Alinco dj596 Service Manual

DJ-596T / DJ-596E

Service Manual

CONTENTS

SPECIFICATIONS

1) GENERAL ................................................................ 2

2) TRANSMITTER ........................................................ 2

3) RECEIVER ............................................................... 2

CIRCUIT DESCRIPTION

1) [RX] ...................................................................... 3~5

2) [TX]........................................................................... 5

3) M38267M8L(XA0844)........................................... 6~8

SEMICONDUCTOR D ATA

1) µPC2710T (XA0449) ................................................ 9

2) S-81350HG-KD-T1 (XA0724) ................................... 9

3) 24LC32AT-I/SN (XA0604) ....................................... 10

4) M5222FP-600C (XA0385) ...................................... 10

5) TC4W53FU (XA0348) ............................................. 11

6) TK10931V (XA0666)............................................... 11

7) NJM2902V-TE1 (XA0596) ...................................... 12

8) NJM2070M (XA0210) ............................................. 12

9) µPD3140GS-E1 (XA0312) ...................................... 13

10) BA4510FV-E2 (XA0537) ......................................... 14

11) S-80845ALMP-EA9-T2 (XA0620) ........................... 14

12) MB88347LPFV-G-BND-EF (XA0599) ..................... 15

13) Transistor, Diode and LED Outline Drawings...........16

14) LCD Connection(EL0044) ....................................... 16

EXPLODED VIEW

1) Front View............................................................... 17

2) Rear View ............................................................... 18

PARTS LIST

MAIN Unit ......................................................... 19~24

Mechanical Parts .................................................... 24

Packing................................................................... 24

ADJUSTMENT

1) Required T est Equipment .................................. 25~26

2) Entering and releasing the adjustment mode .... 27~32

PC BO ARD VIEW .................................................. 33~34

SCHEMATIC DIAGRAM ............................................. 35

BLOCK DIA GRAM...................................................... 36

ALINCO,INC.

SPECIFICATIONS

Gener al

Type DJ-596T DJ-596E

Receiving Range
Transmitter Range

Modulation F2,F3
Frequency Stability
Ant.Impedance
Supply V oltage 6.0~16.0VDC

Current

Transmit
Receive

Battery Save Approx.25mA

Type DJ-596T DJ-596E

Power
Output

Modulation Variable Reactance
Max.Deviation 5kHz
Spurious Emission -60dB or less
Mic.Impedance

External 13.8V
EBP-50N equipped

VHF 136.000-173.995MHz 144.000-145.995MHz
UHF 400.000-511.995MHz 430.000-439.995MHz
VHF 144.000-147.995MHz 144.000-145.995MHz
UHF 420.000-449.995MHz 430.000-439.995MHz

5ppm -10˚C~+60

±
50

Ω

DC13.8V VHF Approx.1.2A UHF:Approx.1.4A

9.6V EBP-50N VHF: Approx.1.2A, UHF Approx.1.5A

Approx.75mA

(

(

˚C

)

:

Transmitter

Approx.5W

:

VHF 4.5W, UHF 4W

±

Approx.2k

Ω

:

(

)

+14˚F~+140˚F

,

)

:

Receiver

Type DJ-596T DJ-596E

System
Intermediate Frequencies 1

Sensitivity

AF Output
Spurious response 60dB or over

Squelch sensitivity Approx.-10dBµ or less

2

(

12dB SINAD)

Double-conversion super heterodyne

st

: 39.15MHz, 2nd : 450kHz

144.000-147.995MHz

420.000-449.995MHz

-15.0dBµ or less
300mW or over MAX
200mW or over 10% Distortion factor 8Ω

(
(

144.000-145.995MHz

430.000-439.995MHz

-15.0dBµ or less

)

)

CIRCUIT DESCRIPTION

1) [RX]

1. RX Method: Double Super Heterodyne Method

1st IF : FM 39.15 MHz
2nd IF :

2. Front End
VHF

UHF

3. Mixer

450 kHz

The signal input from antenna passes through the duplex er FL1 and low pass
filter, then it is amplified at RF amplifier Q17. The amplified signal is led to
band pass filter and band switch D19, then input to the mix er Q16.

The signal input from antenna passes through the duplex er FL1 and low pass
filter, then it is amplified at RF amplifier Q20. The amplified signal is led to
band pass filter and band switch D23, then input to the mix er Q16.

