Motorola EP450 User Manual

MOTOROLA, The Stylized M logo are trademarks of Motorola, Inc. All other product or service names are the property of their respective owners. © 2003 Motorola, Inc. All rights reserved. Printed in U.S.A.

HKLN4215A

™

EP450

Portable Radio Basic Service Manual

EP450 Portable Radio

Basic Service Manual

VHF 146-174 MHz

UHF 403-440 MHz UHF 438-470 MHz UHF 465-495 MHz

Motorola, Inc. 1301 E. Algonquin Road Schaumburg, IL 60196

HKLN4215A

Foreword

This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the e quipment described a nd is current as of the printing dat e. Changes which occur after the printing date may be incorporated by a complet e Manual revision or alternatively as additions.

Note:

Before operating or testing these units, please read the Product Safety and RF Exposure Compliance section.

Product Safety and RF Exposure Compliance

Note:

Before using this product, read the operating instructions for safe usage contained in the Product Safety and RF Exposure booklet enclosed with your radio.

a u t i o

ATTENTION!

This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.

Before using this product, read the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 68P81095C98) to ensure compliance with RF energy exposure limits.

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

Computer Software Copyrights

The Motorola products described in th is manual may include cop yrighted Moto rola computer pr ograms stored in semiconductor memories or other media. La ws 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 de scribed in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in any manner without the express written permission of Motorola. Furthermore, th e purchase of Motorola products sh all not be deemed to gr ant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for the normal no n-exclu sive license to use that arises by opera tion 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 descr ibed herein; nor does it cover any license under its patent rights nor the rights of others.

MOTOROLA, and the Stylized M logo are trademarks of Motorola, Inc. All other product or service names are the property of their respective owners. © 2003 Motorola, Inc. All rights reserved. Printed in U.S.A.

Table of Contents iii

Table of Contents

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

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

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

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

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

List of Figures ...............................................................................................vi

List of Tables ...............................................................................................viii

Chapter 1 Model Charts and Test Specifications.............................. 1-1

1.1 Radio Model Information................................................................................................................1-1

1.2 Model Chart for VHF 146-174 MHz ...............................................................................................1-2

1.3 Non-Display Model ........................................................................................................................1-3

1.4 Model Chart for UHF 403-440 MHz............................................................................................... 1-4

1.5 Model Chart for UHF 438-470 MHz............................................................................................... 1-5

1.6 Model Chart for UHF 465-495 MHz............................................................................................... 1-6

1.7 Display Model ................................................................................................................................1-7

1.8 MIL Standards ...............................................................................................................................1-8

Chapter 2 Theory Of Operation........................................................... 2-1

2.1 Introduction....................................................................................................................................2-1

2.2 Major Assemblies ................... ... .... ... ... ... ....................................... ... ... .... ......................................2-1

2.2.1 Receiver............................................................................................................................2-1

2.2.2 Transmitter........................................................................................................................2-2

Chapter 3 Test Equipment, Service Aids, and Service Tools........... 3-1

3.1 Test Equipment.............................................................................................................................. 3-1

3.2 Service Aids...................................................... ... ... ....................................... ... ............................. 3-2

Chapter 4 Performance Checks ..........................................................4-1

4.1 General..........................................................................................................................................4-1

4.2 Power-Up Self Test.... ....................................... ... ....................................... ... ... ............................. 4-1

4.3 RF Test Mode................................................................................................................................ 4-2

Chapter 5 Radio Alignment Procedures............................................. 5-1

5.1 Introduction....................................................................................................................................5-1

5.2 CPS Programming Setup .......... .... ... ... ... ... ....................................... ... .... ... ................................... 5-1

5.3 Radio Tuning Setup....................................................................................................................... 5-2

5.3.1 Initial Test Equipment Control Settings............................................................................. 5-3

5.4 Transmitter Alignment Options...................................................................................................... 5-3

5.4.1 R eferenc e Os cillat or Warp................... ... ... .... ... .......................................... ... ................... 5-3

5.4.2 Modulation Balance Attenuation ....................................................................................... 5-4

HKLN4215A December 3, 2003

iv Table of Contents

5.4.3 Transmit Power Tuning.....................................................................................................5-5

5.4.3.1 To Perform Transmit High Power Tuning, do the following: ..............................5-6

5.4.3.2 To Perform Transmit Low Power Tuning, do the following: ..............................5-6

5.4.4 VCO Attenuation................... ... ....................................... ... ... ... ... ......................................5-7

5.4.4.1 VCO Attenuation 25 kHz....................................................................................5-7

5.4.4.2 VCO Attenuation 12.5 kHz.................................................................................5-8

5.4.4.3 VCO Attenuation 20 kHz....................................................................................5-8

5.4.5 DTMF Deviation Tuning....................................................................................................5-9

5.4.6 MDC-1200 Deviation Tuning.............................................................. ... ... .... ...................5-10

5.5 Receiver Tuning.......... ....................................... ... ....................................... ... ... ..........................5-10

5.5.1 Rated Volume Tuning .....................................................................................................5-11

5.5.2 Squelch Tuning...............................................................................................................5-12

5.5.2.1 Manual Squelch Tuning...................................................................................5-12

5.5.2.2 Auto Tune ........................................................................................................5-13

5.5.3 RSSI System Level Tuning.............................................................................................5-13

5.5.4 RSSI Display Tuning.......................................................................................................5-14

5.6 Utilities .........................................................................................................................................5-14

5.6.1 Program Serial No. .........................................................................................................5-14

5.6.2 Temp Comp Data Read..................................................................................................5-14

5.6.3 Temp Comp Data Write ..................................................................................................5-14

5.7 Radio-to-Radio Cloning............................... ... .... ... ....................................... ... .............................5-14

Chapter 6 Display Model Disassembly and Re-assembly ................ 6-1

6.1 Introduction ....................................................................................................................................6-1

6.2 Preventive Maintenance ................................................................................................................6-1

6.2.1 Inspection..........................................................................................................................6-1

6.2.2 Cleaning Procedures ........................................................................................................6-1

6.3 Safe Handling of CMOS and LDMOS Devices..............................................................................6-2

6.4 Disassembling and Re-assembling the Radi o — Gen eral........................... ... ... ... .... .....................6-3

6.4.1 Radio Disassembly — Detailed ........................................................................................6-3

6.4.1.1 Front Cover From Chassis Disassembly ...........................................................6-3

6.4.1.2 Dust Cover Disassembly....................................................................................6-6

6.4.1.3 Speaker and Microphone Disassembly .............................................................6-6

6.4.1.4 Keyboard Removal ................................................................... .... .....................6-7

6.4.1.5 PTT Disassembly................................ ... ....................................... ... ... ... ... .........6-7

6.4.1.6 Chassis Disassembly.........................................................................................6-8

6.4.2 Radio Re-assembly - Detailed .................................... ....................................... ... ... .... ... ..6- 9

6.4.2.1 Dust Cover Re-assembly...................................................................................6-9

6.4.2.2 Microphone and Speaker Re-assembly.............................................................6-9

6.4.2.3 Keypad and LCD/Keyboard Re-assembly ............................................. ... .... ...6-1 1

6.4.2.4 Keyboard Retainer Re-assembly..................... ... ... ....................................... ...6-1 2

6.4.2.5 Chassis Assembly/Re-assembly......................................................................6-12

6.4.2.6 Chassis and Front Cover Re-assembly...........................................................6-13

6.4.2.7 PTT Re-assembly..... ... ... ... ....................................... ... ....................................6-15

6.5 Mechanical View and Parts List...................................................................................................6-16

6.5.1 EP450 Display Model Exploded View and Parts List......................................................6-16

Chapter 7 Non-Display Model Disassembly and Re-assembly........ 7-1

7.1 Introduction ....................................................................................................................................7-1

7.2 Preventive Maintenance ................................................................................................................7-1

7.2.1 Inspection..........................................................................................................................7-1

December 3, 2003 HKLN4215A

Table of Contents v

7.2.2 Cleaning Procedures ..................................... ... ... ... .... ...................................... ... .............7-1

7.3 Safe Handling of CMOS and LDMOS Devices.............................................................................. 7-2

7.4 Disassembling and Re-assembling the Radio — General............................................................. 7-3

7.4.1 Radio Disassembly — Detailed .................................. ... ... ... ... .... ...................................... 7-3

7.4.1.1 Front Cover From Chassis Disassembly...........................................................7-3

7.4.1.2 Dust Cover Disassembly ................................................................................... 7-5

7.4.1.3 Speaker and Microphone Disassembly.............................................................7-6

7.4.1.4 PTT Disassembly............................................................................................... 7-6

7.4.2 Chassis Disassembly..................................................................... ... ... .... .........................7-7

7.4.3 Radio Re-assembly - Detailed .......................................................................................... 7-8

7.4.3.1 Dust Cover Re-assembly................................................................................... 7-8

7.4.3.2 Microphone and Speaker Re-assembly ... ....................................... ... ... .... .........7-8

7.4.3.3 Chassis Assembly/Re-assembly ....................................................................... 7-9

7.4.3.4 Chassis and Front Cover Re-assembly........................................................... 7-10

7.4.3.5 PTT Re-assembly............................................................................................ 7-11

7.5 Mechanical View and Parts List................................................................................................... 7-13

