Motorola 89FT4828 User Manual

Table of Contents

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inside front cover

List Of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Portable Radio Model Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Specifications for VHF Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Specifications for UHF Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Specifications for 800 MHz Radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notations Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Radio Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FLASHport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 - Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 - Recommended Test Equipment and Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Service Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Field Programming Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 - Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 - Radio Alignment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Transmit Power Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Transmit Deviation Balance (Compensation) Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Transmit Deviation Limit Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

A

, Motorola, ASTRO, XTS 3500, Private-Line, and Digital Private-Line are trademarks of Motorola, Inc.

® by Motorola Inc., Radio Products Group

8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322
Printed in U.S.A. 9/98

Basic Service Manual

68P81089C80-O

i

ii

6 - Basic Removal/Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Frequency Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Volume Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7 - Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Analog Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

ASTRO Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

RF Board Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

VOCON Board Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8 - Radio-Level Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power-Up Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operational Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Replacement Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside back cover

List Of Figures

Figure 1. Radio Alignment Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Figure 2. RSS Service Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 3. Softpot Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 4. Reference Oscillator Alignment Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 5. Transmit Power Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 6. Transmit Deviation Balance (Compensation) Alignment Screen . . . . . . . . . . . . . . . . . 17

Figure 7. Transmit Deviation Limit Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 8. Partial Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

List of Tables

Table 1. ASTRO XTS 3500 Basic Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Table 2. Recommended Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Table 3. Service Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Table 4. Initial Equipment Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Table 5. Test Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 6. Test Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 7. Receiver Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Table 8. Transmitter Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table 9. Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 10. Transmit Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table 11. Transmit Deviation Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 12. Partial Exploded View Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Table 13. Local Oscillator and First IF Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table 14. Power-Up Error Code Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Table 15. Operational Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table 16. Receiver Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table 17. Transmitter Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Table 18. Encryption Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Related Publications

ASTRO Digital XTS 3500 Model I User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C77

ASTRO Digital XTS 3500 Model II User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C78

ASTRO Digital XTS 3500 Model III User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C79

ASTRO Digital XTS 3500 Detailed Service Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . .68P81089C81

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs
stored in semiconductor memories or other media. Laws in the United States and other countries preserve
for Motorola certain exclusive rights for copyrighted computer programs, including, but not limited to,
the exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly , any
copyrighted Motorola computer programs contained in the Motorola products described in this manual
may not be copied, reproduced, modified, reverse-engineered, or distributed in any manner without the
express written permission of Motorola. Furthermore, the purchase of Motorola products shall not be
deemed to grant either directly or by implication, estoppel, or otherwise, any license under the
copyrights, patents or patent applications of Motorola, except for the normal non-exclusive license to use
that arises by operation of law in the sale of a product.

iii

iv vi

C

or

or

C

or

or

SPECIFICATIONS FOR VHF RADIOS

All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted

GENERAL

FCC Designation: AZ489FT3790
Temperature Range:

Operating:
Storage:

Power Supply: Nickel-Cadmium Battery (NiCd)

Nickel-Metal-Hydride Battery (NiMH)

Lithium-Ion Battery (Li-Ion)

Battery Voltage:

Nominal:
Range:

Transmit Current Drain (Typical): 2300mA
Receive Current Drain (Rated Audio): 290mA
Standby Current Drain:

Recommended Battery:

Ultra-HIgh-Capacity NiCd:

Ultra–High-Capacity NiCd FM: NTN8295*
Ultra–High-Capacity NiMH FM: NTN8299A*

Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III, Division 1,

Groups C, D,E, F, and G. FM Non-incendive:
Class 1, Division 2, Groups A, B, C, and D.

Dimensions (H x W x D)

Note: 2.44" = width at PTT; 2.34" = width at

bottom; 1.83" = depth at speaker; 0.97" = depth
at keypad

Less Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 24.56mm)

With Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm)

–30
–40

°

°

C to +60
C to +85

7.5 Volts

6 to 9 Volts

90mA

NTN8294A

°

°

RECEIVER TRANSMITTER

Frequency Range:

Bandwidth:

Quieting Sensitivity (20dBQ): 0.35
Usable Sensitivity

(12dB SINAD):

Intermodulation:

Selectivity (typical)

(25/30kHz Channel):

Spurious Rejection:

Frequency Stability

°

C; 25

°

(–30+60

Rated Audio:

Distortion (At Rated Audio):

Channel Spacing:

C reference):

0.25

–78dB (typical)

12.5/20/25/30kHz

136-178MHz

42MHz

m

V (typical)

m

V (typical)

–78dB

–70dB

±

.0002%

500mW

2% Typical

RF Power:

136-174MHz:
174-178MHz:

Frequency Range:

Frequency Stability (typical)

(–30 to +60

Emission (Conducted and Radiated): –70dBc

FM Hum and Noise (typical)

(Companion Receiver): 25/30kHz –48dB

Distortion:

Modulation Limiting: 25/30kHz chnls

Emissions Designators:

20K0F1E, 16K0F3E, 11K0F3E,

8K10F1D, and 8K10F1E

°

C; 25

°

C ref.):

20kHz chnls

12.5kHz chnls

1 Watt/5 Watts
1 Watt/4 Watts

136-178MHz

±

.0002%

12.5kHz –42dB

2% Typical

±

5.0kHz

±

4.0kHz

±

2.5kHz

Weight: (w/Helical Antenna)

Less Battery:
With Ultra-High Cap. NiCd: 25.19oz. (693gm)
With Ultra-High Cap. NiMH: 23.45oz. (644gm)

14.10oz. (383gm)

Specifications subject to change without notice

C

or

or

C

or

or

SPECIFICATIONS FOR UHF RADIOS

All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted

GENERAL

FCC Designation: AZ489FT4828
Temperature Range:

Operating:
Storage:

Power Supply: Nickel-Cadmium Battery (NiCd)

Nickel-Metal-Hydride Battery (NiMH)

Lithium-Ion Battery (Li-Ion)

Battery Voltage:

Nominal:
Range:

Transmit Current Drain (Typical): 1700mA
Receive Current Drain (Rated Audio): 290mA
Standby Current Drain:

Recommended Battery:

Ultra-HIgh-Capacity NiCd:

Ultra–High-Capacity NiCd FM: NTN8295*
Ultra–High-Capacity NiMH FM: NTN8299A*

Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III, Division 1,

Groups C, D,E, F, and G. FM Non-incendive:
Class 1, Division 2, Groups A, B, C, and D.

