Service Manual PM200/250
SM-PM200/250-01
PM200/250
Service Manual
Service Manual PM200
AMENDMENT RECORD SHEET
All amendments to this manual should be incorporated as soon as they are received and
recorded below:
Issue No. Effective Date Reason for Change Date Signature
All Engineering Bulletins relevant to this product should be placed at the rear of this
binder. Please ensure that this manual is updated with any replacement pages, which
may accompany these Engineering Bulletins.
Always read all Engineering Bulletins before carrying out work on a radio.
Please read the WARNINGS on the next page before referring to subsequent
sections.
Page 2 of 54
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Service Manual PM200
WARNINGS
1. WARNING! NEVER connect the transceiver to an AC outlet. This may pose a fire hazard
or result in an electric shock.
2. NEVER operate the radio transmitter without a suitable artificial load or antenna connected.
3. NEVER connect the transceiver to a power source of more than 16V DC such as a 24V
battery.
4. NEVER cut the DC power cable between the DC Plug and fuse holder. If an incorrect
connection is made after cutting, the transceiver may be damaged.
5. NEVER place the transceiver where normal operation of the vehicle may be hindered or
where it could cause bodily injury.
6. NEVER expose the transceiver to rain, snow or any liquids.
7. NEVER modify a radio or accessory except as instructed in the service manual, engineering
bulletins or formal communication as this may invalidate any warranty, guarantee or type
approval.
8. USE the supplied microphone only. Other microphones have different pin assignments and
may damage the transceiver. (ACC-700, optional DTMF MIC. ACC-703 )
9. DO NOT use or place the transceiver in areas with temperatures below -30
°C, In areas subject to direct sunlight, such as the dashboard.
+60
10. AVOID operating the transceiver without running the vehicle’s engine. The vehicle’s
battery will quickly run out if the transceiver transmits while the vehicle’s engine is OFF.
11. AVOID placing the transceiver in excessively dusty environments.
12. AVOID the use of chemical agents such as benzene or alcohol when cleaning, as they
damage the transceiver surfaces.
13. BE CAREFUL! The transceiver will become hot when operating continuously for long
°C or above
periods.
14. DO NOT operate this equipment in environments containing explosive materials or
vapours.
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Service Manual PM200
Contents
Amendments ....................................................... 2
Warnings ............................................................. 3
Introduction.......................................................... 6
Using this Manual.........................................................................................6
Amendments to this Manual........................................................................6
Specification ........................................................ 8
General ..........................................................................................................8
Transmitter....................................................................................................10
Receiver.........................................................................................................12
Maintenance and repair..................................... 14
Introduction...................................................................................................14
Test Equipment Connection........................................................................16
Microphone and PTT Connections .............................................................16
Transmitter Performance Tests...................................................................17
Receiver Performance Tests .......................................................................18
Alignment ......................................................................................................20
Disassembly and Re-assembly of the Radio................................21
PLL Alignment.................................................................................21
Transmitter TCXO Alignment.........................................................22
Receiver Alignment ........................................................................22
Receiver Performance Tests..........................................................23
Detailed functional description .......................... 25
UHF Transmit ................................................................................................25
UHF Receive..................................................................................................27
Control Details ..............................................................................................28
Troubleshooting................................................. 29
Diagnostic Function ....................................................................................29
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Service Manual PM200
ASIC ................................................................. 30
ASIC Control ................................................................................................30
APC (Automatic Power Control) ....................... 35
Schematics and PCB layout Index.................... 37
Main Control Schematic
TX RF Schematic
RX RF Schematic
VCO Schematic
Front Panel Schematic
Main PCB Layouts
Front Panel PCB Layouts
Main PCB Silk Ref
Front Panel Silk Ref
RF RX Block Diagram
Parts List............................................................ 38
Mechanical Exploded View..........................................................................38
Parts List .......................................................................................................39
Contact Details .................................................. 54
Note:
Although this manual is a generic manual for PM200 and PM250 there
are a number of differences between PM200 and PM250. A separate
appendix has been written which includes the drawings and part list for
the PM250. Please be aware that all drawings and parts are only
relevant to the PM200. All features and functions are relevant to both
models. The PM250 appendix can be downloaded from the MaxonCIC
website
Page 5 of 54
http://www.maxoncic.co.uk/
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Service Manual PM200
Introduction
This Maxon Service Manual is a comprehensive guide for the maintenance and field repair
of this equipment. It covers all versions of the PM-200/250 radio. Before using this manual
please read the whole of this introductory chapter, this will help you to make the best use
of it. If you have not done so already, please also read the warnings immediately in front of
this chapter before proceeding any further.