The input signal to the mixer Q16 and the 1st local signal are added or
subtracted at mixer Q16, and the crystal filter XF1 selects the signal of

39.15 MHz, then it is amplified at the 1st IF amplifier Q18 after the adja­cent signal is eliminated.
The 1st local signal from VCO output is supplied to the base of mixer Q16
passing through the buffer amplifier Q15. The upper side band of the local
signal is used in VHF band and the lower side band of the local signal is
used in UHF band.

4. IF

The signal amplified at the 1st IF amplifier Q18 is supplied to pin 24 of IC5 for
demodulation. Also the signal of 12.9 MHz from the reference buffer output of
IC 2 is multiplied by 3 at Q19, then it is led to pin 1 of IC5. 2 input signals are
mixed in the mixer circuit inside IC5 and converted into the 2nd IF signal of
450 kHz.
The 2nd IF signal output from pin 3 of IC5 is supplied to pin 7 of IC5 after the
adjacent signal is eliminated at the ceramic filter FL3 in WFM mode, or at the
ceramic filter FL2 in NFM mode. The input 2nd IF signal is demodulated at the
limiter amplifier and quadrature detection circuit inside IC, then output from
pin 12 of IC5 as an AF signal.

3

5. Squelch

6. A udio

7. VCO
VHF

Q24 determines the gain of AF signal output from pin 12 of IC5 according to
the WFM/NFM of IC8. Then the signal is input to pin 19 of IC5. The input signal
passes through the noise filter amplifier and rectifier circuit, then output from
pin 21 of IC5. The output signal is supplied to A/D port of microprocessor IC6,
then the microprocessor IC6 judges it to control ON/OFF of the audio output.

Q24 determines the gain of AF signal output from pin 12 of IC5 according
to the WFM/NFM of IC8. Thereby amplified signal passes through AF switch
IC15 and band pass active filter IC8, then controls AF signal level at the
microprocessor IC6 with the electronic volume IC10. The controlled AF signal
is supplied to the audio power amplifier IC9 pin 2. The input AF signal is
amplified at IC9 and output from pin 6 to drive the speaker, etc.

VCO in VHF band consists of the Colpitts oscillator. D6, D9, L15 and L20
determine the oscillating frequency, and the signal is oscillated at the transis­tor Q4. L20 is passed at shift transistor Q8 when receiving. The oscillated
signal is supplied to pin 2 of PLL-IC2 passing through the buffer amplifier Q7
and Q1.

UHF

8. PLL

VHF

VCO in UHF band consists of the Colpitts oscillator. D16, D18 and L22
determine the oscillating frequency, and the signal is oscillated at the transis­tor Q12. The oscillated signal is supplied to pin 19 of PLL-IC2 passing through
the buffer amplifier Q7 and Q1.

PLL-IC2 is used to control the oscillating frequency of VCO. IC2 is controlled
by the serial control signal sent from the microprocessor IC6. The refer­ence frequency of 12.9 MHz from IC2 oscillates the crystal oscillator X1 in­side the circuit.

IC2 compares the frequency gained by dividing the signal added to pin 2 of
IC2 by the control signal from IC6 with the frequency gained by dividing
the reference frequency of 12.9 MHz inside IC2. When the phase difference
is found as a result of phase comparison, the pulse signal is output from the
charge pump output of pin 8 of IC2, then the signal is converted into the DC
voltage at the passive filter and added to the cathode side of VCO vari-cap D6
and D9 to make the phases equal. In result the stabilized oscillation can be
done at the desired frequency.

4

UHF

2) [TX]

1. Microphone Amplifier

VHF

IC2 compares the frequency gained by dividing the signal added to pin 19 of
IC2 by the control signal from IC6 with the frequency gained by dividing the
reference frequency of 12.9 MHz inside IC2. When the phase difference is
found as a result of phase comparison, the pulse signal is output from the
charge pump output of pin 13 of IC2, then the signal is converted into the DC
voltage at the inside circuit for passive filter and added to the cathode side of
VCO vari-cap D16 and D18 to make the phases equal. In result the stabilized
oscillation can be done at the desired frequency.

The microphone amplifier IC14 has 2 operational amplifiers. The voice is
conv erted into the electric signal through the microphone, then supplied to
IC14. The input signal is amplified and pre-emphasized to be output.

