Motorola Astro XTL 1500, ASTRO XTL 5000 Installation Manual

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Foreword

This manual covers the ASTRO® XTL™1500 digital mobile radio with control head. It includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level and is typical of some local service centers, self-maintained customers, and distributors.

For details on radio operation or component-level troubleshooting, refer to the applicable manuals available separately. A list of related publications is provided in the section “Related Publications,” on page vii.

Product Safety and RF Exposure Compliance

See “Installation Requirements for Compliance with Radio Frequency (RF) Energy Exposure Safety Standards,” on page iii.

Manual Revisions

Changes which occur after this manual is printed are described in FMRs (Florida Manual Revisions). These FMRs provide complete replacement pages for all added, changed, and deleted items. To obtain FMRs, go to https://businessonline.motorola.com.

Parts Ordering

See Appendix A: Replacement Parts Ordering for information on how to obtain replacement parts. For part numbers, refer to the ASTRO XTL 1500 Basic Service Manual (Motorola publication part number 6815853H01)

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.

Document Copyrights

No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola.

Disclaimer

The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.

Trademarks

MOTOROLA, the Stylized M logo, FLASHport, and ASTRO are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners.

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Installation Requirements for Compliance with

Radio Frequency (RF) Energy Exposure Safety

Standards

ATTENTION!

This radio is intended for use in occupational/controlled conditions, where users have full knowledge of their exposure and can exercise control over their exposure to meet FCC limits. This radio device is NOT authorized for general population, consumer, or any other use.

To ensure compliance to RF Energy Safety Standards:

• Install only Motorola approved antennas and accessories

• Be sure that antenna installation is per “Antenna Installation,” on page 2-8 of this manual

• Be sure that Product Safety and RF Safety Booklet enclosed with this radio is available to the end user upon completion of the installation of this radio

Before using this product, the operator must be familiar with the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with each radio (Motorola Publication part number 68P81095C99) to ensure compliance with Radio Frequency (RF) energy exposure limits.

For a list of Motorola-approved antennas and other accessories, visit the following web site which lists approved accessories for your radio model: http://www.motorola.com/cgiss/index.shtml

iii

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Table of Contents v

Table of Contents

Foreword.........................................................................................................ii

Product Safety and RF Exposure Compliance ............................................................................................ii

Manual Revisions ........................................................................................................................................ ii

Parts Ordering ............................................................................................................................................. ii

Computer Software Copyrights ...................................................................................................................ii

Document Copyrights .................................................................................................................................. ii

Disclaimer.................................................................................................................................................... ii

Trademarks ................................................................................................................................................. ii

Installation Requirements for Compliance with

Radio Frequency (RF) Energy Exposure Safety Standards......................iii

Mobile Radio Model Numbering Scheme.....................................................x

Commercial Warranty ...................................................................................xi

Limited Warranty ........................................................................................................................................ xi

MOTOROLA COMMUNICATION PRODUCTS ................................................................................ xi

I. What This Warranty Covers And For How Long .....................................................................xi

II. General Provisions .................................................................................................................xi

III. State Law Rights .................................................................................................................. xii

IV. How To Get Warranty Service ............................................................................................. xii

V. What This Warranty Does Not Cover.................................................................................... xii

VI. Patent And Software Provisions ......................................................................................... xiii

VII. Governing Law................................................................................................................... xiii

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

1.1 Mobile Radio Description............................................................................................................... 1-1

1.1.1 Dimensions ....................................................................................................................... 1-1

1.2.1 Dash Mount Configuration ................................................................................................ 1-2

1.3 Base/Control Stations.................................................................................................................... 1-2

1.4 Tools Required for XTL 1500 Installations..................................................................................... 1-3

Chapter 2 Standard Configurations .................................................... 2-1

2.1 Planning the Installation................................................................................................................. 2-1

2.2 Radio Mounting.............................................................................................................................. 2-4

2.2.2 Locking Kit (Optional) ....................................................................................................... 2-6

2.3 Power Cable and Ignition............................................................................................................... 2-6

2.4 Ignition Sense Cable...................................................................................................................... 2-8

2.5 Antenna Installation ....................................................................................................................... 2-8

2.5.1 Selecting an Antenna Site/Location on a Metal Body Vehicle .......................................... 2-8

2.5.2 Mini-UHF Connection ....................................................................................................... 2-9

2.6 Microphone Hang-Up Clip ........................................................................................................... 2-11

2.6.1 Standard Hang-Up Clip................................................................................................... 2-11

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vi Table of Contents

2.6.2 Handheld Hang-Up Box.................................................................................................. 2-11

2.7 Completing the Installation .......................................................................................................... 2-11

Chapter 3 Options and Accessories Installation ............................... 3-1

3.1 VIP Overview................................................................................................................................. 3-1

3.1.1 VIP Output Connections ................................................................................................... 3-1

3.1.2 Emergency Pushbutton, Footswitch, Horn Relay, and Light Relay Installation ............... 3-2

3.1.2.1 Emergency Pushbutton or Footswitch Installation................................................... 3-2

3.1.2.2 Horn (External Alarm) Relay Installation ................................................................. 3-2

3.1.2.3 Lights (External Alarm) Relay Installation................................................................ 3-2

3.2 Dash-Mount Accessory Installation ............................................................................................... 3-3

3.2.1 MDC Emergency Pushbutton or Footswitch Installation................................................... 3-3

3.2.2 Horn and Lights (External Alarms) Relays........................................................................ 3-3

3.2.3 External Speaker (HSN4031_) ......................................................................................... 3-4

3.3 Accessory Connector Assembly Details (P2) ................................................................................ 3-5

3.3.1 Installation into the Vehicle ............................................................................................... 3-6

3.3.2 Installation onto the Radio ................................................................................................3-6

3.3.3 Disassembly and Assembly.............................................................................................. 3-7

3.3.3.1 Disassembly ............................................................................................................ 3-7

3.3.3.2 Assembly .................................................................................................................3-7

3.3.4 Transceiver Rear Accessory Jack Connection ................................................................. 3-9

Chapter 4 Finishing the Installation: Cable Connection ................... 4-1

Appendix A Replacement Parts Ordering..............................................A-1

A.1 Basic Ordering Information............................................................................................................A-1

A.2 Motorola Online ............................................................................................................................. A-1

A.3 Mail Orders.................................................................................................................................... A-1

A.5 Fax Orders..................................................................................................................................... A-2

A.6 Parts Identification......................................................................................................................... A-2

A.7 Product Customer Service............................................................................................................. A-2

Glossary .........................................................................................Glossary-1

Index .....................................................................................................Index-1

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Table of Contents vii

Related Publications

ASTRO XTL 1500 User’s Guide ................................................................................................. 6815850H01

ASTRO XTL 1500 CD (User’s Guide & Installation Manual)....................................................... 6815852H01

ASTRO XTL 1500 Basic Service Manual.................................................................................... 6815853H01

ASTRO XTL 1500 Detailed Service Manual ............................................................................... 6815854H01

6815851H01-O June 3, 2005

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viii List of Figures

List of Figures

Figure 1-1. Front View of Dash Mount Brick Trunnion ............................................................................ 1-1

Figure 1-2. Side View of Dash Mount Brick Trunnion ............................................................................. 1-1

Figure 1-3. Dash Mount Configuration .................................................................................................... 1-2

Figure 2-1. Mounting Flexibility in Middle Console.................................................................................. 2-2

Figure 2-2. On Top or Under Dash Mounting .......................................................................................... 2-2

Figure 2-3. In Dash Mounting.................................................................................................................. 2-2

Figure 2-4. Radio Installation with transceiver ........................................................................................ 2-3

Figure 2-5. Trunnion Orientation ............................................................................................................. 2-4