Dimensions (H x W x D)

Note: 2.44" = width at PTT; 2.34" = width at

bottom; 1.83" = depth at speaker; 0.97" = depth
at keypad

Less Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 24.56mm)

With Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm)

–30
–40

°

°

C to +60

°

C to +85

°

7.5 Volts

6 to 9 Volts

90mA

NTN8294A

RECEIVER TRANSMITTER

Frequency Range:

Bandwidth:

Quieting Sensitivity (20dBQ): 0.316

Usable Sensitivity

(12dB SINAD):

Intermodulation:

Selectivity (typical)

(25/30kHz Channel):
(12.5kHz Channel):

Spurious Rejection:

Frequency Stability

(–30+60

°

C; 25

°

C reference):

Rated Audio:

Distortion (At Rated Audio):

Channel Spacing:

403-520MHz

0.25

–78dB (typical)

1.5% Typical

12.5/20/25/30kHz

70MHz

m

V (typical)

m

V (typical)

–78dB
–68dB

–75dB

±

.0002%

500mW

RF Power:

403-470MHz:
450-520MHz:

Frequency Range:

Frequency Stability (typical)

(–30 to +60

Emission (Conducted and Radiated): –70dBc

FM Hum and Noise (typical)

(Companion Receiver): 25/30kHz –48dB

Distortion:

Modulation Limiting: 25/30kHz chnls

Emissions Designators:

20K0F1E, 16K0F3E, 11K0F3E,

8K10F1D, and 8K10F1E

°

C; 25

°

C ref.):

20kHz chnls

12.5kHz chnls

1 Watt/5 Watts
1 Watt/5 Watts

403-520MHz

±

.0002%

12.5kHz –42dB

1.5% Typical

±

5.0kHz

±

4.0kHz

±

2.5kHz

Weight: (w/Helical Antenna)

Less Battery:
With Ultra-High Cap. NiCd: 25.19oz. (693gm)
With Ultra-High Cap. NiMH: 23.45oz. (644gm)

14.10oz. (383gm)

Specifications subject to change without notice

vii

SPECIFICATIONS FOR 800 MHz RADIOS

All specifications are per Electronic Industries Association (EIA) 316B unless otherwise noted.

GENERAL RECEIVER TRANSMITTER

FCC Designation: AZ489FT5774

Temperature Range:

Operating: –30°C to +60°C
Storage: –40°C to +85°C

Power Supply: Nickel-Cadmium Battery (NiCd)

or Nickel-Metal-Hydride Battery (NiMH)

or Lithium-Ion Battery (Li-Ion)

Battery Voltage:

Nominal: 7.5 Volts
Range: 6 to 9 Volts

Transmit Current Drain (Typical): 1700mA
Receive Current Drain (Rated Audio): 280mA
Standby Current Drain: 90mA

Recommended Battery:

Ultra-HIgh Capacity NiMH: H335AC

or Ultra–High Capacity NiCd FM: H223AX*
or NiMH FM IS: Q393AB
Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III, Division 1,

Groups D, F, and G

Dimensions (H x W x D)

Note: 2.44" = width at PTT; 2.34" = width at

bottom; 1.83" = depth at speaker; 0.97" = depth
at keypad

Less Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 24.56mm)

With Ultra-High Capacity NiMH Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm)

With Ultra-High Capacity NiCd Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm)

With NiMH FM IS Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x1.65"
(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm)

Frequency Range: 851–870MHz

Bandwidth: 19MHz

Quieting Sensitivity (20dBQ): 0.5mV Max.

Usable Sensitivity

(12dB SINAD): 0.35mV Max.

Intermodulation: –70dB

Selectivity

(25kHz Adjacent Channel): –70dB

Spurious Rejection: –70dB

Frequency Stability

(–30+60°C; 25°C reference): ±.00015%

Rated Audio: 500mW

Distortion (At Rated Audio): 3% Typical

Channel Spacing: 25kHz

RF Power: 3 Watts

Frequency Range: 806–825MHz

851–870MHz

Frequency Stability

(–30 to +60°C; 25°C ref.): ± .00015%

Emission (Conducted and Radiated): –46dBw

FM Hum and Noise

(Companion Receiver): –40dB

Distortion: 3% Typical

Modulation Limiting: ±5kHz
(821-824MHz): ±4kHz

Emissions Designators:

20K0F1E, 16K0F3E, 15K0F2D,

15K0F1D, and 8K10F1E

Weight: (w/Helical Antenna)

Less Battery: 14.10oz. (383gm)
With Ultra-High Cap. NiMH:23.45oz. (644gm)
With Ultra-High Cap. NiCd: 25.19oz. (693gm)
With NiMH FM IS: 23.45oz. (644gm)

viii

Specifications subject to change without notice

CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
equipment damage.

!

C a u t i o n

WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.

!

W A R N I N G

!

DANGER indicates an imminently
hazardous situation which, if not
avoided, will

result in death or injury.

D A N G E R

!

Introduction

1

General

Notations Used
in This Manual

This manual covers information needed for level one troubleshooting. Level
one troubleshooting consists of radio programming, radio alignment, knobs
replacement, and installation and removal of antenna, belt clip, battery, and
universal connector cover . This will be the only level of service allowed for the
service centers, self-maintained customers, and distributors for the first six
months of the life of this product.

Included in this manual are radio specifications for the VHF, UHF, and
800MHz frequency bands, a general description of XTS 3500 models,
recommended test equipment, service aids, radio alignment procedures,
general maintenance recommendations, and procedures for basic assembly
and disassembly.

Throughout the text in this publication, you will notice the use of warnings,
cautions, and notes. These notations are used to emphasize that safety hazards
exist, and care must be taken and observed.

NOTE:

An operational procedure, practice, or
condition, etc., which is essential to
emphasize.

1

Radio
Description

Feature Model I Model II Model III

Display None LCD

Keypad None 3 x 2 button 3 x 6 button

The ASTRO Digital XTS 3500 radios are among the most sophisticated two­way radios available. The radio is presently available in the UHF R2 band;
radios in the UHF R1, VHF, and 800MHz bands will be available by the end of

1999.

One of the newest in a long line of quality Motorola products, the ASTRO
Digital XTS 3500 radio provides improved voice quality across more coverage
area. The digital process called “embedded signalling” intermixes system
signalling information with digital voice, resulting in improved system
reliability and the capability of supporting a multitude of advanced features.
Such features add up to better, more cost-effective two-way radio
communications.

ASTRO Digital XTS 3500 radios are available in two basic models. Table 1
provides a description of their basic features.

Table 1 ASTRO XTS 3500 Basic Features

LCD

4 lines/

12 characters per line

4 lines/

12 characters per line

Channel Capability 48 255 255
Dialing from Prestored List No Yes Yes
Programmable Softkeys No Yes Yes

FLASHport

The ASTRO Digital XTS 3500 radio utilizes Motorola’s revolutionary
FLASHport technology. FLASHport makes it possible to add software that
drives the radio’s capabilities both at the time of purchase and later on.
Previously, changing a radio’s features and capabilities meant significant
modifications, or buying a new radio. But now , similar to how a computer can
be loaded with different software, the radio’s features and capabilities can be
upgraded with FLASHport software.

2

The effects of certain chemicals and their vapors can
have harmful results on certain plastics. Aerosol
sprays, tuner cleaners, and other chemicals should
be avoided.

!

C a u t i o n

Basic Maintenance

2

Introduction
to This Section

Preventive
Maintenance

Inspection

Cleaning

This section of the manual describes preventive maintenance and handling
precautions. Each of these topics provides information vital to the successful
operation and maintenance of your radio.

The ASTRO Digital XTS 3500 radios do not require a scheduled preventive
maintenance program; however, periodic visual inspection and cleaning is
recommended.

Check that the external surfaces of the radio are clean, and that all external
controls and switches are functional. A detailed inspection of the interior
electronic circuitry is not needed.

