Maxon Telecom SP200, SP210 User Manual
SP200/210
Service Manual
Published by Maxon Electronics Ltd
36a Gibson Avenue
Padstow Sydney
NSW Australia 2211
Tel: +61 (0) 2 9707 2000
Fax: +61 (0) 2 9707 3328
e-mail sales@maxon.com.au
Internet: www.maxon.com.au
Any queries regarding information in this manual, please contact the Technical Services Group Leader at the above address.
Information provided in this document is believed correct at time of printing but is subject to change without notic e.
Maxon will not accept liability for any loss, damage or costs howsoever caused as a result of the information provided.
SM-SP200/210 Maxon SP200/210 Radio
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.
Issue 1.0 AMENDMENT RECORD SHEET
03/01 Page i
Maxon SP200/210 Radio SP200/210
WARNINGS
Components containing beryllium oxide are used in the equipment. Dust from this material is a
•
health hazard if inhaled or allowed to come into contact with the skin. Great care must be taken
when handling these components. They must not be broken or subjected to excessive heat.
Never operate the radio transmitter without the correct Maxon antenna, or a suitable artificial
•
load, connected.
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.
Do not operate this equipment in environments containing explosive materials or vapour.
•
WARNINGS Issue 1.0
Page ii 03/01
SP200/210 Maxon SP200/210 Radio
TABLE OF CONTENTS
Page Number
1 INTRODUCTION 1-1
1.1 Using this Manual 1-1
1.2 Amendments to this Manual 1-1
1.3 Contact Information 1-2
2 SPECIFICATIONS 2-1
2.1 General 2-1
3 ACCESSORIES & OPTIONS 3-1
3.1 Pre-Install Check 3-1
3.2 Accessories 3-1
3.3 Options 3-1
4 INSTALLATION, COMMISSIONING & ALIGNMENT 4-1
4.1 Installation 4-1
4.2 Connections 4-1
4.3 Commissioning 4-2
4.3.1 Test Equipment Connection 4-6
4.3.2 Transmitter Performance Tests 4-6
4.3.3 Receiver Performanc e T ests 4-6
4.4 Power Adjustment 4-7
4.5 Alignment 4-8
4.5.1 Preparation 4-8
4.5.2 Disassembly and Re-assembly of the Radio 4-9
4.5.3 PLL Alignment 4-10
4.5.4 Squelch Sensitivit y 4-11
4.5.5 Transmitter Alignment 4-11
4.5.6 Receiver Alignment 4-14
5 DETAILED FUNCTIONAL DESCRIPTION 5-1
5.1 Introduction 5-1
5.2 Common Circuits 5-1
5.3 Audio ASIC 5-2
5.3.1 Audio Signal Path 5-2
5.3.2 Sat Signal Path 5-3
5.3.3 Miscellaneous Signals and Controller 5-3
5.4 Audio/SAT Circuits 5-4
5.5 Common RF Circuits 5-5
5.6 Transmitter 5-7
5.7 Receiver 5-8
6 TROUBLESHOOTING 6-1
6.1 Diagnostic Function 6-1
6.2 Troubleshooting Chart 6-2
6.3 Voltage Charts 6-3
6.3.1 Transistors (Main Circuit) 6-3
6.3.2 Integrated Circuits 6-4
7 PROGRAMMING 7-1
7.1 SMP6100 7-1
7.1.1 Introduction 7-1
7.1.2 Getting Started 7-1
7.1.3 Programming 7-1
Issue 1.0 TABLE OF CONTENTS
03/01 Page iii
Maxon SP200/210 Radio SP200/210
8 EXPLODED MECHANICAL DRAWINGS & PARTS LISTS 8-1
8.1 Parts List 8-1
8.2 Spare Parts 8-1
8.3 Mechanical Parts 8-3
8.4 SL100 VHF Parts List 8-8
8.4.1 V2 Control Circuit 8-8
8.4.2 V2 RF 8-10
8.4.3 TCXO Assembly 8-13
8.4.4 V2 VCO 8-14
8.4.5 V2 Front End 8-14
8.5 SL100 UHF Parts List 8-15
8.5.1 U2 Control Circuit 8-15
8.5.2 U2 RF 8-17
8.5.3 TCXO 8-20
8.5.4 VCO 8-21
9 CIRCUIT DIAGRAMS & PCB LAYOUTS 9-1
10 SPARE PARTS 10-1
10.1 Spare Parts 10-1
10.1.1 Component Replacement 10-2
11 APPENDIX – ACC-2003 ALIGNMENT BOX 11-1
11.1 Purpose 11-1
11.2 Test Equipment 11-1
11.3 Calibration Program 11-1
11.3.1 Operation 11-1
11.3.2 Adjustment of ASIC values 11-4
11.3.3 Transmit Adjustments 11-6
11.3.4 Receive Adjustments 11-7
11.4 Default Settings 11-8
11.4.1 V1 Band Default Settings 11-8
11.4.2 V2 Band Default Settings 11-9
11.4.3 U1 Band Default Settings 11-10
11.4.4 U2 Band Default Settings 11-11
LIST OF FIGURES
Figure 4-1 - Connections and controls............................................................................................................4-1
Figure 4-2 – Connections................................................................................................................................4-2
Figure 4-3 - Hirose connector .........................................................................................................................4-2
Figure 4-4 – Commissioning Test Setup using SK2055 Service Kit...............................................................4-2
Figure 4-5 – Commissioning Kit......................................................................................................................4-3
Figure 4-6 – Test Equipment Set-up using Discrete Test Equipment ............................................................4-4
Figure 4-7 – Test Equipment Set-up using a Communications Test Set........................................................4-4
Figure 4-8 - SK 3100 Service Kit.....................................................................................................................4-5
Figure 4-9 - Back Panel Adjusters ..................................................................................................................4-7
Figure 4-10 - Removal of battery ....................................................................................................................4-9
Figure 4-11 - Replacing the battery.................................................................................................................4-9
Figure 4-12 – Replacing the battery................................................................................................................4-9
Figure 4-13 – Removing the belt clip ..............................................................................................................4-9
Figure 4-14 – Adjustment Points...................................................................................................................4-10
Figure 4-15 – ACC-2003 Alignment Box Test Setup....................................................................................4-12
Figure 5-1 – ASIC Block Diagram...................................................................................................................5-3
Figure 5-2 – Synthesiser Block Diagram ........................................................................................................5-5
Figure 5-3 - Transmitter Block Diagram..........................................................................................................5-7
Figure 5-4 - Receiver Block Diagram..............................................................................................................5-8
WARNINGS Issue 1.0
Page iv 03/01
SP200/210 Maxon SP200/210 Radio
Figure 6-1 – Legend Layout for Top Side of Digital PCB ...............................................................................6-5
Figure 6-2 - Legend Layout for Bottom Side of Digital PCB...........................................................................6-6
Figure 6-3 - Legend Layout for Top Side of RF PCB .....................................................................................6-7
Figure 6-4 - Legend Layout for Bottom Side of RF PCB................................................................................6-8
Figure 8-1 - Exploded Mechanical Drawing 1.................................................................................................8-3
Figure 8-2 - Exploded Mechanical Drawing 2.................................................................................................8-5
Figure 8-3 – Exploded Mechanical Drawin g 3................................................................................................8-6
Figure 9-1 – Digital Board Layout Top Side....................................................................................................9-3
Figure 9-2 - Digital Board Layout Bottom Side...............................................................................................9-4
Figure 9-3 - RF Board Layout Top Side..........................................................................................................9-5
Figure 9-4 - RF Board Layout Bottom Side ....................................................................................................9-6
Figure 9-5 – Front-End Board Layout.............................................................................................................9-7
Figure 9-6 – VCO Board Layout .....................................................................................................................9-7
Figure 9-7 – TCXO Board Layout...................................................................................................................9-8
Figure 11-1 – Calibration Program Initial Screen .........................................................................................11-1
Figure 11-2 - Calibration Program Primary Screen ......................................................................................11-2
Figure 11-3 - ASIC Control Screen (Rx).......................................................................................................11-3
Figure 11-4 - ASIC Control Screen (Tx) .......................................................................................................11-4
Figure 11-5 - ASIC Control Screen (Rx).......................................................................................................11-5
Figure 11-6 - Modulation wave shape ..........................................................................................................11-6
LIST OF TABLES
Table 6-1 – Diagnostics ..................................................................................................................................6-1
Table 6-2 – Troubleshooting chart..................................................................................................................6-2
Table 6-3 - Main Circuit Transistor Voltages ..................................................................................................6-3
Table 6-4 - Integrated Circuit Voltages (Receive) ..........................................................................................6-4
Table 6-5 - Integrated Circuit Voltages (Transmit) .........................................................................................6-4
Table 8-1 - Parts List for Exploded Mechanical Drawing 1.............................................................................8-4
Table 8-2 - Parts List for Exploded Mechanical Drawing 2.............................................................................8-6
Table 3 – V1 Default Frequency Table.........................................................................................................11-8
Table 4 – V1 Default ASIC Settings..............................................................................................................11-8
Table 5 – V2 Default Frequency Table.........................................................................................................11-9
Table 6 – V2 Default ASIC Settings..............................................................................................................11-9
Table 7 - U1 Default Frequency Table........................................................................................................11-10
Table 8 - U1 Default ASIC Settings ............................................................................................................11-10
Table 9 – U2 Default Frequency Table.......................................................................................................11-11
Table 10 – U2 Default ASIC Settings .........................................................................................................11-11
Issue 1.0 TABLE OF CONTENTS
03/01 Page v
Maxon SP200/210 Radio SP200/210
WARNINGS Issue 1.0
Page vi 03/01
SP200 /210 Maxon SP200/210 Radio
1 INTRODUCTION
This Maxon Service Manual is a comprehensive guide to the maintenance and field repair of this
equipment. It covers a number of versions of the SP200/210 radio and its accessories. Differences
between the versions are indicat ed, as appropr iate, in the tex t.
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 on page ii before
proceeding any further.
The range of SP200/210 radios is as follows:
SP200/210 199 fixed channel, (V2) VHF or (U2) UHF radio.
1.1 Using this Manual
At any one time you will need to refer to only a small part of the manual. It has been organised as
follows to make this as easy and as quick as possible.
Chapter 2 - Specification, gives the detailed specification.
Chapter 3 - Accessories and Options. Lists the Accessories and Options that are available.
Chapter 4 - Installation, Commissioning & Alignment. Describes connections to the radio, how to
commission it and how to Align the radio should this becomes necessary. You will also
find it helpful to read the operating instructions in the User Manual and Chapter 7 on
Programming.
Chapter 5 - Detailed Functional Description.
Chapter 6 - Troubleshooting and PCB Drawings.
Chapter 7 - Programming.
Chapter 8 - Exploded Mechanical Drawings and Parts Lists.
Chapter 9 - Circuit Diagrams and PCB Layouts.
Chapter 10 - Spare Parts & Maintenance Policy.
Chapter 11 – ACC-2003 Alignm ent Box
1.2 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 an Engineering Bulletin. Engineering
Bulletin numbers are prefixed with a category letter – A, B or C. e.g.,
CATEGORY C - ENGINEERING BULLETIN 120
Issue 1.0 INTRODUCTION
03/01 Page 1-1
Maxon SP200/210 Radio SP200/210
Category definitions are:
‘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 Europe Works Department on
receipt of such a Bulletin.
‘B’
Category B Engineering Bulletins are for equipment manufactured by Maxon that may have
component batch problem s .
All equipment’s affected, that are in service, are to be returned to the Distributor or Dealer
workshop for modification. Maxon 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.
1.3 Contact Information
Should you have any queries regarding this manual, or the information within it, please contact:
The Technical Support Group
Maxon Electronics Australia.
36a Gibson Aveune
Padstow Sydeny
NSW Australia 2211
Telephone: +61 (0) 2 97072000 Fax: +61 (0) 2 97073328
Technical Support e-mail: engineering@maxon.com.au
Internet: www.maxon.com.au
INTRODUCTION Issue 1.0
Page 1-2 03/01
SP200/210 Maxon SP200/210 Radio
2 SPECIFICATIONS
2.1 General
Performance Specifications
R&TTE Appendix IV CE 168
ETS 300.086 Jan 91
I-ETS 300 219 Oct 93
ETS 300 279 Feb 96
TIA/EIA-603
Band
Channel Spacing
RF Output Power
Modulation Type
Audio Power
Intermediate Frequencies
Number of Channels
Switching Range
Frequency Source
(without retuning)
VHF 146 – 174MHz (V2)
UHF 440 – 470MHz (U2)
12.5kHz or 25kHz
Channel spacing is programmable.
1W / 5W (programmable and variable)
G3E
1W (Internal 4 Ω speaker)
500mW (External 8Ω speaker),
45.1MHz First I.F.,
455kHz Second I.F.
199
V2 146 to 174MHz Rx
146 to 174MHz Tx
U2 440 to 470MHz Rx
440 to 470MHz Tx
Synthesiser
Operation Rating
Power Supply
Current Consumption
Battery Life
All figures stated with Power Save On
Issue 1.0 DRAFT SPECIFICATIONS
03/01 Page 2-1
(minimum)
Intermittent 90:5:5 (STBY:RX:TX)
7.5Vdc nominal
Standby (muted) with battery save on <40mA
Standby (muted) with battery save off <80mA
Unmuted with 100% AF power <250mA
Transmit @ 5W RF output <2.4A
1350mAH >8.5Hrs
Maxon SP200/210 Radio SP200/210
Environmental
Operating Temperature Range
Storage Temperature Range -40 to +80°C (storage)
Charging Temperature Range 0 to +30°C
Humidity EIA/TIA 603 (95%)
Protection against ingress of IEC 529 IP54
dust and water
-15 to +35°C (nominal)
-20 to +55°C (extreme),
Vibration
Robustness Mil Std 810 C Procedures I, II & V
ESD
EMC
Physical Dimensions
Synthesiser
Reference Crystal
Frequency: 12.8MHz
Holder: HC-18
Accuracy:
Ageing Rate: < 2ppm / Year in the first year
Synthesiser Lock Time: < 10mS
Switching Times
Tx to Rx, same frequency < 20mS
Rx to Tx, same frequency < 20mS
Rx to Rx < 20mS
(over switching bandwidth)
Rx to Tx / Tx to Rx < 20mS
(over switching bandwidth)
BS2011 : Part 2.1Fc IEC 68-2-6
Part 2.1Fd IEC 68-2-34
20kV (C-MIC >= 15kV)
EMC Directive 89/336/EEC May 89
112 x 61 x 40mm
(Excluding antenna and with QPA1350 pack)
±
3ppm over –30 to +60°C
< 1ppm / Year in subsequent years
Receiver Sensitivity
Squelch Sensitivity
Adjacent Channel Selectivity
Sub Audio Tones – CTCSS / DCS
Decode Sensitivity
All tones <=9dB SINAD
CTCSS Tone Range 67 – 250Hz @ 0.3% accuracy
DCS Tone Standard Standard & Inverted
Programmer
SPECIFICATIONS DRAFT Issue 1.0
Page 2-2 03/01
Method (decrease signal level @ 10% peak deviation)
<-118dBm (VHF), <-117dBm (UHF)
7 – 12dB SINAD
Better than 70dB
50 – 260Hz @ 0.3% accuracy (non-standard tones)
SMP 6100
SP200/210 Maxon SP200/210 Radio
3 ACCESSORIES & OPTIONS
3.1 Pre-Install Check
The SP200/210, as purchased, is supplied with an Antenna, charger and power supply, belt clip and User
Manual.
3.2 Accessories
A wide range of accessories are available for the SP200/210. The list below represents a summary of
accessories available at the time this manual was published. For up-to-date listings, and for price and
availability, please refer to the current Price Book.
Order Code Description
Batteries
QPA-1350 1350mAh NimH battery.
Chargers
QPA-1185-2 2-pin (European) Intelligent fast charger with mains adapter
QPA-1185-3 3-pin (UK) Intelligent fast charger with mains adapter
QPA-1185 Spare cup for the above chargers (No PSU)
QPA-1195-2 6 + 6 Intelligent fast charger (Euro)
QPA-1195-3 6 + 6 Intelligent fast charger (UK)
CA1246 In-car charger
Speaker / Microphone accessories
MA100-01 Small Remote speaker mic.
MA100-02 Standard Remote speaker mic.
Headset Accessories
HS100-02 Lightweight headset
QPA1432 Lightweight headset
QPA1433 Two-way covert kit
QPA1455 Earbud
HS100-01 Earbud with Earhanger
Cases
CA1487 Lightweight Nylon case.
CA1475 Soft Leather case
CA1476 Soft Leather case with window
CA-7059 Belt Clip
Programmer
SMP6100 SP200/210 Programming Kit
3.3 Options
None
Issue 1.0 ACCESSORIES & OPTIONS
03/01 Page 3-1
Maxon SP200/210 Radio SP200/210
ACCESSORIES & OPTIONS Issue 1.0
Page 3-2 03/01
SP200/210 Maxon SP200/210 Radio
4 INSTALLATION, COMMISSIONING & ALIGNMENT
4.1 Installation
The SP200/210 is a hand-held radio and thus requires no installation.
The User should ensure that the batteries are charged before commencing commissioning tests.
4.2 Connections
1. Antenna connector: socket.
2. Channel Busy / Talk tri-colour LED.
3. Display
4. Main Power switch and volume
control. Fully anti-clockwise is the
OFF position.
5. Battery Release Catch.
6. Speaker.
7. Push To Talk (PTT) button.
8. Microphone.
9. Scan button.
10. Monitor button (unmutes the radio).
11. Channel select keys: Up / Down
keys, used to select channels.
12. Accessories socket (microphone &
speaker)
Note: Socket 12 is the Accessories
Connector, which may be used to
connect the radio to the following:
5
BACK
3
124
6
7
8
9
12
An optional remote speaker / microphone
An optional headset
A PC for programming using
SMP6100software
Issue 1.0 INSTALLATION, COMMISSIONING & ALIGNMENT
03/01 Page 4-1
10
11
Figure 4-1 - Connections and controls
Maxon SP200/210 Radio SP200/210
The Accessory connector is wired as follows:
PTT / Mic
Ground
Speaker
Figure 4-2 – Connections
The small multi-pin connector, which is connected
to the other end of the test lead, is wired
as follows:
PTT / Mic
1
View from
2
connector
3
6
rear of
4
Screen
5
Speaker
Figure 4-3 - Hirose connector
4.3 Commissioning
This section covers the tests, which should be undertaken prior to handover of the radio to the end
user. 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.
COMMUNICATION TEST SET
VOLT METER
DC POWER SUPPLY
RF
..
DEMOD
AF OUT
OSCILLOSCOPE
AF IN
TEST BOX
S2055K
RADIO
Figure 4-4 – Commissioning Test Setup using SK2055 Service Kit
INSTALLATION, COMMISSIONING & ALIGNMENT - Issue 1.0
Page 4-2 03/01
SP200/210 Maxon SP200/210 Radio
Commissioning Equipment
2
1
3
5
4
Figure 4-5 – Commissioning Kit
Note
: For those dealers who already have the SK2055 Service Kit (SL25/55) the audio cable (2),
CA8700, may be purchased. This interfaces the Service Kit to the SP200/210 and allows all simple,
commissioning audio measurements to be made. SMA adapter (5), ME210089 will also be required.
Flexi-pcb (3), ME110016 may be required if simple internal adjustments are to be made.
Note
: The equipment shown in Figure 4-5 allows only VCO and power adjustments to be made to the
SP200/210. The full Service Kit, SK3100, is required for setting deviation.
Please refer to Figure 4-6 for the set-up using discrete test equipment and Figure 4-4 for the set-up
using the Communications Test Set. If the ACC-2003 Interface Box is used, please refer to
Figure 4-7.
Issue 1.0 INSTALLATION, COMMISSIONING & ALIGNMENT
03/01 Page 4-3
Maxon SP200/210 Radio SP200/210
(op
Discrete Test Equipment
RF Signal Generator (with CTCSS/1kHz
tone)
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 Su pply, 0 - 10V 3A min.
RF SIGNAL GENERATOR
AUDIO POWER METER
Combined Equipment
Communications Test Set (e.g. Marconi
TF2955, Stabilock 4015 or similar).
Accessories
ME210089 SMA to BNC Adapter.
CA8700 Audio Lead for use with SK2055
Service Kit to perform audio
measurements.
SK3100 Service Kit
ACC-2002 SL100 Programming Lead
WA TT METER WITH
20dB ATTENUATOR
AUDIO
MODULATION- METER
DISTORTION METER
SINAD METER
Figure 4-6 – Test Equipment Set-up using Discrete Test Equipment
DC POWER SUPPLY
VOLT METER
VOLT METER
DC POWER SUPPLY
TEST BOX
RADIO
AUDIO GENERATOR
COMMUNICATION TEST SET
RF
..
DEMOD
AF OUT
2055SK
OSCILLOSCOPE
SPECTRUM ANALYZER
154.625
FREQUENCY COUNTER
OSCILLOSCOPE
AF IN
INTERFACE BOX
ACC-2003
tional)
RADIO
Figure 4-7 – Test Equipment Set-up using a Communications Test Set
INSTALLATION, COMMISSIONING & ALIGNMENT - Issue 1.0
Page 4-4 03/01
SP200/210 Maxon SP200/210 Radio
SK 3100 Service Kit
1
2
4
3
Figure 4-8 - SK 3100 Service Kit
This kit can be used for commissioning in the same way as the SK2055 (ignoring computer
connections). The above kit also includes a battery eliminator.
Note
: If the Interface Box is used, ensure that it is set to manual, Audio enable is off and PTT is off
before powering up.
If programming the radio with the Battery eliminator connected, the curly cord must be disconnected
from the Interface Box.
The SK 3100 service kit is used with the
SP200/210 radio and provides most of the
interface cables and tools which will be required
for test and alignment of the SP200/210.
Prerequisites
For the following tests, signal generator
modulation level should be set to Average
System Deviation, i.e. 60% of maximum
system deviation.
The SK 3100 Service Kit
programming cable, ACC-2002. This is
does not
provide the
The level should therefore be set to:
available as part of the SMP6100
Programming Kit (see Section 3).
1.5 kHz for 12.5 kHz channel spacing
2.4 kHz for 20 kHz channel spacing
1. ACC-2003 Radio Interface Test Box. This
3.0 kHz for 25 kHz channel spacing
provides an audio interface, a battery
eliminator / programming interface and a
PTT switch.
2. ME210089 SMA to BNC Adapter
3. Trimmer Tools. These are used to adjust
the trimmers and ferrite cores within the
radio.
If the radio has had components installed to
change the channel spacing and/or operating
band from those installed at the factory,
ensure that the correct components are
installed in the receiver and transmitter stages
prior to testing.
4. ME110016 Flexi-PCB. Used to
interconnect the Digital and RF pcbs for
servicing.
Refer to the appropriate Electrical Parts List if
necessary.
Issue 1.0 INSTALLATION, COMMISSIONING & ALIGNMENT
03/01 Page 4-5
Maxon SP200/210 Radio SP200/210
EEPROM programming
Ensure that the radio has the required
customer parameters programmed, otherwise
ensure that the radio is programmed with at
least the lowest, middle and highest Rx/Tx
frequencies prior to aligning the VHF and UHF
scanning handheld series radio.
Ensure that High and Low power are
programmed.
When CTCSS and DCS performance checks
are also required, ensure that the lowest,
middle and highest Rx/Tx frequencies include:
Lowest Rx/Tx freq. ch. 67.0 Hz CTCSS
Middle Rx/Tx freq. ch. DCS Code 072
Highest Rx/Tx freq. ch. 250.3 Hz CTCSS
The middle Rx/Tx frequencies should be
halfway between the lowest and the highest
frequencies.
Programming details are given in Section 7.
4.3.1 Test Equipment Connection
Use a battery or connect the power supply
leads from the battery eliminator to the power
supply. The red, positive, lead connects to
+7.5Vdc. The black, negative, lead connects
to the negative, terminal of the power supply.
A connection diagrams are given in
Figures 4-4, 4-6 or 4-7.
Set the radio to a channel with High power.
4.3.2 Transmitter Performance Tests
Power Output
This test is only possible using the battery
eliminator.
a. Connect the transmitter to the
Communications Test Set (CTS).
b. Set the power supply to 7.5Vdc and
connect a dc voltmeter across the
power supply to monitor the supply
voltage.
e. Switch to a channel with a low power
and ensure that the nominal power is
1W ± 1.5dB.
Frequency Error
a. Check that the transmit frequency is within
+/- 500Hz (VHF) or +/- 750Hz (UHF) of
the frequency which is program med
into the radio.
Deviation and Distortion
a. Set the radio to the middle Tx
frequency.
b. Set the audio signal generator to 1kHz
tone, low output impedance PTT and
adjust the AF generator level for 60%
system deviation:
12.5kHz channel spacing 1.5kHz dev.
20kHz channel spacing 2.4kHz dev.
25kHz channel spacing 3kHz dev.
c. Measure the audio distortion. This
should be less than 5%.
d. Increase the audio signal generator
level by 20dB (10x voltage). The peak
deviation should be:
12.5kHz channel spacing <= 2.25kHz dev.
20kHz channel spacing <= 3.6kHz dev.
25kHz channel spacing <= 4.5kHz dev.
4.3.3 Receiver Performance Tests
Sensitivity
The SINAD performance test may be used to
test the sensitivity of the receiver.
a. Connect the Communications Test Set,
modulated with a 1kHz tone, to the
radio.
b. Set the frequency to correspond to the
Rx frequency of one of the channels
programmed into the radio.
c. Using the Test Box, ensure that the AF
output from the Interface Box is connected
to the CTS SINAD meter.
c. Set the CTS to the same frequency as
the radio. Activate PTT. Check and
record the power output. The nominal
power output is 5W ± 1.5dB (3.5 to 7W)
d. Reduce the power suppl y voltage to
6.0Vdc and PTT. The output power
should be greater than 50% of the level
measured above.
INSTALLATION, COMMISSIONING & ALIGNMENT - Issue 1.0
Page 4-6 03/01
d. Set the volume control to mid-range.
e. Set the Test Set deviation to:
12.5kHz channel spacing 1.5kHz dev.
20kHz channel spacing 2.4kHz dev.
25kHz channel spacing 3kHz dev.
f. Adjust the RF signal generator level
until the SINAD meter reads 12dB.
SP200/210 Maxon SP200/210 Radio
This section is included here as it is not
g. Check that the signal generator RF
level is < -117dBm (UHF) or
< -118dBm (VHF).
Squelch
a. Ensure that both the radio and the
Test Set are set to the
appropriate channel spacing.
b. With the above setting, reduce the RF
level to –130dBm. The radio should be
mute.
c. Adjust the RF level until the SINAD
meter reads 10dB. The radio should
unmute. (
press and hold the monitor button to read
< 10dB SINAD).
Audio Output
a. Set the RF signal generator to 1mV pd
(-47.0dBm) and the tone and deviation
as above.
b. Connect the audio power meter to the
external accessories socket on the
radio, via the test box.
Note
: it will be necessary to
necessary to disassemble the radio in order to
set the power output.
A stable power source is required and
therefore the ACC-2003 Interface Box should
be used as this contains a battery eliminator.
For squelch adjustments, see Section 4.5.6.
20/25kHz
12.5kHz
High
Low
PowerSquelch
Figure 4-9 - Back Panel Adjusters
a. Select a mid-frequency channel with
High Power.
b. Set the PTT switch to on.
c. Adjust the volume control on the radio
under test to maximum (fully clockwise).
The voltmeter should indicate >= 1.55V.
The audio power meter should read
>= 300mW.
d. Decrease the volume control on the radio
so that the voltmeter reads 1.0V. Check
that the audio distortion is <5%.
Note:
The audio power meter should be set to
8Ω.
This concludes the Performance Tests.
If the Radio should fail any of these tests it will
be necessary to turn to the next section on
Alignment.
4.4 Power Adjustment
Note:
Any power adjustments made should be
within R&TTE parameters.
Transmit periods longer than 5 minutes are to
be avoided.
Power setting potentiometers are located
underneath the upper label on the back of
the radio.
with every radio.
A replacement label is shipped
c. Adjust RV1 (High) to give 5W ± 0.1W.
d. Set the PTT switch to off.
e. Select a mid-frequency channel with
Low Power.
f. Set the PTT switch to on.
g. Adjust RV3 (Low) to give 1W ± 0.1W.
h. Set the PTT switch to off.
i. Repeat steps a to h until switching
between the two channels gives Low
Power of 1W and High Power of 5W.
j. Switch to a low frequency, low power
channel.
k. Set the PTT switch to on.
l. Check that the power output is
1W ± 1.5dB (0.7 to 1.41W).
m. Set the PTT switch to off.
n. Repeat steps k to m for a low power,
high frequency channel.
Issue 1.0 INSTALLATION, COMMISSIONING & ALIGNMENT
03/01 Page 4-7
Maxon SP200/210 Radio SP200/210
4.5 Alignment
CAUTION
This radio contains static sensitive devices.
Static safe precautions should be observed, in
particular we would recommend the use of a
suitable floor mat, table mat, bonding cords
and a wrist strap. The soldering iron should
have an earthed tip.
Care should be exercised in the handling of
static sensitive components and they should
always be transported in the correct
containers.
Never remove, or insert, static sensitive
devices with the power applied.
4.5.1 Preparation
To perform the following tests it is necessary
to program the radio as follows:
VHF
Ch. Tx(MHz) Rx(MHz) CTCSS
1 146.025 146.025 None
2 160.025 160.025 None
3 173.975 173.975 None
4 173.975 173.975 67Hz
5 173.975 173.975 250.3
6 146.025 146.025 None
7 160.025 160.025 None
8 173.975 173.975 None
9 173.975 173.975 67Hz
10 173.975 173.975 250.3
Tests without Disassembly
Power Output, Deviation, Balance and
Squelch adjustment do not require the radio to
be disassembled.
UHF
Ch. Tx(MHz) Rx(MHz) CTCSS
1 440.025 440.025 None
2 455.025 455.025 None
3 469.975 469.975 None
4 469.975 469.975 67Hz
5 469.975 469.975 250.3
6 440.025 440.025 None
7 455.025 455.025 None
8 469.975 469.975 None
9 469.975 469.975 67Hz
10 469.975 469.975 250.3
Channel spacing as required. Channels 1 to 5
should be set to Low Power and channels 6 to
10 set to High Power.
Ensure that the Power Save is OFF.
INSTALLATION, COMMISSIONING & ALIGNMENT - Issue 1.0
Page 4-8 03/01
SP200/210 Maxon SP200/210 Radio
4.5.2 Disassembly and Re-assembly of
the Radio
Radio
In order to carry out the following PLL and
Alignment procedures it will be nec es sary to
gain access to the inside of the radio.
Care should be exercised when opening up
the radio for maintenance or repair.
REMOVING AND REPLACING THE
BATTERY
Removal
Holding the radio chassis in one hand, press
and hold the battery release catch (1) on the
top of the battery pack.
Using the other hand, slide the battery down,
towards the bottom of the radio and off the
battery guide rail (2).
Replacement
With the slides of the battery positioned in line
with the radio battery rail guides, slide the
battery into position until a click is heard.
1
Figure 4-10 - Removal of battery
2
Figure 4-11 - Replacing the battery
REMOVING AND REPLACING THE BELT
CLIP
Removal
Lift the locking lever (3) located on the top of
the belt clip with one hand and pull the belt clip
out of the belt clip rail towards the battery /
radio top.
Replacement
With the slides of the belt clip positioned in line
with the belt clip rail guides, slide the belt clip
into position until a click is heard.
Figure 4-12 – Replacing the battery
3
Figure 4-13 – Removing the belt clip
Issue 1.0 INSTALLATION, COMMISSIONING & ALIGNMENT
03/01 Page 4-9
Maxon SP200/210 Radio SP200/210
REMOVING AND REPLACING THE MAIN ASSEMBLY
Removal
With the battery pack removed, there are four,
black, cross-head screws visible.
These can now be removed along with the
black, cross head screw holding the
accessories socket dust cover.
Unscrew the antenna and slide off the volume
control knob.
Replace the battery
but do not
push all of the
way home. Gripping the lower sides of the
battery, and the lower sides of the radio lever
the two apart at the bottom of the radio to
separate the two.
Withdraw the module from the case.
Remove the battery from the module.
This level of disassembly will be enough for
test purposes.
LOCATION OF ADJUSTMENT POINTS
L203
C208
TCXO
TP1
RF PCB
Figure 4-14 – Adjustment Points
Note
: A screwdriver, or similar object, should
never
be used to force open the radio as the
sealing gasket is likely to be damaged.
To reassemble the radio, carry out the above
instructions in reverse, ensuring that the seal
is pushed down into the cover. Take care not
to damage the sealing gasket.
With the two parts of the radio separated, for
servicing, it will be necessary to link the two
pcbs using the flexi-pcb ME110016, which is
part of the Service Kit.
4.5.3 PLL Alignment
Before any alignment is carried out to the
transmitter, or receiver, it is necessary to align
the Phase Locked Loop (PLL). The PLL
consists of the Rx VCO, Tx VCO and TCXO.
If the PLL is out of lock, an audible warning
will be heard UL will appear on the LCD
display.
Note:
This alert will also be heard when a
channel is programmed out of the range of
operation of the radio, or it is not programmed
at all.
Note
: If the power save parameter is
programmed there will be a periodic change at
TP1. Measurement should be based on the
steady state voltage, with power save off.
In order to carry out repairs, the two halves of
the radio may need to be linked using the flexipcb, ME110016.
This is part of the Service Kit and the Interface
Box and leads will also be required for some
of the tests.
Connect the radio under test to the Test
Equipment.
INSTALLATION, COMMISSIONING & ALIGNMENT - Issue 1.0
Page 4-10 03/01
SP200/210 Maxon SP200/210 Radio
Rx VCO
a. Select Channel 1.
b. Check that the VCO tuning voltage at
TP1 is >5.7V +/- 0.25V (VHF) or >1.0V
+/- 0.25V (UHF).
c. Select Channel 3
d. Check that the voltage at TP1 is <12.5V.
Tx VCO
a. Select Channel 1.
b. Set the PTT switch to on and check that
the voltage at TP1 is 1.0V +/- 0.25V
(VHF) or 2.0V +/- 0.25V (UHF).
c. Select Channel 3.
d. Check that the voltage at TP1 is <12.5V.
e. Set the PTT switch to off.
Note
: If TP1 is below 0.6V or above 12.5V, in
any of the above tests, L203 may be adjusted.
L203 is covered in wax and therefore great
care will need to be taken when removing the
wax.
4.5.4 Squelch Sensitivity
The RF input level to open the squelch is
usually set in the range –123.5 to –117dBm
(0.15 to 0.3mV). The squelch should open at
a SINAD between 7 and 12dB (no CCITT).
The squelch should close between 2 and 4dB
of the value at which it opens.
RV2 sets the squelch level for 12.5kHz
channel spacing and RV4 sets the squelch
level for 20/25kHz channel spacing.
Note
: RV2
MUST
be set before RV4.
4.5.5 Transmitter Alignment
Power Adjustment
See Section 4.4.
TCXO
a. Select Channel 2.
b. Set the PTT switch to on.
c. Using the frequency counter, adjust the
TCXO control, so that the transmit
frequency is within +/- 200Hz of the
required frequency.
d. Set the PTT switch to off.
If no further alignment is to be carried out, it
may be necessary to check the squelch
setting.
Issue 1.0 INSTALLATION, COMMISSIONING & ALIGNMENT
03/01 Page 4-11
Maxon SP200/210 Radio SP20/210
All further adjustments require the use of the ACC-2003 Alignment Box.
Refer to the ACC-2003 User Manual (on floppy disk) for operational information.
OSCILLOSCOPE
RADIOCOMMUNICATIONS
TEST SET
SERIAL DATA
DEMOD
AF IN AF OUT
AUDIO
AUDIO IN
ACC-2003
INTERFACE
BOX
AUDIO OUT
DC POWER SUPPLY
Power ATE TXD RXD
ATE AUDIO PTT
Power
SERIAL DATA
7.5VDC @ 2.4A max.
Figure 4-15 – ACC-2003 Alignment Box Test Setup
Please refer to the ACC-2003 Interface Test Jig User Guide for details on how to use the ACC-2003
Interface Box.
The radio should remain programmed as Section 4.5.1 with ASIC values being read as per the
instructions.
Note
: The ASIC programmer
DOES NOT
read frequency data, so only default frequencies will be
displayed even though the actual radio is programmed and operational on different frequencies.
Any adjustments to deviation and balance must be carried out in accordance to the R&TTE directive.
INSTALLATION, COMMISSIONING & ALIGNMENT - Issue 1.0
Page 4-12 03/01
SP200/210 Maxon SP200/210 Radio
Balance Adjustment
a. Select Channel 3 (using software).
b. Set the audio generator to a 310H z tone,
low output impedance, at a level of
400mV.
c. Press Shift + T on the keyboard to
transmit.
d. Adjust TXTRIM2/TXTRIM3 to give a
square wave on the oscilloscope
(check that audio enable is ON on the
Interface Box.
e. Press Shift + R to turn off the transmitter.
Audio deviation adjustment
a. Select Channel 3 and press Shift + T to
turn on the transmitter.
b. Set the audio generator to 1kHz and
adjust its level for 60% peak system
deviation. Ensure that, depending upon
the channel spacing of channel 3, the
deviation is either:
12.5kHz channel spacing 1.5kHz dev.
or 20kHz channel spacing2.4kHz dev.
or 25kHz channel spacing3kHz dev.
c. Measure the audio distortion. This
should be less than 5%.
If necessary, adjust TXTRIM1 to keep within
the system deviation.
h. Press Shift + R to return to receive.
CTCSS / DCS deviation
a. Select Channel 4.
b. Turn off the audio signal generator so
that the RF signal generator is not
modulated.
c. Press Shift + T on the keyboard.
d. Adjust SATRIM2 for the desired CTCSS
tone peak deviation (± 50Hz) which is:
12.5kHz channel spacing 0.25kHz dev.
or 20kHz channel spacing0.4kHz dev.
or 25kHz channel spacing0.5kHz dev.
e. Press Shift + R to return to receive.
f. Select Channel 5.
g. Press Shift + T and check that
the deviation is the same as above.
If the deviation is greater than above,
adjust SATTRIM2.
h. Press Shift + R to return to receive.
i. Select Channel 4.
d. Increase the audio level by 20dB (10x
voltage).
e. Adjust TXTRIM1. to set the deviation to:
12.5kHz channel spacing 2.25kHz dev.
or 20kHz channel spacing3.6kHz dev.
or 25kHz channel spacing4.5kHz dev.
f. Slowly sweep the audio signal generator
between 300Hz and 3kHz. Record the
peak deviation. The peak deviation
should be:
12.5kHz channel spacing <= 2.5kHz dev.
or 20kHz channel spacing<= 4kHz dev.
or 25kHz channel spacing<= 5kHz dev.
If necessary, adjust TXTRIM1 to keep within
the system deviation.
g. Repeat para. f with the radio set to
Channel 1.
j. Press Shift + T to transmit.
k. Turn the audio generator back on so that
the RF signal generator is modulated
with a 310Hz tone.
12.5kHz channel spacing 2.5kHz dev.
or 20kHz channel spacing4.0kHz dev.
or 25kHz channel spacing5.0kHz dev.
l. Press Shift + R to return to receive.
Select Channel 5 and press Shift + T.
Check that the peak deviation is less than:
12.5kHz channel spacing <= 2.5kHz dev.
or 20kHz channel spacing<= 4.0kHz dev.
or 25kHz channel spacing<= 5.0kHz dev.
If necessary, adjust TXTRIM to keep within the
system deviation.
m. Press Shift + R to return to receive.
n. Write the changes to the radio.
Issue 1.0 INSTALLATION, COMMISSIONING & ALIGNMENT
03/01 Page 4-13
Maxon SP200/210 Radio SP200/210
This completes the transmitter alignment
process.
4.5.6 Receiver Alignment
Audio Volume Level
a. Set the test set to the appropriate
frequency at –47dBm with 1kHz tone
modulation at 60% system deviation:
12.5kHz channel spacing 1.5kHz dev.
or 20kHz channel spacing2.4kHz dev.
or 25kHz channel spacing3kHz dev.
b. Select Channel 1.
c. With the calibration program running on
the PC, select Rx_Vol.
d. Turn the volume control to maximum.
e. Using the PageUp and PageDown keys,
press until the desired maximum volume
level is achieved.
Note:
-17.5dB corresponds to 2.10V (+/-0.2V)
into 4 ohm speaker.
At maximum volume, nominal distortion is
10%.
f. Write the changes to the radio.
It may be necessary to carry out adjustment of
the squelch setting, see Section 4.5.4.
This completes the receiver alignment
process.
The following parameters would NOT normally
be adjusted unless specific environmental
conditions necessitate a change:
INTRIM on the receiver (Audio from IF IC.)
SATRIM on the receiver (gain received – sub
audible tone)
Refer to the ACC-2003 User Guide for details.
INSTALLATION, COMMISSIONING & ALIGNMENT - Issue 1.0
Page 4-14 03/01
SP200/210 Maxon SP200/210 Radio
5 DETAILED FUNCTIONAL DESCRIPTION
5.1 Introduction
This section provides a detailed description of the operation of the radio.
5.2 Common Circuits
Power Circuits
Battery voltage, or external voltage through the accessories connector, is applied via a 4A fuse (plus
diode protection) directly to the RF power module and, after the on/off switch, to the dc to dc converter
and voltage regulator. The majority of the circuitry is powered via IC1, which regulates the +7.5V dc
supply down to +5V.
Transistors Q2 and Q32, in conjunction with the Tx Enable and Rx Enable lines from the
microcontroller, apply +5V Tx or +5V Rx to the relevant circuitry during receive or transmit. Thus, for
instance, the receive front end amplifier is only powered during receive and the power control IC is
only powered during transmit.
It is possible to program the radio for power saving. This mode causes the microcontroller to pulse the
Rx Enable line high and low for periods between 100 and 300mS. The time may be selected when
programming the radio. As soon as the radio detects a signal it switches into normal mode.
Microcontroller
The microcontroller (IC403) is a One Time Programmed Processor chip based on the Hitachi HD3837
processor with onboard ROM and RAM.
It controls all functions performed by the radio, in conjunction with control signals from push buttons,
switches etc. It controls the data to/from the EEPROM and to the PLL IC, Audio ASIC as well as
controlling external data from the programmer and alignment interface. The microcontroller generates
the enable lines, controlling routing of signals and the indicators (LED,LCD and bleeps).
The microcontroller also generates and decodes the SAT tones (filtered by the ASIC).
EEPROM
Relevant channel information, such as Rx / Tx frequencies and CTCSS / DCS codes, is stored in the
EEPROM (IC404) which is a X25330. This information may be programmed and erased via the
accessories socket. Certain parameters can also be altered via the pushbuttons and keys on the
radio, i.e. scan channels and priority channel. The EEPROM has 32768 (8x4096) capacity and data is
written serially.
Channel Select Circuit
Up to 199 channels may be selected, using the channel keys on the front panel. Pressing the channel
keys earths pins 40 and 41 of the microcontroller, so enabling the decoding for the appropriate Rx and
Tx frequencies, and associated data, to be selected from the EEPROM.
Issue 1.0 DETAILED FUNCTIONAL DESCRIPTION
03/01 Page 5-1
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