Figure 2-6. Transmission Hump Trunnion Mounting ............................................................................... 2-5

Figure 2-7. Below Dash Trunnion Mounting............................................................................................ 2-5

Figure 2-8. Locking Kit (Optional) ........................................................................................................... 2-6

Figure 2-9. Cabling Interconnect Diagram for Dash Mount..................................................................... 2-7

Figure 2-10. Mini-UHF Connection .......................................................................................................... 2-9

Figure 2-11. Mini-UHF Connector Tool ................................................................................................... 2-10

Figure 3-1. VIP Connector Detail ............................................................................................................ 3-2

Figure 3-2. Emergency Switch Wiring Diagram ......................................................................................3-3

Figure 3-3. Horn/Light Wiring Diagram ................................................................................................... 3-4

Figure 3-4. Speaker Mounting................................................................................................................. 3-5

Figure 3-5. Exploded View of Accessory Connector Assembly (P2) ...................................................... 3-7

Figure 3-6. Rear Accessory Jack Pin Configuration (J2) (Radio Side) ................................................... 3-9

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List of Tables ix

List of Tables

Table 3-1. VIP Output Connections .............................................................................................3-1

Table 3-2. Rear Accessory Jack Pin Functions .........................................................................3-10

Table 3-3. Rear Connector and Front Connector Naming Schemes ......................................... 3-11

Table 3-4. How to Connect to a Computer

(DTE Device) ........................................................3-11

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x Mobile Radio Model Numbering Scheme

Mobile Radio Model Numbering Scheme

Typical Model Number:

Position:

Position 1 - Type of Unit

M = Mobile L = Table Top Station

Positions 2 & 3 - Model Series

20 = XTL 1500

Position 4 - Frequency Band

Less than 29.7MHz

29.7 to 35.99MHz

36 to 41MHz

42 to 50MHz

300 to 345MHz

66 to 80MHz

74 to 90MHz

Product Specific

VHF Range 136 to 162MHz

146 to 178MHz

174 to 210MHz

190 to 235MHz

* For XTL 1500 "U" in Position 4 represents 764-870MHz.

Note: Values represented are not absolute, and are given to indicate range only.

Position 5 - Power Level

0 to 0.7 Watts

0.7 to 0.9 Watts

1.0 to 3.9 Watts

4.0 to 5.0 Watts

5.1 to 6.0 Watts

6.1 to 10 Watts

10.1 to 15 Watts

16 to 25 Watts

Note: Values represented are not absolute, and are given to indicate range only.

Position 6 - Physical Packages

RF Modem Operation

Receiver Only

Standard Control; No Display

Standard Control; With Display

Limited Keypad; No Display

Limited Keypad; With Display

Full Keypad; No Display

Full Keypad; With Display

Limited Controls; No Display

Limited Controls; Basic Display

Limited Controls; Limited Display

Rotary Controls; Standard Display

Enhanced Controls; Enhanced Display

Low Profile; No Display

Low Profile; Basic Display

Low Profile; Basic Display, Full Keypad

Tranceiver with Selectable Control Head

VDV Control Head

Control Head #2

Position 7 - Channel Spacing 0 = 1 = 5KHz 2 = 6.25KHz 3 = 10KHz 4 = 12.5KHz

M20 U RS 9 P W 1 A N S P 0 1

123 4 56 7 8 91011 1213141516

330 to 370MHz

366 to 410MHz

403 to 437MHz

438 to 482MHz

470 to 620MHz

Product Specific

UHF Range 806 to 870MHz*

825 to 870MHz

896 to 941MHz

403-470MHz

1.0 to 1.6GHz

1.5 to 2.0GHz

26 to 35 Watts

36 to 60 Watts

61 to 110 Watts

Up to 125 Watts

1-25 Watts

25-40 Watt

25-45 Watt

10-35 Watt

5 = 15KHz 6 = 20/25KHz 7 = 30KHz 8 = 12.5/25KHz 9 = Variable/Programmable

Positions 13 - 16

SP Model Suffix

Position 12 -

Unique Model Variations

C = Cenelec N = Standard Package

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 10 - Feature Level

1 = Basic 2 = Limited Package 3 = Limited Plus 4 = Intermediate 5 = Standard Package

Position 9 - Primary System Type

Conventional

Privacy Plus

Clear SMARTNET

Advanced Conventional Stat-Alert

Enhanced Privacy Plus

Nauganet 888 Series

Japan Specialized Mobile Radio (JSMR)

Multi-Channel Access (MCA)

CoveragePLUS

MPT1327* - Public

MPT1327* - Private

Radiocom

Tone Signalling

Binary Signalling

Phonenet

IDEN Basic

IDEN Advanced Feature

JSMR Digital

LTR Protocol

Single Sideband

Programmable

Secure Conventional

Secure SMARTNET

TETRA

SmartZone

* MPT = Ministry of Posts and Telecommunications

Position 8 - Primary Operation

Conventional/Simplex

Conventional/Duplex

Trunked Twin Type

Dual Mode Trunked

Dual Mode Trunked/Duplex

Trunked Type I

Trunked Type II

FDMA* Digital Dual Mode

TDMA** Digital Dual Mode

Single Sideband

Global Positioning Satellite Capable

Amplitude Companded Sideband (ACSB)

Digital Dispatch

Programmable

Digital Interconnect

Digital Multi-Service

9600 Capable

TDMA

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

6 = Standard Plus 7 = Expanded Package 8 = Expanded Plus 9 = Full Feature/ Programmable

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Commercial Warranty xi

Commercial Warranty

Limited Warranty

MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty Covers And For How Long

MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication Products listed below (“Product”) against defects in material and workmanship under normal use and service for a period of time from the date of purchase as scheduled below:

ASTRO XTL 1500 Digital Mobile Radio One (1) Year

Product Accessories One (1) Year

Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period. All replaced parts of Product shall become the property of MOTOROLA.

This express limited warranty is extended by MOTOROLA to the original end user purchaser only and is not assignable or transferable to any other party. This is the complete warranty for the Product manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or modifications to this warranty unless made in writing and signed by an officer of MOTOROLA. Unless made in a separate agreement between MOTOROLA and the original end user purchaser, MOTOROLA does not warrant the installation, maintenance or service of the Product.

MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by MOTOROLA which is attached to or used in connection with the Product, or for operation of the Product with any ancillary equipment, and all such equipment is expressly excluded from this warranty. Because each system which may use the Product is unique, MOTOROLA disclaims liability for range, coverage, or operation of the system as a whole under this warranty.

II. General Provisions

This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product. Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW.

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xii Commercial Warranty

III. State Law Rights

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.

This warranty gives specific legal rights, and there may be other rights which may vary from state to state.

IV. How To Get Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial number) in order to receive warranty service and, also, deliver or send the Product item, transportation and insurance prepaid, to an authorized warranty service location. Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada.

V. What This Warranty Does Not Cover

A. Defects or damage resulting from use of the Product in other than its normal and customary

manner.

B. Defects or damage from misuse, accident, water, or neglect.

C. Defects or damage from improper testing, operation, maintenance, installation, alteration,

modification, or adjustment.

D. Breakage or damage to antennas unless caused directly by defects in material workmanship.

E. A Product subjected to unauthorized Product modifications, disassemblies or repairs (includ-

ing, without limitation, the addition to the Product of non-Motorola supplied equipment) which adversely affect performance of the Product or interfere with Motorola's normal warranty inspection and testing of the Product to verify any warranty claim.

F. Product which has had the serial number removed or made illegible.

G. Rechargeable batteries if:

- any of the seals on the battery enclosure of cells are broken or show evidence of tampering.