The following procedures describe the recommended cleaning agents and the
methods to be used when cleaning the external surfaces of the radio. External
surfaces include the housing assembly and battery case. These surfaces should
be cleaned whenever a periodic visual inspection reveals the presence of
smudges, grease, and/or grime.

The only recommended agent for cleaning the external radio surfaces is a 0.5%
solution of a mild dishwashing detergent, such as JOY

®

, in water.

Cleaning External
Plastic Surfaces

The detergent-water solution should be applied sparingly with a stiff, non­metallic, short-bristled brush to work all loose dirt away from the radio. A soft,
absorbent, lintless cloth or tissue should be used to remove the solution and
dry the radio. Make sure that no water remains entrapped near the connectors,
cracks, or crevices.

3

Handling
Precautions

Complementary metal-oxide semiconductor (CMOS) devices, and other high­technology devices, are used in this family of radios. While the attributes of
these devices are many , their characteristics make them susceptible to damage
by electrostatic discharge (ESD) or high-voltage charges. Damage can be latent,
resulting in failures occurring weeks or months later. Therefore, special
precautions must be taken to prevent device damage during disassembly,
troubleshooting, and repair. Handling precautions are mandatory for this
radio, and are especially important in low-humidity conditions.

At this time, troubleshooting and repair of the radio will not be supported by
the field or self-maintained customer. DO NOT attempt to disassemble the

radio.

4

Recommended Test
Equipment and

3

Service Aids

Recommended
Test
Equipment

Motorola

Model Number

R2670 or R2600 System Analyzer This monitor will substitute

R1049A* Digital Multimeter Recommended for ac/dc voltage

The list of equipment contained in Table 2 includes all of the standard test
equipment required for servicing two-way portable radios, as well as several
unique items designed specifically for servicing this family of radios. The
“Characteristics” column is included so that equivalent equipment may be
substituted; however, when no information is provided in this column, the
specific Motorola model listed is either a unique item or no substitution is
recommended.

Table 2 Recommended Test Equipment

Description Characteristics Application

Frequency/deviation meter and

for items with an asterisk (*).

signal generator for wide-range
troubleshooting and alignment.

and current measurements

R1150C* Code Synthesizer Injection of audio and digital

signalling codes

S1053D*
SKN6008A*
SKN6001A*

R1094A Dual-Trace Oscillo-

S1350C*
ST1213B (VHF)*
ST1223B (UHF)*

R1065 Load Resistor 10-watt Broadband For use with wattmeter
S1339A RF Millivolt Meter 100
R1013A* SINAD Meter Receiver sensitivity measurements
S1347D or S1348D

(programmable)

Service Aids

AC Voltmeter
Power Cable for Meter
Test Leads for Meter

scope
Wattmeter

Plug-In Element
RF Dummy Load

DC Power Supply 0-20Vdc, 0-5 Amps

Refer to T able 3, “Service Aids,” for a listing and description of the service aids
designed specifically for servicing this family of radios. These kits and/or parts
are available from the Motorola Parts Division offices listed in the
“Replacement Parts Ordering” section located on the inside back cover of this
manual. While all of these items are available from Motorola, most are
standard shop equipment items, and any equivalent item capable of the same
performance may be substituted for the item listed.

1mV to 300V, 10-Megohm
input impedance

20MHz bandwidth 5mV to
5V/division

50-ohm,
10 watts, maximum
0-1000MHz, 300W

current limited

±

5% accuracy

m

V to 3V RF RF-level measurements

Audio voltage measurements

Waveform measurements

Transmitter power output
measurements

Bench supply for 7.5Vdc

5

Table 3 Service Aids

Motorola Part

Number

RKN-4035D RIB/Radio/Test Set Cable Connects radio to RTX-4005B Test Box and RIB.
REX-4424 Battery Eliminator Interconnects radio to power supply.
RLN-4460A, or

RTX-4005B, or both
RTX-4005A and
RPX-4665A

Field Modification Kit
RLN-1015A or
RLN-4008B

01-80357A57 Wall-Mounted Power Supply Used to supply power to the RIB (120 Vac).
01-80358A56 Wall-Mounted Power Supply Used to supply power to the RIB (220 Vac).
30-80369B71 or

30-80369B72

RVN-4100F Radio Service Software Software on 3-1/2 in. and 5-1/4 in. floppy disks.
58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test

Portable Test Set Enables connection to the universal connector.

Radio Interface Box Enables communications between the radio and the

Computer Interface Cable Use B72 for the IBM PC AT. All other IBM models use

Description Application

Allows switching for radio testing.

computer's serial communications adapter.

B71. Connects the computer's serial communications
adaptor to the RIB.

equipment.

Field
Programming
Equipment

This family of radios can be aligned and programmed in the field. This requires
specific equipment and special instructions. Refer to the applicable “Radio
Service Software User's Guide” for complete field programming information.

6

Performance Checks

4

Introduction
to This Section

Setup

This section covers performance checks used to verify the radio meets
published specifications. The recommended test equipment listed in the
previous section approaches the accuracy of the manufacturing equipment,
with a few exceptions. Accuracy of the equipment must be maintained in
compliance with the manufacturer’s recommended calibration schedule.

Supply voltage can be connected from the battery eliminator. The equipment
required for alignment procedures is connected as shown in the “Radio
Alignment Test Setup” diagram (page 13, Figure 1).

Initial equipment control settings should be as indicated in the following
table, and should hold for all alignment procedures except as noted in T able 4.

Table 4 Initial Equipment Control Settings

System Analyzer Test Set Power Supply

Monitor Mode: Pwr Mon
RF Attn: –70dB
AM, CW, FM: FM
O'scope Source: Mod

O'scope Horiz: 10mSec/Div
O'scope Vert: 2.5kHz/Div
O'scope Trig: Auto
Monitor Image: Hi
Monitor BW: Nar
Monitor Squelch: Mid CW
Monitor Vol: 1/4 CW

Spkr Set: A
Spkr/Load: Speaker DC On/Standby: Standby
PTT: OFF (center)

Voltage: 7.5Vdc

Volt Range: 10Vdc
Current: 2.5Amps

Test Mode

RF Test Mode

When the ASTRO Digital XTS 3500 radio is operating in its normal
environment, the radio's microcomputer controls the RF channel selection,
transmitter key-up, and receiver muting. However, when the unit is on the
bench for testing, alignment, or repair, it is removed from its normal
environment. It cannot receive commands from its system and, therefore, the
internal microcomputer will not key the transmitter nor unmute the receiver .
This prevents the use of normal tune-up procedures. To solve this problem a
special routine, called TEST MODE or “air test,” has been incorporated in the
radio.

7

8

To enter the test mode:

1. Turn the radio on and adjust the volume for a comfortable listening level.
The volume level remains constant once in the test mode.

2. Within 10 seconds after the “

SSSSeeeellllffff TTTTeeeesssstt

tt

” is complete, press Side Button 3

five times in succession.

3. After “

RRRRFFFF TTTTEEEESSSSTT

programmed as the emergency button) once. “

TT

” appears, press the Top Programmable Button (normally

QQ

1111 CCCCSSSSQQ

” appears, indicating:

test frequency 1, carrier squelch mode.

