Ericsson LBI-39175A User Manual

SERVICE SECTION

ORION™

136-174 MHz Dual Bandwidth

SYNTHESIZED TWO-WAY FM RADIO

TABLE OF CONTENTS

DESCRIPTION ........................................................................................................................... 2

INITIAL MEASUREMENTS ..................................................................................................... 2

TRANSMITTER........................................................................................................... 2

RECEIVER.................................................................................................................... 2

MAINTENANCE........................................................................................................................ 3

PREVENTIVE MAINTENANCE ................................................................................ 3

DISASSEMBLY PROCEDURE................................................................................... 4

LBI-39175A

Page

ALIGNMENT PROCEDURES................................................................................................... 7

INTRODUCTION......................................................................................................... 7

TRACKING DATA....................................................................................................... 9

TEST FREQUENCIES.................................................................................................. 9

SETTING TRACKING DATA.....................................................................................10

TRANSMITTER ALIGNMENT.................................................................................................11

PA TRANSISTOR REPLACEMENT...........................................................................11

RECEIVER ALIGNMENT .........................................................................................................12

TEST EQUIPMENT REQUIRED ................................................................................12

ADJUSTMENT PROCEDURES..................................................................................12

SQUELCH ADJUSTMENT..........................................................................................13

TROUBLESHOOTING GUIDE .................................................................................................13

INTRODUCTION.........................................................................................................13

MICROPHONICS.........................................................................................................13

SERVICEABLE PARTS...............................................................................................14

DIAGNOSTIC PROCEDURES ..................................................................................................15

ADDITIONAL TOOLS REQUIRED............................................................................16

ERROR CODES............................................................................................................19

ericssonz

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BI-39175A

DESCRIPTION

This section contains the information required to
service the ORION VHF Dual Bandwidth two-way FM
radio. Included are disassembly procedures, alignment
procedures, and troubleshooting information (see Table of
Contents).

This radio is adjusted by setting personality
parameters stored in the radio's computer memory.
Therefore, all radio alignment procedures require the use
of a Personal Computer (IBM PC or equivalent), along
with a Programming Interface TQ3370, and an ORION
PC Programming Cable TQ3377. PC Programming
Software Version 4.00 or later is also required.

This radio is designed to be serviced by
replacement of modules and/or circuit boards. As such,
there are very few serviceable component parts contained
on any of the circuit boards within the radio. Normally,
defective boards should be replaced, and returned to an
Authorized Service Center. Any serviceable parts are
listed in the troubleshooting guide for the individual
circuit boards.

INITIAL MEASUREMENTS

After the radio has been installed as described in
the Installation Manual, the following measurements
should be made by a certified electronics technician, and
recorded for future reference:

TRANSMITTER

• RF Power into 50 ohm resistive load

• Forward Power into antenna

• Reflected Power from antenna

• Carrier Frequency

• Modulation Deviation

RECEIVER

• 12 dB SINAD Sensitivity from FM signal

generator

Copyright© December 1995, Ericsson Inc.

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MAINTENANCE

PREVENTIVE MAINTENANCE

NOTE

To ensure high operating efficiency, and to prevent mechanical and electrical failures from interrupting system
operations, routine checks should be made of all mechanical and electrical equipment at regular intervals. This
preventive maintenance should include the checks as listed in Table 1, Maintenance Checks.

Table 1 - Maintenance Checks

MAINTENANCE CHECKS INTERVAL

CONNECTIONS - Ground connections and connections to the voltage source
should be periodically checked for tightness. Loose or poor connections to the
power source will cause excessive voltage drops and faulty operation. When
ground connections are not made directly to the battery, the connection from the
battery to vehicle chassis must be checked for low impedance. A high
impedance may cause excessive voltage drops and alternator noise problems.

Every

6

months

ELECTRICAL SYSTEM - Check the voltage regulator and alternator or
generator periodically to keep the electrical system within safe and economical
operating limits. Overvoltage is indicated when the battery loses water rapidly.
Usage of 1 or 2 ounces of water per cell per week is acceptable for batteries in
continuous operation. A weak battery will often cause excessive noise or faulty
operation.

MECHANICAL INSPECTION - Since mobile units are subject to constant
shock and vibration, check for loose plugs, nuts, screws, and parts to make sure
that nothing is working loose. Be sure that all screws are properly torqued.

ANTENNA INSPECTION - The antenna, antenna base, and all contacts should
be kept clean and free from dirt or corrosion. If the antenna or its base should
become coated or poorly grounded, loss of radiation and a weak signal will
result.

ALIGNMENT - The transmitter and receiver measurements should be checked
periodically. Refer to the applicable Alignment Procedure and troublesho oting
sheet for typical voltage readings.

FREQUENCY CHECK - Check transmitter frequency and deviation, as
required by the FCC. Normally, these checks are made when the unit is first put
into operation, after the first six months, and once a year thereafter.

As

Required

Every 6

months

Every 6

months

As

Required

As

Required

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DISASSEMBLY PROCEDURE

To Remove the Unit from the Mounting Bracket

1. Remove Microphone, Power, and Accessory/Remote
Control Cables, as required.

2. Remove the lock screws at the side of the radio unit,
using a No. 20 TORX

3. Pull the radio, and remove the mounting bracket.

To Gain Access to the Circuitry for Servicing

RF Power Amplifier Module

1. Remove the waterproof cover on the bottom of the
module, using #20 TORX

mounting screws are captive.

2. Remove the inner shield by pulling the attached
handle.

Transceiver (TXRX) Module

1. Remove the waterproof top and bottom covers, using
a #20 TORX



are located on the bottom of the module. The screws
on the bottom cover are captive.



driver.



driver. Note that the four

driver. Four co ver mounting screws

NOTE

The VCO/Synthesizer circuitry is exposed by
removing the screws from the shield casting, also
located on the bottom of the module. However,
this is not recommended, except on extreme
situations. If the shield is removed, it should be
replaced using the exact screw torque and
installation sequence given in LBI-38909.