- the damage or defect is caused by charging or using the battery in equipment or service other than the Product for which it is specified.

H. Freight costs to the repair depot.

I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the Prod-

uct, does not function in accordance with MOTOROLA’s published specifications or the FCC type acceptance labeling in effect for the Product at the time the Product was initially distributed from MOTOROLA.

J. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of

the Product.

K. Normal and customary wear and tear.

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Commercial Warranty xiii

VI. Patent And Software Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the extent that it is based on a claim that the Product or parts infringe a United States patent, and MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in any such suit which are attributable to any such claim, but such defense and payments are conditioned on the following:

A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such

claim;

B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its

settlement or compromise; and

C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the

subject of a claim of infringement of a United States patent, that such purchaser will permit MOTOROLA, at its option and expense, either to procure for such purchaser the right to continue using the Product or parts or to replace or modify the same so that it becomes noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and accept its return. The depreciation will be an equal amount per year over the lifetime of the Product or parts as established by MOTOROLA.

MOTOROLA will have no liability with respect to any claim of patent infringement which is based upon the combination of the Product or parts furnished hereunder with software, apparatus or devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary equipment or software not furnished by MOTOROLA which is attached to or used in connection with the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of patents by the Product or any parts thereof.

Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute copies of such Motorola software. MOTOROLA software may be used in only the Product in which the software was originally embodied and such software in such Product may not be replaced, copied, distributed, modified in any way, or used to produce any derivative thereof. No other use including, without limitation, alteration, modification, reproduction, distribution, or reverse engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent rights or copyrights.

VII. Governing Law

This Warranty is governed by the laws of the State of Illinois, USA.

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xiv Commercial Warranty

Notes

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Chapter 1 Introduction

This manual covers the installation procedures for ASTRO XTL 1500 mobile and accessories required to complete the radio system. The radio system consists of a control head, radio, antenna, microphone, cabling, and accessories.

1.1 Mobile Radio Description

1.1.1 Dimensions

Figure 1-1 and Figure 1-2 show the basic dimensions of the dash mount brick trunnion XTL 1500

radio.

When installing the radio, make sure to plan the installation carefully and leave additional room in the rear of the radio for cabling and accessory connections; in the front of the radio for access, controls; and to the sides of the radio so that you may access and install the trunnion wing screws.

8.5"

7.3"

9.7"

2.0"

3.3"

Figure 1-1. Front View of Dash Mount Brick

Trunnion Figure 1-2. Side View of Dash Mount Brick Trunnion

NOTE: The rear accessory connector adds 0.75 in. to the overall length.

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1-2 Introduction: Standard Configurations

1.2 Standard Configurations

1.2.1 Dash Mount Configuration

The control head is mounted on the front of the transceiver housing. Electrical connection between the two takes place within the radio via a flexible circuit board between the connectors on the front of the transceiver and at the back of the control head.

Figure 1-3. Dash Mount Configuration

For details on this configuration, see Section 2.2.1 on page 2-5.

1.3 Base/Control Stations

If mobile radio equipment is installed at a fixed location and operated as a control station or as a fixed unit, the antenna installation must comply with the following requirements in order to ensure optimal performance and compliance with the RF energy exposure limits in the standards and guidelines listed in the 68P81095C99 manual:

• The antenna should be mounted outside the building on the roof or a tower if at all possible.

• As with all fixed site antenna installations, it is the responsibility of the licensee to manage the site in accordance with applicable regulatory requirements and may require additional compliance actions such as site survey measurements, signage, and site access restrictions in order to ensure that exposure limits are not exceeded.

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Introduction: Tools Required for XTL 1500 Installations 1-3

1.4 Tools Required for XTL 1500 Installations

Too l Part Number

11/32 hex driver —

RF cable tool HLN6695_

Regular slot screwdriver of Phillips #2

Pin removal tool 6680163F01

1/4 hex driver —

—

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1-4 Introduction

This Page Intentionally Left Blank

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Chapter 2 Standard Configurations

2.1 Planning the Installation

The XTL 1500 radio operates only in negative ground electrical systems. Before starting the radio installation, make sure that the ground polarity of the vehicle is correct. Accidentally reversing the polarity will not damage the radio, but will cause the cable fuses to blow.

Planning is the key to fast, easy radio installation. Before starting the installation, inspect the vehicle and determine how and where you intend to mount the antenna, radio, and accessories. Plan wire and cable runs to provide maximum protection from inching, crushing, and overheating.

CAUTION Before installing any electrical equipment, check the vehicle manufacturer’s user manual.

The installation of this device should be completed by an authorized servicer or installer.

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2-2 Standard Configurations: Planning the Installation

2.1.1 Installation Examples

Your mobile two-way radio offers only dash mount installation. (see Figure 2-1 through Figure 2-3).

Speaker

(optional)

Battery

Radio

Antenna 1/4-Wavelength

Speaker

Radio

(optional)

Radio

Battery

Antenna 1/4-Wavelength

Figure 2-1. Mounting Flexibility in Middle Console Figure 2-2. On Top or Under Dash Mounting

Speaker

(optional)

Radio

Battery

Antenna 1/4-Wavelength

Figure 2-3. In Dash Mounting

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Standard Configurations: Planning the Installation 2-3

2.1.2 Wiring Diagrams

Figure 2-4 shows the wiring diagram the possible configurations. The title under the figure identifies

the control head configurations. Use the diagram when planning the installation.

HORN RELAY

SPEAKER

(Optional)

MIC

CLIP

MIC

EMERGENCY

BATTERY

(-)

LIGHT RELAY

SWITCH

(+)

FUSE

BLOCK

IGNITION CABLE

(SEE J2

PINOUT)

RED LEAD

POWER

CABLE

TRUNNION

FIREWALL

HOLE

MOUNTING

SCREW

ANTENNA

CONNECTION

SPKR+

VIP OUT 2

12V

(RELAY)

VIP OUT 1

12V

(RELAY)

GROUND

REAR ACCESSORY CONNECTOR

SPKR-

IGNITION

EMERGENCY

Figure 2-4. Radio Installation with transceiver

(For complete pin configuration, see Figure 3-6.)

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2-4 Standard Configurations: Radio Mounting

2.2 Radio Mounting

CAUTION: DO NOT mount the radio on a plastic dashboard

C a u t i o n

The mounting location must be accessible and visible. Select a location that will permit routing the RF antenna cable as directly as possible.

NOTE: For new or existing installations, use only the XTL 1500 trunnion, kit number HLN6861_.

without first reinforcing the dashboard; the weight of the radio may crack or break the dashboard. CAUTION: DO NOT mount the radio on a flat or concave surface where the radio could be partially submersed in water. This is especially important if the cab area of the vehicle is cleaned by spraying with water. If the radio sits in water for a length of time, moisture may seep inside the radio and damage the electronic components. CAUTION: DO NOT allow water to stand in recessed areas of vertically mounted radios. Remove any moisture immediately to prevent it from seeping down into the radio.

RADIO

FRONT

APPLIES TO RADIOS WITH INTEGRAL

OR REMOTE MOUNT CONTROL UNITS

Figure 2-5. Trunnion Orientation

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Standard Configurations: Radio Mounting 2-5

2.2.1 Dash Mount with Trunnion

1. Select the location to mount your radio on the transmission hump (see Figure 2-6) or under the dash (see Figure 2-7). When mounting the trunnion on the transmission hump take care the transmission housing is not affected.

2. Using the trunnion mounting bracket as a template, mark the positions of the holes on the mounting surface. Use the innermost four holes for a curved mounting surface such as the transmission hump, and the four outmost holes for a flat surface such as under the dash.

3. Center punch the spots you have marked and realign the trunnion in position.

4. Secure the trunnion mounting bracket with the four self-drilling screws provided (see

Figure 2-6 and Figure 2-7).

