ASTRO Digital Spectra And Digital Spectra Plus

ASTRO Digital Spectraand Digital Spectra PlusUHF/VHF/800 MHz Mobile RadiosDetailed Service Manual

ForewordThis manual provides sufficient information to enable qualified service technicians to troubleshoot and repair ASTRO Digital Spectra and ASTRO Digital Spectra Plus mobile radios (models W3, W4, W5, W7, and W9) to the component level.For the most part, the information in this manual pertains to both ASTRO Digital Spectra and ASTRO Digital Spectra Plusradios. Exceptions are clearly noted where they occur.For details on radio operation or basic troubleshooting, refer to the applicable manuals available separately. A list of relatedpublications is provided in the section, “Related Publications,” on page xiv.Product Safety and RF Exposure Compliance!CautionBefore using this product, read the operating instructionsfor safe usage contained in the Product Safety and RFExposure booklet enclosed with your radio.ATTENTION!This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.Before using this product, read the RF energy awareness information and operating instructions in theProduct Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number68P81095C99) to ensure compliance with RF energy exposure limits.Manual RevisionsChanges which occur after this manual is printed are described in FMRs (Florida Manual Revisions). These FMRs providecomplete replacement pages for all added, changed, and deleted items, including pertinent parts list data, schematics, andcomponent layout diagrams.Computer Software CopyrightsThe Motorola products described in this manual may include copyrighted Motorola computer programs stored insemiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certainexclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce inany form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in theMotorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed inany manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall notbe deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents orpatent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in thesale of a product.Document CopyrightsNo duplication or distribution of this document or any portion thereof shall take place without the express written permissionof Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronicor mechanical, for any purpose without the express written permission of Motorola.DisclaimerThe information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility isassumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improvereadability, function, or design. Motorola does not assume any liability arising out of the applications or use of any productor circuit described herein; nor does it cover any license under its patent rights nor the rights of others.TrademarksMOTOROLA, the Stylized M logo, ASTRO, and Spectra are registered in the US Patent & Trademark Office. All otherproducts or service names are the property of their respective owners. Motorola, Inc. 2002.ii

Table of ContentsForeword .iiProduct Safety and RF Exposure Compliance .iiManual Revisions .iiComputer Software Copyrights .iiDocument Copyrights .iiDisclaimer.iiTrademarks .iiCommercial Warranty .xvLimited Warranty .xvMOTOROLA COMMUNICATION PRODUCTS .xvI. What This Warranty Covers And For How Long .xvII. General Provisions .xvIII. State Law Rights . xviIV. How To Get Warranty Service . xviV. What This Warranty Does Not Cover. xviVI. Patent And Software Provisions . xviiVII. Governing Law. xviiModel Numbering, Charts, and Specifications.xixMobile Radio Model Numbering Scheme . xixASTRO Digital Spectra Motorcycle 15 Watt (Ranges 1 and 2) Model Chart.xxASTRO Digital Spectra Motorcycle 15 Watt (Ranges 3 and 3.5) Model Chart. xxiASTRO Digital Spectra VHF 10–25 Watt Model Chart. xxiiASTRO Digital Spectra VHF 10–25 and 50–110 Watt Model Chart. xxiiiASTRO Digital Spectra UHF 10–25 Watt Model Chart . xxvASTRO Digital Spectra UHF 20–40 Watt Model Chart . xxviASTRO Digital Spectra UHF 50–110 Watt Model Chart .xxviiiASTRO Digital Spectra 800 MHz Model Chart. xxxASTRO Digital Spectra Plus VHF 25–50 and 50–110 Watt Model Chart. xxxiASTRO Digital Spectra Plus 800 MHz Model Chart.xxxiiiVHF Radio Specifications. xxxvUHF Radio Specifications. xxxvi800 MHz Radio Specifications.xxxviiChapter 11.11.2Introduction . 1-1General . 1-1Notations Used in This Manual. 1-2

ivTable of ContentsChapter 2General Overview. 2-12.12.22.32.4Introduction . 2-1Analog Mode of Operation . 2-2ASTRO Mode of Operation. 2-2Control Head Assembly . 2-22.4.1 Display (W3 Model). 2-22.4.2 Display (W4, W5, and W7 Models) . 2-22.4.3 Display (W9 Model). 2-32.4.4 Vacuum Fluorescent Display Driver. 2-32.4.5 Vacuum Fluorescent Voltage Source (W9 Model) . 2-32.4.6 Controls and Indicators . 2-32.4.7 Status LEDs . 2-32.4.8 Backlight LEDs. 2-32.4.9 Vehicle Interface Ports. 2-42.4.10 Power Supplies . 2-42.4.11 Ignition Sense Circuits . 2-42.5 Power Amplifier. 2-52.5.1 Gain Stages . 2-52.5.2 Power Control . 2-52.5.3 Circuit Protection. 2-52.5.4 DC Interconnect . 2-52.6 Front-End Receiver Assembly . 2-62.7 RF Board Basic. 2-62.8 Voltage-Controlled Oscillator . 2-62.8.1 VHF Radios. 2-62.8.2 UHF and 800 MHz Radios . 2-72.9 Command Board. 2-72.10 ASTRO Spectra Vocoder/Controller Board. 2-72.11 Radio Power . 2-82.11.1 General . 2-82.11.2 B Routing for ASTRO Spectra VOCON Board . 2-9Chapter 33.13.2Theory of Operation. 3-1RF Board. 3-13.1.1 General . 3-13.1.2 Synthesizer . 3-33.1.2.1 Reference Frequency Generation. 3-33.1.2.2 First VCO Frequency Generation . 3-33.1.2.3 Programmable Reference Divider. 3-43.1.2.4 Phase Modulator. 3-53.1.2.5 Loop Filter . 3-53.1.2.6 Auxiliary Control Bits. 3-53.1.2.7 Second VCO . 3-63.1.2.8 Power Distribution. 3-63.1.3 Receiver Back-End . 3-63.1.3.1 First IF. 3-63.1.3.2 ABACUS II IC. 3-7Command Board. 3-83.2.1 Microcontroller and Support ICs . 3-83.2.2 Serial Input/Output IC . 3-83.2.3 Power-Up/-Down Sequence . 3-9July 1, 200268P81076C25-C

Table of Contents3.33.43.5v3.2.4 Regulators . 3-103.2.5 Reset Circuits . 3-103.2.6 Serial Communications on the External Bus . 3-113.2.7 Synchronous Serial Bus (MOSI) . 3-123.2.8 Received Audio. 3-123.2.9 Microphone Audio . 3-123.2.10 Transmit Deviation . 3-133.2.11 RS-232 Line Driver . 3-133.2.12 Flash Programming . 3-133.2.13 Encryption Voltages . 3-133.2.14 Regulator and Power-Control IC. 3-14ASTRO Spectra VOCON Board . 3-153.3.1 General . 3-153.3.2 Controller Section . 3-153.3.3 Vocoder Section . 3-173.3.4 RX Signal Path . 3-183.3.5 TX Signal Path . 3-213.3.6 Controller Bootstrap and Asynchronous Buses . 3-223.3.7 Vocoder Bootstrap . 3-243.3.8 Serial Peripheral Interface (SPI) Bus . 3-243.3.9 Controller Memory Map . 3-243.3.10 Vocoder Memory Map . 3-263.3.11 MCU System Clock. 3-283.3.12 DSP System Clock . 3-283.3.13 Radio Power-Up/Power-Down Sequence. 3-283.3.14 VOCON BOARD Signals . 3-29ASTRO Spectra Plus VOCON Board . 3-383.4.1 General . 3-383.4.2 ASTRO Spectra Plus Controller Section . 3-383.4.3 ASTRO Spectra Plus Vocoder Section. 3-393.4.4 ASTRO Spectra Plus RX Signal Path. 3-413.4.5 ASTRO Spectra Plus TX Signal Path . 3-423.4.6 ASTRO Spectra Plus Controller Bootstrap and Asynchronous Busses . 3-433.4.7 ASTRO Spectra Plus Serial Peripheral Interface Bus . 3-443.4.8 ASTRO Spectra Plus MCU and DSP System Clocks. 3-443.4.9 ASTRO Spectra Plus Voltage Regulators . 3-453.4.10 ASTRO Spectra Plus Radio Power-Up/Power-Down Sequence . 3-46Voltage Control Oscillator . 3-473.5.1 VHF Band . 3-473.5.1.1 General . 3-473.5.1.2 DC Voltage Supplies. 3-473.5.1.3 VCO . 3-473.5.1.4 Synthesizer Feedback . 3-483.5.1.5 RX Buffer Circuitry . 3-483.5.1.6 Frequency Divider and TX Buffer Circuitry . 3-483.5.2 UHF Band . 3-483.5.2.1 General . 3-483.5.2.2 Super Filter 8.6 V. 3-493.5.2.3 VCO . 3-493.5.2.4 Receive Mode (AUX2* Low) . 3-493.5.2.5 Transmit Mode (AUX2* High) . 3-493.5.2.6 Bandshift Circuit. 3-493.5.2.7 Output Buffer . 3-493.5.2.8 First Buffer . 3-4968P81076C25-CJuly 1, 2002