Control Unit (Front Mounted)

1. Expose the Logic/Audio/455 kHz IF circuitry
according to Steps 1 and 2 in

Module

section.

2. Disconnect Flex Circuit PC2 from Connector J701,
by carefully disengaging the locking tab from each
side of the connector with a jeweler's screwdriver or
tweezers. Use extreme care to avoid damaging the
plating runs or surface-mounted components on the
printed wire board (PWB) during this procedure.

3. Turn the radio upside down, and disengage the two
mounting screws, using a #10 TORX

sure to engage the screws in the captivation threads
on the Transceiver chassis. Do this by pulling each
screw upwards with tweezers or needle nose pliers,
while simultaneously turning the screw

counterclockwise with the TORX
38909 for details.

4. Disengage the control unit from the Transceiver
chassis using a pivoting motion about the top ed ge of
the Transceiver chassis.

Transceiver (TXRX)



driver. Be



driver. See LBI-

2. To expose the Logic/Audio/455 kHz IF circuitry,
remove the shield on top of the module by pulling the
attached handle.

5. Disengage the four captive screws on the rear cover,
using a #10 TORX



driver. Slide the rear cover off
the Front Panel Assembly, using care to avoid
damaging the black "O-Ring" moisture gasket

3. To expose the Exciter/RX Front End circuitry,
remove the shield on the bottom of the module by

attached to the rear cover. Note that the Flex Circuit
PC2 slides through a slot opening on the rear cover.

pulling the attached handle.

Control Head (Remote Mounting)

1. Disconnect Remote Control and Accessory cables,
using a small flat bladed screwdriver.

2. Remove the two side mounting screws from the
mounting bracket. Carefully remove the Control
Head assembly from the bracket.

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3. Disengage the four captive screws on the rear half
(also known as the Remote Interface Adapter, or
RIA) of the Control Head. Slide the two halves
apart, using care to avoid damaging the black "O­Ring" moisture gasket attached to the RIA.

4. Disconnect Flex Circuit PC2 from Connector J2, by
carefully disengaging the locking tab from each side
of the connector with a jeweler's screwdriver or
tweezers. Use extreme care to avoid damaging
plating runs or surface-mounted components in the
PWB during this procedure.

LBI-39175

NOTE

For re-assembly of the Control Units (Front and
Remote Mounting) Revision "A" or later, be sure
the black "O-Ring" is lubricated properly with
"HIVAC-G" silicone grease. (See Figures 1A and
1B for intructions.)

Steps:

1. Remove dust and dirt from the black O-Ring gasket.

2 Apply proper amount of the silicone grease to cloth.

To Re-Assemble Unit after Servicing

Essentially follow the reverse of the preceding

instructions. However, in order to preserve moisture
seals, be sure to follow the EXACT torque and
sequencing specifications for screw engagement during re­assembly. These specifications are given in LBI-38909.

3. Put the silicone grease on throughout the surface of
the black O-Ring gasket evenly. (see Figures 1A and
1B)

CAUTION

No fibers of the cloth must remain on the gasket
after silicone is applied.

4. Wipe out protruded silicone grease from the
Rear/RIA Cover.

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Figure 1A - Front Mount Control Unit "O-Ring" Lubrication

Figure 1B - Remote Mount Control Unit "O-Ring" Lubrication

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ALIGNMENT PROCEDURES

INTRODUCTION

All operations of this radio are controlled by an
embedded digital computer, which is programmed with a
personality unique to the customer. In order to align and
test the radio, it must be programmed with a specific test
personality, which will allow conventional operation on
certain test frequencies. Furthermore, certain commands,
known as Test Mode Commands, cause the radio to
perform specific test functions. These will be noted as
required in the following alignment and troubleshooting
instructions.

In order to program an ORION personality, the
radio and control unit must first be connected to a
Personal Computer via a PC Programming Cable and
hardware Programming Interface TQ3370 in one of the
configurations shown in Figures 2 and 3. Accessories
may be connected to the appropriate Accessory Cable
19B802554P1-P4 as needed.

The PC must be equipped with the PC
Programming Software Version 4.0 or later. It is assumed
in this manual that the Service Technician is familiar with
the operation of the PC Programming Software Programs.
Consult the PC Programming Software manuals for
further details regarding this software.

LBI-39175

CAUTION

Before bench testing the radio, be sure of the output
voltage characteristics of your bench power supply.

To protect the transmitter power output transistors
from possible instant destruction, the following input
voltages must not be exceeded

Transmitter unkeyed: 16.5 Volts
Transmitter keyed 16.3 Volts
(50 ohms resistive load)
Transmitter keyed 14.0 Volts
(no load or non-resistive load):

These voltages are specified at the normal vehicle
battery terminals of the radio and take the voltage
drop of standard cables into account. The voltage
limits shown for a non-optimum load is for "worst
case" conditions. For antenna mismatches likely to
be encountered in practice, the actual limit will
approach the 16.3 Volt figure.

Routine transmitter tests should be performed at EIA
Standard Test Voltages (13.6 VDC for loads of 6 to
16 amperes; 13.4 VDC for loads of 16 to 36
amperes). Input voltages must not exceed the limits
shown, even for transient peaks of short duration.

Many commonly used bench power supplies cannot
meet these requirements for load regulation and
transient voltage suppression. Bench supplies which
employ "brute force" regulation and filtering (such as
Lapp Model 73) may be usable when operated in
parallel with a 12 Volt automotive storage battery.

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Figure 2 - ORION Programming Configurations (USA)

Figure 3 - ORION Programming Configurations (EURO)

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TRACKING DATA

The radio personality contains certain
information bytes known as Tracking Data, which allow
the radio computer to calibrate transmitter power,
modulation deviation, and squelch threshold. Normally,
no adjustments need be made to the radio to maintain
specified limits for the above parameters, since the radio
computer makes the necessary adjustments using the
Tracking Data established at the factory. However,
should Transmitter PA, Synthesizer, or Logic Circuit
boards be replaced, it may be necessary to alter the
Tracking Data to re-set these parameters properly.