4. Each additional press of Side Button 3 will advance to the next test
channel. (Refer to Table 5.)

5. Pressing Side Button 2 will scroll through and access test environments as
shown in Table 6.

NOTE: Transmit into a load when keying a radio

under test.

Table 5 Test Frequencies

Test Channel UHF Band 2

TX #1 450.025
RX #1 450.075
TX #2 465.225
RX #2 465.275
TX #3 475.125
RX #3 475.275
TX #4 484.975
RX #4 485.025
TX #5 500.275
RX #5 500.225
TX #6 511.975
RX #6 511.925
TX #7 519.975
RX #7 519.925

Table 6 Test Environments

Display Description Function

CSQ Carrier Squelch RX: unsquelch if carrier detected

TX: mic audio

TPL Tone Private-

Line

AST ASTRO

RX: unsquelch if carrier and tone (192.8 Hz) detected
TX: mic audio + tone (192.8 Hz)

RX: none
TX: 1200Hz tone *

* All deviation values are based on deviation tuning of this mode.

Control Top
and Keypad
Test Mode

To check the display, buttons, and switches, perform the following tests:

1. Turn the radio on and adjust the volume for a comfortable listening level.
The volume level remains constant once in the test mode.

2. Within 10 seconds after the “
five times in succession.

3. After “

TTTTEEEESSSSTT

4. Next, press and hold the T op Programmable Button; all segments on the
display will light, and the LED on the control top will illuminate a red
color.

5. Release the Top Programmable Button; “33
that the Top Programmable Button is in the open condition.

6. Press the Top Programmable Button again; “33
indicates that the Top Programmable Button is in the closed condition.

7. Rotate the Mode/Zone Selector Switch; “44
which indicates that the selector switch is in mode/zone position 1
through 15.

8. Rotate the Two-Position (A/B) Switch; “66

9. Cycle through the Three-Position Programmable Switch; “66
“66

RRRRFFFF TTTTEEEESSSSTT

TT

” appears on the display.

667777////1111

,” and “66

TT

” appears on the display, press Side Button 1 once, “CC

667777////2222

” appear.

SSSSeeeellllffff TTTTeeeesssstt

tt

” is complete, press Side Button 3

CCHHHH

33////0000

” appears, which indicates

33////1111

” appears, which

44////0000

” through “44

665555////0000

” and “66

665555////1111

44////11115555

” appears,

” appear.

667777////0000

,”

10.Rotate the Volume Control; “22

11.Press Side Button 1; “99

12.Press Side Button 2; “99

13.Press Side Button 3; “99

14.Press the PTT Switch; “11

15.Keypad Checks:

- Press 0, “44

- Press 1, “44

- Press 2, “55

- Press 3, “55

- Press 4, “55

- Press 5, “55

- Press 6, “55

- Press 7, “55

- Press 8, “55

- Press 9, “55

- Press *, “55

448888////1111

449999////1111

550000////1111

551111////1111

552222////1111

553333////1111

554444////1111

555555////1111

556666////1111

557777////1111

558888////1111

996666////1111

” appears; release, “99

997777////1111

”appears; release, “99

998888////1111

”appears; release, “99

11////1111

” appears; release, “11

” appears; release, “44
” appears; release, “44
” appears; release, “55
” appears; release, “55
” appears; release, “55
” appears; release, “55
” appears; release, “55
” appears; release, “55
” appears; release, “55
” appears; release, “55
” appears; release, “55

22////0000

” through “22

448888////0000

449999////0000

550000////0000

551111////0000

552222////0000

553333////0000

554444////0000

555555////0000

556666////0000

557777////0000

558888////0000

22////222255555555

” appear.

996666////0000

” appears.

997777////0000

” appears.

998888////0000

” appears.

11////0000

” appears.

” appears.
” appears.
” appears.
” appears.
” appears.
” appears.
” appears.
” appears.

” appears.
” appears.
” appears.

- Press #, “55

- Press <, “11

- Press O, “11

- Press >, “11

559999////1111

” appears; release, “55

1122228888////1111

” appears; release, “11

1122229999////1111

” appears; release, “11

1133330000////1111

” appears; release, “11

559999////0000

1122228888////0000

1122229999////0000

1133330000////0000

” appears.

” appears.

” appears.

” appears.

9

- Press the left-hand M key on the top row of keys, “11
release, “11

1133331111////0000

” appears.

1133331111////1111

” appears;

- Press the center N key, “11

1133332222////1111

- Press the right-hand M key, “11

1133333333////0000

“11

” appears.

” appears; release, “11

1133333333////1111

” appears; release,

1133332222////0000

” appears.

Table 7 Receiver Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference
Frequency

Rated Audio Mode: GEN

Distortion As above, except to

Sensitivity
(SINAD)

Mode: PWR MON 4th
channel test frequency❖

Monitor: Frequency error.
Input at RF In/Out

Output level: 1.0mV RF 4th
channel test frequency❖

Mod: 1kHz tone at 3kHz
deviation

Monitor: DVM: ac Volts

distortion
As above, except SINAD;

lower the RF level for 12dB
SINAD

TEST MODE,
4 CSQ output
at antenna

TEST MODE,
4 CSQ

As above As above Distortion < 3.0%

As above PTT to OFF (center) RF input to be <

PTT to continuous
(during the
performance check)

PTT to OFF (center);
meter selector to Audio
PA

Frequency error to
be £ ±1.2kHz

Set volume control
to 3.74Vrms

0.35mV

Noise Squelch
Threshold (only
radios with
conventional
system need to
be tested)

❖ See Table 6

RF level set to 1mV RF As above PTT to OFF (center);

meter selection to
Audio PA; spkr/load to
speaker

As above, except change
frequency to a
conventional system. Raise
RF level from zero until
radio unsquelches.

Out of TEST
MODE; select
a conventional
system

As above Unsquelch to

Set volume control
to 3.74Vrms

occur at < 0.25mV.
Preferred SINAD =
8-10dB

10

Table 8 Transmitter Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference
Frequency

Power RF As above As above,

Voice
Modulation

Voice
Modulation
(internal)

PL Modu­lation (radios
with conven­tional, clear
mode, coded
squelch oper­ation only)

Mode: PWR MON 4th
channel test frequency❖

Monitor: Frequency
error. Input at RF In/Out

Mode: PWR MON 4th
channel test frequency❖
atten to –70, input to RF
In/Out.

Monitor: DVM, ac Volts.
Set 1kHz Mod Out level
for 0.025Vrms at test set,
80mVrms at ac/dc test
set jack

Mode: PWR MON 4th
channel test frequency❖
atten to –70, input to RF
In/Out

Change frequency to a
conventional transmit
frequency; BW to narrow

TEST MODE,
4 CSQ

4 CSQ

As above,
4 CSQ

TEST MODE,
4 CSQ, output
at antenna

Conventional
coded
squelch
personality
(clear mode
operation) 4
TPL

PTT to continuous
(during the
performance check).

As above Refer to Maintenance

As above, meter
selector to mic

Remove modulation
input

As above Deviation: UHF: ³ 500Hz

Frequency error to be £
±1.2kHz.

Specifications page in
front of manual.

