Icom IC-FR6100, IC-FR6000 Service Manual

UHF FM REPEATER

S-14419XZ-C1 Feb. 2008

INTRODUCTION CAUTION

This service manual describes the latest service information for the IC-FR6000 UHF DIGITAL REPEATER at the time of publication.

MODEL VERSION

USA-01 400–470 MHz

IC-FR6000

IC-FR6100 EUR-01 400–470 MHz

USA-02 450–520 MHz EXP-01 400–470 MHz EXP-02 450–520 MHz

FREQUENCY

RANGE

CH. SPACING

6.25/12.5/25.0 kHz

12.5/25.0 kHz

12.5/20.0/25.0 kHz

POWER

50 W

25 W

UNIT ABBREVIATIONS:

F=FRONT UNIT M=MAIN UNIT CN=CONNECT UNIT

NEVER connect the repeater to an AC outlet or to a DC power supply that uses more than specifed. This will ruin the repeater.

DO NOT expose the repeater to rain, snow or any liquids. DO NOT reverse the polarities of the power supply when

connecting the repeater. DO NOT apply an RF signal of more than 20 dBm (100 mW)

to the antenna connector. This could damage the repeater’s front-end.

To upgrade quality, any electrical or mechanical parts and internal circuits are subject to change without notice or obligation.

ORDERING PARTS

Be sure to include the following four points when ordering replacement parts:

1. 10-digit Icom parts numbers

2. Component name

3. Equipment model name and unit name

4. Quantity required

1110003491 S.IC TA31136FNG IC-FR6000 MAIN UNIT 5 pieces 8820001210 Screw 2438 screw IC-FR6000 Top cover 10 pieces

Addresses are provided on the inside back cover for your convenience.

REPAIR NOTES

1. Make sure the problem is internal before disassembling the repeater.

2. DO NOT open the repeater until the repeater is disconnected from its power source.

3. DO NOT force any of the variable components. Turn them slowly and smoothly.

4. DO NOT short any circuits or electronic parts. An insulated tuning tool MUST be used for all adjustments.

5. DO NOT keep power ON for a long time when the repeater is defective.

6. DO NOT transmit power into a Standard Signal Generator or a Sweep Generator.

7. ALWAYS connect a 50 dB to 60 dB attenuator between the repeater and a Deviation Meter or Spectrum Analyzer when using such test equipment.

8. READ the instructions of test equipment throughly before connecting a test equipment to the repeater.

Icom, Icom Inc. and

logo are registered trademarks of Icom Incorporated (Japan) in the United States, the United

Kingdom, Germany, France, Spain, Russia and/or other countries.

SECTION 1 SPECIFICATIONS

SECTION 2 INSIDE VIEWS

SECTION 3 DISASSEMBLY INSTRUCTION

SECTION 4 OPTIONAL UNIT INSTALLATION

SECTION 5 CIRCUIT DESCRIPITON

5-1 RECEIVER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 TRANSMITTER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-3 OTHER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-4 CPU (M: IC20) PORT ALLOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

SECTION 6 ADJUSTMENT PROCEDURES

6-1 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 FREQUENCY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 TRANSMIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-4 RECEIVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

SECTION 7 PARTS LIST

SECTION 8 MECHANICAL PARTS

SECTION 9 BOARD LAYOUTS

SECTION 10 BLOCK DIAGRAM

SECTION 11 VOLTAGE DIAGRAM

FRONT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

MAIN UNIT (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

MAIN UNIT (2/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

MAIN UNIT (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

CONNECT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

SECTION 1 SPECIFICATIONS

M GENERAL

• Frequency coverage 400–470 MHz [USA-01], [EXP-01] 450–520 MHz [USA-02], [EXP-02]

• Conventional channels max. 32 ch

• Type of emission Wide

• Antenna impedance 50 Ω (Nominal)

• Operating temperature range –22˚F to +140˚F (–30˚C to +60˚C) –25˚C to +55˚C

• Power supply requirement

(nominal)