Table 2 - Tracking Data Frequencies (Low Split)

LBI-39175

Furthermore, if the Tracking Data is lost, specialized
procedures are required to load new Tracking Data.
therefore, it is
of the Tracking Data of every radio as it is received from
the factory. The frequencies at which Tracking Data is
established are given in the "Test Frequencies" section.

VERY IMPORTANT

to establish a record

TEST FREQUENCIES

The following frequencies are those for which
Tracking Data is established, and are used as Test
Frequencies:

Parameter RF Power Modulation

Deviation

f1L (MHz) 136.0000 136.0000 136.0000
f1H (MHz) N/A 139.9950 N/A
f2L (MHz) 140.0050 140.0050 140.0050
f2H (MHz) N/A 143.9950 N/A
f3L (MHz) 144.0050 144.0050 144.0050
f3H (MHz) N/A 147.9950 N/A
f4L (MHz) 148.0050 148.0050 148.0050
f4H (MHz) 153.0000 153.0000 153.0000

Table 3 - Tracking Data Frequencies (High Split)

Parameter RF Power Modulation

Deviation
f1L (MHz) 150.0000 150.0000 150.0000
f1H (MHz) N/A 155.4950 N/A
f2L (MHz) 155.5050 155.5050 155.5050
f2H (MHz) N/A 161.4950 N/A
f3L (MHz) 161.5050 161.5050 161.5050
f3H (MHz) N/A 167.4950 N/A
f4L (MHz) 167.5050 167.5050 167.5050
f4H (MHz) 174.0000 174.0000 174.0000

Squelch Set

Squelch Set

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SETTING TRACKING DATA

Normally, Tracking Data is set at the factory, and need not be re-loaded. However, the following repair situations

require re-loading some or all of the Tracking Data:

SITUATION NEW TRACKING DATA

Replace PA module RF Power, Squelch (Check: Re-load if necessary.)

Replace TXRX module RF Power, Modulation Deviation, Squelch, Feature

Encryption, and Data Offset

Replace Control Unit module None

Replace Synthesizer PWB Modulation Deviation and Data Offset

Replace Logic PWB RF Power, Squelch, Modulation Deviation, Feature

Encryption, and Data Offset.

To re-load Tracking Data, connect the radio in
the appropriate configuration as shown in Figures 2 and 3,
and perform the following steps:

1. Using the PC Pro gramming Software , make sure the

radio is programmed in the following sequence:

a. Customer Operational Software (if necessary)

b. Tracking Data (First Iteration -- Tracking Data

originally shipped with the radio is a good

starting point.)

c. Feature Encryption File (if necessary). Note: In

order to load an Encryption File into a new

Logic PWB, After Market Services must first be

contacted at 1-800-368-3277 for authorization

code. Otherwise the file will not load.

d. Personality, which contains a Conventional

System using the frequencies given in Tables 2

and 3.

2. Connect the radio unit in the normal operating

configuration. Activate the radio unit, and, using a
Service Monitor HP8920A or equivalent, measure the
Transmitter Power, Modulation Deviation, and
Squelch Threshold for each of the applicable
frequencies given in Tables 2 and 3. Measurements
should be within the following limits:

Parameter Limit

TX Modulation Deviation
30 kHz channel spacing 4.4 ±0.1 kHz

12.5 kHz channel spacing 2.25 ±0.1 kHz

TX High Power 110 W Model 110 +4, -0 W

50 W Model 50 +2, -0 W
25 W Model 25 +0, -1 W

TX Mid Power 25 W Model 15 +.5, -.5 W

TX Low Power 110 W Model 55 +2, -0 W

50 W Model 25 +1, -0 W
25 W Model 6 +.5 -.5 W

RX Squelch Threshold 8 +1, -0 dB

SINAD

3. If measurements are within the limits, the job is
complete. If the measurements are not within the
limits stated, re-connect the Programming
Maintenance Software "MRKMAINT." Display the
Tracking Data screen. For those frequencies where
measurements are not within the stated limits, enter
new Tracking Data, following instructions on the
screen. Program into the radio personality, and exit.

4. Repeat Steps 2 and 3 until the measurements at every
frequency given in Tables 2 and 3 are within the
limits specified.

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TRANSMITTER ALIGNMENT

The Transmitter consists of synthesizer, exciter,
and power amplifier. These have been calibrated at the
factory so the radio computer automatically adjusts RF
power and modulation deviation, based upon Tracking
Data. The following adjustments can be made by EGE
PC Programming Software:

1. Modulation Devia tion -- Change T racking Data using

"MRKMAINT" maintenance software. Follow the
procedure given in "TRACKING DATA" section.
Be sure to record the new Tracking Data and
modulation levels. DO NOT CHANGE TRACKING
DATA UNLESS THE LOGIC OR SYNTHESIZER
HAS BEEN REPLACED. DO NOT CHANGE
TRACKING DATA FOR ANY FREQUENCY
OTHER THAN THAT GIVEN IN TABLES 2 AND

3.

2. RF Power -- Set RF power for system (EDACS) or

channel (CONVENTIONAL) in the radio personality,
using "EDACS3" programming software. DO NOT
CHANGE TRACKING DATA UNLESS THE PA
MODULE OR LOGIC PWB HAS BEEN
REPLACED. DO NOT CHANGE TRACKING
DATA FOR ANY FREQUENCY OTHER THAN
THAT GIVEN IN TABLES 2 AND 3.

There are no other adjustments to be made on the

transmitter. However, there are components located on
the synthesizer and power amplifier, which appear to be
adjustable. These are summarized as follows:

Synthesizer: CV240, CV280, RV201

Power Amp - 25 W: RV1

Power Amp - 50 and 110 W: RV2

NOTICE

The components listed above have been set at the factory

and are NOT adjustable.