Deviation: UHF: ³ 3.6kHz
but £ 5.0kHz

Press PTT switch on radio.
Say “four” loudly into the
radio mic. Measure
deviation: UHF: ³

3.8kHz but £ 5.0kHz

but £ 1000Hz

Talkaround
Modulation
(radios with
conventional,
clear mode,
talk-around
operation
only)

Talkaround
Modulation
(radios with
conventional,
secure mode,
talkaround
operation
only) (**)

** The secure mode, talkaround modulation test is only required for trac mode radios which do not have clear mode

talkaround capability.

❖ See Table 6

Change frequency to
conventional talk­around frequency.

Mode: PWR MON
deviation, attenuation to
–70, input to RF In/Out.

Monitor: DVM, ac volts
Set 1kHz Mod Out level
for 25mVrms at test set.

Change frequency to
conventional talk­around frequency.

Mode: PWR MON
deviation, attenuation to
–70, input to RF In/Out.

Monitor: DVM, ac volts
Mod: 1kHz out level

for25mVrms at test set.

Conventional
talkaround
personality
(clear mode
operation)
1 CSQ

Conventional
talkaround
personality
(secure mode
operation).
Load key into
radio 1 sec.

As above Deviation: UHF: ³ 3.8kHz

but £ 5.0kHz

As above Deviation: UHF: ³ 3.6kHz

but £ 4.4kHz

11

Radio Alignment

Procedures 5

Introduction
to This Section

This section describes both receiver and transmitter radio alignment
procedures.

General A personal computer (PC) and radio service software (RSS) are required to align

the radio. Refer to the applicable RSS manual for installation and setup
procedures for the software. To perform the alignment procedures, the radio
must be connected to the PC, radio interface box (RIB), and a universal test set
as shown in Figure 1.

SYSTEM ANALYZER

OR COUNTER

WATTMETER

TX

AUDIO GENERATOR

RX

SINAD METER

AC VOLTMETER

BATTERY

ELIMINATOR

REX-4424

RTL-4224A

RADIO

SMA-BNC

58-80348B33

PROGRAM/TEST CABLE

RKN-4035D

RKN-4046A

TRANSMIT

BNC

TEST SET

TEST SET

RLN-4460A or

RTX-4005B

RTX-4005B

30 dB PAD

30 dB PAD

RF GENERATOR

RECEIVE

SET TO APPROX. 450mV FOR Tx

AUDIO IN

MEASURE 80mV FOR Tx

COMPUTER

RIB

RIB

RLN-1015A or

RLN-4008B

RLN-4008B

RIB POWER SUPPLY

01-80357A57 (120V)

COMPUTER INTERFACE

CABLE

30-80369B71

30-80369B72 (IBM "AT" ONLY)

DATA
BUSY
GND

Figure 1 Radio Alignment Test Setup

All service and tuning procedures are performed from the SERVICE menu,
which is selected by pressing B from the MAIN MENU. Figure 2 illustrates
how the RSS alignment SERVICE screens are organized.

13

SERVICE

F2 -

TRANSMITTER ALIGNMENT MENU

B

HELPF1 -

A

REFERENCE OSCILLATOR ALIGNMENT

F2 -

B

F3 -

TRANSMIT POWER ALIGNMENT

C

TRANSMIT DEVIATION BALANCE

F4 -

D

(COMPENSATION) ALIGNMENT

F5 -

TRANSMIT DEVIATION LIMIT ALIGNMENT

E

EXIT, RETURN TO SERVICE MENUF10 -

J

F3 -

RECEIVER ALIGNMENT MENU

C

FRONT END BANDPASS FILTER ALIGNMENTF2 -

B

Figure 2 RSS Service Menu Layout

All SERVICE screens read and program the radio codeplug directly; you do
NOT have to use the RSS GET/SAVE functions to use the SERVICE menus.

Do NOT switch radios in the middle of any SERVICE
procedure. Always use the EXIT key to return to the
MAIN menu screen before disconnecting the radio.

!

C a u t i o n

The SERVICE screens introduce the concept of the “softpot,” an analog
SOFTware-controlled POTentiometer used for adjusting all transceiver
alignment controls.

Each SERVICE screen provides the capability to increase or decrease the
‘softpot’ value with the keyboard UP/DOWN arrow keys respectively. A
graphical scale is displayed indicating the minimum, maximum, and
proposed value of the softpot, as shown in Figure 3.

015

Improper exits from the SERVICE screens may leave
the radio in an improperly configured state and
result in seriously degraded radio or system
performance.

14

Min.

Value

Max.

Value

Figure 3 Softpot Concept

Adjusting the softpot value sends information to the radio to increase
(or decrease) a dc voltage in the corresponding circuit. For example,
pressing the UP arrow key at the Reference Oscillator screen instructs
the radio’s microcomputer to increase the voltage across a varactor in
the reference oscillator, which increases the frequency.

In ALL cases, the softpot value is just a relative number corresponding
to a digital-to-analog (D/A) generated voltage in the radio.

Perform the following procedures in the sequence indicated.

NOTE: Some of the following screens may

vary depending upon the radio under
test and the version of radio service
software you are using. Refer to your
radio service software user’s guide.

Reference
Oscillator
Alignment

Adjustment of the reference oscillator is critical for proper radio
operation. Improper adjustment will result not only in poor operation,
but also in a misaligned radio that will interfere with other users
operating on adjacent channels. For this reason, the reference
oscillator should be checked every time the radio is serviced. The
frequency counter used for this procedure must have a stability of 0.1
ppm (or better).

1. From the SERVICE MENU, press B to select the TRANSMITTER
ALIGNMENT MENU.

2. Press B again to select the REFERENCE OSCILLATOR alignment
screen. See Figure 4.

MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot.
XTS Model: H24SDC9PW5AN

MAIN:SERVICE:TX ALIGN:REF OSC

REFERENCE OSCILLATOR

--------------------

Frequency Current Value

--------- -------------

519.975 150 New Softpot Value.....150

Transmitter..On
0 255
MIN |----+----+----+----+----+----+----+----+----+----+----+----| MAX

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
HELP TOGGLE PROGRAM EXIT
PTT VALUE

Figure 4 Reference Oscillator Alignment Screen

3. Press P (or

or [RETURN]) to select a frequency field

Z

(starting with the highest frequency shown). Then, press F to
key the radio. The screen will indicate that the radio is
transmitting.

15

4. Measure the transmit frequency on your service monitor.

5. Use the É/Ç arrow keys to adjust the reference oscillator softpot value.
See Table 9.

Table 9 Reference Oscillator Alignment

Band Target

UHF ±100 Hz

6. Press F again to dekey the radio.

7. Press H to program the new softpot value.

8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or
press J twice to return to the SERVICE MENU.

Transmit
Power
Alignment

NOTES:

• All power measurements are to be made at the antenna port.

• The transmitter power setting keeps the radiated power at or below

the level specified in the exclusionary clause for low power devices
of IEEE Standard C95.1-1991.

1. From the SERVICE MENU, press B to select the TRANSMITTER
ALIGNMENT MENU.

2. Press C to select the TRANSMIT POWER alignment screen. The screen
will indicate the transmit frequencies to be used. See Figure 5.

MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot.
XTS Model: H24SDC9PW5AN

MAIN:SERVICE:TX ALIGN:TX POWER

TRANSMIT POWER

--------------
Current Value New Softpot Value
Frequency High Pwr Low Pwr High Pwr Low Pwr

--------- -------- ------- -------- -------

450.025 10 23 10 23

465.225 11 28 11 28

475.125 20 33 20 33

484.975 33 40 33 40

500.275 43 45 43 45

511.975 58 58 58 58

519.975 58 58 Transmitter..On 58 58
0 127
MIN |---+---+---+---+---+---+---+---+---+---+---+---+---+---+---+---| MAX

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
HELP TOGGLE PROGRAM EXIT
PTT VALUE

16

Figure 5 Transmit Power Alignment Screen

3. Press P (or

or [RETURN]) to select a frequency field (starting with

Z

the highest frequency shown). Then, press F to key the radio. The
screen will indicate that the radio is transmitting.

4. Use the É/Ç arrow keys to adjust the transmit power per the values
shown in Table 10.

Table 10 Transmit Power Settings

Transmit
Deviation
Balance
(Compensation)
Alignment

UHF Power Level

Test Frequencies

450-512MHz 512-520MHz

1 Watt 1.2W - 1.4W 1.2W - 1.4W

5 Watts 5.2W - 5.4W 3.2W - 3.4W

5. Press F to dekey the radio.

6. Press H to program the value.

7. Repeat steps 3-6 for the remaining frequencies.

8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or
press J twice to return to the SERVICE MENU.

Compensation alignment balances the modulation sensitivity of the VCO and
reference modulation (synthesizer low-frequency port) lines. The
compensation algorithm is critical to the operation of signalling schemes that
have very-low-frequency components (for example, DPL) and could result in
distorted waveforms if improperly adjusted.

1. From the SERVICE MENU, press B to select the TRANSMITTER
ALIGNMENT MENU.

2. Press D to select the TRANSMIT DEVIATION BALANCE
(COMPENSATION) alignment screen. The screen will indicate the
transmit frequencies to be used. See Figure 6.

MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot.
XTS Model: H24SDC9PW5AN

MAIN:SERVICE:TX ALIGN:BAL ATTN

TRANSMIT DEVIATION BALANCE (COMPENSATION)

-----------------------------------------
Current
Frequency Value New Softpot Value

--------- ------- -----------------

450.025 30 30

465.225 30 30

475.125 30 30

484.975 45 45

500.275 45 45

511.975 45 45

519.975 45 Transmitter..Off 45
0 63
MIN |---+---+---+---+---+---+---+---+---+---+---+---+---+---+---+---| MAX

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
HELP TOGGLE LOW TOGGLE HIGH PROGRAM EXIT
TONE PTT TONE PTT VALUE

Figure 6 Transmit Deviation Balance (Compensation) Alignment Screen

3. Press P (or

or [RETURN]) to select a frequency field (starting with

Z

the lowest frequency shown).

4. Press D. This will cause the radio to key and the radio’s DSP IC to inject
an 80Hz tone into the RF board.

5. Measure the deviation and record this value.

6. Press D to dekey the radio.

17

7. Press F. This will cause the radio’s DSP IC to change the injection tone
to 3kHz, 100mVrms. Use the É/Ç arrow keys to adjust the deviation to
within ±2% of the value recorded in step 5.

8. Repeat steps 4-7 until the 3kHz tone deviation is within ±2% of the 80Hz
tone deviation.

9. Press F again to dekey the radio.

10.Press H to program the new softpot value.

11.Repeat steps 3-10 for the remaining frequencies.

12.Press J once to return to the TRANSMITTER ALIGNMENT MENU, or
press J twice to return to the SERVICE MENU.

Transmit
Deviation
Limit
Alignment

IMPORTANT NOTE:

Put the radio in the RF test mode and scroll to
the ASTRO test environment, indicated by
“AST” on the display (refer to the
“Performance Checks” section for details). All
other deviation values are derived from the
ASTRO test environment mode transmit
deviation limit.

1. From the SERVICE MENU, press B to select the TRANSMITTER
ALIGNMENT MENU.

2. Press E to select the TRANSMIT DEVIATION LIMIT alignment screen.
The screen will indicate the transmit frequencies to be used. See Figure 7.

MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot.
XTS Model: H24SDC9PW5AN

MAIN:SERVICE:TX ALIGN:DEV.LIMIT

TRANSMIT DEVIATION LIMIT

------------------------
Current
Frequency Value New Softpot Value

--------- ------- -----------------

450.025 175 175

465.225 175 175

475.125 180 180

484.975 180 180

500.275 180 180

511.975 180 180

519.975 180 Transmitter..Off 180
0 32767
MIN |----+----+----+----+----+----+----+----+X---+----+----+----| MAX

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
HELP TOGGLE PROGRAM EXIT
PTT VALUE

18

Figure 7 Transmit Deviation Limit Alignment Screen

3. Press P (or

or [RETURN]) to select a frequency field (starting with

Z

the lowest frequency shown).

4. Press F to key the radio. Then use the É/Ç arrow keys to adjust for a
deviation per the values shown in Table 11.

Table 11 Transmit Deviation Limit

Band Deviation (Hz)

UHF 2785 - 2885

5. Press F again to dekey the radio.

6. Press H to program the softpot value.

7. Repeat steps 3-6 for the remaining frequencies.

8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or
press J twice to return to the SERVICE MENU.

19

Basic Removal/Installation

Procedures 6

Introduction
to This Section

Antenna

Installing the
Antenna

Removing the
Antenna

This section gives basic procedures for removing and installing the XTS 3500
radio’s:

• Antenna,

• Battery,

• Belt Clip,

• Universal Connector Cover,

• Volume Knob, and

• Frequency Knob.

Screw the threaded end of the antenna into the antenna receptacle on the top
of the radio. Rotate the antenna clockwise until it seats firmly against the
bushing.

Rotate the antenna counterclockwise until its threaded end unscrews from the
radio’s antenna receptacle.

Battery NOTE: The battery is shipped uncharged, and must be

charged for at least 16 hours before use.

To avoid a possible explosion:

• DO NOT replace the battery in an area labeled

!

!

“hazardous atmosphere.”

• DO NOT discard batteries in a fire.

W A R N I N G

If your radio is programmed with volatile-key retention
(consult your service technician), encryption keys will be

!

retained for approximately 30 seconds after battery removal.

C a u t i o n

21

Installing the
Battery

1. Turn off the radio and hold it with the back of
the radio facing upward

2. Insert the top edge of the battery into the area
at the top of the radio between the radio’s
case and chassis. Make sure the three tabs on
the radio chassis align with the three slots
under the top edge of the battery.

3. Rotate the battery toward the radio, and
squeeze the battery and radio together until
the battery “clicks” in place.

Removing the
Battery

1. Turn off the radio and hold it so that the release
button on the bottom of the battery is facing
upward.

2. Press downward on the release button so the
battery disengages from the radio.

3. Remove the battery completely away from the
radio

Belt Clip NOTE: The battery must be removed from the radio

before the belt clip can be installed or removed.