• Current drain (Approx.) Receiving 500 mA (stand-by), 1900 mA (max. audio)

• Dimensions

(Projections not included)

• Weight (Approx.) 12 Ib

Narrow 8K50F3E/8K10F1E/8K10F1D Narrow 8K50F3E Digital 4K00F1E/4K00F1D/4K00F3E/6K00F3E

13.6 V DC (Negative ground) 13.2 V DC (Negative ground)

Transmitting 15 A (at 50 W) Transmitting 7.0 A (at 25 W) 19

16K0F3E/11K0F3E/11K0F7E/ 1K0F7D/ 11K0F7W

/32 (W)×3 15⁄32 (H)×10 1⁄4 (D) in. 483 (W)×88 (H)×260 (D) mm

/16 oz. 5.6 kg

M TRANSMITTER

• Output power 50 W 25 W

• Modulation Variable reactance frequency modulation

• Max. frequency deviation ±5.0 kHz (Wide)

±2.5 kHz (Narrow)

• Frequency stability ±0.5 ppm ±0.5 kHz

• Spurious emissions 80 dB typ. 0.25 μW (≤1 GHz), 1.00 μW (>1 GHz)

• Adjacent channel power Wide 73 dB typ. Wide 73 dB min.

Narrow 67 dB typ. Narrow 65 dB min. Digital 65 dB typ. Digital 60 dB min.

• Audio harmonic distortion 1% typ. (at AF 1 kHz 40% deviation)

• Audio frequency response +2 dB to –8 dB of 6 dB/oct. Wide/Middle from 300 Hz–3000 Hz

• FM Hum and noise

(300 Hz–3000 Hz, 750 us)

Wide 50 dB typ. Narrow 45 dB typ.

[FR6000] [FR6100]

400–470 MHz

Wide 16K0F3E

– Middle 14K0F3E

[FR6000] [FR6100]

– ±4.0 kHz (Middle)

– Middle 73 dB min.

Narrow from 300 Hz–2550 Hz

1 - 1

M RECEIVER

[FR6000] [FR6100]

• Receive system Double-conversion superheterodyne system

• Intermediate frequencies 1st IF: 46.35 MHz, 2nd IF: 450 kHz

• Sensitivity Wide/Narrow

0.25 μV typ. at 12 dB SINAD Digital

0.25 μV typ. at 5% BER

• Squelch sensitivity (at threshold)

Wide/Narrow

0.25 μV typ.

Wide/Middle/Narrow –10 dBμ max. at 12 dB SINAD

Digital 0 dBμV emf max. at 1% BER (PN9)

Wide/Middle/Narrow

0.25 μV typ.

• Adjacent channel selectivity Wide 78 dB typ. Wide 70 dB min.

– Middle 70 dB min. Narrow 56 dB typ. Narrow 60 dB min. Digital 63 dB typ. Digital 45 dB min.

• Spurious response Wide/Narrow 70 dB Wide/Middle/Narrow 70 dB min. Digital 65 dBµV emf Digital 70 dBµ Vemf min.

• Intermodulation Wide 70 dB min.

– Middle 70 dB min. Narrow 70 dB min. Digital 71 dBµV emf min.

• Hum and noise Wide 50 dB typ. Wide 45 dB min. – Middle 43 dB min.

Narrow 45 dB typ. Narrow 40 dB min. Digital 55 dB typ. Digital 55 dB min.

• Audio output power

(at 5% distortion with a 4 Ω load)

• Audio output impedance 4

4.0 W typ. 3.5 W min.

Specifications are measured in accordance with TIA–603–B (for Wide and Narrow) or EN 300 166 (Digital) for FR6000. Specifications are measured in accordance with EN 300 086 (for Wide, Middle and Narrow) or EN 300 166 (Digital) for FR6100.

All stated specifications are subject to change without notice or obligation.