ANY RE-ADJUSTMENT OF THESE COMPONENTS WILL

VOID THE WARRANTY OF THIS PRODUCT.

PA TRANSISTOR REPLACEMENT

WARNING

The RF Power Transistors used in the transmitter
contain Beryllium Oxide, a
the ceramic or other encapsulation is opened,
crushed, broken, or abraded, the dust may be
hazardous if inhaled. Use care in replacing
transistors of this type.

To Replace the PA RF Transistors

1. Unsolder one lead at a time with a 50-watt soldering
iron. Use a scribe or X-acto

away from the printed circuit board until the solder
cools. Remove the mounting screws.

2. Lift out the transistor. Remove any old solder from
the printed circuit board with a vacuum de-soldering
tool. Special care should be taken to prevent damage
to the printed circuit board runs because part of the
matching network is included in the base and
collector runs.

3. Trim the new transistor leads (if required) to the lead
length of the removed transistor.

TOXIC

substance. If



knife to hold the lead

These components have been set at the factory, and

are

NOT ADJUSTABLE

THESE COMPONENTS WILL VOID THE
WARRANTY OF THIS PRODUCT.

. ANY RE-ADJUSTMENT OF

4. Apply a coat of silicone grease to the transistor
mounting surface. Place the transistor in the
mounting hole. Align the leads as shown on the
Outline Diagram. Then replace the transistor
mounting screws using moderate torque (9.4 kg.cm).

5. Solder the leads to the printed circuit pattern. Start
at the inner edge of the mounting hole and solder the
remaining length of transistor lead to the board. Take
care not to use excessive heat that causes the printed

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wire board runs to separate from the board. Check
for shorts and solder bridges before applying power.

CAUTION

Failure to solder the transistor leads as directed
may result in the generation of RF loops that
could damage the transistor or may cause low
power output.

RECEIVER ALIGNMENT

Alignment of the Front End and Local Injection
circuits are not required because band-pass filters are
employed in the ORION wide-band synthesized radio
receiver.

NOTE

Before aligning the receiver or making any
adjustments to the radio, be sure that the outp uts
of the 9 Volt Regulators IC230, IC503, and
IC481 are 9.0 ±0.2 VDC.

ADJUSTMENT PROCEDURES

Receiver Frequency Adjustment

No receiver frequency adjustment is required.

2nd Receiver Oscillator

Using a frequency counter to monitor T er minal TP5,

set L521 for a frequency of 44.645 MHz ±200 Hz.

TEST EQUIPMENT REQUIRED

• Distortion Analyzer

• AC Voltmeter

• RF Signal Generator

• Frequency Counter (136-174 MHz)

• 4-Ohm, 25 Watt Resistor

• Audio Isolation Transformer (1:1)

19A116736P1 or equivalent **

∗ These four items can be replaced with a Service

Monitor HP8920A or its equivalent.

** See Figure 4. This is not needed if instrument

input is unbalanced with respect to ground.

∗

∗

∗

∗

IF/FM Detector Alignment

Apply a 1000 microvolt, on-frequency test signal
modulated by 1000 Hz with standard deviation to antenna
jack J1.

Connect a 4-ohm, 25-watt resistor in place of the
speaker. Connect the isolation transformer input across
the resistor. Connect the isolation transformer output to
the Distortion Analyzer (see Figure 4).

Adjust the VOLUME control for 15 watts output
(7.75 VRMS) using the Distortion Analyzer as a
voltmeter.

Set the output signal level of the RF signal generator
so as to obtain 12 dB SINAD at the audio output.

Adjust coils L502, L504, L505, and L507 to obtain
minimum 12 dB SINAD.

Set the output signal level of the RF generator to
1000 microvolts.

Adjust L523 for maximum audio output.

Adjust RV501 for XTONEDEC output at ORCC to
500 mVRMS.

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TRANSFORMER

4-OHM
LOAD

Figure 4 - Audio Isolation Transformer

SQUELCH ADJUSTMENT

Squelch threshold has been set at the factory to 8 dB
SINAD. Adjustment of the threshold requires changing
the Tracking Data. To change the Squelch Tracking Data,
follow the iterative procedure set forth in the
"TRACKING DATA" section, except let the desired
squelch threshold level replace the 8 +1, -0 dB SINAD
level set at the factory. BE SURE TO CHANGE THE
TRACKING DATA FOR ALL FREQUENCIES GIVEN
IN TABLES 2 AND 3. Otherwise the level will not be
consistent across the frequency band.

ISOLATION

1 : 1

Not required if instrument
input is balanced with respect
to ground.

DISTORTION
ANALYZER

OR

AC VOLTMETER

MICROPHONICS

Synthesized radios tend to be sensitive to shock and
vibration, creating microphonics. The construction of the
ORION radio with its die-cast aluminum frame, cast
shield, and multiple board-mounting screws, provides a
high degree of immunity. When removing printed circuit
boards or shields, note the location of all mounting
hardware.

When servicing the radio be sure that no solder build ­up has occurred on the chassis or shield.

TROUBLESHOOTING GUIDE

INTRODUCTION

This radio is designed to be serviced by replacement
of modules and/or circuit boards. As such, there are very
few serviceable component parts contained on any of the
circuit boards within the radio. Normally, defective
boards should be replaced, and returned to an Authorized
Service Center. A list of serviceable parts is given in the
next section.

To assure a high degree of resistance to microphonics
be sure to replace exactly, all hardware removed. Be sure
that all mounting screws are properly torqued and shields
are in place. Refer to the Mechanical Layout Diagram
found in LBI-38909.

NOTE

Loose or rubbing parts, especially in the VCO
area, are particularly sensitive and can cause
microphonics. Again, be certain all hardware is
properly installed and torqued.

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SERVICEABLE PARTS

Control Unit - Switch Circuit CDF-368B/M

No serviceable parts.

Control Unit - Panel Control CMC-638

No serviceable parts.