Installing the
Belt Clip

1. Hold the battery in one hand so that the top of
the battery faces upward, and the back of the
battery faces you.

2. Holding the belt clip in the other hand with its
top facing upward, align the slide assembly on
the front of the belt clip with the slots on the
back of the battery.

3. Slide the belt clip downward toward the bottom
of the battery until the belt clip “clicks” in place.

Slide

Assembly

Slots

Belt Clip

Removing the
Belt Clip

22

1. Hold the battery (with belt clip installed) in one
hand so that the top of the battery faces upward,
and the front (radio side) of the battery faces
you.

2. At the top of the battery, press down on the belt
clip’s metal tab and slide the belt clip upward
until it disengages from the battery.

3. Continue to slide the belt clip upward until it is
free from the battery.

Press

Down

Battery

Metal

Tab

Universal
Connector
Cover

!

When the universal connector is not in use, keep it covered
with the universal connector cover.

C a u t i o n

Installing the
Universal
Connector Cover

Removing the
Universal
Connector Cover

1. Looking at the antenna side of the radio,
insert the top (flat) hooked end of the cover
into the slot on the top of the radio, above
the universal connector. Press downward on
the cover’s top to seat it in the slot.

2. While holding the cover seated in the top
slot, insert the cover’s bottom (rounded)
hooked end into the slot below the universal
connector. Press firmly inward on the cover’s
bottom until it snaps in place.

1. Looking at the antenna side of the radio,
insert a flat-bladed screwdriver into the area
between the lower end of the universal
connector cover and the slot below the
universal connector.

2. Pry upward on the cover’s lower end until it
disengages from the radio.

Top

Hooked End

Bottom

Hooked End

Bottom

Slot

Top
Slot

Frequency
Knob

Removing the
Frequency Knob

Installing the
Frequency Knob

NOTES:

• Refer to Figure 8, the Partial Exploded View, and Table 12, the

Partial Exploded View Parts List. Numbers in parentheses ( ) refer to
item numbers in Figure 8 and Table 12.

• The battery (7) should be removed from the radio before installing
or removing the frequency knob (1).

1. Hold the radio in one hand so that the top of the radio faces upward, and
the front of the radio faces you.

2. With the other hand, grasp the frequency knob (1) and pull it upward,
while pushing it toward the back of the radio, until it is free from the
frequency insert (3).

3. While pressing the insert’s (3) two snap tabs away from the frequency
control shaft so that the insert disengages from the shaft, use needle-nosed
pliers to lift the insert up and off of the frequency control shaft.

4. Remove the secure lever (4) and the lightpipe (5).

1. Hold the radio so that the top of the radio faces upward, and the front of
the radio faces you.

23

2. Align the lightpipe (5) so that its straight tab is over the slot for the
illuminated pointer. Push the tab down into the slot so that it is securely
seated.

3. Place the secure lever (4) on the frequency control shaft, aligning it so that
its pointer is at the front of the radio and its two inner slots line up with
the two keys on the shaft. Slide the secure lever down to the bottom of the
shaft.

4. If you are replacing the escutcheon (2), remove the backing paper from
the escutcheon, align its alignment marker with the alignment notch
(between numbers 4 and 5) on the insert, and adhere it to the insert.

5. Place a new frequency insert (3) and escutcheon (2) on the frequency
control shaft, aligning the insert’s D-shaped hole with the D-shaped shaft.
Press downward firmly on the insert until it “snaps” in place on the shaft.

6. Place the frequency knob (1) on the frequency insert (3), aligning it’s
pointer with the number “1” on the escutcheon (2). Press firmly
downward on the knob until it seats securely in place.

Volume Knob NOTES:

• Refer to Figure 8, the Partial Exploded View, and Table 12, the
Partial Exploded View Parts List. Numbers in parentheses ( ) refer to
item numbers in Figure 8 and Table 12.

Removing the
Volume Knob

Installing the
Volume Knob

• The battery (7) should be removed from the radio before installing
or removing the volume knob (8).

1. Hold the radio in one hand so that the top of the radio faces upward, and
the front of the radio faces you.

2. With the other hand, grasp the volume knob (8) and pull it upward, while
pushing it toward the back of the radio, until it is free from the volume
insert (9).

3. While pressing the volume insert’s (9) two snap tabs away from the
volume control shaft so that the insert disengages from the shaft, use
needle-nosed pliers to pull the insert up and off of the volume control
shaft. Discard the removed volume insert.

4. Using needle-nosed pliers or some other pointed instrument, remove the
o-ring (21).

1. Place the o-ring (21) inside a new volume insert (9), and press it downward
until it seats securely at the bottom of the insert.

2. Hold the radio so that the top of the radio faces upward, and the front of
the radio faces you.

3. Place the volume insert (9) on the volume control shaft, aligning its D­shaped hole with the D-shaped shaft. Press downward firmly on the insert
until it “snaps” in place on the shaft.

24

4. Place the volume knob (8) on the volume insert (9), aligning the two lugs
on the inside of the knob with the insert’s two snap tabs. Press firmly
downward on the knob until it seats securely in place.

1

2

3

6

4

7

Alignment Marker

Alignment Notch

15

5

8

9

21

16

17

18

10

11

A

B

C

20

XTS 3000

12
13

14

Figure 8 Partial Exploded View

HOME

DEF

3

ABC

2

MNO

1

GHI

4

PRS

7

6

JKL

5

WXY

9

TUV

8
0

25

Table 12 Partial Exploded View Parts List

ITEM

NO.

10 3305574Z01 LABEL, Motorola, Back
11 - - - - - - - - - - LABEL, Flashport
12 - - - - - - - - - - LABEL, Radio Serial Number
13 - - - - - - - - - - LABEL, Approval Agency
14 3305630Z02 LABEL, Bottom

MOTOROLA

PART NO.

1 3605370Z01 KNOB, Frequency
2 1305374Z01 ESCUTCHEON, Frequency
3 4305373Z01 INSERT RETAINER, Frequency Knob
4 4305375Z01 LEVER, Secure Frequency
5 6105376Z01 LIGHTPIPE INDICATOR/STOP, Frequency
6 NTN8266A CLIP, Belt
7 NTN8298A Battery, NiCd
8 3605371Z01 KNOB, Volume
9 4305372Z01 INSERT RETAINER, Volume Knob

DESCRIPTION

15 NAF5037A

or NAF5039A
or NAF5042A

16 - - - - - - - - - - ESCUTCHEON, Concentric Switch (optional)
17 - - - - - - - - - - ESCUTCHEON, Toggle (optional)
18 1505579Z01 COVER, Dust, Universal Connector
19 3305573Z01 LABEL, Motorola, Front
20 3505586Z01 Gortex
21 3205379W01 O-Ring

ANTENNA, 800MHz Whip (806-870 MHz)
ANTENNA, 800MHz Dipole (806-870 MHz)
ANTENNA, 800MHz Stubby Quarterwave

(806-870 MHz)

26

Basic Theory of

Operation 7

General
Overview

The ASTRO Digital XTS 3500 radio is a wideband, synthesized, fixed-tuned
radio available in the UHF band. All ASTRO Digital XTS 3500 radios are
capable of both analog operation and ASTRO mode (digital) operation in

12.5kHz or 25kHz bandwidths.
The ASTRO Digital XTS 3500 radio includes the following major assemblies:

• VOCON Board - contains the microcontrol unit (MCU) and its associated
memory and memory management integrated circuit (IC), the audio
power amplifier, and a switching regulator. The board also contains the
digital signal processor (DSP) and its support IC and associated memories.