1 - 2

SECTION 2 INSIDE VIEWS

1st mixer (DBM) (D62, L27, 32)

Discriminator (X3)

TX power AMP (IC22)

Ref. OSC (X1)

PLL IC (TX lopp) (IC3)

• MAIN UNIT (TOP VIEW)

IF IC (IC5)

RX VCOs

PLL IC (RX loop) (IC4)

2nd IF filter (Wide) (FI1) 2nd IF filter (Narrow) (FI2)

FUNCTION

(Ref.No.) AF SW (IC35)

AF AMP

(IC34) DSP (IC12)

Optional digital unit slot

FUNCTION (Ref.No.)

• MAIN UNIT (BOTTOM VIEW)

TX VCOs

Liner codec (IC8)

FUNCTION (IC40)

5V regulator (CPU5V) (IC30)

Power SW (VCC line) (Q57)

8V regulator (8V line) (IC27)

8V regulator (T8V line) (Q45)

5V regulator (+5V line) (Q41)

CPU (IC20)

CPU clock (X5)

EEPROM (IC21)

5V regulator (DSP5V line) (IC39)

2 - 1

AF POWER AMP. (IC509)

SPEAKER SW (Q508)

• FRONT UNIT

ANALOG SW (IC506)

LCD DRIVER (IC500)

FRONT CPU (IC503)

CLOCK OSC (X501)

2 - 2

SECTION 3 DISASSEMBLY INSTRUCTION

1. Removing the front panel

q Unscrew 11 screws from the top cover.

e Disconnect the cable from the MAIN UNIT assembly, and remove the front panel.

w Unscrew 7 screws from the front panel.

2. Removing the MAIN UNIT assembly

q Uscrew 5 screws which settles the MAIN UNIT assembly.

w Turn the MAIN UNIT assembly upside down.

3. Removing the MAIN UNIT

q Unscrew 9 screws, and remove the cover. (If you are going to install an optional unit, see page 4-1 for the installation.)

PWR TX RX

TX RX

PWR

PWR TX RX

(To be continued to next page)

3 - 1

MAIN

Black

Red

w Unsolder 2 points at the ANT cases. e Unscrew 4 screws from the ANT cases,

and remove them.

r Disconnect the flat cabe from J4 and the

speaker cable from J9.

Flat cable

Disconnect

MAIN

Unsolder

ANT case

Unscrew

ANT case

t Unsolder 2 points at the bottom of ANT connectors. y Unsolder 4 points at the PA module leads. u Unscrew 2 screws from W4.

J9J9J9

Disconnect

i Remove the clip from the side of chassis. o Unscrew 15 screws from the MAIN UNIT, then take off

the MAIN UNIT PCB from the chassis.

Unsolder 2 points

Black

Red

Unscrew

Unsolder 4 points

Clip

15 screws

3 - 2

SECTION 4 OPTIONAL UNIT INSTALLATION

Install UT-109R or UT-110R as follows.

q Disassembly the repeater until the MAIN UNIT is exposed. (See the page 3-1) w Modify the patterns on the MAIN UNIT as below.

A and F; Cut the pattern

e Remove the protective paper of optional unit, and install it to the J1 as below.

r Replace the cover, screws, etc. to recover the whole assembly.

B; Short the pattern

PWR TX RX

NOTE: When uninstalling the scrambler unit

Be sure to recover the disconnected or connected points, otherwise no TX modulation or AF output is available.

4 - 1

SECTION 5 CIRCUIT DESCRIPTION

5-1 TRANSMITTER CIRCUITS

TX PLL CIRCUIT

TX PLL IC (IC3) outputs resulting signal of phasecomparison of REF signal (15.3 MHz) and feedback OSC signal from TX VCO. The phase-difference signal is passed through the active loop ﬁ lter (Q4, 10, 13)and applied to the TX VCO. The voltage of TX LV is adjusted to appropr iate one. The OSC signal of TX VCO is FM-modulated by applied modulation signals.