7.5.1 EP450 Non-Display Exploded View and Parts List......................................................... 7-13

Chapter 8 Troubleshooting Tables .....................................................8-1

8.1 Power-Up Error Codes ........... ... .... ... ....................................... ... ...................................... ... ..........8-1

8.2 Operational Error Codes................................................................................................................8-1

8.3 Troubleshooting Table for Receiver..................... ....................................... ... ................................ 8-2

8.4 Troubleshooting Table for Transmitter........................................................ ... ... .... ......................... 8-3

Appendix A Accessories.........................................................................A-1

Appendix B Warranty, Service Support, and Replacement Parts .......B-1

1.1 Scope of Manual............................................................................................................................1-1

1.2 Warranty ........................................................................................................................................1-1

1.2.1 Warranty Period and Return Instructions.......................................................................... 1-1

1.2.2 After Warranty Period ....................................................................................................... 1-1

1.3 Replacement Parts Ordering ...................................... ... ... ... ....................................... ... ... .... .........1-1

1.3.1 Basic Ordering Information.. ... ... ....................................... ... ... ....................................... ... 1-1

1.3.2 Motorola Online ................................................................................................................ 1-2

1.3.3 Mail Orders .................................................................................... ... ................................ 1-2

1.3.4 Telephone Orders............................................................................................................. 1-2

1.3.5 Fax Orders........................................................................................................................1-2

1.3.6 Parts Identification ............................................................................................................1-2

1.4 Technical Support..........................................................................................................................1-3

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

HKLN4215A December 3, 2003

vi Table of Contents

List of Figures

Figure 2-1. Major Assemblies Block Diagram..... .... ... ... ... .... ... ....................................... ... ... ... ... .... .....2-1

Figure 2-2. Transceiver Block Diagram ..............................................................................................2-2

Figure 3-1. Programming/Test Cable .. .... ... ....................................... ... ... ... .........................................3-4

Figure 3-2. Wiring of the Connectors..................................................................................................3-4

Figure 4-1. Radio Tuning Setup..........................................................................................................4-1

Figure 4-2. Side Button Locations.......................................................................................................4-2

Figure 5-1. CPS Programming Setup ..................................................... ....................................... .....5-1

Figure 5-2. Radio Tuning Setup..........................................................................................................5-2

Figure 5-3. Reference Oscillator Warp Window..................................................................................5-3

Figure 5-4. Modulation Balance Window ............................................................................................5-4

Figure 5-5. Transmit Power Window (High Power).............................................................................5-5

Figure 5-6. VCO Attenuation Window (12.5 kHz)...............................................................................5-7

Figure 5-7. DTMF Deviation Tuning Window............. ... ... .... ... ... ... .... ..................................................5-9

Figure 5-8. MDC-1200 Deviation Tuning Window ............................................................................5-10

Figure 5-9. Rated Volume Tuning Window................ ... ... .... ... ... ... ....................................... ... ... .... ...5 -11

Figure 5-10. Squelch Tuning Window............. ... ... .... ... ....................................... ... ... ... .......................5-12

Figure 5-11. RSSI Tuning..... ... .... ... ....................................... ... ... ... .... ..................................... ...........5-13

Figure 5-12. Side Button Locations.....................................................................................................5-15

Figure 6-1. Battery Removal............................ ... ....................................... ... .... ... ...............................6-3

Figure 6-2. Antenna and Knob Removal. ... ... ....................................... ... ... ... ......................................6-4

Figure 6-3. Chassis Removal........... ... ....................................... ... .... ... ...............................................6-4

Figure 6-4. Keyboard Flex Connection ...............................................................................................6-5

Figure 6-5. Microphone and Speaker Connection s .......................................... ... ...............................6-5

Figure 6-6. Dust Cover Disassembly ................................................... ... ... ... .... ... ...............................6-6

Figure 6-7. Removal Speaker-Microphone Assembly .. ... .... ... ... ....................................... ... ... ... .... ... ..6- 6

Figure 6-8. Keypad Removal ........................................................ .... ... ... ... .........................................6-7

Figure 6-9. PTT Removal.................... .... ... ... ... ....................................... ... ... .... ... ... ............................6-8

Figure 6-10. Removal of Main Board from Chassis.................................................. ... .... ... ... ...............6-8

Figure 6-11. Dust Cap Re-assembly.. ... .... ... ....................................... ... ...................................... .........6-9

Figure 6-12. Microphone Re-assembly..... ...................................... .... ...................................... ... .... ...6-10

Figure 6-13. Speaker Re-assembly ............................................. ... .... ... ... ...................................... ....6-10

Figure 6-14. Keypad Re-assembly ................. ... ... ....................................... ... ....................................6-11

Figure 6-15. LCD/Keypad Board Re-assembly............................... ....................................... ... ... .... ...6 -1 1

Figure 6-16. Keyboard Retainer Re-assembly....................................................................................6-12

Figure 6-17. Main Board onto Chassis Re-assembly .........................................................................6-13

Figure 6-18. Microphone and Speaker Wires Re-assembly ...............................................................6-14

Figure 6-19. Keyboard Flex Cable Connection...................................................................................6-14

Figure 6-20. Fastening the Chassis................... ....................................... ... ... ....................................6-15

Figure 6-21. PTT Re-assembly....................... ....................................... ... ... ... .... ... .............................6-15

Figure 6-22. EP450 Full Keypad Radio Exploded View......................................................................6-16

Figure 7-1. Battery Removal............................ ... ....................................... ... .... ... ...............................7-3

Figure 7-2. Antenna and Knob Removal. ... ... ....................................... ... ... ... ......................................7-4

Figure 7-3. Chassis Removal........... ... ....................................... ... .... ... ...............................................7-4

Figure 7-4. Microphone and Speaker Connection s .......................................... ... ...............................7-5

Figure 7-5. Dust Cover Disassembly ................................................... ... ... ... .... ... ...............................7-5

Figure 7-6. Removal Speaker-Microphone Assembly .. ... .... ... ... ....................................... ... ... ... .... ... ..7- 6

Figure 7-7. PTT Removal.................... .... ... ... ... ....................................... ... ... .... ... ... ............................7-7

Figure 7-8. Removal of Main Board from Chassis............... ... ... ... ....................................... ... ... .... .....7-7

Figure 7-9. Dust Cap Re-assembly..... .... ...................................... .... ... ... ... .........................................7-8

Figure 7-10. Microphone Re-assembly..... ...................................... .... ...................................... ... .... .....7-8

December 3, 2003 HKLN4215A

Table of Contents vii

Figure 7-11. Speaker Re-assembly...................................................................................................... 7-9

Figure 7-12. Installation of Main Board onto Chassis.........................................................................7-10

Figure 7-13. Microphone and Speaker Wires Re-assembly...............................................................7-11

Figure 7-14. Fastening the Chassis.................................................................................................... 7-11

Figure 7-15. PTT Re-assembly........................................................................................................... 7-12

Figure 7-16. EP450 Non-Display Radio Exploded View.....................................................................7-13

HKLN4215A December 3, 2003

viii Table of Contents

List of Tables

Table 1-1. Radio Model Number (Example: LAH65KDC9AA2AN)....................................................1-1

Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications.....................1-8

Table 3-1. Recommended Test Equipment.......................................................................................3-1

Table 3-2. Service Aids......................................................................................................................3-2

Table 3-3. Recommended Service Tools ..........................................................................................3-2

Table 4-1. Initial Equipment Control Settings ....................................................................................4-2

Table 4-2. Test Environments............................................................................................................4-3

Table 4-3. Test Channel Spacing ......................................................................................................4-3

Table 4-4. Test Frequencies..............................................................................................................4-4

Table 4-5. Receiver Performance Checks.........................................................................................4-4

Table 4-6. Transmitter Performance Checks.....................................................................................4-5

Table 5-1. Initial Equipment Control Settings ....................................................................................5-3

Table 5-2. Reference Oscillator Specifications..................................................................................5-4

Table 5-3. Transmit High/Low Power Level.......................................................................................5-6

Table 5-4. Deviation Specifications ..................................................................................................5-8

Table 5-5. Squelch Deviation Values...............................................................................................5-12

Table 8-1. Power-Up Error Code Display ..........................................................................................8-1

Table 8-2. Operational Error Code Display........................................................................................8-1

Table 8-3. Receiver Troubleshooting Table.......................................................................................8-2

Table 8-4. Transmitter Troubleshooting Table...................................................................................8-3

Related Publications

E-Series Detailed Service Manual........................................................................HKLN4216

E-Series Interactive User CD ............... ... ... ... .... ...................................... .... ... ... ...HKLN4212

December 3, 2003 HKLN4215A

Chapter 1 Model Charts and Test Specifications

H = Portable

1.1 Radio Model Information

The model number and serial number are locate d on a label attached to the back of your radio. You can determine the RF output power , frequency ban d, protocols , and ph ysica l pac kages . The example below shows one portable radio model number and its specific characteristics.