The signal output from microphone amplifier is adjusted the maximum
frequency deviation in WFM mode at VR1, then adjusted the maximum
frequency deviation in NFM mode at VR2. The adjusted signal is added to the
cathode of VCO vari-cap D11 for deviation to change the capacity of the
oscillation circuit resulting the FM deviation.

UHF

2. Power Amplifier

The signal output from microphone amplifier is adjusted the maximum
frequency deviation in WFM mode at VR3, then adjusted the maximum
frequency deviation in NFM mode at VR4. Then the adjusted signal is
adde d t o the cathode of VCO vari-cap D17 for deviation to change the
capacity of the oscillation circuit resulting the FM deviation.

The oscillated signal at VCO is supplied to the power amplifier Q5, passing
through buffer amplifier Q7, driv er amplifier IC1 and Q6. The power-amplified
signal is supplied to the antenna through the duplex er after the harmonics are
attenuated enough.

5

3) M38267M8L (XA0844)

CPU
Terminal Connection

(TOP VIEW)

6

No.

1
2 P66/AN6 SQL I Noise level input for squelch
3 P65/AN5 BAT I Low battery detection input
4 P64/AN4 TIN I CTCSS/DCS tone input
5 P63/SCLK22/AN3 BP1 I Band plan 1
6 P62/SCLK21/AN2 UND O DCS signal mute
7 P61/SOUT2/AN1 DCSW O DCS signal mute
8 P60/SIN2/AN0 FKEY I Function key input

9 P57/ADT/DA2 DCS O CTCSS/DCS tone output
10 P56/DA1 DTOUT O DTMF output/EVR control output
11 P55/ CNTR1 C5C O C5V power ON/O FF out put
12 P54/ CNTR0 TBST O Tone burst output
13 P53/RTP1 STB2 O Strobe for DAC
14 P52/RTP0 RVC O VHF-RX power ON/OFF out put
15 P51/PWM3 CLK O Serial clock output
16 P50/PWM0 DATA/UL I/O Serial data output/Unlock input
17 P47/SROY1 RUC O UHF-RX power ON/OFF output
18 P46/SCLK1 STB1 O Strobe for PLL
19 P45/TXD CTX O UART data transmission output
20 P44/RXD CRX I UART data reception input
21 P43/∅/TOUT BEEP/BP2 I/O Beep tone output/Band plan 2
22 P42/INT2 RE2 I Rotar y encoder input
23
24 P40 SD O Signal detection output
25
26 P76 DSQ I Digital squelch input
27 P75 SSTB O Strobe signal to scramble IC
28 P74 AFS O AF switch output
29 P73 C/S O Digital scramble ON/OFF
30 P72 DUD I Digital u n it detect
31 P71 SCR I Scramble IC ready signal
32 P70/INTO BU I Back up signal detection input
33
34
35
36
37
38 VSS VSS CPU GND
39 P27 PSW I Power switch input
40 P26 SDA O Serial da ta output for EEPROM
41 P25 SCL O Serial clock output for EEPROM
42 P24 RE1 I Rotary encoder input
43 P23 KI0 I Key matrix input
44 P22 KI1 I Key matrix input
45 P21 KI2 I Key matrix input
46 P20 KI3 I Key matrix input
47 P17 KO3 O Key matrix out put

48 P16 KO2 O Key matrix out put

Terminal

P67/AN7 SMT I S-meter input

P41/INT1 STL I Steal input

RESET RESET I Reset input

XCIN NC _

XCOUT NC

XOUT XOUT O Clock output

P77 PT5 I PTT input

Signal I/O Description

,

_

_

_

XIN XIN I Clock input

_

Tuning voltage output

7

No.

49 P15/SEG39 KO1 O Key matrix output
50 P14/ SEG38 KO0 O Key matrix output
51 P13/ SEG37 PUC O UHF-PLL power ON/OFF output
52 P12/ SEG36 PVC O VHF-PLL power ON/OFF output
53 P11/ SEG35 TUC O UHF-TX power ON/OFF output
54 P10/ SEG34 AFP O AF AMP power ON/OFF output
55 P07/SEG33 TVC O VHF-TX power ON/OFF output
56 P06/SEG32 R5C O RX power ON/OFF output
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78

79 SEG9 SEG9 O

80
81
82
83
84
85
86
87
88

89
90
91
92 CO M 3 COM3 O LCD COM3 output

93 CO M 2 COM2 O LCD COM2 output
94 CO M 1 COM1 O LCD COM1 output
95 CO M 0 COM0 O LCD COM0 output
96 VL3 VL3 I LCD power supply
97 VL2 VL2 I LCD power supply
98