5. Ensure that the plastic guides are aligned (horizontal) to the grooves of the trunnion. Slide the radio into the grooves until it snaps into place (see Figure 2-6). Secure the radio with the two wing screws provided.

Wing Screw

Trunnion

Plastic Guides

Tabs

Groove

Threaded Hole

for Wing Screw

Figure 2-6. Transmission Hump Trunnion Mounting

Trunnion

Wing Screw

Holes for

Microphone

S-Hook

6815851H01-O June 3, 2005

Wing Screw

Groove

Threaded Hole for Wing Screw

Figure 2-7. Below Dash Trunnion Mounting

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2-6 Standard Configurations: Power Cable and Ignition

2.2.2 Locking Kit (Optional)

If an optional locking kit is used (shown in Figure 2-8), position the lock bottom housing on the trunnion before installing the radio mounting screws. Then slip the top lock housing on and remove the key. You can install the lock on either side of the radio, and by rotating it 180°, you can also install it on dash installations.

Existing

Mounting

Screw

Lock

Housing

Lock

Figure 2-8. Locking Kit (Optional)

2.3 Power Cable and Ignition

Route the red radio power cable from the radio to the vehicle’s battery compartment, using accepted industry methods and standards. Be sure to grommet the firewall hole to protect the cable. Remove the 15-amp (part number 6580283E06) or 20-amp (part number 6580283E07) fuse from the fuseholder and connect the red lead of the radio power cable to the positive battery terminal using the hardware provided as shown in Figure 2-9. Connect the black lead to a convenient solid chassis ground point. DO NOT connect the black lead directly to the battery’s negative terminal.

Always connect the IGNITION LINE (thin red wire) located at the rear of the radio to the vehicle's ignition switch (see Figure 2-9). The radio is programmable through CPS to allow ignition to disallow the radio from powering up without ignition or to power up with ignition.

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Standard Configurations: Power Cable and Ignition 2-7

COMPARTMENT

VEHICLE BATTERY

VEHICLE

PART OF

VEHICLE

ON/ACC

IGNITION SWITCH

WIRING

GROMMET

SEE NOTE

3A OR 4A FUSE

(-)

VEHICLE

(+)

15A OR 20A

BATTERY

FUSE

(RED/BATTERY HOT)

RADIO POWER CABLE

MAEPF-27646-B

RADIO COMPARTMENT = OPERATOR COMPARTMENT

CAUTION

A good chassis connection via the black primary

power cable is essential for radio operation and

RADIO IGNITION

CABLE (thin RED)

(Optional)

SPEAKER

MICROPHONE

RADIO

Rear connector

to prevent damage to the radio and cable kit.

Connection to the vehicle frame is desirable.

RADIO POWER CABLE (BLK/GROUND)

Figure 2-9. Cabling Interconnect Diagram for Dash Mount

Caution: Always wire the radio’s IGNITION line to the car’s ignition switch.

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2-8 Standard Configurations: Ignition Sense Cable

2.4 Ignition Sense Cable

Motorola supplies an ignition sense cable and recommends that it be used with every mobile installation. The ignition sense cable allows the radio to be turned on and off with the vehicle ignition switch, and allows the radio to “remember” the state of the radio on/off switch, even if it is changed while the vehicle is off.

Note that this feature can be turned on/off via Motorola CPS software.

• Always connect the red ignition cable (orange for remote) to “ignition” at the fuse block.

Note that for remote mount installations, the green and orange leads are connected, not the red lead from the rear of the radio.

The ignition sense cable uses either a 3-amp (P/N 6580283E01) or 4-amp (P/N 6580283E02) fuse.

For other considerations when connecting the ignition cable, see the XTL 1500 Basic Service Manual (Motorola publication part number 6815853H01).

2.5 Antenna Installation

IMPORTANT NOTE: To assure optimum performance and compliance with RF Energy Safety

standards, these antenna installation guidelines and instructions are limited to metal-body vehicles with appropriate ground planes and take into account the potential exposure of back seat passengers and bystanders outside the vehicle.

NOTE: For mobile radios with rated power of 7 watts or less, the only installation restrictions are to

use only Motorola approved antennas and install the antenna externally on metal body vehicles. For mobile radios with rated power greater than 7 Watts, always adhere to all the guidelines and restrictions in section 2.5.1 below.

2.5.1 Selecting an Antenna Site/Location on a Metal Body Vehicle

1. External installation – Check the requirements of the antenna supplier and install the

vehicle antenna external to a metal body vehicle in accordance with those requirements.

2. Roof top – For optimum performance and compliance with RF Energy Safety standards,

mount the antenna in the center area of the roof.

3. Trunk lid – On some vehicles with clearly defined, flat trunk lids, the antennas of some radio

models (see restrictions below) can also be mounted on the center area of the trunk lid. For vehicles without clearly defined, flat trunk lids (such as hatchback autos, sport uitility vehicles, and pick-up trucks), mount the antenna in the center area of the roof.

Before installing an antenna on the trunk lid,

- Be sure that the distance from the antenna location on the trunk lid will be at least 85 cm (33 inches) from the front surface of the rear seat-back to assure compliance with RF Energy Safety standards.

- Ensure that the trunk lid is grounded by connecting grounding straps between the trunk lid and the vehicle chassis.

IF THESE CONDITIONS CANNOT BE SATISFIED, THEN MOUNT THE ANTENNA ON THE ROOF TOP!

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Page 27

Standard Configurations: Antenna Installation 2-9

4. Mounting restrictions for certain radio models

For 40 Watt UHF models, the 1/4 wave antenna

should be mounted only in the center area of the roof, not on the trunk lid, to assure compliance with RF Energy Safety standards.

5. Ensure that the antenna cable can be easily routed to the radio. Route the antenna cable as far away as possible from any vehicle electronic control units and associated wiring.

6. Check the antenna location for any electrical interference.

7. Ensure that any other mobile radio antenna on this vehicle is at least one foot (30.48 cm) away from this antenna.

NOTE: Any two metal pieces rubbing against each other (such as seat springs, shift levers,

trunk and hood lids, exhaust pipes, etc.) in close proximity to the antenna can cause severe receiver interference.

2.5.2 Mini-UHF Connection

To ensure a secure connection of an antenna cable's mini-UHF plug to a radio's mini-UHF jack, their interlocking features must be properly engaged. If they are not properly engaged, the system will loosen. Using a tool (pliers or wrench) will not overcome a poor engagement, and is not recommended.

NOTE: Applying excessive force with a tool can cause damage to the antenna or the connector (e.g.,

stripping threads, deforming the collar or connector, or causing the connector to twist in the housing opening and break).

The mini-UHF connector tool (Motorola part number HLN6695_) is designed to securely tighten the antenna plug–radio jack connection without damaging either the plug or the jack.

Motorola recommends the following sequence to ensure proper attachment of the system (see

Figure 2-10):

Coax Conductor

Plug (Pin)

Collar Pulled

Back to Flange

Flange

Mini UHF

Jack

Cable

Figure 2-10. Mini-UHF Connection

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2-10 Standard Configurations: Antenna Installation

1. Make sure that there is sufficient slack in the antenna cable.

2. Make sure that the collar of the antenna cable plug is loose and does not bind.

3. Make sure that the mini-UHF jack is tight in the radio housing.

4. Slide the collar back against the flange. Insert the antenna cable plug’s pin fully into the radio jack, but do not engage the threads.

5. Ensure that the plug’s and jack’s interlocking features are fully seated. Check this by grasping the crimp on the cable jack, rotating the cable, and noting any movement. If the features are seated correctly, there should be NO movement.