TX VCO CIRCUITS

There are 2 VCOs; VCO for band LOW (Q23, D10, 14, L19) and band HIGH (Q22, D9, 13, L18), and these VCO (=OSC freq.) are switched by the VCO SW (Q27, 28). The OSC frequencies of these VCO are adjusted (=Locked) by the TX LV signal (Lock Voltage). The modulation signals applied to the Var iable Capacitor (VD; D17 or D18) vary the capacitor reactance of it for FM modulation. The output signals of these VCOs are applied to the power AMP circuits via buffers (Q24, 35).

A portion of these output signals are passed through the doubler (Q33) to extract 2nd harmonics, then applied to the PLL IC (IC3) via the LPF.

YGR/PA CIRCUITS

The output signals from TX VCOs are ampliﬁ ed by pre-AMPs (Q37, 38), the amplified the PA module (IC22) to obtain required TX power. The power-amplified TX signals are passed through the ANT SW (D44) and LPF (for harmonics removal) then applied to the TX ANT.

APC CIRCUIT

D45, D48 and D49 detect the TX power and the detected voltage are applied to the IC23 of APC circuit. Comparing the detected voltage (in proportion to TX power) and power setting voltage (as a reference voltage), IC23 adjusts the bias (pin 2: VGG) of PA module to control the TX power.

MODULATION CIRCUITS

The audio signals from the Microphone (MIC signals) are applied to the MIC AMP (IC25). The ampliﬁ ed MIC signals are passed through the SW IC (IC35) which signal selects the source of MIC signals from J5 (from MIC) and from D-SUB connector (DEXM).

5-2 RECEIVER CIRCUITS

RX PLL CIRCUIT

The RX PLL IC (IC4) outputs resulting signal of phasecomparison of REF signal from the TCXO (X2: 15.3 MHz) and feedback OSC signal from RX VCO. The phasedifference signal is passed through the active loop ﬁ lter (Q6, 11, 14) and applied to the RX VCO. The voltage of RX LV (lock voltage) is adjusted to appropriate one by “RX LVA” signal.

A portion of reference frequency signal from the TCXO (X2:

15.3 MHz) is passed through the tripler (Q2) to extract 3rd harmonics, then applied to theIF IC (IC5).

RX VCO

There are 2 VCOs; VCO for band LOW (Q21, D8, 16, L21) and band HIGH (Q20, D7, 15, L20), and these VCO (=OSC freq.) are switched by the VCO SW (Q26, 30). The OSC frequencies of these VCO are adjusted (=Locked) by the RX LV signal (Lock Voltage). The output signals of these VCOs are applied to the 1st mixer (L27, 32, D62) via buffers (Q25,

34) and LO AMP (Q65). A portion of these output signals are passed through the

buffer (Q25) doubler (Q32) to extract 2nd harmonics, then applied to the PLL IC (IC4) via the LPF.

RF BPF CIRCUITS

RX signals from the RX ANT connector (J11) are passed through the 1st stage of BPF (D28, 29, 31, 32, L44, 47) then amplified by the RF AMP (Q36). The amplified RX signals are passed through the 2nd stage of BPF to remove unwanted signals for good image response then applied to the 1st mixer (L27, 32, D62).

Being mixed with 1st LO from the RX VCO, the RX signals are converted into the 46.35 MHz 1st IF signal. The 1st and 2nd stage of the BPF are tune to the pass band frequency by applying the tracking voltage “T1” and “T2” from the DAC (IC17). The gain of low noise RF AMP (Q36) is controlled by the AGC circuit (Q39, D27) according to the RX signal strength.

The MIC signals from the SW IC are ampliﬁ ed by an AMP (IC1) then applied to the LINEAR CODEC IC (IC8) where the MIC signals are converted in to the digital signals. The converted digital signals are processed (pre-emphasis, limit, etc.) by the DSP (IC12), then recovered to the analog audio signals. The AF signals are ampliﬁ ed by IC1 and leveladjusted by Ele.VR (IC2), then applied to the TX VCO and TCXO (X1) as the modulation signals.