Remote Control Unit - RIA NQZ-4882

J2 Connector, 18 Pin B19/5JBAX00020

Radio Unit - System Control CMC-682

F601 Fuse, 5 Amp B19/5ZFAP00008

IC604 AF Power Amplifier B19/5DAAA00350

J701 Connector, 18 Pin B19/5JDAG00315

Radio Unit - Power Amplifier 110 Watts
CAH-515H

C25 Capacitor, 270 pF (136-153 MHz) B19/5CAAA05042
C25 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03175
C26 Capacitor, 270 pF (136-153 MHz) B19/5CAAA05042
C26 Capacitor, 200 pF (150-174 MHz) B19/5CAAA05122
C27 Capacitor, 200 pF (150-174 MHz) B19/5CAAA05122
C28 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03175
C33 Capacitor, Mica, 47 pF B19/5CMAB01252

C33 Capacitor, Mica, 47 pF B19/5CMAB01252
HC1 Power Module (136-153 MHz) B19/5DHAA00049
HC1 Power Module (150-174 MHz) B19/5DHAA00050
TR2 Transistor, NPN B19/5TCAF00510
TR3 Transistor, NPN B19/5TCAF00510

Radio Unit - Power Amplifier 55 Watts CAH-515L

C8 Capacitor, 270 pF (136-153 MHz) B19/5CAAA05042
C8 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03175
C9 Capacitor, 270 pF (136-153 MHz) B19/5CAAA05042
C9 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03175

C159 Capacitor, Mica, 47 pF B19/5CMAB01252

HC1 Power Module, (136-153 MHz) B19/5DHAA00051
HC1 Power Module, (150-174 MHz) B19/5DHAA00052
TR1 Transistor, NPN B19/5TCAF00510

Radio Unit - Power Amplifier 25 Watts CAH-515E

Radio Unit - IF CMF-135

No serviceable parts.

Radio Unit - Synthesizer/Receiver/Exciter
CMN-352

No serviceable parts.

HC1 Power Module, (136-153 MHz) B19/5DHAA00049
HC1 Power Module, (150-174 MHz) B19/5DHAA00050

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DIAGNOSTIC PROCEDURES

This product can be easily measured for maintenance
using a Communications Service Monitor, of which
several models are available. A typical test configuration
for the ORION product is shown in Figure 5. It is also

possible to combine this test configuration with the PC
Programming configuration shown in Figures 2 and 3.
This usually results in increased efficiency, since the
service technician can alternate between programming and
hardware testing, as the need arises.

Figure 5 - Typical ORION Test Configuration

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ADDITIONAL TOOLS REQUIRED

• RF Power Attenuator (30 dB, 150 watt, for transmitters with RF power beyond the capabilities of a Service

Monitor)

• Digital Voltmeter

• Oscilloscope (optional)

TRANSMITTER

SYMPTOM DIAGNOSTIC PROCEDURE

No RF power output. a. Program a Conventional System with frequencies given in Tables 2 and 3.

Use "EDACS3" PC Programming utility.

b. Check the RF Power Tracking Data, using "MRKMAINT" PC

Programming utility. The Data should be the same as that shipped with the
radio from the factory. I it has failed, re-enter the Tracking Data using the
procedure set forth in the "TRACKING DATA" section.

c. Check TP 1 on the Power Amplifier PWB for A+. If it has failed, check the

power cable fuse.

d. Key the radio and measure the DC voltage at TP4 (9 VDC typical, when

keyed). If it has failed, trace TXENABLE signal back to Logic PWB.

e. Unscrew the PA module from the rest of the radio unit. Remove P1 from

J151, and connect an RF wattmeter to J151. Be sure to AC couple J151 to
the wattmeter. Key the radio and measure the exciter power at J151.
Power should be 400-700 mW. If it has failed, replace the Synthesizer
PWB, and reload the Modulation Tracking Data. If this passes, replace the
PA PWB.

Frequency too low/high. Adjust XU201 on the Synthesizer PWB. If the frequency is still out of

specification, replace the Synthesizer PWB.

Low or no modulation. a. Program a Conventional System with frequencies given in Tables 2 and 3.

Use "EDACS3" PC Programming utility.

b. Check the Modulation Tracking Data, using "MRKMAINT" PC

Programming utility. Data should be the same as that shipped with the radio
from the factory. If this has failed, re-enter the Tracking Data using the
procedure set forth in the "TRACKING DATA" section.

c. Apply a 1000 mVRMS, 1 kHz audio signal to the MIC connector Pin 1

(Pin 2 is ground reference). Key the radio (make sure the antenna
connector is connected to the proper 50 ohm load). Check for an audio
signal at TP202 on the Synthesizer PWB. If this has failed, replace the
Logic PWB. Be sure to perform the complete re-programming on the new
Logic PWB, If this passes, replace the Synthesizer PWB, and re-load the
Modulation Tracking Data.

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A

RECEIVER

SYMPTOM DIAGNOSTIC PROCEDURE

Low RF sensitivity. a. Pr ogram a Conventional System with frequencies given in Tables 2 and 3.

Use "EDACS3" PC Programming utility.

b. Unscrew the PA module from the TXRX module. Disconnect the coaxial

cable P2 from J401 on the Synthesizer PWB. Do not disconnect any other
cable.

c. Set the frequency of the RF signal generator to the middle of the split.

Apply a standard RF signal to J401, and measure 12 dB SINAD sensitivity.
Sensitivity should be better than 0.29 µV. If this passes, replace the PA
PWB.

d. If this fails, re-align the receiver, as instructed in the "ALIGNMENT"

section, and re-check the sensitivity at J401

e. If this passes, re-assemble with the PA module and re-check the sensitivity

at the antenna connector. If this passes, the job is complete

f. If the above fails, substitute a known good Synthesizer PWB, and re-check

the sensitivity. If this fails, replace the Logic PWB. Be sure to perform the
complete re-programming on the new Logic PWB. If this passes, replace
the synthesizer PWB, and re-load the Modulation Tracking Data.