6. Finger-tighten the antenna cable plug’s collar onto the radio’s jack.

7. Give a final tug, by hand, to the collar, and retighten by hand as firmly as possible.

8. Slip the mini-UHF connector tool over the coaxial cable, using the gap between the tool’s legs (see Figure 2-11). Then, slide the tool up onto the plug’s knurled collar. Squeeze the two straight legs of the tool firmly together between your thumb and index finger and turn clockwise (as shown) to tighten the collar. It should take 1/4 turn or less. When you feel the tool slipping on the collar, the connection has been properly tightened. The tool can also be used to loosen a tight collar.

NOTE: DO NOT use pliers or any other device to grip the tightening tool. It has been designed to

allow you to achieve the proper torque on the collar without overtightening. Overtightening the collar can damage the connector and the radio.

HLN6695_

(

)

(1) Squeeze

Firmly Together

Figure 2-11. Mini-UHF Connector Tool

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Standard Configurations: Microphone Hang-Up Clip 2-11

2.6 Microphone Hang-Up Clip

2.6.1 Standard Hang-Up Clip

The hang-up clip must be within reach of the operator(s). Measure this distance before actually mounting the bracket. Since the bracket has a positive-detent action, the microphone can be mounted in any position. The microphone hang-up clip must be grounded.

Use the hang-up clip as a template to locate the mounting holes. To avoid interference when removing the microphone, install the flathead screw in the top clip hole.

2.6.2 Handheld Hang-Up Box

Use the hang-up box (HUB) as a template to locate the mounting holes. Be sure the HUB will be within easy reach of the operator. Open the accessory cable connector and connect the HUB control wire to location 3 of the accessory connector. Connect the other control wire from the HUB to a convenient solid chassis ground point.

2.7 Completing the Installation

Complete the installation by connecting the power wires and plugging in the microphone cable. Be sure to connect the microphone S-hook to the holes in the trunnion provided (see Figure 2-7) for strain relief.

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2-12 Standard Configurations: Completing the Installation

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Chapter 3 Options and Accessories Installation

3.1 VIP Overview

The vehicle interface port (VIP) allows the control head to operate outside circuits and to receive inputs from outside the control head. There are three VIP outputs which are used for relay control. There are also three VIP inputs which accept inputs from switches.

3.1.1 VIP Output Connections

The VIP output pins are on the back or the rear of the accessory panel (J2). The pin information is shown in Figure 3-6. Use these connections to wire control relays. One end of the relay should connect to switched B+ voltage, while the other side connects to a software controlled ON/OFF switch inside the control head. The relay can be normally on or normally off depending on the configuration of the VIP outputs. There are two VIP output connections, as follows:

Table 3-1. VIP Output Connections

VIP Number

12418

22419

The function of these VIP outputs can be field programmed in the control head. Typical applications for VIP outputs are external horn/lights alarm and horn ring transfer relay control. For further information on VIP outputs, see the control head programming manual.

CAUTION: XTL 1500 radios equipped with the following features

C a u t i o n

are capable of transmitting automatically, even if the radio is turned off:

All XTL 1500 have accessory connector pins 14 and 15 connected together to allow the radio to power down. Opening this connection by REMOVING the accessory connector, or otherwise failing to maintain a normally closed path, could, if left unchecked, drain the vehicle battery, and possibly cause transmissions to occur.

SW B+ Pin

Number

• MDC Status/Message

• MDC Emergency

• Trunking Products

• Automatic Vehicle Location

• Other Special Data Products

On/Off

Switched

Pin Number

Page 32

3-2 Options and Accessories Installation: VIP Overview

3.1.2 Emergency Pushbutton, Footswitch, Horn Relay, and Light Relay Installation

CAUTION: When connecting the various microphones available,

C a u t i o n

Perform the following installation procedure:

1. Select an appropriate place to mount the option or accessory hardware.

2. Connect the male-pin control leads (wires) to the VIP connector in the appropriate location (see Table 3-1). Figure 3-1 shows how wires are plugged into the connector and how to use an extraction tool to remove wires.

3. Route the accessory-to-control head cables under floor coverings or behind panels so that the vehicle occupants do not snag or break the wires.

make sure to attach the S-hook provided on the microphone cable (see Figure 2-7 in Chapter 2) to the dash or remote mount trunnion to avoid damage to the microphone control head interconnect.

CRIMPED

RECEPTACLE

VIP

GASKET

EXTRACTION

VIP

CONNECTOR

TOOL

WIRE

MAEPF-21424-O

Figure 3-1. VIP Connector Detail

3.1.2.1 Emergency Pushbutton or Footswitch Installation

Mount the switch using the hardware that comes with the kit. Connect the emergency switch wires to a ground pin and a VIP IN pin on the VIP connector.

1. Remove JU1008 (emergency to ground) from the control head remote back housing (HLN6432_).

2. Place JU1007 (emergency to VIP IN 2) on the control head remote back housing (HLN6432_).

3. Remove R84 (if installed) from the control head.

4. Install the emergency switch between pins 3 (VIP IN 2) and 20 (ground) of the control head back connector.

3.1.2.2 Horn (External Alarm) Relay Installation

Mount the horn relay in a suitable location (normally under the dash). Connect the relay contacts across the horn ring switch, typically found in the steering column. Connect the two control wires to a SW B+ pin and a VIP OUT pin on the VIP connector.

3.1.2.3 Lights (External Alarm) Relay Installation

Mount the light relay in a suitable location (normally under the dash). Connect the relay contacts across the headlamp ON/OFF switch. Connect the two control wires to a SW B+ pin and a VIP OUT pin on the VIP connector.

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Options and Accessories Installation: Dash-Mount Accessory Installation 3-3

3.2 Dash-Mount Accessory Installation

For dash-mounted configurations, the accessories must be installed through the accessory connector assembly that is located on the rear of the radio, adjacent to the power connector. Motorola-approved accessories are supplied with male terminals crimped to a 20-gauge wire specifically designed to fit the plug of the accessory connector assembly.

Insert the male terminal into the accessory connector assembly in the appropriate location and connect the accessory connector assembly in the rear accessory port (see Figure 3-6). Do not use other generic terminals in the plug. Generic terminals can cause electrical intermittencies and may cause damage to the plug.

3.2.1 MDC Emergency Pushbutton or Footswitch Installation

Mount the footswitch using the hardware that comes with the kit. Open the accessory cable connector housing; remove the jumper wire. Connect the emergency switch wires to pins 14 and 15 (see Figure 3-2). Close the connector housing; route the finished cable from the switch location to the control head location.

SPST NORMALLY CLOSED EMERGENCY SWITCH

NOTE 1: REMOVE BLACK JUMPER WIRE INSIDE ACCESSORY CONNECTOR HOUSING. INSERT WIRES FROM EMERGENCY SWITCH

NOTE 1

PIN 14

PIN 15

ACCESSORIES

CONNECTOR

EMER

GND

Figure 3-2. Emergency Switch Wiring Diagram

3.2.2 Horn and Lights (External Alarms) Relays

For installations that use the horn/lights option, select a suitable location for mounting (normally under the dash) and, referring to Figure 3-3, perform the following procedure:

1. Horn Relay—Connect the relay contacts across the horn ring switch, typically found in the steering column. Open the accessory cable connector and connect the two control wires (male pins) into locations 18 and 24 of the connector.

2. Lights Relay—Connect the relay across the headlamp ON/OFF switch, typically found in the steering column. Open the accessory cable connector and connect the two control wires (male pins) into locations 19 and 24 of the accessory connector.