SIGNALING (ENCODE)

The Continious Tone (CTCSS/DTCS), Single Tone (5-Tone/ DTMF/CW_ID) signals are encoded in the DSP (IC12), and mixed with MIC signals, level-adjusted by Ele. VR (IC2), then applied to the TX VCO and TCXO (X1) for modulation.

5 - 1

IF FILTER/IF AMP CIRCUITS

The 1st IF signal from the 1st mixer (L27, 32, D62) is amplified by the post AMP (Q63, 64) and 1st stage of IF AMP (Q7) then ﬁ ltered by crystal ﬁ lter (FI3 or FI4), and then applied to the IF IC (IC5).

The crystal ﬁ lters (FI3 or FI4) are switched by the “NWC１” signal from the CPU (IC20) according to the RX mode; Wide (Middle), Narrow and Digital.

Being mixed with the 2nd LO, the 1st IF signal is converted into the 450 kHz 2nd IF signal then detected by the internal quadrature detector (X3 as a discriminator) to demodulate. The demodulated AF signals are ampliﬁ ed by the AF AMP (IC36), and applied to the LINER CODEC (IC8). The AF signals are converted into the digital signal then processed by the DSP (IC12) then recovered to the analog audio signals.

The ceramic ﬁ lters (FI1 or FI2) are switched by the “NWC2” signal from the CPU (IC20) according to the RX mode; Wide (Middle), Narrow and Digital.

5-3 OTHER CIRCUITS

POWER SUPPLY

The power supply is switched by Q57 (ON/OFF). 5V (REF5) from the regulator (IC30) is passed through L58 to supply to CPU. The 5V also supplies to other sections of the repeater via Q41 as “+5V.”

8V from the regulator (IC27) are supplies to various circuits, and also supplies to TX circuits as “T8V” and RX circuits as “8V.”

5V from the regulator (IC39) supplies DSP as “DSP5” and supplies logic circuits; CPU, DSP, etc. via regulators (IC13, 14, 15).

The regulator “F8V” (IC41) provides the supply for FRONT UNIT.

COMPANDER

The compander in the DSP (IC12) compresses the amplitude of MIC signals in TX, and expands in RX to provide high quality recovered sounds.

The 450 kHz 2nd IF signal is ampliﬁ ed by IC7 then applied to the DSP (IC12) via ADC (IC9) and digital demodulated. The processed digital signal is converted into the analog audio signal by the LINEAR CODEC (IC8).

AF AMPLIFIER CIRCUITS

The AF signals from the LINEAR CODEC are ampliﬁ ed by the AF AMP (IC36) and level-adjusted by DAC (IC2), then applied to IC28 via IC29 to be power-ampliﬁ ed.

SIGNALING (DECODE)

The Continious Tone (CTCSS/DTCS), Single Tone (5-Tone/ DTMF/CW_ID) signals in the demodulated AF signals are decoded in the DSP (IC8).

LED

DS1 (BUSY), DS2(PWR) and DS3 (TX) indicate the repeater’s status: Power ON, T/RX and Cloning.

5 - 2

5-4 CPU (M: IC20) PORT ALLOCATION

Pin No.

140–144 D0–D4 DSP data bus line. I/O –

1–11 D5–D15 DSP data bus line. I/O –

15–28 A1–A14 DSP data bus line. I/O –

29 HRW DSP data line. I/O – 32 FANS Cooling fan (CH: MF1) rotation detect. I "H"=While the cooling fan is rotating. 33 TLED TX indicator LED control signal. O "H"=TX 34 LEDR RX indicator LED control signal. O "H"=Squelch open. 35 PLSCK PLL (M: IC4) serial clock. O – 36 PLSSO PLL (M:IC4) serial data. O – 41 PWON Power line "VCC" control signal. O "H"=Power ON. 42 AFON2 AF power AMP. (M: IC28) control signal. O "H"=AF power AMP ON.