High audio distortion a. Program a Conventional System with frequencies given in Tables 2 and 3.

Use "EDACS3" PC Programming utility.

b. Apply a standard 1000 µV RF signal [with 1 kHz audio modulation at 3

kHz deviation (1.5 kHz for 12.5 kHz channel spacing)] at one of the
programmed RF frequencies in the center of the split to J1001. Set the
volume control to produce 15 watts at the 4-ohm speaker load

c. Measure the audio distortion at the "VOL HI" output (J1003 Pin 13

referenced to Pin 12). If this passes (3% THD), replace IC604 Audio
Power Amplifier on the Logic PWB.

d. If this fails, re-align the receiver per alignment procedure. Re-check the

distortion at the speaker load or "VOL HI."

e. If this fails, replace the Logic PWB. If this passes, the job is finished.

17

L

BI-39175A

CONTROL UNIT

SYMPTOM DIAGNOSTIC PROCEDURE

Radio dead at power-on
(display dark and no
lighted indicators)

a. Check the battery connections and the Red lead A+ fuse on the power

cable.

b. Turn the unit "OFF," then simultaneously press and hold the

"EMERGENCY" and "OPTION" buttons, while turning the unit "ON."
All indicator lights and all display dots should light. Release the buttons
and the display should show the following message:



- 1993 or  - 1994
EGE EGE

This indicates the Control Unit is functioning correctly. If this passes,
check programming and feature encryption, using "EDACS3" PC
Programming utility.

c. If this fails, measure A+ voltage at MIC connector Pin 6 (referenced to

ground at Pin 7). If this fails, check fuse F601 on the Logic PWB for A+
on each side of the part. Replace the PWB if it is open circuited.

d. If the fuse is OK, check the connection of the Flex Circuit PC2 with J701

on the Logic PWB. If this fails, reconnect PC2, making sure the side tabs
are locked. Re-check the MIC connector Pin 6 for A+.

e. If this passes, check the programming and feature encryption, using

"EDACS3" PC Programming utility. If this symptom persists, substitute a
known good Logic PWB, and re-program.

The Display lights, then
goes dead.

f. If no A+ is present at MIC Pin 7, check for A+ on the Logic PWB J704 Pin

3. If this fails, check the J704/J1004 connection. If this fails, replace the
PA module. If this passes, replace the Logic PWB.

a. Turn the unit "OFF," then simultaneously press and hold the

"EMERGENCY" and "OPTION" buttons, while turning the unit "ON."
All the indicator lights and all display dots should light. Release the buttons
and the display should show the following message:



- 1993 or  - 1994
EGE EGE

This indicates the Control Unit is functioning correctly. If this passes,
check programming and feature encryption, using "EDACS3" PC
Programming utility.

b. If this passes, check the connection of the Flex Circuit PC2 with J701 on

the Logic PWB. If this passes re-connect it making sure the side tabs are
locked.

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GENERAL

SYMPTOM DIAGNOSTIC PROCEDURE

Any hardware malfunction PWB substitution is a valid technique for service and repair of the ORION

product, since there are only a few circuit boards in the product:

1. RF Power Amplifier

2. Logic/IF/Audio

3. Synthesizer/Exciter/RX Front End

4. Control Unit Panel Control

5. Control Unit Switching

6. Control Unit RIA (Remote Only)

7. DSP (AEGIS Only)
The service shop should be equipped with a set of the above PWB's which can

be used for substitution. Defective PWB's can be isolated simply by substituting
one at a time. It is recommended that the Logic PWB used for substitution be
pre-programmed with a conventiona l system and frequency set given in Tables
2 and 3.

ERROR CODES

This section lists all the ORION radio errors and
warnings. Each error code in the list includes an
explanation of what went wrong and what action to take to
correct the problem. The error codes are divided into three
different categories:

1. Fatal Operational Error Codes - These are errors that

are displayed during the radio normal operation or on

the radio power-up (Fatal System Errors). These

errors will cause the radio to reset.

2. Non-Fatal Operational Error Codes - These are errors

that are displayed during the radio normal operation

or on the radio power-up. The radio will not reset.

3. Radio Programming Errors - These are errors that are

displayed on the radio or the programming PC

display during radio programming.

All System Groups ORION

System Errors

Fatal system errors will cause the radio to display an
error message/code and then reset the radio to its starting
operation. The reset condition will remain until the fatal
error(s) is corrected.

Non-Fatal errors are displayed for a short period
(about 2 seconds) then normal radio operation will
resume.

The errors are displayed on the radio as shown in
Figure 6.

19

L

BI-39175A

message

ERR = xxxx

Figure 6 - Error Message/Code Display

where xxx is the error code and the message is

one of the messages listed below

FATAL ERRORS NON-FATAL ERRORS

ERROR MESSAGE DESCRIPTION ERROR MESSAGE DESCRIPTION

HARDWARE ROM errors UNKNOWN
SOFTWARE General software failure FEAT ERR Feature encryption error
TRACKING Tracking data fatal error DSP ERR DSP error

NO LOCK Synthesizer not locking
FREQDATA Frequency data fatal error
PERSDATA Personality errors

20

A

ROM Fatal Systems Errors

ROM fatal errors may be corrected by cycling the radio power (turn it off then on). When the power cycle does not

correct the problem the radio must be serviced.