Using this Manual
The organization of this manual has been made to access the location and referencing of
information, as quickly as possible.
Section 3 - Installation, Commissioning & Alignment. This describes connections to the
radio, how to commission it and how to align the radio should this become necessary.
Section 4 - Detailed Functional Description.
Section 5 - Troubleshooting..
Amendments to this Manual
From time to time during its lifetime, this product will be changed and improved. To cover
such changes, amendments to this manual will be issued in the form of replacement
and/or additional pages. It is important that anyone working on a product has all the
relevant information. Therefore you should incorporate amendments to this manual on
receipt. Please follow the instructions accompanying the amendment (in the form of an
Engineering Bulletin) and be sure to complete the amendment record at the front of this
manual.
On occasion it may be necessary to issue product information more quickly than can be
achieved with an amendment. In this case the information will be distributed as a Maxon
Engineering Bulletin. Engineering Bulletin numbers are prefixed with a category letter – A,
B or C.
E.g. CATEGORY C – ENGINEERING BULLETIN 120
Category C describes how Maxon recommends an improvement and/or a modification to
make an improvement to a product
Engineering Bulletin 120 index number allocated to this bulletin.
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Service Manual PM200
‘A’ Category A Engineering Bulletins will only be released if, by using the equipment
manufactured by Maxon or its subcontractors, a risk to operator safety or an infringement
of Type Approval is probable.
All units affected should be returned for modification to Maxon CIC Europe Works
Department on receipt of such a Bulletin.
‘B’ Category B Engineering Bulletins are for equipment manufactured by Maxon CIC
that may have component batch problems.
All equipment affected that is in service is to be returned to the Distributor or Dealer
workshop for modification. Maxon CIC will supply replacement components free of charge.
‘C’ Category C Engineering Bulletins are for improvement or modification to equipment
manufactured by Maxon.
Dealer/Distributor to modify affected units in the field on the next service call. Maxon will
supply components free of charge.
Please place these at the back of this manual and refer to them before carrying out any
work. This Service Manual should be updated with any accompanying replacement pages.
You may wish to retain the previous issue pages for future reference.
Page 7 of 54
Service Manual PM200
Specification
General
Performance Specifications R&TTE Directive 1999/5/EC
ETSI EN 300 086-1/-2; ETSI EN 300113-2
EMC Directive 89/336/EEC
ETSI EN 301 489-1/-5
LV Directive 73/23/EEC EN 60950-1
72/245 EC as assembled by 2004/104/EC
Frequency coverage (UHF) 440.000 – 480.000MHz
(VHF) 146.000 – 174.000MHz
Channel Spacing 12.5 kHz, / 25 kHz
(12.5 / 25 kHz switchable by CPU control)
RF Output Power PM200 2W - 25W nominal (+/-20%)
RF Output Power PM250 5W - 45W nominal (+/-20%)
Modulation Type F3E/G3E
Audio Power 4W (Internal 16 Ω speaker)
Intermediate Frequencies 45.1MHz First I.F.
455 kHz Second I.F.
Number of Channels 208 Channels
Frequency Source PLL Synthesiser
Frequency Stability +/- 2.5ppm
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Service Manual PM200
Power Supply 13.8Vdc nominal
10.8Vdc minimum (extreme)
15.6Vdc maximum (extreme)
Current Consumption OFF <10µA
Standby (muted)<140mA
Unmuted with 25% AF power <350mA
Unmuted with 50% AF power <450mA
Unmuted with 100% AF power <1000mA
Transmit @ 2W RF output <2.0A
Transmit @ 25W RF output <7.0A
Environmental
Temperature Range
Operating -15 to +35°C (nominal)
-20 to +55°C (extreme),
Humidity EIA/TIA 603 (95%)
ESD 20kV (C-MIC = 15kV)
EMC EMC Directive 89/336/EEC May 89
ETS 301 489-1/-5
Physical Dimensions 161.8(W) mm x 168.8(D) mm x 44(H) mm
Weight 1.46kgs
Programmer PM200 PC Programmer
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Service Manual PM200
Transmitter
Test Method is ETS 300.086 2001 unless stated. Performance without Sub-Audio
Modulation.
PM200 Power Output
High Power 25W nominal adjusted
Low Power 2W nominal adjusted
PM250 Power Output
High Power 45W nominal adjusted
Low Power 5W nominal adjusted
Audio Freq. Deviation
Nominal Peak
12.5 kHz +/-1.5 kHz +/-2.5 kHz
25 kHz +/-3.0 kHz +/-5.0 kHz
With or without audio sub-modulation (10% peak deviation)
Audio Characteristic
(Method as FTZ17 TR 2049 July 1988)
Modulation Type F3
Within +1/-3dB of limit wrt 1 kHz:
300Hz to 2.55 kHz for 12.5kHz channel spacing
300Hz to 3.0 kHz for 20 / 25kHz channel spacing
TX Spurious Emission (conducted and radiated)
Below 1GHz Better than –36dBm
1 – 4GHz Better than –30dBm
MIC Sensitivity
At Accessory/Mic connector 12mV +/- 3.5mV
Values for 60% peak dev.
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Service Manual PM200
Transmitter Audio Distortion (Without CTCSS)
1 kHz < 5% (nominal)
Transmitter Audio Distortion (With CTCSS)
1 kHz < 8% (nominal)
Audio frequency = 1 kHz, with any CTCSS freq. combined.
Hum and Noise (Residual Modulation)
Method as FTZ 17 TR 2049 July 1988
Better than 40dB (with PSOPH)
Sub Audio Tones - CTCSS
Tone Range 67 to 250.3Hz @ 0.3% accuracy
Tone Standard RS-220A EIA
Nominal Tone 10% (8-15%) Pk Sys Dev.
Sub Audio Tones - DCS
Tone Standard Normal and Inverted
Tone Deviation 10% (3%) Pk System Dev. (UK)
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Service Manual PM200
Receiver
Test Method is ETS 300.086 2001 unless stated. Performance without Sub-Audio
Modulation
Sensitivity
12dB SINAD (nominal) UHF: Better than –117dBm
Amplitude Characteristic Within +/- 3dB
Co-channel Rejection
12.5 kHz From 0dB to –12dB
25 kHz From 0dB to –8dB
Adjacent Channel Selectivity
Nominal
12.5 kHz Better than 60dB
25 kHz Better than 70dB
Spurious Response Rejection
Better than 70dB (100 kHz – 4GHz)
Intermediation Response Rejection
+/- 25 / 50 kHz Better than 65dB
+/- 50 / 100 kHz Better than 65dB
Blocking >85dB
(+/-1MHz, +/-5MHz, +/-10MHz)
Rx Spurious Emissions (radiated) - nominal
9 kHz – 1GHz Better than –57dBm
1GHz – 4GHz Better than –47dBm
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Service Manual PM200
AF Power 4W max. (Internal 16Ω speaker)
AF Distortion – Method as FTZ 17 TR 2049
1 kHz < 5% (nominal)
RX Hum and Noise
Method as TIA / EIA-603
12.5 kHz <40dB No PSOPH
25 kHz <40dB No PSOPH
Sub Audio Tones - CTCSS
Tone Range 67 to 250.3Hz @ 0.3% accuracy
Tone Standard ETSI 300.219
Decode Sensitivity
Method (Decrease Signal Level, @ 10% peak dev. with no audio tone)
All Tones <=9dB SINAD
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Service Manual PM200
Maintenance and repair
Introduction
This section covers the tests which should be undertaken prior to customer handover.
All of the following tests can be carried out without having to gain access to the interior of
the radio.
Recommended Test Equipment
The alignment and performance test procedures assume the use of the following
equipment. The functions of most of the equipment may be found in a “Communications
Test Set”. This type of equipment is available from a number of test equipment
manufacturers.
Throughout this book, reference will be made to the use of the Communications Test Set.
Where applicable, the equivalent discrete item of test equipment may be used. For
example, if measuring power, a stand-alone power meter and a dummy load could be
used instead of the Test Set
Discrete Test Equipment
RF Signal Generator
RF Power Meter
RF Frequency Counter
Spectrum Analyser and notch filter
(optional)
Audio Signal Generator
Audio Power Meter
SINAD Meter
Modulation Meter
Oscilloscope
Voltmeter
DC Power Supply, 0 - 15V 10A min.
Use fig.1 as a suggested connection diagram to connect up the recommended
Note:
discrete test equipment.
Page 14 of 54
Combined Equipment
Communications Test Set (e.g. HP
8920B, Stabilock 4040 or similar).
Accessories
PM200 Microphone.
ACC - 2006
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Service Manual PM200
Test Equipment Configuration
(Fig. 1)
Prerequisites
For the following tests, signal generator modulation level should be set to Average
System Deviation, i.e. 60% of maximum system deviation.
The level should therefore be set to:
1.5 kHz for 12.5 kHz channel spacing
3.0 kHz for 25 kHz channel spacing
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Service Manual PM200
EEPROM programming
Ensure that the EEPROM has the required customer parameters programmed, otherwise
ensure that a test EEPROM is programmed with at least the lowest, middle and highest
RX/TX frequencies prior to aligning the UHF scanning mobile radio.
Test Equipment Connection
Test equipment connections for performance and Alignment tests are shown in figure 1.
Connect the power supply leads as follows:
1. Ensure the power supply is switched off.
2. Positive lead of the power supply to the red wire terminal tag of the 13.8V D.C.
connector.
3. Negative lead of the power supply to the black wire terminal tag of the 13.8V D.C.
connector.
Microphone and PTT connections.
The microphone and PTT connections are via the 6 pin socket on the front panel. The
specification for the connector is shown in figure 2. RX audio can be monitored at the
3.5mm jack on the rear panel.
Connect
pin outs
1 Data In/out
2 GND
3 N/F
4 HOOK IN
5 MIC_HI_INPUT
6 PTT_INPUT
7 +8V
8 BUSY_I/O
(Fig. 2)
Page 16 of 54
Function
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Service Manual PM200
Transmitter Performance Tests
Power Output
a) Connect the transmitter to the Communications Test Set (CTS) with the power meter
set to read 25W for the PM200.
b) Set the power supply to 13.8Vdc and connect a dc voltmeter across the power supply
to monitor the supply voltage.
c) Set the CTS to the same frequency as the radio and then set the PTT to start
transmitting. Check and record the power output. The nominal power output is 2W for
low power and 25W for high power.
d) Reduce the power supply voltage to 11Vdc and then set the PTT to start transmitting.
The output power should be greater than 65% of the level measured above.
Frequency Error
a) Using the frequency counter check that the transmit frequency is within +/- 750Hz of
the frequency which is programmed into the radio.
Distortion and Deviation Measurements
a) Set the radio to the middle TX frequency. Connect the oscilloscope to the AF output of
the modulation meter.
b) Set the audio signal generator to 1 kHz tone, low output impedance and adjusts its
level for 60% system deviation:
12.5 kHz channel spacing 1.5kHz dev.
25 kHz channel spacing 3kHz dev.
c) Press and hold the PTT button.
d) Measure the audio distortion. This should be less than 5%.
e) Increase the audio signal generator level by 20dB (10x voltage). The peak deviation
should be:
12.5 kHz channel spacing <= 2.2 kHz dev.
25 kHz channel spacing <= 4.3 kHz dev.
Page 17 of 54
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