43 AFON AF output select signal. O 44 ESCL Serial clock to the EEPROM (M: IC21). O –

45 ESDA Serial data to the EEPROM (M: IC21). O – 46 TXC TX power line "T8V" control signal. O "H"=TX 47 RXC RX power line "R8V" control signal. O "H"=RX 48 RPLST RX PLL (M: IC4) strobe. O – 49 TPLST TX PLL (M: IC3) strobe. O – 50 RUNLK RX PLL (M: IC4) unlock signal. I "L"=Unlocked 51 TUNLK TX PLL (M: IC3) unlock signal. I "L"=Unlocked 52 XCTS Serial data from the RS-232 line driver (M: IC26). I – 53 XRTS Serial data to the RS-232 line driver (M: IC26). O – 55 EXDA External D/A port. O – 56 BEEP Beep sounds (square waves). O –

57–59 OPV3–OPV1 Optional unit detect. I –

60 MMUT MIC mute signal to the installed optional unit. O "H"=MIC mute 61 HANG Microphone hang-up detect. I "L"=Hang-up 62 PTT [PTT] key input. (pull up) I – 63 RMUT RX mute signal to the installed optional unit. O "H"=RX mute 64 EXAD External A/D port. I – 65 TEMP Temperature detect. I – 68 RLVIN RX PLL lock voltage. I – 69 BATV Voltage monitor (divided voltage of "VCC"). I – 70 TLVIN TX PLL lock voltage. I – 71 RSSI RSSI signal from the IF IC (M: 5). I – 74 XTXD External data to the RS-232 driver (M: IC26). O – 75 XRXD External data from the RS-232 driver (M: IC26). I – 76 TMUT TX mute signal. O "H"=TX mute 77 HINT DSP IC control signal. O – 78 INT1 DSP IC control signal. O – 79 HRDY DSP IC control signal. O – 81 HDS1 DSP IC control signal. O – 82 HDS2 DSP IC control signal. O –

100 RES CPU reset signal from the reset IC (F: IC501). O –

101–108 EXIO1–EXIO8 External data bus line. I/O +5 V pull-up

112 POSW [PWR] key input. (pull-up) I – 113 NOIS Noise detect. I "H"=RX signal is absent (squelch close). 114 CSFT Clock frequency shift signal. O – 119 SSO Serial data to the seri-para converter (M: IC31). O – 120 SCK Clock signal to the seri-para converter (M: IC31). O – 121 EXIO9 External data bus line. I/O +5 V pull-up 122 DSDA Serial data to the DAC (M: IC17). O –

LINE NAME DESCRIPTION

IN/

OUT

"H= AF signals are output from the

[ACCESSORY CONNECTOR].

CONDITION

5 - 3

3-4 CPU (M: IC20) PORT ALLOCATION (continued)

Pin No.

123 DAST Strobe to the DAC (M: IC2). O – 125 FMDA Data from the FRONT CPU (F: IC502). I – 126 MFDA Data to the FRONT CPU (F: IC502). O – 127 OPT2 Port for optional unit. O – 128 OPT1 Port for optional unit. I – 129 OPT3 Port for optional unit. I – 131 CSO Port for optional unit. O – 132 CSI Port for optional unit. I – 133 EXOE Output enable signal to the seri-para converter (M: IC31). O – 134 EXST Strobe to the seri-para converter (M: IC31). O – 135 DRES Reset signal to the DSP IC (M: IC12). O – 136 HCS DSP data line. I/O – 138 GPIO2 DSP data line. I/O – 139 GPIO1 DSP data line. I/O –

LINE NAME DESCRIPTION

IN/

OUT

CONDITION

5 - 4

+ 30 hidden pages

Icom IC-FR6100, IC-FR6000 Service Manual

INTRODUCTION CAUTION

CONTENTS

SECTION 1 SPECIFICATIONS

SECTION 2 INSIDE VIEWS

SECTION 5 CIRCUIT DESCRIPTION