Table 1-1. Radio Model Number (Example: LAH65KDC9AA2AN)

Type of

Unit

LA H 65 K

LA = Motorola Internal Use

Model Series

Freq. Band

VHF

(146-174

MHz)

(403-440

MHz)

UHF

(438-470

MHz)

UHF

(465-495

MHz)

Power

Level

4 W or

5 W

Physical

Packages

Non

Display

Full

Display

Channel Spacing

Pro-

gramma-

ble

Protocol

Conven-

tional

Feature

Level

16 CH

64 CH

Model

Revision

Model

Package

1-2 Model Charts and Test Specifications: Model Chart for VHF 146-174 MHz

1.2 Model Chart for VHF 146-174 MHz EP450, VHF, 146-174 MHz

Model Description

LAH65KDC9AA2AN EP450, 146-174 MHz, 5 W, 16 Ch. Non-Display Model

LAH65KDH9AA4AN EP450, 146-174 MHz, 5 W, 64 Ch. Display Model

Item Description

X PMUD1857_ EP450, 146-174 MHz, 5 W, 16 Ch. Non-Display Model

X PMUD1859_ EP450, 146-174 MHz, 5 W, 64 Ch. Display Model X X PMLD4222_ EP450, Back Cover Kit. 146-174 MHz X PMLN4601_ Non-Display, Front Housing Kit, 16 Ch.

X PMLN4603_ Full Display, Front Housing Kit, 64 Ch. X X NNTN4496_R Ni-Cd Battery, 1100 mAH X X NNTN4497_R Li-Ion Battery, 1800 mAH X X NNTN4851_ NiMH Battery, 1400 mAH X X NNTN4970 Slim Li-Ion Battery, 1600 mAH X X WPLN4138_R Rapid 90-Min. Desktop Charger w/US Plug X X WPLN4139_R Rapid 90-Min. Desktop Charger w/Euro Plug X X WPLN4142_R Rapid 90-Min. Desktop Charger w/Argentina Plug X X WPLN4140_R Rapid 90-Min. Desktop Charger w/UK Plug X X RLN5644

X X NAD6502_R Antenna, 146-174 MHz, 14cm X X HKLN4212 E-Series Interactive User CD X = Indicates compatibility with model(s)

" Belt Clip

2.5

December 3, 2003 HKLN4215A

VHF Test Specifications 1-3

1.3 VHF Test Specifications

General

VHF

Channel Capacity: 16 or 64 Channels Power Supply: 7.5 Volts ±20% Dimensions (HxWxD)

with Battery: High Capacity Li-Ion

Weight: with Battery:

High Capacity Li-Ion 397g (14.0 oz.)

Average Battery Life @ (5-5-90* Duty Cycle): High Capacity Li-Ion

Model Number: LAH65KDC9AA2_N,

Frequency Range: 146-174 MHz Channel Spacing: 12.5/20/25 kHz Temper at ur e Ran g e: -30° to 60°C Frequency Stability: ±2.5 ppm

130.5mm x 62mm x 45mm

" x 2.44" x 1.77")

(5.12

17 hr low power/ 12 hr high power

LAH65KDH9AA4_N

T ransmitter

VHF

RF Output Li-Ion @ 7.5 V:

Frequency: 146-174 MHz Channel Spacing: 12.5/20/25 kHz Spurious/Harmonics: -36 dBm < 1 GHz

FM Noise: -40 dB (12.5 kHz)

Modulation Limitation: ±2.5 kHz @ 12.5 kHz/

Audio Response: (from 6 dB/oct. Pre-emphasis, 300 to 3000 Hz)

Audio Distortion: @ 1000 Hz, 60% Rated Max. Dev.

Low 1 W

-30 dBm > 1 GHz

-45 dB (25 kHz)

±5 kHz @ 25 kHz +1 to -3 dB

High 5 W

FCC ABZ99FT3045

*5% receive; 5% transmit; 90% standby.

Receiver

VHF

12.5 kHz

Channel Spacing: 12.5/20/25 kHz Sensitivity

12 dB EIA SINAD: Adjacent Channel

Selectivity: Intermodulation: -70 dB Freq. Stability

(-30° C to +60° C): Spur Rejection: -75 dB Image and 1/2 I-F

Rejection: Audio Output

@ <5% Distortion:

0.25 µV (typical)

-60 dB -70 dB

0.00025%

-70 dB

500 mW into 24

VHF

25kHz

Ω

Specifications subject to change without notice. All electrical specifications and methods refer to EIA/TIA 603 standards.

1-4 Model Charts and Test Specifications: Model Chart for UHF 403-440 MHz

1.4 Model Chart for UHF 403-440 MHz EP450, UHF, 403-440 MHz

Model Description

LAH65QDC9AA2AN EP450, 403-440 MHz, 4 W, 16 Ch. Non-Display Model

LAH65QDH9AA4AN EP450, 403-440 MHz, 4 W, 64 Ch. Display Model

Item Description

X PMUE1972_ EP450, 403-440 MHz, 4 W, 16 Ch. Non-Display Model

X PMUE1974_ EP450, 403-440 MHz, 4 W, 64 Ch. Display Model X X PMLE4288_ EP450, Back Cover Kit. 403-440 MHz X PMLN4601_ Non-Keypad, Front Housing Kit, 16 Ch.

X PMLN4603_ Full Keypad, Front Housing Kit, 64 Ch. X X NNTN4496_R Ni-Cd Battery, 1100 mAH X X NNTN4497_R Li-Ion Battery, 1800 mAH X X NNTN4851_ NiMH Battery, 1400 mAH X X NNTN4970 Slim Li-Ion Battery, 1600 mAH X X WPLN4138_R Rapid 90-Min. Desktop Charger w/US Plug X X WPLN4139_R Rapid 90-Min. Desktop Charger w/Euro Plug X X WPLN4142_R Rapid 90-Min. Desktop Charger w/Argentina Plug X X WPLN4140_R Rapid 90-Min. Desktop Charger w/UK Plug X X RLN5644 2.5” Belt Clip X X NAE6483_R Antenna, 403-520 MHz, Whip X X HKLN4212 E-Series Interactive User CD X = Indicates compatibility with model(s)

December 3, 2003 HKLN4215A

Model Charts and Test Specifications: Model Chart for UHF 438-470 MHz 1-5

1.5 Model Chart for UHF 438-470 MHz

EP450, UHF, 438-470 MHz

Model Description

LAH65RDC9AA2AN EP450, 438-470 MHz, 4 W, 16 Ch. Non-Display Model

LAH65RDH9AA4AN EP450, 438-470 MHz, 4 W, 64 Ch. Display Model

Item Description

X PMUE1966_ EP450, 438-470 MHz, 4 W, 16 Ch. Non-Display Model

X PMUE1968_ EP450, 438-470 MHz, 4 W, 64 Ch. Display Model X X PMLE4283_ EP450, Back Cover Kit. 438-470 MHz X PMLN4601_ Non-Display, Front Housing Kit, 16 Ch.

X PMLN4603_ Display, Front Housing Kit, 64 Ch. X X NNTN4496_R Ni-Cd Battery, 1100 mAH X X NNTN4497_R Li-Ion Battery, 1800 mAH X X NNTN4851_ NiMH Battery, 1400 mAH X X NNTN4970 Slim Li-Ion Battery, 1600 mAH X X WP LN4 1 38 _ R Rapid 90-Min. Deskto p Char ge r w/US Plug X X WPLN4139_R Rapid 90-Min. Desktop Charger w/Eur o Pl ug X X WP LN4 1 42 _ R Rapid 90-Min. Desktop Charge r w/Ar g en tin a Plug X X WPLN4140_R Rapid 90-Min. Desktop Charger w/UK Plug X X RLN5644

X X NAE6483_R Antenna, 403-520 MHz, Whip X X HKLN4212 E-Series Interactive User CD X = Indicates compatibility with model(s)

" Belt Clip

2.5

HKLN4215A December 3, 2003

1-6 Model Charts and Test Specifications: Model Chart for UHF 465-495 MHz

1.6 Model Chart for UHF 465-495 MHz EP450, UHF, 465-495 MHz

Model Description

LAH65SDC9AA2AN EP450, 465-495 MHz, 4 W, 16 Ch. Non-Display Model

LAH65SDH9AA4AN EP450, 465-495 MHz, 4 W, 64 Ch. Display Model

Item Description

X PMUE1978_ EP450, 465-495 MHz, 4 W, 16 Ch. Non-Display Model

X PMUE1980_ EP450, 465-495 MHz, 4 W, 64 Ch. Display Model X X PMLE4284_ EP450, Back Cover Kit. 465-495 MHz (1/4W) X PMLN4601_ Non-Display, Front Housing Kit, 16 Ch.

X PMLN4603_ Display, Front Housing Kit, 64 Ch. X X NNTN4496_R Ni-Cd Battery, 1100 mAH X X NNTN4497_R Li-Ion Battery, 1800 mAH X X NNTN4851_ NiMH Battery, 1400 mAH X X NNTN4970 Slim Li-Ion Battery, 1600 mAH X X WPLN4138_R Rapid 90-Min. Desktop Charger w/US Plug X X WPLN4139_R Rapid 90-Min. Desktop Charger w/Euro Plug X X WPLN4142_R Rapid 90-Min. Desktop Charger w/Argentina Plug X X WPLN4140_R Rapid 90-Min. Desktop Charger w/UK Plug X X RLN5644 2.5” Belt Clip X X NAE6483_R Antenna, 403-520 MHz, Whip X X HKLN4212 E-Series Interactive User CD X = Indicates compatibility with model(s)

December 3, 2003 HKLN4215A

UHF Test Specifications 1-7

1.7 UHF Test Specifications

General

UHF

Channel Capacity: 16 or 64 Channels Power Supply: 7.5 Volts ±20% Dimensions (HxWxD)

with Battery: High Capacity Li-Ion

Weight: with Battery:

High Capacity Li-Ion 397g (14.0 oz.)