MAEPF-27617-O

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Page 34

3-4 Options and Accessories Installation: Dash-Mount Accessory Installation

CONNECT

ACROSS HORN

RING SWITCH

CONNECT

ACROSS HEAD

LAMP SWITCH

VIP OUT 2

(LIGHTS)

VIP OUT 1

(HORN)

SWB+

Figure 3-3. Horn/Light Wiring Diagram

3.2.3 External Speaker (HSN4031_)

CAUTION: DO NOT use an external speaker which exceeds 7.5W or is below 8 Ohm. Use ONLY HSN4031_ speaker kit

C a u t i o n

SPST

N.O.

RELAY

12V COIL

SPST

N.O.

RELAY

12V COIL

VIP OUT 1

SWB+

VIP OUT 2

PIN 1

PIN 24

PIN 19

ACCESSORIES

CONNECTOR

MAEPF-27618-O

CAUTION: DO NOT ground the radio's speaker leads. This system has a floating speaker output (dc voltage on both leads); damage

C a u t i o n

to the audio circuit will result if either lead is grounded or if they are shorted together.

The speaker kit includes a trunnion bracket that allows the speaker to be mounted in a variety of ways. With the trunnion bracket, the speaker can mount permanently on the dashboard or in accessible firewall areas. The trunnion allows the speaker to tilt for best operation. Mount the speaker out of the way so that it will not be kicked or knocked around by the vehicle occupants. Mount the speaker as follows:

1. Use the speaker mounting bracket as a template to mark the mounting hole locations.

2. Use the self-drilling screws provided to fasten the trunnion.

3. Attach the speaker and fasten to the trunnion with two wing screws.

4. Route the speaker wires under the carpet or floor covering, or behind the kick panels. Be sure the wires are out of the way and will not be snagged and broken by the occupants of the vehicle.

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Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-5

Trunnion

Dashboard

Bracket

Firewall

Figure 3-4. Speaker Mounting

3.3 Accessory Connector Assembly Details (P2)

The XTL 1500 accessory connector assembly is mounted on the right rear of the radio, opposite the antenna and adjacent to the power connector. It is fastened to the radio via jackscrews and held together by the two cover screws. It is a multi-functional connector that allows for many different types of adaptations. All approved accessory wires are securely strain-relieved through the exiting slots at the back of the accessory connector assembly. The terminations that are supplied with all accessories are designed to be fully engaged and locked into the plug connector (P/N 6680163F01). They can also be detached for service with the assistance of a terminal removal tool. The accessory connector assembly can be serviced multiple times for future installation upgrades.

The accessory connector assembly, supplied with every XTL 1500 dash-mounted radio, is equipped with a 26-pin plug assembly, two covers, two jackscrews, two cover screws, one emergency jumper, one ignition sense cable assembly, and one speaker pigtail. The jumper is provided to complete the circuit for emergency mode. If this circuit becomes open, the radio will be set to emergency mode.

MAEPF-25764-O

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Page 36

3-6 Options and Accessories Installation: Accessory Connector Assembly Details (P2)

3.3.1 Installation into the Vehicle

CAUTION Before installing any electrical equipment, check the vehicle manufacturer’s

user manual. The installation of this device should be completed by an authorized servicer

or installer.

1. Disconnect the negative terminal from the vehicle’s battery. Make sure that the battery cable is secured such that it will not power the vehicle’s electrical system.

2. Place the accessory connector assembly in the approximate location for the permanent installation of the radio. Allocate a sufficient service loop for ease of removing and servicing the radio.

3. Route the ignition wire to either an ignition switch circuit or a power source that is always hot (see Section 2.4 on page 2-8). In either case, verify that the source will be capable of withstanding a load of 4 amps (see the wiring diagrams in the vehicle manufacturer’s service manual). Always use the supplied fuse holder to prevent damage to the radio.

4. Secure wires with tie straps or electrical tape to prevent damage to or entanglement of the wire. If wires are passed through drilled holes through firewalls or through any other metal panels within the vehicle, the holes must be fitted with a rubber grommet (not supplied) to prevent shaving of the wire’s protective jacket, which could cause electrical shorting.

NOTE: If the speaker pigtail is connected to the speaker assembly (optional), Be sure not to route the

speaker pigtail or wires through any areas that could cause potential damage to them. The audio system is a floating ground; therefore, any speaker lines that come into contact with the ground can cause damage to the radio. Check all wires for electrical shorts; properly repair any electrical shorting issues immediately.

5. If there are no issues, reconnect the battery. Follow the vehicle manufacturer’s instructions for the proper procedure.

3.3.2 Installation onto the Radio

The accessory connector assembly is fastened to the back of the radio by jackscrews. The radio should be fully mounted and secured in its trunnion prior to connecting the accessory connector assembly to the radio. Be sure when connecting the accessory connector assembly to the radio that there are no foreign materials in the mating surfaces. Do not force the connector on. It should slide on with very little resistance. Be sure that both jackscrews are engaged in their threaded holes before tightening them. Finger tighten the jackscrews securely to prevent loosening.

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Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-7

3.3.3 Disassembly and Assembly

3.3.3.1 Disassembly

1. Disconnect the negative terminal from the vehicle’s battery. Make sure that the battery cable is secured such that it will not power the vehicle’s electrical system. See Figure 3-5.

2. Unscrew both jackscrews completely.

3. Pull the accessory connector assembly out from the radio.

4. Loosen both cover screws, but do not remove them completely.

5. Pull the jackscrews away from the plug and hold them back.

6. Pry apart the accessory connector assembly covers.

7. Attach any new wire to its proper location by pushing in the male terminal. When you hear a pop, the wire is engaged. To verify that the wire is engaged, tug gently on the wire and be sure it does not come out. Do not overload the wire: severe damage will result to the plug.

3.3.3.2 Assembly

1. Place the plug in one cover. Be sure that the flange of the plug is in the slot of the cover. See

Figure 3-5.

2. Push the jackscrew through the plug to hold it in.

3. Position each wire across the strain-relief features in the cover. Avoid damaging loads on the plug by allowing some slack in each wire in the accessory connector assembly’s wire chamber.

4. Place the second cover onto the plug. Be sure that the flange is protruding through both covers.

Figure 3-5. Exploded View of Accessory Connector Assembly (P2)

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3-8 Options and Accessories Installation: Accessory Connector Assembly Details (P2)

5. Squeeze the covers together bending the wires in the strain-relief features. You may need a pair of pliers to seat the assembly covers.

6. Once the covers are fully seated, fasten them with the cover screws. Tighten the screws firmly but do not over-tighten them. Be sure none of the wires are pinched.

7. Reattach the accessory connector assembly to the back of the radio and fasten it by fingertightening the jackscrews to prevent any loosening.

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Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-9

3.3.4 Transceiver Rear Accessory Jack Connection

Figure 3-6 shows the complete pin configuration for the J2 rear accessory jack and Table 3-2

explains the functions of each of the pins.

SPKR-

IGNITION

SWB+

AUX MIC

MONITOR

RX FILT

AUDIO

SPKR+

VIP

OUT 2

VIP

OUT 1

ONE

WIRE

PTT

EMERGENCY

GROUND

CHAN

ACT

USB PWR

RTS

CTS

BUSY

RESET

USB+

USB-

RXD

TXD

BUS-

BUS+

GROUND

MAEPF-27619-O

Figure 3-6. Rear Accessory Jack Pin Configuration (J2) (Radio Side)

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Page 40

3-10 Options and Accessories Installation: Accessory Connector Assembly Details (P2)

Table 3-2. Rear Accessory Jack Pin Functions

Pin No.

Pin Name Pin Function

Pin No.