99

100 VL1 VL1 I LCD power supply

Terminal

P05/SEG31 SEG31 O
P04/SEG30 SEG30 O
P03/SEG29 SEG29 O
P02/SEG28 SEG28 O
P01/SEG27 SEG27 O
P00/SEG26 SEG26 O
P37/SEG25 SEG25 O
P36/SEG24 SEG24 O
P35/SEG23 SEG23 O
P34/SEG22 SEG22 O
P33/SEG21 SEG21 O
P32/SEG20 SEG20 O
P31/SEG19 SEG19 O
P30/SEG18 SEG18 O

SEG17 SEG17 O
SEG16 SEG16 O
SEG15 SEG15 O
SEG14 SEG14 O
SEG13 SEG13 O
SEG12 SEG12 O
SEG11 SEG11 O
SEG10 SEG10 O

SEG8 SEG8 O
SEG7 SEG7 O
SEG6 SEG6 O
SEG5 SEG5 O
SEG4 SEG4 O
SEG3 SEG3 O
SEG2 SEG2 O
SEG1 SEG1 O
SEG0 SEG0 O

VCC VDD CPU power t ermina l
VREF VREF AD converter power supply
AVSS AVSS AD converter GND

Signal I/O

LCD segment signal

_
_

_

C2 NC
C1 NC

_
_

_

Description

8

SEMICONDUCTOR DATA

µµ

1)

µPC2710T (XA0449)

µµ

RF Amplifier

Parameter Symbol Condition Ratings Unit
Supply voltage Vcc 5.0 V
Circuit current Icc Vcc=5V, no signa 22 mA
Power gain GP Vcc=5V, f=500MHz 33 dB
Staturated output power Po(sat) Vcc=5V, f=500MHz, Pin=-8dBm +13.5 dBm
Noise figure NF Vcc=5V, f=500MHz 3.5 dB
Upper frequency (-3dB) fu Vcc=5V, Reference freq. =100MHz 1000 MHz
Isolation ISL Vcc=5V, f=500MHz 39 dB
Input return loss RL in Vcc=5V, f=500MHz 6 dB
Output return loss RL out Vcc=5V, f=500MHz 12 dB
Gain flatness Gp Vcc=5V, f=0.1~0.6GHz 0.8 dB

Test Circuit

Vcc

T op Vie w

1000p

6

50W

IN OUT

1000p

1

2, 3, 5

4

2) S-81350HG-KD-T1 (XA0724)

Top View

1 V

OUT

2 GND

E

K D

1 2 3

3

3

VIN

L: 20.5T. 2mml.D.

0.25UEW

50Ω

1000p

V

DD

2

3

V

SS

GND

GND

Input

*

+

-

V

REF

*

Output

GND

Vcc

1

OUT

9

3) 24LC32AT-I/SN (XA0604)

32K 2.5V I2C Serial EEPROM

PDIP

A0
A1
A2

Vss SDA

Vcc
WP
SCL

4) M5222FP-600C (XA0385)

Electronic V olume

Name

A0..A2

Vss

SDA
SCL

WP Write Protect Input
Vcc

User Configurable Chip Selects
Ground

Serial Address/Data I/O
Serial Clock

+2.5V~6.0V Power Supply

Function

10

6) TK10931V (XA0666)

Pin Assignment / BLOCK Diagram (Top View)

5) TC4W53FU (XA0348)

OSC(B)

OSC(E)

MIX OUTPUT

Vcc

AM IF INPUT

DECOUPLING

FM IF INPUT

DECOUPLING

DECOUPLING

1 2 3 4 5 6 7 8 9 10 11 12

AMP

FM

OSC

MIXER

AMP

AM

COMP

AMP

Vref

AGC

RECT

Vcc

24 23 22 21 20 19 18 17 16 15 14 13

RF INPUT

GND

COMP OUTPUT

COMP INPUT

NOISE AMP OUTPUT

NOISE AMP INPUT

AM AGC INPUT

AGC AMP OUTPUT

RF AGC OUTPUT

11

LIM OUTPUT

QUAD INPUT

FM DET OUTPUT

RSSI

FM DET

DET

AM

RSSI OUTPUT

AM SW

AM DET OUT

7) NJM2902V-TE1 (XA0596)

Quad Single Supply Operational Amplifier

8) NJM2070M (XA0210)

12