Average Battery Life @ (5-5-90* Duty Cycle): High Capacity Li-Ion

Model Numbers: LAH65QDC9AA2_N

Modulation Limitation: ±2.5 kHz @ 12.5 kHz/

Channel Spacing: 12.5/20/25 kHz Temperature Range: -30° to 60°C Frequency Stability: ±2.5 ppm FCC ABZ99FT4057 403-440MHz

*5% receive; 5% transmit; 90% standby.

130.5mm x 62mm x 45mm

" x 2.44" x 1.77")

(5.12

17 hr low power/ 12 hr high power

LAH65QDH9AA4_N LAH65RDC9AA2_N LAH65RDH9AA4_N LAH65SDC9AA2_N LAH65SDH9AA4_N

±5 kHz @ 25 kHz

ABZ99FT4056 438-470MHz ABZ99FT4058 465-495MHz

T ransmitter

UHF

RF Output Li-Ion @ 7.5 V:

Frequency: 403-440 MHz

Channel Spacing: 12.5/20/25 kHz Freq. Stability:

(-30° C to +60° C) Spurious/Harmonics: -36 dBm < 1 GHz

FM Noise: -40 dB (12.5 kHz)

Audio Response: (from 6 dB/oct. Preemphasis, 300 to 3000 Hz)

Audio Distortion: @ 1000 Hz, 60% Rated Max. Dev.

Low 1 W

438-470 MHz 465-495 MHz

0.00025%

-30 dBm > 1 GHz

-45 dB (25 kHz) +1 to -3 dB

<3%

High 4 W

Receiver

UHF

12.5 kHz

Channel Spacing: 12.5/20/25 kHz Frequency: 403-440 MHz

438-470 MHz 465-495 MHz

UHF

25kHz

Sensitivity 12 dB EIA SINAD:

Adjacent Channel Selectivity:

Intermodulation: -70 dB Freq. Stability

(-30° C to +60° C): Spur Rejection: -75 dB Image and 1/2 I-F

Rejection: Audio Output

@ <5% Distortion:

Specifications subject to change without notice. All electrical specifications and methods refer to EIA/TIA 603 standards.

0.25 µV (typical)

-60 dB -70 dB

0.00025%

-70 dB

500 mW into 24Ω

1-8 Model Charts and Test Specifications: MIL Standards

1.8 MIL Standards

Table 1-2. MIL STDS 810 C, D, E, and F: Applicable to UHF and VHF Specifications (8.2 and 8.4)

Military S tandards 810 C, D, E, & F: Parameters/Methods/Procedures

810C 810D 810E 810F

Applicable

MIL-STD

Low Pressure

High Temperature

Low Temperature

Temperature Shock

Solar Radiation

Rain 506.1 1,2 506.2 1,2 506.3 1,2 506.4 1 Humidity 507.1 2 507.2 2,3 507.3 2,3 507.4 3 Salt Fog 509.1 1 509.2 1 509.3 1 509.4 1 Dust 510.1 1 510.2 1 510.3 1 510.4 1 Vibration 514.2 8,10 514.3 1 514.4 1 514.5 1 Shock 516.2 1,2,5 516.3 1,4 516.4 1,4 516.5 1

Methods Procedures Methods Procedures Methods Procedures Methods Procedures

500.1 1 500.2 2 500.3 2 500.4 1

501.1 1,2 501.2 1,2 501.3 1,2 501.4 1,2

502.1 1 502.2 1,2 502.3 1,2 502.4 1,2

503.1 1 503.2 1 503.3 1 503.4 1

505.1 1 505.2 1 505.3 1 505.4 1

December 3, 2003 HKLN4215A

Chapter 2 Theory Of Operation

2.1 Introduction

This chapter provides a basic theory of operation for the radio components.

2.2 Major Assemblies

• Transceiver Board – contains all transmit, receive, and audio circuitry.

• Display (Display models only) – 8 characters (14 segments star burst) and 10 icons with backlighting, liquid-crystal display (LCD).

Keypad Board (Display models only) – Display model: a 2-button menu keypad with 2-way navigation button, and a 3 x 4 alphan umeric keypad.

Transceiver Board (Figure 2-1).

ntenna

Battery

Spkr

M140

Transceiver

Board

J301

J491

Figure 2-1. Major Assemblies Block Diagram

J460

J470

Mic

Keypad

Board

Display

2.2.1 Receiver

Incoming RF signals from the antenna are first routed through the harmonic filter and antenna switch, part of the transmitter circuitry, before being applied to the receiver front end. The receiver front end consists of a preselector filter, RF amplifier, interstage filter, and a double-balanced first mixer (Figure 2-2).

The mixer output is applied to a diplexer network which matches the 44.85 MHz IF signal to the crystal filter, and terminates the mixer into 50 ohms at all other frequencies.

The receiver back-end is a dual conversion design. High IF selectivity is provided by a 4-pole fundamental mode 44.85 MHz crystal filter. The output is matched to an IF amplifier stage. The output of the IF amplifier is applied to the input of the receiver IFIC.

2-2 Theory Of Operation: Major Assemblies

The IFIC is a low-voltage monolithic FM IF system incorporating a mixer/oscillator, two limiting IF amplifiers, quadrature detector, logarithmic received signal strength indicator (RSSI), voltage regulator and audio , and RSSI O p Amps. The secon d LO frequency, 44.395 MHz, is determined by a crystal oscillator. The second mixer converts the 44.85 MHz high IF frequency to 455 kHz.

Additional IF selectivity is provided by two ceramic filters. The first ceramic filter is a 4-pole filter used between the second mixer and IF amp. The second ceramic filter is a 6-pole filter and is used between the IF amp and the limiter input. F or the second cer amic filter, a wider filter is used for 20/25 kHz channel spacing, and a narrower filter is used for 12.5 kHz channels.

A ceramic resonator provides ph ases vs. frequency characteristic required by the quadrature detector , with 90 degree phase shift occurring at 455 kHz. The output of the IFIC is the recovered audio signal which is fed to the audio IC for amplification and signal conditioning. The outpu t of the audio IC is injecting into the audio PA which drives the 24 Ohm speaker.

2.2.2 Transmitter

• When the radio is transmitting, microphone audio is passed through the audio IC, where preemphasis and low-pass (splatter) filtering are done. The output of the aud io IC is used to modulate the TX VCO, which creates the modulated carr ie r. The modulated carrier is then amplified by the pre-driver and power amplifier circuit, which transmits the signal under dynamic power control

Audio PA

Spkr

Mic

Recovered Audio

Ceramic

Resonator

SSI

Ref. Osc.

Frac N

Mod

Audio IC

Demodulator

BW_SEL

Switching

IF IC

Loop Filter

Cer Fltr

Tx VCO

Circuit

Rx VCO

Circuit

VCOBIC

IF Amp

Tx Out

Rx Out

Crystal

Filter

Predriver

Mixer

Module

Power

Cntr

Image

Filter

T/R

Switch

Filter

Preselector

LNA

Harmoni

Filter

Figure 2-2. Transceiver Block Diagram

December 3, 2003 HKLN4215A

Chapter 3 Test Equipment, Service Aids, and

Service Tools

3.1 Test Equipment

Table 3-1 lists test equipment required to service the EP450 Radios.

Table 3-1. Recommended Test Equipment

Motorola Part No. Description Characteristics Application

R2600 series System analyzer This item will substitute for

items with an asterisk (*)

*R1074 Fluke 87 digital multi-

meter

Fluke 85 RF probe 500 MHz, 30 VAC max Use with Fluke 87 digital multi-

*R1377 AC voltmeter 1 mV to 300 mV, 10 mega-

R1611 Dual channel

100 MHz oscilloscope (Agillent)

S1339 RF millivolt meter 100 µV to 3V RF, 10 kHz to

*R1013 or *R1370

SINAD meter or SINAD meter with

RMS

True RMS metering, 200 kHz frequency counter, 32-segment bar graph with backlit display

ohm input impedance Two-channel, 100 MHz

bandwidth, 200 M sample rate/sec, 2 MB memory/ channel

1 GHz frequency range Without RMS audio volt-

meter or With RMS audio voltmeter

Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment

Digital voltmeter is recommended for AC/DC voltage and current measurements

meter for RF voltage measurements.

Audio voltage measurements

Waveform measurements

RF level measurements

Receiver sensitivity measurements

3-2 Test Equipment, Service Aids, and Service Tools: Service Aids

3.2 Service Aids

Table 3-2 lists service aids recommended for working on the EP450 Radios. 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.

Table 3-2. Service Aids

Motorola Part

No.

RLN4460 Portable Test Set Enables connection to the audio/accessory jack.

RLN4510 Battery Interface Regulates DC current and voltage between radio and

RVN4195 Customer Programming Soft-

ware and Tuner Software on

CD ROM AAPMKN4004 Programming Test Cable Connects radio to RIB (RLN4008). AAPMKN4003 Radio to Radio Cloning Cable

RLN4008 Radio Interface Box Enables communications between the radio and the

5886564Z01 RF Adaptor Adapts radio’s antenna port to BNC cabling of test

0180305K08 Shop Battery Eliminator Interconnects radio to power supply. HSN9412 Wall-Mounted Power Supply Used to supply power to the RIB (120 VAC).

Description Application

Allows switching for radio testing.

power supply. Program customer option and channel data.

Allows a radio to be duplicated from a master radio by transferring programmed data from the master radio to the other.

computer’s serial communications adapter.

equipment.

3080369B71 or 3080369B72

6686533Z01 Knob Remover/Chassis Opener Used to remove the front cover assembly. HKN9216 IBM Computer Interface Cable Connection from computer to RIB. 8180384N65 Housing Eliminator Allows testing of the radio outside of the housing. RLN5583 Flashing Adapter Flashing/CPS cable for authorized service centers.

Motorola Part

No.

RSX4043 TORX screwdriver Tighten and remove chassis screws 6680387A70 T6 TORX bit Removable TORX screwdriver bit R1453 Digital readout solder station Digitally controlled soldering iron RLN4062 Hot air workstation, 120 V Tool for hot air soldering/desoldering of surface

Computer Interface Cable Use B72 for the IBM PC AT or newer (9-pin serial

port). Use B71 for older models (25-pin serial port) . Connects the computer’s serial communications adapter to the RIB (PLN4008).

Table 3-3. Recommended Service Tool s

Description Application

mounted integrated circuits

December 3, 2003 HKLN4215A

Test Equipment, Service Aids, and Service Tools: Service Aids 3-3

Table 3-3. Recommended Service Tools (Continued)

Motorola Part

No.

Description Application

0180386A78 Illuminated magnifying glass with

lens attachment

Illumination and magnification of components

0180302E51 Master lens system 0180386A82 Anti-static grounding kit Used during all radio assembly and disassembly pro-

cedures 6684253C72 Straight prober 6680384A98 Brush 1010041A86 Solder (RMA type), 63/67,

0.5mm diameter, 1 lb. spool

0180303E45 SMD tool kit (included with

R1319A) R1319 ChipMaster (110 V) Surface mount removal and assembly of surface R1321 ChipMaster (220 V)

mounted integrated circuits and/or rework station

shields. Includes 5 nozzles. ChipMaster Nozzles: 6680332E83 PLCC-28* nozzle 6680332E82 PLCC-44* nozzle 6680332E94 PLCC-52 nozzle 6680332E96 PLCC-84 nozzle 6680334E67 QFP-160 nozzle 6680333E46 SOL-18 nozzle 6680332E84 SOIC-20 nozzle 6680332E87 SOL-20J nozzle 6680333E45 SOL-24 nozzle 6680333E55 TSOP-64 nozzle

* Included with ChipMaster packages

Soldering and Un-soldering IC’s

HKLN4215A December 3, 2003

3-4 Test Equipment, Service Aids, and Service Tools: Service Aids

Programming/Test Cable

3.5mm mono

2.5mm stereo

Figure 3-1. Programming/Test Cable

2.5mm stereo and

3.5mm

3.5mm Tip (Speaker +)

3.5mm Sleeve

2.5mm Tip (Microphone)

2.5mm

2.5mm Center

25 POSITION

MALE CONNECTOR

P2 P3

36.0”

CABLE

Orange

Blue

White

25 POSITION

FEMALE CONNECTOR

36.0”

CABLE

ohm

1UF,16V 5%

Spiral

Yellow

25 pin Male D Connector

Components molded inside

1 5

24 7

33K

20 8

15 16 9

25 pin Female

D Connector

1 15

4 11

To Test Box

Figure 3-2. Wiring of the Connectors

December 3, 2003 HKLN4215A

Chapter 4 Performance Checks

4.1 General

These radios meet published specifications through their manufacturing process by utilizing highaccuracy laboratory-quality test equipment. The recom mended field service equipment is as accur ate as the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacture r’s recommended calibration schedule.

Power Supply

Power Cable

RLN5410

Battery Eliminator

Radio

RF Adaptor 5886564Z01

Program/

Test Cable

AAPMKN4004

BNC

Test Box

RLN4460

RIB

RLN4008

30 dB Pad

Transmit

30 dB Pad

RF Generator

Receive

Audio In

Computer Interface Cable

Tx Data

Rx Data

Gnd

Service Monitor or

Counter

Wattmeter

Audio Gener ator

Sinad Meter

AC Voltmeter

4.2 Power-Up Self Test

Applying power to the r a dio by using the on/off v olume cont rol, starts a self-test routine which checks the RAM, EEPROM hardware and EEPROM checksum. Pressing and holding SB1 while turning on the radio causes the self-test routine to check for the ROM checksum as well. If these checks are successfully completed, the radio will generate the Self-Test Pass Tone. If the self-test is not successful, a Self-Test Fail Tone is heard.

RIB Power Supply

Figure 4-1. Radio Tuning Setup

4-2 Performance Checks: RF Test Mode

Supply voltage can be connected from the battery eliminator. The equipment required for alignment procedures is connected as shown in the Radio Performance Checks Setup diagram (Figure 4-1).

Initial equipment control settings should be as indicated in Table 4-1 and should be the same for all performance checks and tuner alignment procedures.

Table 4-1. Initial Equipment Control Settings

Service Monitor Test Set Power Supply

Monitor Mode: Power Monitor Spkr set: C Voltage: 7.5 Vdc RF Attenuation: -70 Spkr/load:

AM, CW, FM: FM PTT: OFF Volt Range: 10 V Oscilloscope Source: Mod

Oscilloscope Horiz: 1 0 mSec/Div Oscilloscope Vert: 2.5kHz/Div Oscilloscope Trig: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: mid CW Monitor Vol: 1/4 CW

4.3 RF Test Mode

When the EP450 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer code plug configuration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment using a special routine, called RF TEST MODE. This mode allows bench testing of the radio at various test frequencies across the entire band, at both high and low transmit power (if applicable), at various channel spacings, and with different coded or carrier squelch types. Any customer specific programming in the radio will not be changed or affected by use of the RF Test Mode.

Load

DC on/standby: Standby

Current: 2.5 A

Side Button 1

Side Button 2

Figure 4-2. Side Button Locations

December 3, 2003 HKLN4215A

Performance Checks: RF Test Mode 4-3

To enter test mode:

1. Turn the radio on . Within ten seconds after the self test is complete (self test tone is heard), press SB2 (Side Button 2 in

Figure 4-2) five times in succession. If the self test complete tone is not heard, see Error Codes

information in Chapter 8. Entry into the test mode is indicated by a positive indicator tone followed by a good key chirp (GKC). Upon entering test mode, the radio is in the carrier squelch mode.

2. Press SB1 (Side Button 1) and scroll through and access test environments as shown in

Table 4-2.

3. Press SB2 and scroll through the channel spacin g available as shown in Table 4-3.

4. T urn the channel selector knob to change the test chan nel f or that en vironment as sho wn in Table 4-4.

5. Press the PTT on a test channel to cause the radio to transmit at the test frequency for t he channel.

Table 4-2. Test Environments

No. of

Beeps

1 GKC*

1 BKC*

2 BKC

3 BKC

5 BKC

9 BKC

Description Function

Carrier Squelch RX: unsquelch if carrier detected

TX: mic audio

Tone Private-Line RX: unsquelch if carrier and tone (192.8 Hz) detected

TX: mic audio + tone (192.8 Hz)

Digital Private-Line RX: unsquelch if carrier and digital code (131) detected

TX: mic audio + digital code (131)

Dual-Tone Multiple Frequency

RX: unsquelch if carrier detected TX: selected DTMF tone pair

Unsquelch Open RX: constant unsquelch

TX: mic audio

High-Speed Signaling

RX: unsquelch if carrier detected TX: 1500 Hz tone

* “BKC” means Bad Key Chirp (low-pitched tone), “GKC” means Good Key Chir p (high-pitched only).

Table 4-3. Test Channel Spacing

No. of BKC Channel Spacing

1 25 kHz 2 12.5 kHz 3 20 kHz

HKLN4215A December 3, 2003

4-4 Performance Checks: RF Test Mode

Table 4-4. Test Frequencies

Channel Selector

Switch Position

1 Low Power 8 High Power

2 Low Power 9 High Power

3 Low Power 10 High Power

4 Low Power 11 High Power

5 Low Power 12 High Power

6 Low Power 13 High Power

7 Low Power 14 High Power

Test Channel

TX#1 or #8 RX#1 or #8

TX#2 or #9 RX#2 or #9

TX#3 or #10 RX#3 or #10

TX#4 or #11 RX#4 or #11

TX#5 or #12 RX#5 or #12

TX#6 or #13 RX#6 or #13

TX#7 or #14 RX#7 or #14

VHF R2

(MHz)

UHF R1

(MHz)

UHF R2

(MHz)

UHF R3

(MHz)

146.625 403.625 438.625 465.625

150.775 409.775 443.775 470.775

155.275 415.275 448.275 475.275

160.125 421.125 454.125 480.125

164.475 427.475 459.475 485.475

169.475 433.475 464.475 490.475

173.875 439.875 469.875 494.875

Table 4-5. Receiver Performance Checks

Test Name Communications Analyzer Radio Test Set Comments

Reference Frequency

Mode: PWR MON 4th channel test frequency

Monitor: Frequency error Input at RF In/Out

TEST MODE,

T est Channel 4 carrier squelch output at

PTT to continuous (during the performance check)

Frequency error to be ±200 Hz VHF ±500 Hz UHF

antenna

Rated Audio Mode: GEN

Output level: 1.0m V RF 4th channel test frequency

Mod: 1 kHz tone at

TEST MODE T est Channel 4

carrier squelch

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

Set volume control to

3.24Vrms

3 kHz deviation

Monitor: DVM: AC Volts Distortion As above, except to distortion As above As above Distortion <5.0% Sensitivity

(SINAD)

As above, except SINAD,

lower the RF level for 12 dB

As above PTT to OFF

(center)

RF input to be <0.30 µV (0.25 µV typical).