ERROR NAME MESSAGE CODE DESCRIPTION

FATAL_SYS_TRAP HARDWARE 0 Fatal system error trap number.
FATAL_NMI_ERROR HARDWARE 1 NMI occurred outside of sleep.
FATAL_RAM_ERROR HARDWARE 2 8K RAM test error.
FATAL_ROM_CHKSUM HARDWARE 3 32K ROM checksum test error.
FATAL_FLSH_CHKSUM HARDWARE 4 Flash checksum test error.
FATAL_ASIC_LOAD HARDWARE 10 ASIC driver failed initialization.
FATAL_ICP_LOAD HARDWARE 11 ICP driver failed initialization.
FATAL_ASP_LOAD HARDWARE 12 ASP driver failed initialization.
FATAL_EE_LOAD HARDWARE 13 EEPROM driver failed initialization.
FATAL_ICP_PORTNIT HARDWARE 14 ICP digital I/O initialization failed.
FATAL_INTOUT_LOAD HARDWARE 15 Standard input/output driver failed initialization.
FATAL_INTIN_LOAD HARDWARE 16 Standard input driver failed initialization.
FATAL_RADIO_LOAD HARDWARE 17 RADIO driver failed initialization.
FATAL_MODEM_LOAD HARDWARE 18 MODEM driver failed initialization.
FATAL_EXTIO_LOAD HARDWARE 19 External I/O driver failed initialization.
FATAL_SCI_LOAD HARDWARE 20 Serial communication interface driver failed initialization.
FATAL _ICP_CHKSUM HARDWARE 21 ICP prom checksum.
FATAL_ADI_NOACK HARDWARE 30 ADI did not respond to command.
FATAL_ADI_QUNDERFLOW HARDWARE 31 ADI Rx circular queue underflowed.
FATAL_LCD_NOACK HARDWARE 40 LCD did not acknowledge message.
FATAL_LCD_HARD_FAIL HARDWARE 41 LCD hardware is invalid.
FATAL_SCI_NOHEAP HARDWARE 50 Serial communication interface out of heap (RAM memory) space.
FATAL_ICP_NOACK HARDWARE 60 ICP did not acknowledge message.
FATAL_EXTIO_ICPFAIL HARDWARE 70 ICP failed in a fork.
FATAL_RADIO_ASPWRT HARDWARE 80 Radio driver could not write to ASP.
FATAL_ROM_NOHEAP HARDWARE 90 Software memory error - ROM task.
FATAL_BL_NOHEAP HARDWARE 91 Software memory error - Boot loader.
FATAL_BL_SCI_ATACH HARDWARE 92 Boot loader could not attach to SCI.

LBI-39175

Operational Software Non-Fatal System Errors

ERROR NAME MESSAGE CODE DESCRIPTION

PIFEAT_SNR_ERROR FEAT ERR 550 Feature encryption - Can not read radio ROM serial number.
PIFEAT_READ_ERROR FEAT ERR 551 Personality feature encryption read failure or data not available.
PIFEAT_CRC_ERROR FEAT ERR 552 Decryption failure. Personality feature encryption CRC failure.
RI_DSPDOWN_NOATTEMPT DSP ERR 850 DSP not found
AEGIS_ADIDOWN_
NOTFOUND
AEGIS_ADIDOWN_CRCFAIL DSP ERR 852 DSP file not found.
AEGIS_ADIDOWN_ENCERR DSP ERR 853 Radio feature encryption does not match DSP file.
AEGIS_ADIDOWN_PMFAIL DSP ERR 854 DSP file is corrupted or hardware failure. RE-program radio or power cycle the

AEGIS_ADIDOWN_DMFAIL DSP ERE 855 DSP file is corrupted or hardware failure. Re-program radio or power cycle radio.
AEGIS_ADIDOWN_BIOSERR DSP ERR 856 Hardware failure.
AEGIS_KEYLOAD_
NOBANKS
AEGIS_PVT_NONE FEAT ERR 870 Private is not feature encrypted.

DSP ERR 851 DSP file not found.

radio.

DSP ERR 860 Personality did not assign banks for the keys.

21

L

BI-39175A

Operational Software Fatal System Errors

ERROR NAME MESSAGE CODE DESCRIPTION

RADC_PITD_ERROR TRACKING 200 Personality tracking data error. Re-program the tracking data.
RADC_PIHW_ERROR PERSDATA 201 Personality hardware data error. Re-program the personality.
RADC_FREQ_ERROR FREQDATA 202 Personality frequency data error. Re-program the personality.
RADC_PITD_MALLOC_ERROR SOFTWARE 203 Personality tracking data malloc error. Re-program the tracking data.
RADC_PITD_CKSUM_ERROR SOFTWARE 204 Personality tracking data checksum error. Re-program the tracking data.
DACS_NO_LOCK NO LOCK 300 Synthesizer did not lock or became unlocked. Check the frequencies in the PC

DACS_MODEM_FATAL_ERROR SOFTWARE 301 Unable to correctly configure the modem for EDACS operation. Re-program

DACS_RADC_FAILURE SOFTWARE 302 Power cycle the radio.
DACS_MODEM_RXOVR SOFTWARE 304 Hardware Modem overflow. Power cycle the radio.
DACS_MODEM_RXAVR SOFTWARE 305 Power cycle the radio.
CONV_RADC_ERROR SOFTWARE 400 Error calling RADC function. Power cycle the radio.
CONV_NOLOCK_ERROR NO LOCK 401 Synthesizer became unlocked. check the frequencies in the PC programmer

CONV_PUT_UIMSG_ERROR SOFTWARE 402 UI message buffer not enabled. Power cycle the radio.
CONV_MODEM_RXOVR SOFTWARE 403 Conventional DIGV modem overflow.
CONV_MODEM_RXAVR SOFTWARE 404 Conventional DIGV modem underflow.
CONV_MODEM_FATAL_ERROR SOFTWARE 405 Unable to correctly configure the modem for conventional DIGV operation.
CONV_PERS_ERROR PERSDATA 407 Conventional personality error.
PI_NOPERS_ERROR PERSDATA 500 Personality data is not present. Program the personality.
PI_CRC_ERROR PERSDATA 501 Flash personality CRC did not match EEPROM. Re-program the personality.
PI_DESC_CRC_ERROR PERSDATA 502 Crucial personality data has incorrect CRC. Re-program the personality.
PI_MALLOC_ERROR SOFTWARE 503 Could not allocate memory to store crucial personality data.
UI_FATAL_DEVICE_ERROR PERSDATA 600 Input/Output device error.
UI_FATAL_SWTO_
MALLOC_ERROR
UI_FATAL_SWTO_MAX_ERROR SOFTWARE 602 Software error, power cycle the radio.
UI_FATAL_WINDOW_MAX_
ERROR
UI_FATAL_WINDOW_MALLOC_
ERROR
UI_FATAL_MESSAGE_INVPARM SOFTWARE 605 Invalid parameter to UI_PUT_MESSAGE(). software error, report how error