Pin Name Pin Function

1 GND Ground 14 GND Ground

2 BUS+ SB9600 BUS+ Data 15 EMERGENCY Emergency

3 BUS- SB9600 BUS- Data 16 PTT* Pu s h To Ta l k

4 TXD RS232 Transmit Data 17 ONE WIRE One-Wire Data

5 RXD RS232 Receive Data 18 VIP OUT 1 Vehicular Interface Output

6 USB- USB - (Data) 19 VIP OUT 2 Vehicular Interface Output

7 USB+ USB + (Data) 20 SPKR+ Speaker + (3.2 ohm

minimum impedance)

8 RESET SB9600 RESET 21 RX FILT AUDIO Receive Filtered Audio Out

9 BUSY SB9600 BUSY 22 MONITOR Monitor Overrides PL

10 CTS RS232 Clear-To-Send 23 AUX MIC Rear Microphone Input

11 RTS RS232 Request-To-Send 24 SW B+ Switched Battery Voltage

12 USB PWR USB Power (5V from USB

25 Ignition Ignition Sense

accessory/cable)

13 CHAN ACT Channel Activity (qualified

received signal)

This pin must be connected to ground by jumper on accessory cable if emergency is disabled, even if disabled by

26 SPKR- Speaker - (8 ohm minimum

impedance)

CPS. If enabled, this line must be grounded via a switch, which is normally closed. The emergency debounce time is programmable via CPS.

Pulling this line to ground will activate PTT function, activating the AUX_MIC input.

Fixed level (independent of volume level) received audio signal, including alert tones. Flat or de-emphasis are programmed by CPS. Output voltage is approximately 100 mVrms per 1kHz of deviation. The DC offset is 1.4V.

This output is used to detect when a rear microphone accessory is taken off-hook, to override PL to alert the user to busy traffic prior to transmitting.

This microphone signal is independent of the microphone signal on the front accessory connector. The nominal input level is 80mVrms for 60% deviation but can also support 300 mVrms for future APCO accessories. The DC impedance is 660 ohms and the AC impedance is 560 ohms.

Note: Please see the XTL 1500 Basic Service manual (Motorola publication part number 6815853H01) for more

detailed descriptions of these pins.

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Options and Accessories Installation: Accessory Connector Assembly Details (P2) 3-11

Table 3-3. Rear Connector and Front Connector Naming Schemes

J2 Pin Number J2 Pin Name

J2-4 UARTA_TX No change TX_DCE

J2-5 UARTA_RX No change RX_DCE

J2-10 UARTA_CTS Becomes RTS RTS_DCE

J2-11 UARTA_RTS Becomes CTS CTS_DCE

As indicated for front and rear connectors

Pin function as a true “DCE” device according to EIA standard

Pin Alternate Name

EIA Compatible Name at

Rear Connector J2

Table 3-4. How to Connect to a Computer1 (DTE Device)

Radio Pin Direction

DB9 (Female) Serial Port

Connector

= DCE

Interface

Output TX_DCE = pin 2 pin 2 = RX_DTE Input

Input RX_DCE = pin 3 pin 3 = TX_DTE Output

Output RTS_DCE = pin 8 pin 8 = CTS_DTE Input

Input CTS_DCE = pin 7 pin 7 = RTS_DTE Output

EIA standard

The DB9 (female) serial port cable can be added to the P2 rear accessory cable (Figure 3-5).

Note: TX to RX and RTS to CTS, not “same to same” (e.g., not TX to TX).

DB9 (Male) Serial Port

Connector = DTE

Interface

Data Device Pin

Direction

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3-12 Options and Accessories Installation: Accessory Connector Assembly Details (P2)

This Page Intentionally Left Blank

June 3, 2005 6815851H01-O

Page 43

Chapter 4 Finishing the Installation: Cable Connection

Perform the following if it has not been previously done:

1. The microphone can be plugged into the lower left corner of the control head front panel. Connect the microphone cable S-hook (see Figure 2-7 in Chapter 2) into the hole in the cable

strain relief bracket on the mounting trunnion.

2. Be sure the control head is OFF. Install the 15- or 20-amp fuse in the radio power cable fuseholder and the 3- or 4-amp fuse(s) in the ignition cable fuseholder(s).

3. Turn the radio ON at the control head and verify proper operation of all controls and indicators. Radio operation in some installations require turning on the ignition. Perform a complete operational check of the radio.

4. Dress the control and power cables out of the way to prevent damage (pull any excess cable into the trunk area) securing with clamps and tie wraps where necessary.

Page 44

4-2 Finishing the Installation: Cable Connection

Notes

June 3, 2005 6815851H01-O

Page 45

Appendix A Replacement Parts Ordering

A.1 Basic Ordering Information

When ordering replacement parts or equipment information, the complete identification number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufficient description of the desired component to identify it.

Crystal orders should specify the crystal type number, crystal and carrier frequency, and the model number in which the part is used.

The ASTRO XTL 1500 Digital Mobile Radio Basic Service Manual (Motorola publication part number 6815853H01) includes complete parts lists and parts numbers.

A.2 Motorola Online

Motorola Online users can access our online catalog at

https://www.motorola.com/businessonline

To register for online access:

• Domestic customers: please call 800-814-0601 (U.S. and Canada).

• International customers: please go to h

“Sign Up Now.”

ttps://www.motorola.com/businessonline and click on

A.3 Mail Orders

Send written orders to the following addresses:

Replacement Parts/ Test Equipment/Manuals/ Crystal Service Items:

Motorola Inc. Radio Products and Services Division* Attention: Order Processing 2200 Galvin Drive Elgin, IL 60123 U.S.A.

Federal Government Orders:

Motorola Inc. U.S. Federal Government Markets Division Attention: Order Processing 7230 Parkway Drive Landover, MD 21076 U.S.A.

International Orders:

Motorola Inc. Radio Products and Services Division* Attention: Order Processing 2200 Galvin Drive Elgin, IL 60123 U.S.A.

Page 46

A-2 Replacement Parts Ordering: Telephone Orders

A.4 Telephone Orders

Radio Products and Services Division* (United States and Canada) 7:00 AM to 7:00 PM (Central Standard Time) Monday through Friday (Chicago, U.S.A.) 1-800-422-4210 1-847-538-8023 (International Orders)

U.S. Federal Government Markets Division (USFGMD) 1-800-826-1913 Federal Government Parts - Credit Cards Only 8:30 AM to 5:00 PM (Eastern Standard Time)

A.5 Fax Orders

Radio Products and Services Division* (United States and Canada) 1-800-622-6210 1-847-576-3023 (International)

USFGMD (Federal Government Orders) 1-800-526-8641 (For Parts and Equipment Purchase Orders)

A.6 Parts Identification

Radio Products and Services Division* (United States and Canada) 1-800-422-4210, menu 3

A.7 Product Customer Service

Customer Response Center (Non-technical Issues) 1-800-247-2346 FAX:1-800-247-2347

*The Radio Products and Services Division (RPSD) was formerly known as the Customer Care and Services Division (CCSD) and/or the Accessories and Aftermarket Division (AAD).

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Glossary Glossary

This glossary contains an alphabetical listing of terms and their definitions that are applicable to ASTRO portable and mobile subscriber radio products.

Term Definition

A/D See analog-to-digital conversion.

Abacus IC A custom integrated circuit providing a digital receiver intermediate

frequency (IF) backend.

ADC See analog-to-digital converter.

ADDAG See Analog-to-Digital, Digital-to-Analog and Glue.

ALC See automatic level control.

analog Refers to a continuously variable signal or a circuit or device designed

to handle such signals. See also digital.

Analog-to-Digital, Digital-to-Analog and Glue

analog-to-digital conversion

analog-to-digital converter

APCO 25 A standard of digital two-way radio communications, developed by the

Association of Public-Safety Communications Officials

automatic level control

An integrated circuit designed to be an interface between the radio’s DSP, which is digital, and the analog transmitter and receiver ICs.