SINAD. Noise

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

RF level set to 1 mV RF As above PTT to OFF

(center), meter selection to Audio PA, spkr/ load to speaker

As above, except change fre-

quency to a conventional sys-

tem. Raise RF level from zero

until radio unsquelches.

out of TEST MODE; select a conventional system

As above Unsquelch to occur at

Set volume control to

3.24 Vrms

<0.25 µV. Preferred SINAD = 6-9 dB

*. See Table 4-4

December 3, 2003 HKLN4215A

Performance Checks: RF Test Mode 4-5

Table 4-6. Transmitter Performance Checks

Test Name Communications Analyzer Radio Test Set Comments

Reference Frequency

Power RF As above As above As above Refer to Maintenance

Voice Modulation

Voice Modulation (internal)

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 1 kHz Mod Out level for

0.025 Vrms at test set, 80m Vrms at AC/DC test set jack

Mode: PWR MON 4th channel test frequency

atten to -70, input to RF In/ Out

TEST MODE, T est Channel 4 carrier squelch Output at antenna

As above As above, meter

TEST MODE, T est Channel 4 carrier squelch Output at antenna

PTT to continuous (during the performance check)

selector to mic

Remove modulation input

Frequency error to be ±200 Hz VHF ±500 Hz UHF

Specifications Deviation:

VHF, UHF

≥ 4.0 kHz but ≤ 5.0 kHz

(25 kHz Ch Sp).

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

≥ 4.0 kHz but ≤ 5.0 kHz

(25 kHz Ch Sp)

DTMF Modulation

PL/DPL Modulation

*. See Table 4-4

As above, 4th channel test frequency

As above 4th channel test frequency

BW to narrow

TEST MODE,

T est Channel 4 DTMF Output at antenna

TEST MODE,

Test Channel 4 TPL DPL

As above Deviation:

VHF, UHF but

≤ 3.45 kHz

(25 kHz Ch Sp)

As above Deviation:

VHF, UHF but

≤ 1000 Hz

(25 kHz Ch Sp).

≥ 3.05 kHz

≥ 500Hz

HKLN4215A December 3, 2003

4-6 Performance Checks: RF Test Mode

Notes:

December 3, 2003 HKLN4215A

Chapter 5 Radio Alignment Procedures

5.1 Introduction

This chapter provides an ov erview of the Commercial Series Customer Prog ramming Softw are (CPS) and the Global Tuner as designed for use in a Windows® 98/NT4/2 000/ME/XP environment. Both cover all the functions of the traditional Radio Service Software (RSS) package.

They are both available in the CPS Tuner (CD ROM) Kit (RVN4195).

5.2 CPS Programming Setup

Refer to online help files for the CPS Programming procedures. (See Figure 5-1 for CPS Programming Setup).

Radio

Test Box

RLN4460

Battery

Program/

Test Cable

AAPMKN4004

Tx Data

RIB

RLN4008

RIB Power Supply

Computer Interface Cable

Rx Data

Gnd

Figure 5-1. CPS Programming Setup

5-2 Radio Alignment Procedures: Radio Tuning Setup

5.3 Radio Tuning Setup

A Windows 98/NT4/2000/ME/XP PC (personal co mputer) and Global Tuner are required to tune the radio. To perform the tuning procedures, the radio must be connected to the PC, RIB (Radio Interface Box) and Universal Test Set as shown in Figure 5-2 below. Refer to online help files for the tuning procedures.

Power Supply

Power Cable RLN5410

Battery Eliminator

Radio

RF Adaptor 5886564Z01

Program/

Test Cable

AAPMKN4004

BNC

Test Box

RLN4460

RIB

RLN4008

30 dB Pad

Transmit

30 dB Pad

RF Generator

Receive

Audio In

Computer Interface Cable

Tx Data

Rx Data

Gnd

Service Monitor or

Counter

Wattmeter

Audio Gener ator

Sinad Meter

AC Voltmeter

RIB Power Supply

Figure 5-2. Radio Tuning Setup

December 3, 2003 HKLN4215A

Radio Alignment Procedures: Transmitter Alignment Options 5-3

5.3.1 Initial Test Equipment Control Settings

The initial test equipment control settings are listed in Table 5-1.

Table 5-1. Initial Equipment Control Settings

Service Monitor Test Set Power Supply

Monitor Mode: Power Monitor Speaker set: A Voltage: 13.2 Vdc RF Attenuation: -70 Speaker/load:

AM, CW, FM: FM PTT: OFF Volt Range: 20 V Oscilloscope Source: Mod

Oscilloscope Horizontal: 10 mSec/Div Oscilloscope Vertical: 2.5 kHz/Div Oscilloscope Trigger: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: mid CW Monitor Volume: 1/4 CW

5.4 Transmitter Alignment Options

Note:

5.4.1 Reference Oscillator Warp

This is an important operation which aff ects all de viat ion v alues such as DT MF, MDC-1200 Signaling etc. The frequency will drift if not warped properly. Perform this operation pr ior to all other transmit tuning operations in order to minimize heating and because of the impact of warp on signaling

operations.

When checking the RF power output of the radio with a test set, always use a pad of at least 30 dB attached to the radio end of the RF cable. This will avoid an RF mismatch and ensure a stab le RF reading th at will not c hange with v arying lengths of connecting cable.

Speaker

DC on/standby: Standby

Current: 20 A

Figure 5-3. Reference Oscillator Warp Window

HKLN4215A December 3, 2003

5-4 Radio Alignment Procedures: Transmitter Alignment Options

1. Under Tx Align menu, select Reference Oscillator Warp (Figure 5-3).

2. There is only 1 frequency point shown which is always the last non-0 transmit frequency point,

which will normally be F7.

3. Click on the slider thumb and press PTT Toggle to key up the radio at the corresponding frequency point.

4. Monitor the transmit frequency.

5. Adjust the slider, spin or edit control (press ENTER to confirm selection/send a softpot value) until

the frequency is as close as possible to the indicated transmit frequency. (Refer to Table 5-2).

6. Dekey the radio by pressing PTT Toggle.

7. Program the warp value into the radio by pressing the Program button.

8. Exit the Reference Oscillator W arp function.

Table 5-2. Reference Oscillator Specifications

RF Band Target

VHF (146-174) ±174 Hz UHF Band 1 (403-440) ±440 Hz UHF Band 2 (438-470) ±470 Hz UHF Band 3 (465-495) ±495 Hz

5.4.2 Modulation Balance Attenuation

Note:

When using test box RLN4460:

• Inject the signal into the radio via the METER IN terminal and

• Set the METER IN selector switch to “VOL”.

• Inject the signal into the radio via the AUDIO IN terminal.

• Set the METER OUT toggle switch to the “MIC PORT” position

• Set the METER OUT selector switch to “MIC”.

Figure 5-4. Modulation Balance Window

December 3, 2003 HKLN4215A

Radio Alignment Procedures: Transmitter Alignment Options 5-5

Compensation alignment balances the modulation sensitivity of the VCO and reference modulation (synthesizer low frequency port) lines. The compensat ion algorithm is critical to the operation of signaling schemes that hav e v ery low frequency comp onents (Digit al Private -Line) and cou ld result in distorted waveforms if improperly adjusted. To perform Modulation Balance tuning, follow the following steps.

1. Under the Tx Align menu, select Mod Balance Attn (Figure 5-4).

2. Begin with the lowest fr equen cy ( i.e. the first frequency point from th e t op). Pre ssing PTT Toggle

without selecting any slider control at the corresponding frequency point will key the radio up at the first frequency point.

3. Inject 80 Hz at an amplitude of 1.78 V.

4. Record the deviation obtained. Typical values should range from [(1.70-2.30 kHz. Modulation is only tuned in the 25 kHz channel spacing mode.

5. Inject 3 kHz. Set the amplitude to 1.5 V.

6. Change the modulation balance attenuation setting until the Tx de via t ion is as recor ded in ste p 4 .

7. Inject 80 Hz at an amplitude of 1.78 V.

8. Check the deviation again. If the Tx deviation changes, record the reading and repeat steps 5-8

until the Tx deviation remains the same.

9. Press PTT Toggle to dekey the radio. Cho ose t he next frequency, key up and repeat steps 3 t o 8 until all seven tuning points are done.

10. Program the softpot valu e by pressing the Program button.

11. Exit the Modulation Balance Function.

5.4.3 Transmit Power Tuning

Note: The maximum available power level given in the table below must not be exceeded.

There are separate alignment procedures for High and Low power.