UI_FATAL_RI_MSGBUF_FULL SOFTWARE 606 UI Task message buffer full error. Software error, report how error was

UI_FATAL_RISYS_MSGBUF_FULL SOFTWARE 607 Radio Interface System (EDACS/CONV) task message buffer full.
UI_FATAL_CI_MSGBUF_FULL SOFTWARE 608 CI Task message buffer full.
UI_FATAL_DEVICE_
NOTSUPPORTED
UI_FATAL_AUXIO_MALLOC_
ERROR
UI_FATAL_NET_DEVICE_ERROR SOFTWARE 611 Network I/O device error
UI_FATAL_INVALID_CUID SOFTWARE 612 CU ID is invalid or CU not connected. Insure that CU ID is CUA and DUAL

UI_FATAL_NO_TONE_DATA SOFTWARE 613 No tone data is available in personality.
UI_FATAL_UII0_MSGBUF_FULL SOFTWARE 614 UI I/0 BBOS message buffer full.
AEGIS_ADI_OVERFLOW SOFTWARE 801 ADI Transmit event not serviced in time and buffer has overflown.
AEGIS_RXBUF_MALLOC_ERROR SOFTWARE 802 No memory available.
AEGIS_KEYLOAD_MALLOC_
ERROR
AEGIS_KEYLOAD_ERROR SOFTWARE 804 General Keyload error has occurred.
AEGIS_DATAMEM_MALLOC_
ERROR
AEGIS_KEYLOAD_NOTABL SOFTWARE 806 No key table was found in EEPROM.

SOFTWARE 601 Software memory error.

SOFTWARE 603 Too many open windows.

SOFTWARE 604 Software memory error.

PERSDATA 609 I/O device type (from personality) not supported.

SOFTWARE 610 Software memory error.

SOFTWARE 803 No Keyloader table memory available.

SOFTWARE 805 No memory is allocated for data.

programmer and re-program the radio personality.

the personality.

and re-program the radio personality.

was encountered.

encountered.

is disabled in personality.

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LBI-39175

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Radio Programming Errors

Programming errors are divided into three categories:

1. Protocol Errors - These are errors produced by the low level communication routines.

2. Radio Errors - These are errors that are returned from the radio ROM or operating software.

3. PC Errors - These are errors that are produced by the PC Programming software.

MESSAGE CODE DESCRIPTION

Successful 0 Command was performed successfully.
Protocol - Canceled by receiver 5 x328 protocol received a cancel. The radio detected a cancel command.
Protocol - Canceled by sender 6 x 328 protocol transmitted cancel. The radio is canceling the read command.
Protocol - Terminate transmission 7 x328 protocol received an end of transmission.
Protocol - Transmit error 8 x328 protocol could not transmit. Reliable communication cannot be established. It could be

Protocol - Protocol initialization error 9 x328 protocol not initialized or failed to initialize.
Radio - Programmed successfully 10 Radio responded with a success. Radio acknowledged successful programming.
Radio - Comport configuration failed 11 Radio could not configure its comport (hardware failure).
Radio - Flash erase failed 12 Radio failed to erase the flash memory. The radio flash memory part is unusable or it cannot

Radio - Flash write failed 13 Radio failed in writing to the flash memory. Retry the programming process (hardware

Radio - Flash code CRC did not match 14 Flash code not programmed correctly. CRC did not match. The operating software will not

Radio - Canceled by receiver 15 The radio operating software received a cancel command.
Radio - Canceled by sender 16
Radio - End of transmission received 17 The radio software received or sent an end of transmission.
Radio - Transmit error 18 Radio could not transmit the required data. Check all hardware connections and try

Radio - Invalid command 19 Radio did not understand the received command.
Radio - No application code 20 No application code is loaded, the radio cannot accept personality commands. Re-program the

Radio - Application code error 21 The radio application code failed to perform the command.
Radio - EEPROM programming error 22 Could not program the radio EEPROM part.
Radio - Baud rate has changed 23 The radio acknowledged a successful baud communication baud rate change.
PC - Cannot allocate memory 50 The PC programming software could not allocate adequate memory space to perform the

PC - Cannot open data file 51 The specified file (code or personality) could not be opened (file does not exist or has access

PC - Cannot read data file 52 The specified file (code or personality) could not be read.
PC - Cannot write to file 53 The specified file (code or personality) could not be written.
PC - File not found 54 The specified file (code or personality) is not found in the current directory.
PC - File is larger than radio memory 55 The radio flash part size is unknown or the operating software file size is larger than the radio's

PC - Incorrect Tracking Data RF band

split
PC - Incorrect Tracking Data version 58 Incorrect Tracking Data version.
PC - Tracking Data checksum error 59 Tracking Data checksum error.
PC- Time-out, radio not responding 60 Radio is not connected or not turned on or the selected PC comport number is invalid.
PC - Comport configuration error 61 Comport configuration error, cannot set comport.
PC - Abort, message canceled 62 Aborted by operator, message canceled.
PC - Requested personality data does

not exist

the radio or PC hardware problems (programming cable, interface box, or radio hardware).

detect the 12 volts power. Check the programming box and cables.

failure).

execute. Re-program the radio.

programming again.

operating software (flash code) and re-program the personality.

function.

protection).

flash memory size.

57 Incorrect Tracking Data RF band split.

63 The personality table does not exist (Tracking or Encryption table).

23

Ericsson Inc.

Private Radio Systems
Mountain View Road
Lynchburg, Virginia 24502
1-800-592-7711 (Outside USA, 804-592-7711) Printed in U.S.A.