• RF Board - contains all transmit, receive, and frequency generation
circuitry including the digital receiver back-end IC and the reference
oscillator.

• Controls/Universal Flex - contains volume/on/off switch, frequency
selector switch, push-to-talk (PTT) switch, monitor button, several
function-selectable switches, universal connector, speaker, and
microphone.

• Display (Full-Featured Model Only) - a four-line, 12-character liquid
crystal display (LCD).

• Keypad (Full-Featured Model Only) - a 3 x 6 keypad.

Analog Mode
of Operation

When the radio is receiving, the signal comes from the antenna connector to
the RF board, passes through the RX/TX switch and the receiver front end. The
signal is then filtered, amplified, and mixed with the first local-oscillator signal
generated by the voltage-controlled oscillator (VCO).

The resulting intermediate frequency (IF) signal is fed to the IF circuitry , where
it is again filtered and amplified. This amplified signal is passed to the digital
back-end IC, where it is mixed with the second local oscillator to create the
second IF at 450kHz. It is then converted to a digital bit stream and mixed a
third time to produce a baseband signal. This signal is passed to the VOCON
board through a current-driven differential output.

On the VOCON board, the digital-signal processor (DSP) support IC digitally
filters and discriminates the signal, and passes it to the digital-signal processor
(DSP). The DSP decodes the information in the signal and identifies the
appropriate destination for it. For a voice signal, the DSP will route the digital
voice data to the CODEC for conversion to an analog signal. The CODEC will
then present the signal to the audio power amplifier, which drives the speaker .
For signalling information, the DSP will decode the message and pass it to the
microcontrol unit.

27

When the radio is transmitting, microphone audio is passed through gain
stages to the CODEC, where the signal is digitized. The CODEC passes digital
data to the DSP, where pre-emphasis and low-pass (splatter) filtering are done.
The DSP passes this signal to a digital/analog (D/A) converter, where it is
reconverted into an analog signal and scaled for application to the voltage­controlled oscillator as a modulation signal.

Transmitted signalling information is accepted by the DSP from the
microcontrol unit, coded appropriately, and passed to the D/A converter,
which handles it the same as a voice signal. Modulation information is passed
to the synthesizer along the modulation line. A modulated carrier is provided
to the RF PA, which transmits the signal under dynamic power control.

ASTRO Mode
of Operation

RF Board Basic
Theory of
Operation

In the ASTRO mode (digital mode) of operation, the transmitted or received
signal is limited to a discrete set of deviation levels, instead of continuously
varying. The receiver handles an ASTRO-mode signal identically to an analog­mode signal up to the point where the DSP decodes the received data. In the
ASTRO receive mode, the DSP uses a specifically defined algorithm to recover
information.

In the ASTRO transmit mode, microphone audio is processed identically to an
analog mode with the exception of the algorithm the DSP uses to encode the
information. This algorithm will result in deviation levels that are limited to
discrete levels.

The receiver front end consists of a preselector, an RF amplifier, a second
preselector, and a mixer. The RF amplifier is a dual-gate, gallium- arsenide
based IC. The mixer is a double-balanced, active mixer coupled by
transformers. Injection is provided by the VCO through an injection filter . See
Table 13 for local oscillator (LO) and first IF information.

Table 13 Local Oscillator and First IF Frequencies

UHF

LO Frequency Range 376.65-446.65MHz
First IF Frequency 73.35MHz

28

The frequency generation function is performed by three ICs and associated
circuitry. The reference oscillator provides a frequency standard to the
synthesizer/prescaler IC, which controls the VCOB IC. The VCOB IC actually
generates the first LO and transmit-injection signals and buffers them to the
required power level. The synthesizer/prescaler circuit module incorporates
frequency-division and comparison circuitry to keep the VCO signals stable.
The synthesizer/prescaler IC is controlled by the microcontrol unit through a
serial bus. Most of the synthesizer circuitry is enclosed in rigid metal cans on
the RF board to reduce microphonic effects.

The receiver back end consists of a two-pole crystal filter, an IF amplifier, a
second two-pole crystal filter, and the digital back-end IC. The two-pole filters
are wide enough to accommodate 4kHz modulation. Final IF filtering is done
digitally in the DSP.

The digital back-end IC consists of an amplifier, the second mixer, an
IF analog-to-digital converter, a baseband down-converter, and a

2.4MHz synthesis circuit to provide a clock to the DSP-support IC on
the VOCON board. The second LO is generated by discrete
components external to the IC. The output of the digital back-end IC
is a digital bit stream that is current driven on a differential pair for a
reduction in noise generation.

The transmitter consists of an RF driver IC that gets an injection signal
from the VCO and a final-stage power amplifier. Transmit power is
controlled by a power-control IC that monitors the output of a
directional coupler and adjusts PA control voltages correspondingly.
The signal passes through a RX/TX switch that uses PIN diodes to
automatically provide an appropriate interface to transmit or receive
signals. Antenna selection is done mechanically in the control top.

VOCON Board Basic
Theory of
Operation

The vocoder and controller (VOCON) board contains the radio’s
microcontrol unit with its memory and support circuits, the digital­signal processor (DSP), its memory devices, and the DSP-support IC,
voltage regulators, audio, and power control circuits. Connected to the
VOCON board are the display board, RF board, keypad board,
controls/universal flex, and (optional) encryption module.

The microcontrol unit controls receive/transmit frequencies, power
levels, display, and other radio functions, using either direct logic
control or serial communications paths to the devices.The
microcontrol unit executes a stored program located in the FLASH
ROM. Data is transferred to and from memory by the microcontrol
unit data bus. The memory location from which data is read, or to
which data is written, is selected by the address lines.

The DSP-support IC is supplied with a 16.8MHz clock from the RF
board. Both the DSP and the microprocessor have their clocks
generated by the DSP-support IC. They can both be adjusted so that
the harmonics do not cause interference with the radio’s receive
channel.

The regulator and power-control circuits include 3.3-volt analog, 3.3­volt digital, and 5-volt regulators. The audio PA is sourced from 7.5V.
The regulator’s power-down mode is controlled by the microcontrol
unit, which senses the position of the on/off switch. The 5-volt
regulator has an error pin for low-voltage resets.

The DSP performs signalling and voice encoding and decoding as well
as audio filtering and volume control. This IC performs Private-Line®/
Digital Private Line™ (PL/DPL) encode and alert-tone generation. The
IC transmits pre-emphasis on analog signals and applies a low-pass
(splatter) filter to all transmitted signals. It requires a clock on the
EXTAL pin. An 8kHz interrupt signal generated by the DSP-support IC
is also required for functionality. It is programmed using parallel
programming from the microcontrol unit.

29

The audio CODEC performs analog-to-digital and digital-to-analog
conversions on audio signals. The DSP controls squelch deviation, and
executes receiver and transmitter filtering. The DSP-support IC
receives a 2.4MHz clock, and receives data and formats it for the DSP.

30