Note:

Figure 5-5. Transmit Power Window (High Power)

HKLN4215A December 3, 2003

5-6 Radio Alignment Procedures: Transmitter Alignment Options

Table 5-3. Transmit High/Low Power Level

RF Band (MHz) Model Number High Power(W) Low Power (W)

16 Channel VHF 146-174 H65KDC9AA2AN 5.2-5.5 1.1-1.3 64 Channel VHF 146-174 H65KDH9AA4AN 5.2-5.5 1.1-1.3 16 Channel UHF 1 403-440 H65QDC9AA2AN 4.2-4.5 1.1-1.3 64 Channel UHF 1 403-440 H65QDH9AA4AN 4.2-4.5 1.1-1.3 16 Channel UHF 2 438-470 H65RDC9AA2AN 4.2-4.5 1.1-1.3 64 Channel UHF 2 438-470 H65RDH9AA4AN 4.2-4.5 1.1-1.3 16 Channel UHF 3 465-495 H65SDC9AA2AN 4.2-4.5 1.1-1.3 64 Channel UHF 3 465-495 H65SDH9AA4AN 4.2-4.5 1.1-1.3

5.4.3.1 To Perform Transmit High Po wer Tuning, do the following:

1. Under the Tx Align menu, select Transmit Power, then select High (Figure 5-5).

2. Press PTT Toggle. This will key the radio up at 1st test frequency (F1).

3. Adjust the high power level to be as defined by Table 5-3. Move the slider/spin control or keying in values in the edit control (press ENTER to confirm your selection after typing in the softpot value).

4. Press PTT Toggle to dekey the radio, go to the next frequency point by selecting t he slider , typ ing

in the edit control box (press ENTER to confirm selection after ty ping in the softpot value) or toggling the softpot value using the spin control.

5. Press PTT Toggle again to key up the radio at the selected frequency point.

6. Repeat steps 3-5 for the remaining test frequencies (F2-7)

7. Press Program to store the softpot values into the radio’s codeplug.

8. Exit the Transmit High Power function.

9. If the radio uses only high power channels, proceed to adjust modulation. If low power channels

are used, perform Transmit Low Power Tuning as defined.

5.4.3.2 To Perform Transmit Low Power Tuning, do the follow ing: -

1. Under the Tx Align menu, select Transmit Power, and then select Low.

2. Press PTT Toggle. This will key the radio up at 1st test frequency (F1).

3. Adjust the power level to be as defined by country power level s p ecifications by moving the

slider/spin control or keying in values in the edit control (press ENTER to confirm your selection after typing in the softpot value).

4. Press PTT Toggle to dekey the radio, go to the next frequency point by selecting t he slider , typ ing in the edit control box (press ENTER to con firm your selection ) or toggling t he softpo t v alue u sing the spin control.

5. Press PTT Toggle again to key up the radio at the selected frequency point.

6. Repeat steps 3-5 for the remaining test frequencies (F2-F7).

7. Press Program to store the softpot values into the radio’s codeplug.

8. Exit the Transmit Low Power function.

December 3, 2003 HKLN4215A

Radio Alignment Procedures: Transmitter Alignment Options 5-7

5.4.4 VCO Attenuation

Note:

Modulation Balance Tuning must be done first. The Transmit Deviation Limit softpot sets the maximum deviation of the carrier. Tuning is performed for all (12.5 kHz, 20 kHz and 25 kHz) channel bandwidths. Tuning for 25 kHz channels must be done first for all frequency points. Tuning for 12.5 and 20 kHz channels determines only the offset to the previously tuned de viation f or 25 kHz tuning c hannel spacing. For 12.5, and 20kHz channels, only the last non-0 transmit frequency point (normally F7) is used for tuning. The 30 kHz channel bandwidths that use 5.0 kHz maximum system deviation are covered by the 25 kHz tuning.

When using test box RLN4460:

• Set the METER OUT toggle switch to the “MIC PORT” position

• Set the METER OUT selector switch to “MIC”.

• Inject a 1 kHz tone with the levels given below for each radio model to AUDIO IN.

• Measure the level at the radio input at the AC/DC meter.

Figure 5-6. VCO Attenuation Window (12. 5 kHz)

5.4.4.1 VCO Attenuation 25 kHz

1. Under the Tx Align menu, select VCO Attenuation 25 kHz (Figure 5-6).

2. Begin with the lowest frequency. Select the thumb of the slider at the lowest frequency point and

then press the PTT Toggle button to key up the radio at the corresponding frequency point. The spin control can also be toggled via its up/down arrow buttons. The softpot value can also be typed into the edit control (press ENTER to confirm your selection/send a softpot value).

3. Inject 1 kHz at an appropriate level until 2.3 V rms is measured at the AC/DC METER (radio input) if using test box RLN4460.

4. Record the deviation obtained.

5. Adjust the slider; adjust the spin control or key in softpot values (press ENTER to confirm) for the frequency point until the deviation is within the range specified in Table 5-4.

6. Dekey the radio (Press the PTT Toggle button). Choose the next fr equency, key up and repeat

steps 3 to 6 until all seven tuning points are done.

HKLN4215A December 3, 2003

5-8 Radio Alignment Procedures: Transmitter Alignment Options

7. Program the softpot value by pressing the Program button.

8. Exit the VCO Attn. 25 kHz function.

5.4.4.2 VCO Attenuation 12.5 kHz

Note:

1. Under the Tx Align menu, select VCO Attenuation 12.5 kHz.

2. Press PTT Toggle to key up the radio at the last non-0 transmit frequency point (normally F7).

3. Inject 1 kHz at an appropriate level until 2.3 V rms is measured at the AC/DC METER (radio

4. Record the deviation obtained.

5. Adjust the slider, adjust the spin control or key in softpot values (press ENTER to confirm) for the

6. Press PTT Toggle to dekey the radio.

7. Program the softpot value by pressing the Program button.

8. Exit the VCO Attenuation 12.5 kHz function.

Tuning of Modulation Balance Attenuation and VCO Attenuation for 25 kHz channel bandwidth must be done first.

input) if using test box RLN4460.

frequency point until the deviation is within the range specified in Table 5-4.

5.4.4.3 VCO Attenuation 20 kHz

Note:

1. Under the Tx Align menu, select VCO Attenuation 20 kHz.

2. Press PTT Toggle to key up the radio at the last non-0 transmit frequency point (normally F7).

3. Inject 1 kHz: at an appropriate level until 2.3V rms is measured at the AC/DC METER (radio

4. Record the deviation obtained.

5. Adjust the slider; adjust the spin control or key in softpot values (press ENTER to confirm) for the

6. Press PTT Toggle to dekey the radio.

7. Program the softpot value by pressing the Program button.

8. Exit the VCO Attn. 20 kHz function.

Tuning of Modulation Balance Attn. and VCO Attn. for 25 kHz channel bandwidth must be done first.

input) if using test box RLN4460.

frequency point until the deviation is within the range specified in Table 5-4.

Table 5-4. Deviation Specifications

Band Channel Spacing Deviation (kHz)

UHF/VHF 25 kHz 4.40 - 4.60 UHF/VHF 12.5 kHz 2.20 - 2.30 UHF/VHF 20 kHz 3.40 - 3.60

December 3, 2003 HKLN4215A

Radio Alignment Procedures: Transmitter Alignment Options 5-9

5.4.5 DTMF Deviation Tuning

This tuning option controls the Dual Tone Multi-Frequency deviation. Please note that Modulation Balancing and VCO Attenuation have to be performed prior to this tuning operation. Not doing so will result in the wrong deviation value being obtained while tuning the DTMF.

Figure 5-7. DTMF Deviation Tuning Window

1. Under Tx Align, select DTMF Deviation (Figure 5-7).

2. Press PTT Toggle to key the radio. Monitor the deviation obtained.

3. Adjust the slider, spin or edit control (press ENTER to confirm your selection /send a softpot v alue) until a deviation of 3.1-3.4 kHz is obtained.

4. Press PTT Toggle again to dekey the radio.

5. Program the softpot value into the radio by pressing Program.

6. Exit the DTMF Deviation function.

HKLN4215A December 3, 2003

5-10 Radio Alignment Procedures: Receiver Tuning

5.4.6 MDC-1200 Deviation Tuning

This tuning option controls the MDC-1200 Signaling de viation. Please note that Mo dulation Bala ncing and VCO Attenuation have to be performed prior to this tuning operation. Not doing so will result in the wrong deviation value being obtained while tuning this feature.

Figure 5-8. MDC-1200 Deviation Tuning Window

1. Under the Tx Align, select MDC-1200 Signaling (Figure 5-8).

2. Press PTT Toggle to key the radio up. Monitor the deviation obtained.

3. Adjust the slider, spin or edit control (press ENTER to confirm the selection/send a softpot value) until a deviation of 3.3-3.7 kHz is obtained.

4. Press PTT Toggle again to dekey the radio.

5. Program the softpot value into the radio by pressing the Program.

6. Exit the MDC-1200 Deviation fu nction.

5.5 Receiver Tuning

The following sub-sections contain the procedures to tune the radio r eceiver. These procedures include:

• Rated Volume

• Squelch Tuning Front End Filter Tuning

December 3, 2003 HKLN4215A

Radio Alignment Procedures: Receiver Tuning 5-11

5.5.1 Rated Volume Tuning

Note:

When using test box RLN4460, the received audio output is taken from the AC/DC METER OUT terminals with the METER OUT rotary switch set to RX. The rated audio tuning procedure automatically configures the radio for 25 KHz. This means that a 3 kHz (for 25 kHz channel spacing) de viation m ust al wa ys be us ed, irrespecti ve of the radio channel bandwidth.