viTable of Contents3.63.73.5.2.9 Doubler . 3-503.5.2.10 Synthesizer Feedback . 3-503.5.2.11 Second Buffer . 3-503.5.2.12 Receive/Transmit Switch . 3-503.5.3 800 MHz Band . 3-503.5.3.1 General . 3-503.5.3.2 Super Filter 8.6 V . 3-503.5.3.3 VCO . 3-503.5.3.4 Receive Mode-AUX 1* and AUX 2* High. 3-513.5.3.5 Transmit Mode-AUX 1* High; AUX 2* Low . 3-513.5.3.6 TalkAround Mode-AUX 1* Low; AUX 2* Low. 3-513.5.3.7 VCO Buffer. 3-513.5.3.8 First Buffer Circuit . 3-513.5.3.9 Doubler . 3-513.5.3.10 Second Buffer . 3-523.5.3.11 K9.4 V Switch. 3-52Receiver Front-End. 3-533.6.1 VHF Band . 3-533.6.1.1 General . 3-533.6.1.2 Theory of Operation . 3-533.6.2 UHF Band . 3-533.6.2.1 General . 3-533.6.2.2 Theory of Operation . 3-543.6.3 800 MHz Band . 3-543.6.3.1 General . 3-543.6.3.2 Theory of Operation . 3-54Power Amplifiers . 3-553.7.1 VHF Band Power Amplifiers . 3-553.7.1.1 High-Power Amplifier . 3-553.7.1.1.1 Transmitter. 3-553.7.1.1.2 Antenna Switch and Harmonic Filter. 3-563.7.1.1.3 Power Control Circuitry . 3-573.7.1.2 25/10-Watt Power Amplifier . 3-593.7.1.2.1 Antenna Switch and Harmonic Filter. 3-603.7.1.2.2 Power Control Circuitry . 3-603.7.1.3 50-Watt Power Amplifiers . 3-633.7.1.3.1 Transmitter. 3-633.7.1.3.2 Antenna Switch and Harmonic Filter. 3-643.7.1.3.3 Power Control Circuitry . 3-653.7.2 UHF Band Power Amplifiers . 3-683.7.2.1 High-Power Amplifier . 3-683.7.2.1.1 Transmitter. 3-683.7.2.1.2 Antenna Switch and Harmonic Filter. 3-693.7.2.1.3 Power Control Circuitry . 3-693.7.2.2 40-Watt Power Amplifier . 3-723.7.2.2.1 Transmitter. 3-723.7.2.2.2 Antenna Switch and Harmonic Filter. 3-733.7.2.2.3 Power Control Circuitry . 3-743.7.3 800 MHz Band Power Amplifiers . 3-773.7.3.1 15- and 35-Watt Amplifiers . 3-773.7.3.1.1 Transmitter. 3-773.7.3.1.2 Antenna Switch and Harmonic Filter. 3-783.7.3.1.3 Power Control Circuitry . 3-793.7.3.1.4 Temperature Sensing . 3-81July 1, 200268P81076C25-C

Table of ContentsChapter 44.14.24.34.44.5viiTroubleshooting Procedures . 4-1ASTRO Spectra Procedures. 4-14.1.1 Handling Precautions. 4-14.1.2 Voltage Measurement and Signal Tracing. 4-24.1.3 Power-Up Self-Check Errors . 4-24.1.3.1 Power-Up Sequence. 4-34.1.4 RF Board Troubleshooting. 4-54.1.4.1 Display Flashes “FAIL 001” . 4-54.1.4.1.1 Incorrect Values at U602, Pin 19 .

Digital Spectra and ASTRO Digital Spectra Plus mobile radios (mode ls W3, W4, W5, W7, and W9) to the component level. For the most part, the information in this manual pertains to both ASTRO Digital Spectra and ASTRO Digital Spectra Plus radios. Exceptions are clearly noted where they occur.