Conversion of an instantaneous dc voltage level to a corresponding digital value. See also D/A.

A device that converts analog signals into digital data. See also DAC.

Association of Public-Safety Communications Officials, providing maximum radio spectrum efficiency; competition in system life cycle procurements; effective, efficient and reliable intra-agency and interagency communications; and “user friendly” equipment. See also

Association of Public-Safety Communications Officials.

An association dedicated to an industry-wide effort (known as APCO 25 or Project 25) to set the recommended voluntary standards of uniform digital two-way radio technology for public safety organizations. This allows radio interoperability with multiple vendor products which are all APCO 25 compatible. See also APCO 25.

A circuit in the transmit RF path that controls RF power amplifier output, provides leveling over frequency and voltage, and protects against high VSWR.

band Frequencies allowed for a specific purpose.

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Glossary-2

Term Definition

BBP See baseband interface port.

baseband interface port

Synchronous serial interface to the transceiver board used to transfer transmit and receive audio data.

BGA See ball grid array.

ball grid array A type of IC package characterized by solder balls arranged in a grid

that are located on the underside of the package.

CODEC See coder/decoder.

coder/decoder A device that encodes or decodes a signal.

CPS See Customer Programming Software.

Customer Programming

Software with a graphical user interface containing the feature set of an ASTRO radio.

Software

D/A See digital-to-analog conversion.

DAC See digital-to-analog converter.

DCE Data communication equipment: The EIA definition for device (i.e.,

radio) data communications using the RS232 protocol. The correct data communication wiring requires the device’s TX pins (output) to connect to the RX pins (input) and the RTS pins (output) to connect to the CTS pins (input). It is incorrect to attach the “same name” to “same name”.

default A pre-defined set of parameters.

digital Refers to data that is stored or transmitted as a sequence of discrete

symbols from a finite set; most commonly this means binary data represented using electronic or electromagnetic signals. See also

analog.

digital-to-analog conversion

digital-to-analog

Conversion of a digital signal to a voltage that is proportional to the input value. See also A/D.

A device that converts digital data into analog signals. See also ADC.

converter

Digital Private-Line A type of digital communications that utilizes privacy call, as well as

memory channel and busy channel lock out to enhance communication efficiency.

digital signal processor

A microcontroller specifically designed for performing the mathematics involved in manipulating analog information, such as sound, that has been converted into a digital form. DSP also implies the use of a data compression technique.

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Term Definition

Glossary-3

digital signal processor code

Object code executed by the Digital Signal Processor in an ASTRO subscriber radio. The DSP is responsible for computation-intensive tasks, such as decoding ASTRO signaling.

DPL See Digital Private-Line. See also PL.

DSP See digital signal processor.

DSP code See digital signal processor code.

DTE Data terminal equipment: i.e., a computer.

DTMF See dual tone multi-frequency.

dual tone multifrequency

The system used by touch-tone telephones. DTMF assigns a specific frequency, or tone, to each key so that it can easily be identified by a microprocessor.

EEPOT Electrically Programmable Digital Potentiometer.

EEPROM See Electrically Erasable Programmable Read-Only Memory.

Electrically Erasable Programmable Read-Only Memory

A special type of PROM that can be erased by exposing it to an electrical charge. An EEPROM retains its contents even when the power is turned off.

FCC Federal Communications Commission.

firmware Code executed by an embedded processor such as the Host or DSP in

a subscriber radio. This type of code is typically resident in non-volatile memory and as such is more difficult to change than code executed from RAM.

FGU See frequency generation unit.

flash A non-volatile memory device similar to an EEPROM. Flash memory

can be erased and reprogrammed in blocks instead of one byte at a time.

FLASHcode A 13-digit code which uniquely identifies the System Software Package

and Software Revenue Options that are enabled in a particular subscriber radio. FLASHcodes are only applicable for radios which are upgradeable through the FLASHport process.

FLASHport A Motorola term that describes the ability of a radio to change memory.

Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to, again and again.

FMR See Florida Manual Revision.

Florida Manual Revision

A publication that provides supplemental information for its parent publication before it is revised and reissued.

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Glossary-4

Term Definition

frequency Number of times a complete electromagnetic-wave cycle occurs in a

fixed unit of time (usually one second).

frequency generation unit

This unit generates ultra-stable, low-phase noise master clock and other derived synchronization clocks that are distributed throughout the communication network.

General-Purpose

Pins whose function is programmable.

Input/Output

GPIO See General-Purpose Input/Output.

host code Object code executed by the host processor in an ASTRO subscriber

radio. The host is responsible for control-oriented tasks such as decoding and responding to user inputs.

IC See integrated circuit.

IF Intermediate Frequency.

IMBE A sub-band, voice-encoding algorithm used in ASTRO digital voice.

inbound signaling word

Data transmitted on the control channel from a subscriber unit to the central control unit.

integrated circuit An assembly of interconnected components on a small semiconductor

chip, usually made of silicon. One chip can contain millions of microscopic components and perform many functions.

ISW See inbound signaling word.

key-variable loader A device used to load encryption keys into a radio.

kHz See kilohertz.

kilohertz One thousand cycles per second. Used especially as a radio-frequency

unit.

KVL See key-variable loader.

LCD See liquid-crystal display.

LED See light emitting diode.

light emitting diode An electronic device that lights up when electricity is passed through it.

liquid-crystal display An LCD uses two sheets of polarizing material with a liquid-crystal

solution between them. An electric current passed through the liquid causes the crystals to align so that light cannot pass through them.

LO Local oscillator.

low-speed handshake

150-baud digital data sent to the radio during trunked operation while receiving audio.

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Glossary-5

Term Definition

LSH See low-speed handshake.

Master In Slave Out SPI data line from a peripheral to the MCU.

Master Out Slave In SPI data line from the MCU to a peripheral.

MCU See microcontroller unit.

MDC Motorola Digital Communications.

MDI MCU/DSP Interface internal to the Patriot IC.

MHz See Megahertz.

Megahertz One million cycles per second. Used especially as a radio-frequency

unit.

microcontroller unit Also written as µC. A microprocessor that contains RAM and ROM

components, as well as communications and programming components and peripherals.

MISO See Master In Slave Out.

MOSI See Master Out Slave In.

multiplexer An electronic device that combines several signals for transmission on

some shared medium (e.g., a telephone wire).

MUX See multiplexer.

NiCd Nickel-cadmium.

NiMH Nickel-metal-hydride.

OMPAC See over-molded pad-array carrier.

open architecture A controller configuration that utilizes a microprocessor with extended

ROM, RAM, and EEPROM.

oscillator An electronic device that produces alternating electric current and

commonly employs tuned circuits and amplifying components.

OSW See outbound signaling word.

OTAR See over-the-air rekeying.

outbound signaling word

over-molded padarray carrier

Data transmitted on the control channel from the central controller to the subscriber unit.

A Motorola custom IC package, distinguished by the presence of solder balls on the bottom pads.

over-the-air rekeying Allows the dispatcher to remotely reprogram the encryption keys in the

radio.

PA Power amplifier.

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Glossary-6

Term Definition

paging One-way communication that alerts the receiver to retrieve a message.

Patriot IC A dual-core processor that contains an MCU and a DSP in one IC

package.

PC Board Printed Circuit Board. Also referred to as a PCB.

phase-locked loop A circuit in which an oscillator is kept in phase with a reference, usually

after passing through a frequency divider.

PL See private-line tone squelch.

PLL See phase-locked loop.

private-line tone squelch

Programmable Read-Only Memory

A continuous sub-audible tone that is transmitted along with the carrier.

Motorola Astro XTL 1500, ASTRO XTL 5000 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual