz), 10-25 Watt, 128 Channels D04JHF9PW5AN Model W5 (136-162 MHz); 10-25 Watt, 128 Channels D04JHH9PW7AN Model W7 (136-162 MHz), 10-25 Watt, 255 Channels T04JHH9PW9AN...

  • Page 22: Astro Digital Spectra Vhf 25-50 And 50-110 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO Digital Spectra VHF 25–50 and 50–110 Watt Model Chart Model Number Description D04JKH9PW3AN Model W3 (136-145.9 MHz), 25-50 Watt, 128 Channels D04JKF9PW4AN Model W4 (136-162 MHz), 25-50 Watt, 128 Channels D04JKF9PW5AN Model W5 (136-162 MHz); 25-50 Watt, 128 Channels D04JKH9PW7AN Model W7 (136-162 MHz), 25-50 Watt, 255 Channels T04JKH9PW9AN...

  • Page 23: Astro Digital Spectra Vhf 10-25 And 50-110 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications ASTRO Digital Spectra VHF 10–25 and 50–110 Watt Model Chart (cont.) Model Number Description D04JKH9PW3AN Model W3 (136-145.9 MHz), 25-50 Watt, 128 Channels D04JKF9PW4AN Model W4 (136-162 MHz), 25-50 Watt, 128 Channels D04JKF9PW5AN Model W5 (136-162 MHz); 25-50 Watt, 128 Channels D04JKH9PW7AN Model W7 (136-162 MHz), 25-50 Watt, 255 Channels T04JKH9PW9AN...

  • Page 24: Astro Digital Spectra Uhf 10-25 Watt Model Chart

    xxii Model Numbering, Charts, and Specifications ASTRO Digital Spectra UHF 10–25 Watt Model Chart Model Number Description D04RHH9PW3AN Model W3 (438-470 MHz), 10-25 Watt, 255 Channels D04RHF9PW4AN Model W4 (438-470 MHz), 10-25 Watt, 128 Channels D04RHF9PW5AN Model W5 (438-470 MHz), 10-25 Watt, 128 Channels D04RHH9PW7AN Model W7 (438-470 MHz), 10-25 Watt, 255 Channels T04RHH9PW9AN...

  • Page 25: Astro Digital Spectra Uhf 20-40 Watt Model Chart

    Model Numbering, Charts, and Specifications xxiii ASTRO Digital Spectra UHF 20–40 Watt Model Chart Model Number Description D04QKH9PW3AN Model W3 (403-433 MHz), 20-40 Watt, 128 Channels D04QKF9PW4AN Model W4 (403-433 MHz), 20-40 Watt, 128 Channels D04QKF9PW5AN Model W5 (403-433 MHz), 20-40 Watt, 128 Channels D04QKH9PW7AN Model W7 (403-433 MHz), 20-40 Watt, 255 Channels T04QKH9PW9AN...

  • Page 26: Astro Digital Spectra Uhf 20-40 Watt Model Chart (Cont.)

    xxiv Model Numbering, Charts, and Specifications ASTRO Digital Spectra UHF 20–40 Watt Model Chart (cont.) Model Number Description D04QKH9PW3AN Model W3 (403-433 MHz), 20-40 Watt, 128 Channels D04QKF9PW4AN Model W4 (403-433 MHz), 20-40 Watt, 128 Channels D04QKF9PW5AN Model W5 (403-433 MHz), 20-40 Watt, 128 Channels D04QKH9PW7AN Model W7 (403-433 MHz), 20-40 Watt, 255 Channels T04QKH9PW9AN...

  • Page 27: Astro Digital Spectra Uhf 50-110 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO Digital Spectra UHF 50–110 Watt Model Chart Model Number Description T04QLF9PW4AN Model W4 (403-433 MHz), 50-110 Watt, 128 Channels T04QLF9PW5AN Model W5 (403-433 MHz), 50-110 Watt, 255 Channels T04QLH9PW7AN Model W7 (403-433 MHz), 50-110 Watt, 255 Channels T04QLH9PW9AN Model W9 (403-433 MHz), 50-110 Watt, 255 Channels T04RLF9PW4AN...

  • Page 28: Astro Digital Spectra Uhf 50-110 Watt Model Chart (Cont.)

    xxvi Model Numbering, Charts, and Specifications ASTRO Digital Spectra UHF 50–110 Watt Model Chart (cont.) Model Number Description T04QLF9PW4AN Model W4 (403-433 MHz), 50-110 Watt, 128 Channels T04QLF9PW5AN Model W5 (403-433 MHz), 50-110 Watt, 255 Channels T04QLH9PW7AN Model W7 (403-433 MHz), 50-110 Watt, 255 Channels T04QLH9PW9AN Model W9 (403-433 MHz), 50-110 Watt, 255 Channels T04RLF9PW4AN...

  • Page 29: Astro Digital Spectra 800 Mhz Model Chart

    Model Numbering, Charts, and Specifications xxvii ASTRO Digital Spectra 800 MHz Model Chart Model Number Description D04UJF9PW3AN Model W3 (800 MHz), 35 Watt, 128 Channels D04UJF9PW4AN Model W4 (800 MHz), 35 Watt, 128 Channels D04UJF9PW5AN Model W5 (800 MHz), 35 Watt, 128 Channels D04UJF9PW7AN Model W7 (800 MHz), 35 Watt, 255 Channels T04UJF9PW9AN...

  • Page 30: Astro Digital Spectra Plus Vhf 25-50 And 50-110 Watt Model Chart

    AAHN4045_ W4 Control Head HLN6486_ High-Power Interconnect Board HLN6432_ Control Head Back Housing HLN6396_ W5,W7 Control Head Board HCN1078_ W9 Control Head NTN9801_ ASTRO Spectra Plus UCM HMN1080_ Microphone HMN1061_ Microphone HSN4018_ Speaker HSN6001_ Speaker HLN4921_ Control Head (W9) Trunnion...

  • Page 31: Astro Digital Spectra Plus Vhf 25-50 And 50-110 Watt Model Chart (Cont.)

    Model Numbering, Charts, and Specifications xxix ASTRO Digital Spectra Plus VHF 25–50 and 50–110 Watt Model Chart (cont.) Model Number Description D04JKH9SW7AN Model W7 (136-162 MHz), 25-50 Watt, 512 Channels D04KKH9SW3AN Model W3 (146-174 MHz), 25-50 Watt, 512 Channels D04KKF9SW4AN Model W4 (146-174 MHz), 25-50 Watt, 128 Channels D04KKF9SW5AN Model W5 (146-174 MHz);...

  • Page 32: Astro Digital Spectra Plus Uhf 20-40 Watt Model Chart

    Model Numbering, Charts, and Specifications ASTRO Digital Spectra Plus UHF 20–40 Watt Model Chart Model Number Description D04QKH9SW3AN Model W3 (403-433 MHz), 20-40 Watt, 512 Channels D04QKF9SW4AN Model W4 (403-433 MHz), 20-40 Watt, 128 Channels D04QKF9SW5AN Model W5 (403-433 MHz), 20-40 Watt, 128 Channels D04QKH9SW7AN Model W7 (403-433 MHz), 20-40 Watt, 512 Channels T04QKH9SW9AN...

  • Page 33: Astro Digital Spectra Plus Uhf 20-40 Watt Model Chart (Cont.)

    RF Board HSN4018_ Speaker NTN9801_ UCM, ASTRO Spectra Plus X = Item Included O = Optional _ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number. * = kit not available. Order piece parts from the Customer Care and Services Division.

  • Page 34: Astro Digital Spectra Plus Uhf 50-110 Watt Model Chart

    xxxii Model Numbering, Charts, and Specifications ASTRO Digital Spectra Plus UHF 50–110 Watt Model Chart Model Number Description T04QLH9SW3AN Model W3 (403-433 MHz), 50-110 Watt, 512 Channels T04QLF9SW4AN Model W4 (403-433 MHz), 50-110 Watt, 128 Channels T04QLF9SW5AN Model W5 (403-433 MHz), 50-110 Watt, 128 Channels T04QLH9SW7AN Model W7 (403-433 MHz), 50-110 Watt, 512 Channels T04QLH9SW9AN...

  • Page 35: Astro Digital Spectra Plus Uhf 50-110 Watt Model Chart (Cont.)

    HSN6001_ Speaker O O O O O O O O O O O O O O O NTN9801_ UCM, ASTRO Spectra Plus X = Item Included O = Optional _ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.

  • Page 36: Astro Digital Spectra Plus 800 Mhz Model Chart

    xxxiv Model Numbering, Charts, and Specifications ASTRO Digital Spectra Plus 800 MHz Model Chart Model Number Description M04UGF9SW4AN Model W4 (800 MHz), 15 Watt, 128 Channels M04UGF9SW5AN Model W5 (800 MHz), 15 Watt, 128 Channels M04UGH9SW7AN Model W7 (800 MHz), 15 Watt, 512 Channels D04UJH9SW3AN Model W3 (800 MHz), 35 Watt, 512 Channels D04UJF9SW4AN...

  • Page 37: Astro Digital Spectra Plus 800 Mhz Model Chart (Cont.)

    Model Numbering, Charts, and Specifications xxxv ASTRO Digital Spectra Plus 800 MHz Model Chart (cont.) Model Number Description M04UGF9SW4AN Model W4 (800 MHz), 15 Watt, 128 Channels M04UGF9SW5AN Model W5 (800 MHz), 15 Watt, 128 Channels M04UGH9SW7AN Model W7 (800 MHz), 15 Watt, 512 Channels D04UJH9SW3AN Model W3 (800 MHz), 35 Watt, 512 Channels D04UJF9SW4AN...

  • Page 38: Vhf Radio Specifications

    xxxvi Model Numbering, Charts, and Specifications VHF Radio Specifications GENERAL RECEIVER TRANSMITTER FCC Designations: AZ492FT3772 Frequency Range: Frequency Range: AZ492FT3773 Range 1: 136–162 MHz Range 1: 136–162 MHz Range 2: 146–174 MHz Range 2: 146–174 MHz Temperature Range: Operating: –30°C to +60°C Channel Spacing: 12.5 kHz, 25 kHz Rated Output Power:...

  • Page 39: Uhf Radio Specifications

    Model Numbering, Charts, and Specifications xxxvii UHF Radio Specifications GENERAL RECEIVER TRANSMITTER FCC Designations: AZ492FT4786 Frequency Range: Frequency Range: AZ492FT4787 Range 1: 403–433 MHz Range 1: 403–433 MHz Range 2: 438–470 MHz Range 2: 438–470 MHz Temperature Range: Range 3: 450–482 MHz Range 3: 450–482 MHz...

  • Page 40: 800 Mhz Radio Specifications

    xxxviii Model Numbering, Charts, and Specifications 800 MHz Radio Specifications GENERAL RECEIVER TRANSMITTER FCC Designations: AZ492FT5759 Frequency Range: 851–869 MHz Frequency Range: AZ492FT5751 Repeater Mode: 806–824 MHz Channel Spacing: 12.5 kHz/20 kHz/25 kHz Talkaround Mode: 851–869 MHz Temperature Range: Operating: –30°C to +60°C Input Impedance: 50 Ohm...

  • Page 41: Chapter 1 Introduction

    Chapter 1 Introduction Notations Used in This Manual Throughout the text in this publication, you will notice the use of note, caution, warning, and danger notations. These notations are used to emphasize that safety hazards exist, and due care must be taken and observed.

  • Page 42: Flashport

    1.2.1 FLASHport® The ASTRO Digital Spectra and Digital Spectra Plus radios utilize Motorola’s revolutionary FLASHport technology. FLASHport makes it possible to add software that drives the radio’s capabilities both at the time of purchase and later on. Previously, changing a radio’s features and capabilities meant significant modifications, or buying a new radio.

  • Page 43: Model W3 Control Head

    Introduction: Control Head Descriptions 1.3.1.1 Model W3 Control Head On/Off Orange Programmable Programmable Button Button Button (T1) (T2) (T3) Indicator Display Push-To-Talk Button (PTT) Switch Side Button 1 (S1) H O M E Side Button 2 (S2) Side Button 3 (S3) Volume V O L MOD E...

  • Page 44: Models W4, W5, W7, And W9 Controls Head

    Introduction: Control Head Descriptions 1.3.1.3 Models W4, W5, W7, and W9 Controls Head PAGE Page SECURE Emer EMERGENCY SCAN SELECT MONITOR PHONE CALL DIRECT HOME Phon Scan Call Home HORN/ Mode Volume LIGHTS XMIT BUSY MODE POWER ON/OFF/ PRIORITY/ DIRECT KNOB VOLUME KNOB NON-PRIORITY...

  • Page 45: Models W4, W5, W7, And W9 Controls

    Introduction: Control Head Descriptions FUNCTION PRIORITY DIMMER BUTTON INDICATOR STATUS* CONTROL XMIT BUSY Emer Scan Call FUNCTION ON/OFF INDICATORS Phon MESSAGE* Mode Home MODE VOLUME SELECT HOME RECALL DELETE ROCKER ROCKER SQUELCH NON-PRIORITY KEYPAD INDICATOR * Optional buttons (included but not installed or programmed) Figure 1-5.
  • Page 46 Introduction: Control Head Descriptions • Option Buttons — The option buttons are used for turning options on and off, such as Phone, Scan, Emergency Call, and Secure. • Display — The vacuum fluorescent (VF) display’s primary function is to display mode numbers, mode names, volume level, and the status of options.

  • Page 47: Chapter 2 Basic Maintenance

    Chapter 2 Basic Maintenance Introduction This section of the manual describes preventive maintenance, handling precautions, and some basic repair procedures and techniques. Each of these topics provides information vital to the successful operation and maintenance of your radio. Preventive Maintenance Radios are shipped from the factory with a worst-case frequency error of ±200 Hz for VHF, ±300 Hz for UHF, and ±500 Hz for 800 MHz.

  • Page 48: Cleaning External Plastic Surfaces

    • Disconnect all power from the unit before ESD-sensitive components are removed or inserted unless otherwise noted. • Use a static-safeguarded workstation, through the use of an anti-static kit (Motorola part number 01-80386A82). This kit includes a wrist strap, two ground cords, a static-control table mat and a static-control floor mat.
  • Page 49 • Make skin contact with a conductive work surface first and maintain this contact when the device is set down or picked up. • Always wear a conductive wrist strap when servicing this equipment. The Motorola part number for a replacement wrist strap that connects to the table mat is 42-80385A59.
  • Page 50 Basic Maintenance: Handling Precautions Notes February 3, 2003 6881076C20-E...

  • Page 51: Chapter 3 Basic Theory Of Operation

    Chapter 3 Basic Theory of Operation Introduction The following theory will help isolate the problem to a particular board. Using circuit board replacement as the basic service approach maximizes the working time of the radio. General Overview The ASTRO Digital Spectra and Digital Spectra Plus radios are wideband, synthesized, fixed-tuned radios.

  • Page 52: Analog Mode Of Operation

    Basic Theory of Operation: Analog Mode of Operation Analog Mode of Operation 3.3.1 Receive Operation When the radio is receiving, the signal comes from the antenna/antenna-switch on the power amplifier board to the front-end receiver assembly. The signal is then filtered, amplified, and mixed with the first local-oscillator signal generated by the voltage-controlled oscillator (VCO).

  • Page 53: Display (W9 Model)

    Basic Theory of Operation: Control Head Assembly 3.5.2 Display (W9 Model) The control head assembly for a W9 model has an 11-character, alphanumeric, vacuum fluorescent display. It needs three separate voltages to operate: the cathode needs 35V to accelerate electrons to the anode;...

  • Page 54: Vehicle Interface Port (Vip)

    Basic Theory of Operation: Power Amplifier 3.5.8 Vehicle Interface Port (VIP) 3.5.8.1 Remote-Mount The VIPs allow the control head to operate outside circuits and to receive inputs from outside the control head. There are three VIP outputs that are used for relay control. There are also three VIP inputs that accept inputs from switches.

  • Page 55: Power Control

    Basic Theory of Operation: Front-End Receiver Assembly 3.6.2 Power Control A directional coupler and detector network controls power. It senses the forward power from the last gain stage and feeds the detected voltage back to the command board control circuitry, where it is compared to a reference voltage set during power-set procedures.

  • Page 56: Voltage-Controlled Oscillator (Vco)

    Basic Theory of Operation: Voltage-Controlled Oscillator (VCO) Synthesizing for the first and second VCO is performed by the prescaler and synthesizer ICs. These ICs are programmed through a serial data bus from signals generated on the VOCON board. A dc voltage, generated on the command board, sets the synthesizer’s reference oscillator frequency of 16.8MHz.

  • Page 57: Vocon (Vocoder/Controller) Board

    Basic Theory of Operation: VOCON (Vocoder/Controller) Board The regulator and power control circuits include an unswitched +5V discrete circuit and the regulator/ power control IC, which produces both switched +5V and 9.6V. The unswitched +5V source is used as a reference for its switched +5V source. Filtered unswitched +5V is used for the microcontrol circuits.
  • Page 58 Basic Theory of Operation: VOCON (Vocoder/Controller) Board The VOCON board controls receive/transmit frequencies, the display, and various radio functions, using either direct logic control or serial communication to external devices. The connector J801 provides an interface between the encryption module and the VOCON board for encrypting voice messages.

  • Page 59: Chapter 4 Test Equipment, Service Aids, And Tools

    The Characteristics column is included so that equivalent equipment can be substituted; however, when no information is provided in this column, the specific Motorola model listed is either a unique item or no substitution is recommended.

  • Page 60: Service Aids And Recommended Tools

    ASTRO Digital Spectra and ASTRO Digital Spectra Plus radios. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance can be substituted for the item listed.

  • Page 61: Table 4-4. Common Service Aids For Board-Level Troubleshooting

    Test Equipment, Service Aids, and Tools: Service Aids and Recommended Tools Table 4-4. Common Service Aids for Board-Level Troubleshooting Motorola Description Application Part Number 30-80370E06 Extender Cable Provides extension cable for VOCON Board (connectors P501/J501) RPX-4725A (includes Command and Control Service...

  • Page 62: Table 4-5. Service Aids For Astro Digital Spectra Board-Level Troubleshooting

    Test Equipment, Service Aids, and Tools: Service Aids and Recommended Tools Table 4-5 lists additional service aids that can be used in troubleshooting ASTRO Digital Spectra radios. Table 4-5. Service Aids for ASTRO Digital Spectra Board-Level Troubleshooting Motorola Description Application Part Number RLN-4008_...

  • Page 63: Field Programming Equipment

    Test Equipment, Service Aids, and Tools: Field Programming Equipment Table 4-6. Service Aids for ASTRO Digital Spectra Plus Board-Level Troubleshooting Motorola Description Application Part Number 30-85001D01 Programming Flash Cable Used with Tuner Software, CPS, and FLASHport RVN-4185 Customer Programming Programming and radio alignment software on CD Software and Tuner Software Table 4-7.

  • Page 64: Astro Digital Spectra W3 Smart Rib Issue

    Test Equipment, Service Aids, and Tools: Field Programming Equipment The following items, available through the Customer Care and Services Division (except the computer), are required when programming ASTRO Digital Spectra Model radios. Table 4-8. ASTRO Digital Spectra Field Programming Items Type or Part Number Description 01-80300B10...

  • Page 65: Astro Digital Spectra Plus

    Test Equipment, Service Aids, and Tools: Field Programming Equipment In mid-power radios, when this cable is used, programming must be done through the rear accessory connector. 4.3.2 ASTRO Digital Spectra Plus The ASTRO Digital Spectra Plus radios use a flash memory device to store information on frequencies, squelch codes, signaling codes, time-out timer durations, and other parameters.
  • Page 66 Test Equipment, Service Aids, and Tools: Field Programming Equipment Notes February 3, 2003 6881076C20-E...

  • Page 67: Chapter 5 Performance Checks

    Chapter 5 Performance Checks Introduction This section covers performance checks used to verify that the radio meets published specifications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with the manufacturer’s recommended calibration schedule.

  • Page 68: Test Mode

    Figure 5-2. ASTRO Digital Spectra Plus Performance Checks Test Setup Test Mode NOTE: The test mode for the ASTRO Spectra radio is different from the standard Spectra radio, but is similar to the ASTRO portable test mode. Be sure to transmit into a load when keying a radio under test.

  • Page 69: Rf Test Mode

    Performance Checks: Test Mode Table 5-1. Test-Mode Displays (Continued) Display Name Description Appears Encryption Firmware Firmware version for encryption When the radio is secure equipped Encryption Type 1 Type of encryption being used When the radio is secure equipped Encryption Type 2 Type of encryption being used When the radio is secure...

  • Page 70: Table 5-2. Test Frequencies

    Performance Checks: Test Mode 2. In RF test mode, press the Volume rocker to adjust the volume. The volume display for the ASTRO Digital Spectra will be in 256 increments, not the usual 16, while in the test mode. This allows for precise setting of rated audio, etc. For the ASTRO Digital Spectra Plus, the volume is still displayed as a value between 0 to 15.

  • Page 71: Control Head Test Mode

    Performance Checks: Test Mode Table 5-3. Signaling Types Display Modulation Demodulation Type None None Carrier Squelch 192Hz 192Hz Private-Line 1200Hz ASTRO (digital) None None Open Squelch When in the transmit test mode, DTMF modulation produces a sidetone in the speaker. All signaling types will continually modulate the transmitted signal for detection/measurement by external instruments.

  • Page 72: Receiver Performance Checks

    5/9/94 5/9/94 Performance Checks: Receiver Performance Checks KEY 81 KEY 100 KEY 102 KEY 49 KEY 80 KEY 99 KEY 101 KEY 103 KEY 50 Phon KEY 51 Mode Scan Call KEY 53 KEY 54 KEY 82 KEY 56 XMIT KEY 83 KEY 57 BUSY...

  • Page 73: Transmitter Performance Checks

    Performance Checks: Transmitter Performance Checks Table 5-4. Receiver Performance Checks (Continued) Test Name System Analyzer Radio Test Condition Comments Sensitivity As above, except SINAD, lower TEST MODE, Release PTT RF input to be (SINAD) the RF level for 12 dB SINAD 1 CSQ switch.
  • Page 74 Performance Checks: Transmitter Performance Checks Table 5-5. Transmitter Performance Checks (Continued) Test Test Name System Analyzer Radio Comments Condition PL Modulation Change frequency to 1st channel TEST MODE, Remove Deviation: (radios with test frequency**; 1 TPL modulation input VHF, UHF, and 800 conventional, clear B/W to narrow from dummy...

  • Page 75: Chapter 6 Radio Alignment Procedure

    Chapter 6 Radio Alignment Procedure Introduction This section describes both receiver and transmitter radio alignment procedures using either of the following radio alignment software: • ASTRO Digital Spectra Radio Service Software (DOS-based) • ASTRO Digital Spectra and Digital Spectra Plus Tuner software (Windows-based) 6.2.1 ASTRO Digital Spectra An IBM or IBM PC-compatible computer and radio service software (RSS) are required to align the...

  • Page 76: Softpot

    Radio Alignment Procedure: RSS SERVICE F2 - TRANSMITTER ALIGNMENT MENU F1 - HELP F2 - REFERENCE OSCILLATOR ALIGNMENT F3 - TRANSMIT POWER ALIGNMENT F4 - TRANSMIT CURRENT LIMIT F5 - TRANSMIT DEVIATION BALANCE (COMPENSATION) ALIGNMENT F6 - TRANSMIT DEVIATION LIMIT ALIGNMENT F10 - EXIT, RETURN TO SERVICE MENU Figure 6-2.

  • Page 77: Reference Oscillator Alignment

    Radio Alignment Procedure: RSS 6.2.3 Reference Oscillator Alignment Radios are shipped from the factory with a worst-case frequency error of ±200 Hz for VHF, ±300 Hz for UHF, and ±500 Hz for 800 MHz. These specifications are tighter than the more stringent FCC requirement of 1.5 ppm for all bands.

  • Page 78: Transmit Power Alignment

    Radio Alignment Procedure: RSS MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. ASTRO Model: T04SLF9PW7AN MAIN:SERVICE:TX ALIGN:REF OSC REFERENCE OSCILLATOR -------------------- Frequency Current Value --------- ------------- 869.9875 New Softpot Value..72 Transmitter..On MIN |----+----+----+----X----+----+----+----+----+----+----+----| MAX HELP TOGGLE PROGRAM EXIT VALUE Figure 6-4.

  • Page 79: Figure 6-5. Transmit Power Alignment Screen

    1. From the SERVICE MENU, press F2 to select the TRANSMITTER ALIGNMENT MENU. 2. Press F3 to select the TRANSMIT POWER alignment screen. The screen will indicate the transmit frequencies to be used ( Figure 6-5 MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. ASTRO Model: T04SLF9PW7AN...

  • Page 80: Transmit Current Limit Alignment

    2. Press F4 to select the TRANSMIT CURRENT LIMIT alignment screen. The screen will indicate the transmit frequencies to be used ( Figure 6-6 NOTE: The current limit before alignment should be set to 15 (for no limiting). MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. ASTRO Model: T04SLF9PW7AN...

  • Page 81: Transmit Deviation Balance (Compensation) Alignment

    Radio Alignment Procedure: RSS 8. Press F10 once to return to the TRANSMITTER ALIGNMENT MENU, or press F10 twice to return to the SERVICE MENU. 6.2.6 Transmit Deviation Balance (Compensation) Alignment NOTE: Compensation alignment is only required after replacing (or servicing) the command board, VOCON (vocoder/controller) board, RF board, or the VCO board.

  • Page 82: Transmit Deviation Limit Alignment

    Radio Alignment Procedure: RSS MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. ASTRO Model: T04SLF9PW7AN MAIN:SERVICE:TX ALIGN:BAL ATTN TRANSMIT DEVIATION BALANCE (COMPENSATION) ----------------------------------------- Current Frequency Value New Softpot Value --------- ------- ----------------- 806.0125 821.0125 851.0125 866.0125 869.9875 Transmitter..Off...

  • Page 83: Figure 6-8. Transmit Deviation Limit Alignment Screen

    3. From the SERVICE MENU, press F2 to select the TRANSMITTER ALIGNMENT MENU. 4. Press F6 to select the TRANSMIT DEVIATION LIMIT alignment screen ( Figure 6-8 MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. ASTRO Mobile Model: T04SLF9PW7AN...

  • Page 84: Bit Error Rate (Ber) Performance Check

    A personal computer (PC) and Tuner Software are required to align the radio. Please refer to the CPS Programming Installation Guide (Motorola part number 6881095C44) for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the computer and to a universal test set, as shown in the following figure.

  • Page 85: Figure 6-9. Astro Digital Spectra Plus Radio Alignment Test Setup

    CONTROL HEAD COMPUTER For dash mount applications, ASTRO Spectra Plus program/flash cable (30-85001D01) will be connected to the microphone port on the control head. For remote mount the 30-85001D01 will be connected to the flashport connector on the front face of the radio (P506).

  • Page 86: Figure 6-10. Tuner Menu Layout

    6-12 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Figure 6-10. Tuner Menu Layout The alignment screens introduce the concept of the “softpot,” an analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls. Do NOT switch radios in the middle of any alignment procedure.

  • Page 87: Figure 6-11. Typical Softpot Adjustment Screen

    Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-13 Figure 6-11. Typical Softpot Adjustment Screen Adjusting the softpot value sends information to the radio to increase (or decrease) a voltage in the corresponding circuit. For example, left-clicking the UP spin button ( ) on the Reference Oscillator screen instructs the radio’s microcomputer to increase the voltage across a varactor in the reference oscillator, which increases the frequency.

  • Page 88: Radio Information

    6-14 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6.3.1 Radio Information Figure 6-12 shows a typical Radio Information screen. All of the data appearing here is informational and cannot be changed.. Figure 6-12. Radio Information Screen 6.3.2 Reference Oscillator Alignment Reference oscillator alignment is required after replacing (or servicing) the transceiver board.

  • Page 89: Figure 6-13. Reference Oscillator Alignment Screen

    Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-15 - Attenuation: 20dB - Mon RF in: RF I/O - Meter: RF Display - Mode: STD - Input Level: uV or W - Display: Bar Graphs - Squelch: Mid-range or adjust as necessary •...

  • Page 90: Transmit Power Alignment

    6-16 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Table 6-3. Reference Oscillator Alignment Band Target 800 MHz ±100 Hz 6. Left-click the Program (Digital Spectra) or Program All (Digital Spectra Plus) button on the screen to dekey the radio and save the tuned values. 7.

  • Page 91: Table 6-4. Transmit Power Settings

    Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-17 2. Left-click the desired frequency field (starting with the highest frequency shown). 3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen indicates whether the radio is transmitting.

  • Page 92: Transmit Current Limit Alignment

    6-18 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6.3.4 Transmit Current Limit Alignment This procedure is required for mobile radios only. Transmit Current Limit adjustment is required after replacing (or servicing) the RF Board. This alignment procedure limits the transmitter current drain of the radio. 1.
  • Page 93 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-19 This procedure needs to be performed at multiple frequencies to allow for proper alignment across the entire RF band. The RF band is divided into frequency zones with a calibration point (value) in each zone.

  • Page 94: Transmit Deviation Limit Alignment

    6-20 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Figure 6-16. Transmit Deviation Balance (Compensation) Alignment Screen 6. Left-click the PTT Tone: Low button. 7. Left-click the PTT Toggle button on the screen to enable transmission. The screen indicates whether the radio is transmitting.

  • Page 95: Figure 6-17. Transmit Deviation Limit Alignment Screen

    Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-21 This test can be done with either the R-2670 Communication Analyzer or the 8901_ Series Modulation Analyzer. The method of choice is the R-2670 analyzer. 1. Initial set up using the R-2670 Communication Analyzer: - Connect a BNC cable between the “DEMOD OUT”...

  • Page 96: Bit Error Rate (Ber) Test

    6-22 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 5. Left-click the PTT Toggle button on the screen to make the radio transmit. Wait approximately 5 seconds until the deviation/voltage displayed on the analyzer stabilizes. The screen indicates whether the radio is transmitting.

  • Page 97: Transmitter Test Pattern

    Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software 6-23 Figure 6-18. Bit Error Rate Test Screen 6.3.8 Transmitter Test Pattern This screen is used to transmit specific test patterns at a desired frequency so that the user can perform tests on the radio’s transmitter and contains the following fields: •...
  • Page 98 6-24 Radio Alignment Procedure: ASTRO Digital Spectra and Digital Spectra Plus Tuner Software Notes February 3, 2003 6881076C20-E...

  • Page 99: Chapter 7 Encryption

    Chapter 7 Encryption Universal Crypto Module Kits This information applies to both conventional and trunked systems. The following tables contain the Universal Crypto Module (UCM) kits for the ASTRO Digital Spectra and Digital Spectra Plus radios. 7.1.1 ASTRO Digital Spectra Table 7-1.

  • Page 100: Secure Emergency Operation

    Encryption: Load an Encryption Key • The secure status annunciator not lit (OFF) indicates that the transmitted signal is non- encrypted. Whether the current personality is strapped for secure or clear, the secure status annunciator correctly displays the transmit operation as being either secure (encrypted) or clear (non-encrypted). NOTE: You cannot change from secure to clear while the PTT button is pressed.

  • Page 101: Models W4, W5, W7, And W9

    Encryption: Erase a Key 7.2.2 Models W4, W5, W7, and W9 To load an encryption key into a Model W4, W5, W7, or W9 radio: 1. Turn on the radio and set the volume level. The position of the D button is not important. 2.

  • Page 102: Models W4, W5, W7, And W9

    Encryption: Erase a Key 7.3.2 Models W4, W5, W7, and W9 The Select Key to Erase feature allows you to manually select any one, or all, of the encryption keys to erase. 1. To enter the Advanced Model W4 Secure menu, press HOME SECURE and hold the  button...

  • Page 103: Erase A Single Key (Model W3)

    Encryption: Erase a Single Key (Model W3) Erase a Single Key (Model W3) To erase a single key: 1. Press the  button below SNGL to request erasure of the selected key. ERASE SNGL KEY , YES and NO are displayed. 2.

  • Page 104: Models W4, W5, W7, And W9

    Encryption: Over-the-Air Rekeying 7.5.2 Models W4, W5, W7, and W9 1. To enter the Advanced Model W4 Secure menu, press HOME SECURE and hold the  button Home Phon Scan Call until a tone sounds. Mode Volume XMIT BUSY SECURE MODE INDICATOR KNOB...

  • Page 105: Astro Digital Spectra Model W3

    Encryption: Over-the-Air Rekeying 7.6.1 ASTRO Digital Spectra Model W3 1. Press  until REKY appears. 2. Press  below REKY . REQUEST REKY is displayed. 3. Press the PTT button to send the rekey request. PLEASE WAIT is displayed. 4. One of the following occurs: The radio sounds five tones when the...
  • Page 106 Encryption: Over-the-Air Rekeying If the display shows NO ACK and a bad-key tone sounds, then the dispatcher has not acknowledged your request after the radio has tried five times to send it. The radio then returns to the display message in step 2, allowing you to retry the request.

  • Page 107: Astro Digital Spectra Models W4, W5, W7, And W9

    Encryption: Over-the-Air Rekeying 7.6.2 ASTRO Digital Spectra Models W4, W5, W7, and W9 1. To enter the Advanced Model W4 Secure menu, press HOME SECURE and hold the  button Home Phon Scan Call until a tone sounds. Mode Volume XMIT BUSY SECURE...

  • Page 108: Advanced Secure Operation

    7-10 Encryption: Advanced Secure Operation 5. One of the following occurs: If the radio receives an acknowledgment from the dispatcher, five tones sound. If the radio does not receive an acknowledgment from the dispatcher, the display shows NO ACK . After the radio is rekeyed, it displays REKEYED and returns to dispatch mode.

  • Page 109: Chapter 8 Disassembly/Reassembly Procedures

    Chapter 8 Disassembly/Reassembly Procedures Introduction This section details the procedures necessary to remove and replace the printed circuit boards in the ASTRO Digital Spectra and Digital Spectra Plus radios. After troubleshooting and determining which board needs to be replaced, disconnect the test equipment, the antenna cable, and unhook the dc power.

  • Page 110: Required Tools And Supplies

    Small, flat-blade screwdriver 2.5 mm hex-key driver Torx® T8, T10, and T15 drivers 3.0 mm Allen wrench Thermal compound (Motorola part number 11-83166A01, or equivalent) Electromagnetic Interference (EMI) metallic shielding tape (Motorola part number 11-85984D01, or equivalent) 8.2.2 Control Head Boards 8.2.2.1 Model W3...

  • Page 111: Models W4, W5, And W7

    Disassembly/Reassembly Procedures: Replacement Procedures 11. Remove the circuit board assembly from the housing. 12. Remove the keypad [6] from the housing assembly [7]. 8.2.2.2 Models W4, W5, and W7 NOTE: For the following procedure, refer to Chapter 11: Exploded Views and Parts Lists , beginning page 11-3 , for the exploded view and associated parts list applicable to the model being...

  • Page 112: Model W9

    Disassembly/Reassembly Procedures: Replacement Procedures 7. Carefully separate the printed circuit board, internal spacer, and elastomer keypad assembly from the front panel. On rotary control head models, care must be taken not to damage the flex circuit when separating the printed circuit board from the front housing. Do not disturb the buttons in the front panel.

  • Page 113: Remote Back Housing Interface Board

    When working with chips and SOT (small outline transistor) parts, use extreme caution when heating. Never reuse a chip or SOT part; always replace with the correct Motorola part. 6. Install the new PC board with the elastomer keypad, the ON/OFF switch gasket, the “D”...

  • Page 114: Remote Interconnect Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8.2.4 Remote Interconnect Board 8.2.4.1 Low-/Mid-Power Radios 1. Remove the two front panel screws using a 2.5mm hex key driver. 2. Grasp the front panel firmly, and carefully unplug it from the radio. 3. Remove the three screws that hold the remote interconnect board to the front panel using a Torx T10 driver.

  • Page 115: Power Amplifier Board

    Disassembly/Reassembly Procedures: Replacement Procedures 13. Fold the ribbon cable down flat. Replace the top cover and torque the two screws to 6-8 in.- lbs. These screws are self-tapping and caution should be used so that the screws enter the previously cut threads. 8.2.5 Power Amplifier Board 8.2.5.1 Low-/Mid-Power Radios...

  • Page 116: 800 Mhz Radios

    RX front end. This will facilitate assembly. 12. Apply a thin white coat of thermal compound (for example, Motorola part no. 11-83166A01) in the power transistor mounting locations of the chassis where the thermal compound was removed.

  • Page 117: Pc Board Installation

    If the power transistor insulator was not disturbed, it is not necessary to clean beneath it. 3. Apply a new, uniform coat of thermal compound (e.g., Motorola part no. 11-83166A01), which is thick enough to fill all small air voids, to the mounting surfaces.

  • Page 118: Back-End Installation

    8-10 Disassembly/Reassembly Procedures: Replacement Procedures APPLY TERMINAL COMPOUND HERE PASS DEVICE INSULATION HERE Figure 8-4. PA Board Screw Fastening Sequence (800 MHz 20- and 35-Watt PA) 7. Place the power module shield over the power module. 8. Install the power module and shield with two compression washers and screws (torque 6-8 in.-lbs.).

  • Page 119: Vocon (Vocoder/Controller) Board

    Disassembly/Reassembly Procedures: Replacement Procedures 8-11 7. Tighten the mounting screws (torque 8-10 in.-lbs.). 8. 20- and 35-watt radios only: Press the PA compartment shield, and install the PA cover. 8.2.6 VOCON (Vocoder/Controller) Board NOTE: If you want to keep the information currently stored in the radio code plug, save its contents with the appropriate application software before you remove the original VOCON board.

  • Page 120: High-Power Radios

    8. To reassemble the command board, apply a thin coat of thermal compound (for example, Motorola part no. 11-83166A01) to the audio amplifier mounting surface. NOTE: Do not use a thick coating of compound as it could degrade the thermal efficiency of the heatsink.

  • Page 121: Receiver Front-End Board

    9. Reconnect both coaxial cables. 10. Clean the chassis surface with isopropyl alcohol, and place a new piece of EMI metallic shielding tape (Motorola Part No. 11-85984D01) over the coaxial cable passing through the front of the chassis. NOTE: The EMI metallic shielding tape must cover the hole in the receiver front-end board.

  • Page 122: Low-/Mid-Power Radio

    8-14 Disassembly/Reassembly Procedures: Replacement Procedures 9. Carefully remove the front-end receiver board from the radio chassis cavity and disconnect the coaxial cable beneath it. NOTE: Be careful to insert the Rx injection coaxial cable straight into the receptacle on the VCO board, and be sure it is fully inserted.

  • Page 123: Low-/Mid-Power Radio

    Disassembly/Reassembly Procedures: Replacement Procedures 8-15 8.2.9.2 High-Power Radio 1. Turn the radio topside down and remove the four bottom-cover screws, and remove the bottom cover. 2. Remove the power amplifier and RF board shields. 3. Remove the six VCO board shield screws and remove the VCO board shield. 4.

  • Page 124: High-Power Radio

    8.3.1 Power Amplifiers 1. Apply a thin coat of thermal compound (for example, Motorola Part No. 11-83166A01) to the pre-driver, driver and final device heatsink mounting surfaces. NOTE: Do not use a thick coating of compound as it could degrade the thermal efficiency of the heatsink.

  • Page 125: Command Board

    NOTE: This assumes the PA is attached, the control head is detached, and the control head interconnect board is disconnected. 1. Before reassembly, apply a thin coat of thermal compound (for example, Motorola Part No. 11-83166A01) to the bottom of the audio PA.

  • Page 126: Fastener Torque Chart

    8-18 Disassembly/Reassembly Procedures: Fastener Torque Chart B. Pivot the circuit board’s display down under the retention features in the housing and rotate the board downward, ensuring that the board is positioned between the snap fea- tures. Ensure that the microphone assembly’s [8] wire passes through the opening in the circuit board.
  • Page 127 Disassembly/Reassembly Procedures: Fastener Torque Chart 8-19 Table 8-3. Fastener Torque Chart (Continued) Repair Part Number Description Torque Where Used (in.-lbs.) 03-10943J15 Screw, tapping M3.5X8 8-10 Controller board attachment (except for control head and remote dash board) 03-10943R55 Screw, tapping M3X8 Pivot pin (high-power) 03-10945A11 Screw, plastite M3X16...
  • Page 128 8-20 Disassembly/Reassembly Procedures: Fastener Torque Chart Notes February 3, 2003 6881076C20-E...

  • Page 129: Chapter 9 Basic Troubleshooting

    (Refer to the section, “Service Aids and Recommended Tools,” on page 4-2 for the appropriate Motorola service aids and tools parts numbers.) Replacement Board Procedures Once a problem has been isolated to a specific board, use one of the following recommended repair procedures: •...

  • Page 130: Table 9-1. Astro Digital Spectra Power-Up Error Codes

    Basic Troubleshooting: Power-Up Error Codes 9.3.1 ASTRO Digital Spectra Table 9-1. ASTRO Digital Spectra Power-Up Error Codes Error Code Description Corrective Action 01/02 External EEPROM checksum Reprogram the codeplug. non-fatal error 01/81 ROM checksum failure Reprogram the FLASH memory. 01/82 External EEPROM checksum Reprogram the codeplug.

  • Page 131: Table 9-2. Astro Digital Spectra Plus Power-Up Error Codes

    Basic Troubleshooting: Power-Up Error Codes 9.3.2 ASTRO Digital Spectra Plus Table 9-2. ASTRO Digital Spectra Plus Power-Up Error Codes Error Error Code Description Corrective Action Type ERROR 01/02 FLASH ROM Codeplug NON- Reprogram the codeplug. Checksum FATAL ERROR 01/12 Security Partition NON- Reprogram the security Checksum...

  • Page 132: Astro Digital Spectra

    Basic Troubleshooting: Operational Error Codes Table 9-2. ASTRO Digital Spectra Plus Power-Up Error Codes (Continued) Error Error Code Description Corrective Action Type FAIL 08/81 Siren ROM Checksum FATAL Replace the siren. Error ERROR 09/10 Secure Hardware Error NON- Replace the secure module. FATAL FAIL 09/90 Secure Hardware Fatal...

  • Page 133: Astro Digital Spectra

    Basic Troubleshooting: Transmitter Troubleshooting 9.4.2 ASTRO Digital Spectra Plus Table 9-4. ASTRO Digital Spectra Plus Operational Error Codes Error Error Code Description Corrective Action Type FAIL 001 Synthesizer Out-of-Lock NON- 1. Reprogram codeplug FATAL 2. Replace RF board. FAIL 002 Personality checksum or NON- Reprogram codeplug.
  • Page 134 Basic Troubleshooting: Transmitter Troubleshooting Table 9-5. Transmitter Troubleshooting Chart (Continued) Correction or Test (Measurements Symptom Possible Cause Taken at Room Temperature) No Modulation VCO Board 1. All modulation testing should be done with the radio keyed and 1Vrms on the microphone high line of the microphone.
  • Page 135 Basic Troubleshooting: Transmitter Troubleshooting Table 9-5. Transmitter Troubleshooting Chart (Continued) Correction or Test (Measurements Symptom Possible Cause Taken at Room Temperature) Check Deviation and Retune, if necessary. Microphone Compensation Sensitivity Microphone Speak loudly into the microphone while monitoring the microphone line (pin 6 of P502).
  • Page 136 Basic Troubleshooting: Transmitter Troubleshooting Table 9-5. Transmitter Troubleshooting Chart (Continued) Correction or Test (Measurements Symptom Possible Cause Taken at Room Temperature) Can’t Set VOCON Board Vary deviation and compensation controls Compensation from maximum to minimum. With the low frequency source active (using the appropriate radio programming Chapter 6: Radio software–see...

  • Page 137: Receiver Troubleshooting

    1 of J500. If not there, check for A+ at pin 30 of 502. If OK, then replace the command board. ASTRO Spectra Plus Check U410 pin 1 for 1.8 Vdc. VOCON Board Check U411 pin 1 for 3.0 Vdc.
  • Page 138 9-10 Basic Troubleshooting: Receiver Troubleshooting Table 9-6. Receiver Troubleshooting Chart (Continued) Correction or Test (Measurements Taken Symptom Possible Cause at Room Temperature) No Receiver Audio PA Circuit 1. Check codeplug to ensure correct frequency Audio or and signaling (PL, DPL) is enabled (use the Receive Does appropriate radio programming software).
  • Page 139 Basic Troubleshooting: Receiver Troubleshooting 9-11 Table 9-6. Receiver Troubleshooting Chart (Continued) Correction or Test (Measurements Taken Symptom Possible Cause at Room Temperature) RF Sensitivity Synthesizer Not On Check local oscillator frequency. Poor Frequency/Working If off by more than 250 Hz, then go to the page 9-12 Synthesizer Troubleshooting Chart ( Antenna Switch...

  • Page 140: Synthesizer Troubleshooting

    9-12 Basic Troubleshooting: Synthesizer Troubleshooting NOTE: The P501 pins can be probed on the extender cable (see the P501 Extender Cable diagram on page 10-6 Synthesizer Troubleshooting The following table can help you troubleshoot problems that might occur in the synthesizer section of your radio.
  • Page 141 Basic Troubleshooting: Synthesizer Troubleshooting 9-13 Table 9-7. Synthesizer Troubleshooting Chart (Continued) Correction or Test (Measurements Symptom Possible Cause Taken at Room Temperature) Synthesizer Synthesizer Not Locked Check the synthesizer lock line (pin 14 of Malfunctioning J500). If > 1 V, then the synthesizer is not locked. Go to Does Not Lock on Some Channels above.
  • Page 142 9-14 Basic Troubleshooting: Synthesizer Troubleshooting Notes February 3, 2003 6881076C20-E...

  • Page 143: Chapter 10 Functional Block Diagrams And Connectors

    Chapter 10 Functional Block Diagrams and Connectors This chapter contains the ASTRO Digital Spectra and Digital Spectra Plus functional block diagrams and connector locations.

  • Page 144: Digital Spectra Functional Block Diagram (Models W3, W4, W5, W7, And W9)

    10-2 Functional Block Diagrams and Connectors: Digital Spectra Functional Block Diagram (Models W3, W4, W5, W7, and W9) 10.1 Digital Spectra Functional Block Diagram (Models W3, W4, W5, W7, and W9) HIGH-POWER PA MID/LOW-POWER PA ANTENNA ANTENNA CONNNECTOR CONNNECTOR DIRECTIONAL LPF/ FRONT-END COUPLER/...

  • Page 145: Digital Spectra Plus Functional Block Diagram (Models W3, W4, W5, W7, And W9)

    Functional Block Diagrams and Connectors: Digital Spectra Plus Functional Block Diagram (Models W3, W4, W5, W7, and W9) 10-3 10.2 Digital Spectra Plus Functional Block Diagram (Models W3, W4, W5, W7, and W9) HIGH-POWER PA MID/LOW-POWER PA ANTENNA ANTENNA CONNNECTOR CONNNECTOR DIRECTIONAL LPF/...

  • Page 146: Radio Connectors

    10-4 Functional Block Diagrams and Connectors: Radio Connectors 10.3 Radio Connectors FIL AUD SHLD BATT - PTT/ VIP 1 DATA BATT + ANALOG EMER BUS + SENSE VIP IN 1 EMGCY (A+) VIP 2 SPKR SPARE SWB + BATT - IGN - BUS + VIP 2...

  • Page 147: Radio Connector Locations

    Functional Block Diagrams and Connectors: Radio Connector Locations 10-5 10.4 Radio Connector Locations 10.5 Radio Connector Locations (cont.) COMMAND BOARD (VIEWED FROM SIDE 1) DASH-MOUNT RADIO ANTENNA P503 P502 F500 U450 J500 P104 P501 MAEPF-24496-O Figure 10-8. Dash-Mount Radio Connector Locations P502 ANTENNA Figure 10-10.

  • Page 148: Extender Cable (P501)

    10-6 Functional Block Diagrams and Connectors: Extender Cable (P501) 10.6 Extender Cable (P501) 10.7 Control Head Cabling Diagram CONTROL HEAD RADIO P1001 IGN+ IGN- P501 BATT+ EXTENDER BATT+ CABLE (3080370E06) BATT- (FACING TOWARD SPARE 2 SPARE 2 CONTROL HEAD) BATT- EMERGENCY EMERGENCY SPARE 1...

  • Page 149: Chapter 11 Exploded Views And Parts Lists

    Chapter 11 Exploded Views and Parts Lists This chapter contains the exploded views and associated parts lists for each of the ASTRO Digital Spectra and Digital Spectra Plus control heads. Tables containing pushbutton parts lists are also included.

  • Page 150: Model W3 Hand-Held Control Head Exploded View

    Exploded Views and Parts Lists: Model W3 Hand-Held Control Head Exploded View 11.1 Model W3 Hand-Held Control Head Exploded View Table 11-1. Model W3 Hand-Held Control Head Exploded View Parts List Item No. Motorola Part No. Description Not available LABEL...

  • Page 151: Model W4 Rotary Control Head Exploded View

    Exploded Views and Parts Lists: Model W4 Rotary Control Head Exploded View 11-3 11.2 Model W4 Rotary Control Head Exploded View Table 11-2. Model W4 Rotary Control Head Parts List Item No. Motorola Part No. Description 0380077M01 SCREW, Control Head Mounting (Qty 2) 3602113Z05...

  • Page 152: Models W5 And W7 Pushbutton Control Head Exploded View

    Exploded Views and Parts Lists: Models W5 and W7 Pushbutton Control Head Exploded View 11.3 Models W5 and W7 Pushbutton Control Head Exploded View Table 11-3. Models W5 and W7 Pushbutton Control Head Parts List Item No. Motorola Part No. Description 3880227M04 SWITCH, On/Off Cap...

  • Page 153: Model W9 Pushbutton Control Head Exploded View

    Exploded Views and Parts Lists: Model W9 Pushbutton Control Head Exploded View 11-5 11.4 Model W9 Pushbutton Control Head Exploded View Table 11-4. Model W9 Pushbutton Control Head Parts List (Continued) Item No. Motorola Part No. Description 3205145X01 GASKET, Internal Frame 6105126X01...

  • Page 154: Low-Power (15W) Radio Exploded View

    11-6 Exploded Views and Parts Lists: Low-Power (15W) Radio Exploded View 11.5 Low-Power (15W) Radio Exploded View Table 11-5. Low-Power (15W) Radio Parts List (Continued) Item No. Motorola Part No. Description 4205566W01 CLIP, Encryption Board (Optional) 2880260M03 HEADER, Floating 0780086N01...

  • Page 155: Mid-Power (20-40/25-50/35W) Radio Exploded View

    Exploded Views and Parts Lists: Mid-Power (20-40/25-50/35W) Radio Exploded View 11-7 11.6 Mid-Power (20-40/25-50/35W) Radio Exploded View Table 11-6. Mid-Power (20-40/25-50/35W) Radio Parts List Table 11-6. Mid-Power (20-40/25-50/35W) Radio Parts List Item Motorola Item Motorola Description Description Part No. Part No.

  • Page 156: High-Power (50-110W) Radio Exploded View

    11-8 Exploded Views and Parts Lists: High-Power (50-110W) Radio Exploded View 11.7 High-Power (50-110W) Radio Exploded View Table 11-7. High-Power (50-110W) Radio Parts List Table 11-7. High-Power (50-110W) Radio Parts List Item Motorola Item Motorola Description Description Part No. Part No.

  • Page 157: Motorcycle Interconnect Board And Assembly

    Figure 11-8. Motorcycle Interconnect Board and Assembly (HLN6365) Exploded View Table 11-9. Low- and Mid-Power Interconnect Board and Assembly (HLN6344) Parts List Table 11-8. Motorcycle Interconnect Board and Assembly (HLN6365) Parts List Item No. Motorola Part No. Description Item No. Motorola Part No.

  • Page 158: Small Pushbutton Parts

    11-10 Exploded Views and Parts Lists: Small Pushbutton Parts 11.10 Small Pushbutton Parts 11.11 Large Pushbutton Parts Table 11-11. Large Pushbutton Parts List (Continued) Table 11-11. Large Pushbutton Parts List (Continued) Graphic Graphic Graphic Graphic Table 11-10. Small Pushbutton Parts List Table 11-11.

  • Page 159: Appendix A Replacement Parts Ordering

    Chart in the front of this manual, read the Transceiver Board or VOCON Board note, and include the proper information with your order. Motorola Online Motorola Online users can access our online catalog at https://www.motorola.com/businessonline To register for online access, please call 800-814-0601 (for U.S. and Canada Service Centers only).

  • Page 160: Telephone Orders

    Replacement Parts Ordering Telephone Orders Telephone Orders Customer Care and Services Division* (United States and Canada) 7:00 AM to 7:00 PM (Central Standard Time) Monday through Friday (Chicago, U.S.A.) 1-800-422-4210 1-847-538-8023 (International Orders) U.S. Federal Government Markets Division (USFGMD) 1-800-826-1913 Federal Government Parts - Credit Cards Only 8:30 AM to 5:00 PM (Eastern Standard Time) Fax Orders Customer Care and Services Division*...

  • Page 161: Glossary

    Glossary Glossary This glossary contains an alphabetical listing of terms and their definitions that are applicable to ASTRO portable and mobile subscriber radio products. Term Definition See analog-to-digital conversion. Abacus IC A custom integrated circuit providing a digital receiver intermediate frequency (IF) backend.
  • Page 162 Glossary-2 Term Definition See Customer Programming Software. Customer Software with a graphical user interface containing the feature set of an Programming ASTRO radio. See also RSS. Software See digital-to-analog conversion. See digital-to-analog converter. default A pre-defined set of parameters. digital Refers to data that is stored or transmitted as a sequence of discrete symbols from a finite set;...
  • Page 163 FLASHcodes are only applicable for radios which are upgradeable through the FLASHport process. FLASHport A Motorola term that describes the ability of a radio to change memory. Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to, again and again.
  • Page 164 SPI data line from a peripheral to the MCU. Master Out Slave In SPI data line from the MCU to a peripheral. See microcontroller unit. Motorola Digital Communications. MCU/DSP Interface internal to the Patriot IC. See Megahertz. Megahertz One million cycles per second. Used especially as a radio-frequency unit.
  • Page 165 Data transmitted on the control channel from the central controller to the word subscriber unit. over-molded pad- A Motorola custom IC package, distinguished by the presence of solder array carrier balls on the bottom pads. over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the radio.
  • Page 166 Glossary-6 Term Definition See Push-to-Talk. Push-to-Talk The switch or button usually located on the left side of the radio which, when pressed, causes the radio to transmit. When the PTT is released, the unit returns to receive operation. radio frequency The portion of the electromagnetic spectrum between audio sound and infrared light (approximately 10 kHz to 10 GHz).
  • Page 167 Glossary-7 Term Definition RPCIC Regulator/power control IC. RPT/TA See repeater/talkaround. See Radio Service Software. See real-time clock. Receive. RX DATA Recovered digital data line. See Serial Audio CODEC Port. SCI IN Serial Communications Interface Input line. Serial Audio CODEC SSI to and from the GCAP II IC CODEC used to transfer transmit and Port receive audio data.
  • Page 168 Glossary-8 Term Definition Standby mode An operating mode in which the radio is muted but still continues to monitor data. static RAM A type of memory used for volatile, program/data memory that does not need to be refreshed. Synchronous Serial DSP interface to peripherals that consists of a clock signal line, a frame Interface synchronization signal line, and a data line.
  • Page 169 Glossary-9 Term Definition vocoder An electronic device for synthesizing speech by implementing a compression algorithm particular to voice. See also voice encoder. vocoder/controller A PC board that contains an ASTRO radio’s microcontroller, DSP, memory, audio and power functions, and interface support circuitry. voice encoder The DSP-based system for digitally processing analog signals, and includes the capabilities of performing voice compression algorithms or...
  • Page 170 Glossary-10 Notes February 3, 2003 6881076C20-E...

  • Page 171: Index

    Index Index controls and indicators .......... 3-3 descriptions ............1-2 ignition sense circuits ..........3-4 power supplies ............3-4 status LEDs ............3-3 Numerics theory of operation ..........3-2 controls, control head .........1-5, 3-3 800 MHz radio specifications ....... xxxviii copyrights computer software .............ii document ..............ii...
  • Page 172 Index-ii ASTRO Digital Spectra Plus ........4-7 equipment ............. 4-5 FLASHport technology ..........1-2 notations frequencies, test ............5-4 manual ..............1-1 front-end receiver theory of operation ....... 3-5 warning, caution, and danger ........ 1-1 front-panel access test-mode displays ...... 5-2 operation handling precautions ..........
  • Page 173 Index-iii small ..............11-10 screen reference oscillator alignment ......6-4 radio service menu ............. 6-2 descriptions ............1-1 transmit current limit alignment ......6-6 features ..............1-2 transmit deviation balance (compensation) information screen ..........6-14 alignment ............ 6-8 upgrading with FLASHport ........1-2 transmit deviation limit alignment ......
  • Page 174 Index-iv current limit alignment RSS ..............6-6 tuner ..............6-18 UHF specifications ..........xxxvii current limit alignment screen RSS ..............6-6 tuner ..............6-18 deviation balance (compensation) alignment RSS ..............6-7 board replacement ..........8-14 tuner ..............6-18 theory of operation ..........3-6 deviation balance (compensation) alignment screen vehicle interface port RSS ..............
  • Page 176 Motorola, Inc. 8000 West Sunrise Boulevard Ft. Lauderdale, FL 33322 MOTOROLA, the Stylized M Logo, ASTRO, and Spectra are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners.

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