Figure 5-9. Rated Volume Tuning Window

Perform the rated volume tuning procedure as follows:

1. Under the Rx Align menu, select Rated Volume (Figure 5-9).

2. Inject a -47 dBm RF signal modulated with 1 kHz tone at 3 KHz (for 25 kHz channel spacing).

3. Adjust the softpot value by using the slider, keying in the edit box (press ENTER to confirm the

selection or send a softpot value), or via the spin controls. Re peat this until 500 mW (3.24 V) audio power is obtained. Rated Audio tuning is only done for 25 kHz channel spacing.

4. Press Program to commit the softpot value into the radio.

5. Exit the rated volume tuning function.

HKLN4215A December 3, 2003

5-12 Radio Alignment Procedures: Receiver Tuning

5.5.2 Squelch Tuning

Note: 1. Squelch tuning can only be accomplished after reference oscillator warping.

2. When using the test bo x RLN4460, the received audio output is taken from the AC/ DC METER OUT terminals with the METER OUT rotary switch set to RX. It is recommended that Rated V o lume Tuning be performed so the correct 10 dB SINAD level can be obtained.

3. This tuning method is performed f or m ultiple squelc h tuning channels and m ultiple channel spacings.

Figure 5-10. Squelch Tuning Window

5.5.2.1 Manual Squelch Tuning

Perform the squelch tuning procedure as follows:

1. Under the Rx Align menu, select Squelch Attenuation. Select Squelch Attenuation 12.5 kHz or Squelch Attenuation 25 kHz Channel Spacing variations (Figure 5-10).

Apply an RF signal modulated with a 1 kHz tone at 60% rated deviation listed in rent frequency point (F1 being the first) of 10 dB SINAD. That is, adjust the reference signal level until 10 dB SINAD is obtained at the SINAD meter. Squelch tuning can either be done manually (see Manual Squelch Tuning for procedure) or by A uto Squelch (see Manual Squelch Tuning for procedure). To obtain 10 dB, unmute the radio first by dragging the corresponding slider value to 1.

Table 5-5. Squelch Deviation Values

Channel Spacing Rated System Deviation Signal Generator Deviation

25 kHz 5.0 kHz 3.0 kHz

12.5 kHz 2.5 kHz 1.5 kHz 20 kHz 4.0 kHz 2.4 kHz

December 3, 2003 HKLN4215A

Table 5-5

for cur-

Radio Alignment Procedures: Receiver Tuning 5-13

3. Set softpot to its maximum value to mute the radio.

4. Adjust the softpot value b y usin g the slider, keying in the edit box or using the spin controls . Press ENTER to confirm the selection or use the spin controls. Do this until the radio is totally unmu ted.

Verify the squelch closing by inputting a signal level of 4 dB lower than that of the 10 dB SINAD level.

5. Repeat Steps 2 through 4 of Manual Squelch Tuning, for frequency points F2-F7.

6. Press Program to commit the softpot values into the radio.

7. Exit the Squelch Tuning function.

5.5.2.2 Auto Tune

Note:

When you press the Auto Tune button, the radio automatically returns an optimum squelch value. After you press the button, the radio may need time to produce an optimal setting for the squelch

attenuation. The following steps describe the auto tune process:

1. Select current frequency point (F1 being the f irst), then press Auto Tune.

2. Repeat Steps 3-4 of the Manual Squelch Tuning section for frequency points F2-F7.

Note:

Proceed with caution since this procedure automatically programs the softpot value into your radio.

Auto Tune will automatically update your radio’s codeplug. Please be careful when using it.

5.5.3 RSSI System Level Tuning

Figure 5-11. RSSI Tuning

1. Under the Rx Align menu, select RSSI Tuning (Figure 5-11).

2. Inject an on channel signal to the radio at -47 dBm at the frequency listed. Modulate the signal

with a 1 kHz tone at 60% deviation (3 kHz) to verify that the radio is receiving the desired frequency. RSSI tuning is only done at 25 kHz channel spacing.

3. Change the level to the defined dBm level in the softpot box. (-115 dBm or -105 dBm).

4. Press the Update button for the soft spot to be tuned to the RSSI value correlating to the applied

level. The programmed RSSI value will be displayed.

HKLN4215A December 3, 2003

5-14 Radio Alignment Procedures: Utilities

5. Adjust the input level to reflect the next soft spot value. Repeat steps 3 and 4 to tune the next value.

5.5.4 RSSI Display Tuning

1. Under the Rx Align menu, select RSSI Display Tuning.

2. Inject an on channel signal to the radio at -47 dBm at the frequency listed. Modulated the signal

with a 1 kHz tone at 60% deviation (3 kHz) to verify the radio is receiving the desired frequency. RSSI tuning is only done at 25 kHz channel spacing.

3. Change the level to that which is needed to produce 12 SINAD ( approximately -119 dBm).

4. Press the Update button fo r th e soft spot to be tuned to th e RSSI value correlating to the applied

level. The programmed RSSI value will be displayed.

5. Adjust the input level to -90 dBm.

6. Press the Update button fo r th e soft spot to be tuned to th e RSSI value correlating to the applied

level. The programmed RSSI value will be displayed.

5.6 Utilities

5.6.1 Program Serial No.

The Program Serial No. option under the Utilities heading allow the radio serial number to be programmed. However, the serial number of a particular radio can only be programmed if it was originally blank. If the serial number of the radio was not blank, then access to the screen will be denied.

5.7 Radio-to-Radio Cloning

1. Cloning is the process of cop ying the con tent of o ne r ad io ( source r a dio) into an other r a dio (d esti-

nation radio). Radio content refers to system-type features such as frequency, squelch type options, trunking, etc.

Note:

Radio functionality inherent in one radio cannot be cloned to another radio that does not contain the same functionality. Tuning and alignment information are not transferable and are not affected by cloning.

1. Signaling Identification Numbers (IDs) are duplicated in the cloning process. Unique IDs may be

Note:

The source radio’s serial number cannot be blank.

assigned with the CPS.

Unsuccessful cloning attempts generates a continuous tone and may be an indication that the destination radio’s codeplug is corrupted.

December 3, 2003 HKLN4215A

Radio Alignment Procedures: Radio-to-Radio Cloning 5-15

Procedure:

1. Turn source and target radios off.

2. Connect cloning cable (AAPMKN4003 ) to the side connector of both radios.

3. Turn on the destination radio.

4. Press and hold the two side buttons at the same time on the source radio and then power up the

source radio (Figure 5-12). Both radios produce a “clone-entry” tone.

5. Release both side buttons, 1 and 2.

6. When cloning is completed, the source radio pr oduce’s a “clone-exit” tone and both the source

and destination radios reset.

7. Turn both radios off.

8. Disconnect the cloning cable from both radios and turn them on for normal operation.

Side Button 1

Side Button 2

Figure 5-12. Side Button Locations

HKLN4215A December 3, 2003

5-16 Radio Alignment Procedures: Radio-to-Radio Cloning

Notes:

December 3, 2003 HKLN4215A

Chapter 6 Display Model Disassembly and

Re-assembly

6.1 Introduction

This section provides details about the following:

• Preventive maintenance (inspection and cleaning)

• Safe handling of CMOS and LDMOS devices

• Disassembly and re-assembly of the radio

• Repair procedures and techniques

6.2 Preventive Maintenance

The radios do not require a scheduled preventive maintenance program; however, yearly verification of technical parameters and periodic visual inspection and cleaning is recomm ended.

6.2.1 Inspection

Check that the e xternal surf aces of the ra dio are clean, and that all external controls and switches are functional. It is not recommended to inspect the int erior electronic circuitry.

6.2.2 Cleaning Procedures

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

Note:

The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit boards and their components is isopropyl alcohol (70% by volume).

CAUTION: The effects of certain chemicals and their vapors can have harmful results on certain plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.

Cleaning External Plastic Surfaces

Apply the 0.5% detergent-water solution sparingly with a stiff, non-metallic, short-bristled brush to work all loose dirt away from the radio. Use a soft, absorbent, lintless cloth or tissue to remove the solution and dry the radio . Make su re that no w ater remains ent rapped near t he connectors , crac ks, or crevices.

Internal surfaces should be cleaned only when the radio is disassembled for service or repair.

6-2 Display Model Disassembly and Re-assembly: Safe Handling of CMOS and LDMOS Devices

Cleaning Internal Circuit Boards and Components

Isopropyl alcohol (70%) may be applied with a stiff, non-metallic, short-bristled brush to dislodge embedded or caked materials located in hard-to-reach areas. The brush stroke should direct the dislodged material out and away from the inside of the radio. Make sure that controls or tunable components are not soaked with alcohol. Do not use high-pressure air to hasten the drying process since this could cause the liquid to collect in unw a nte d places . After completing the cleaning process , use a soft, absorbent, lintless cloth to dry the area. Do not brush or apply any isopropyl alcohol to the frame, front cover, or back cover.

Note:

Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage).

6.3 Safe Handling of CMOS and LDMOS Devices

Complementary metal-oxide semiconducto r (CMOS) de vices are used in this f amily of radios , and are susceptible to damage by electrostatic 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 CMOS circuits and are especially important in low humidity conditions. DO NOT attempt to disassemble the radio without first referring to the f ollo wing CAUTION statement.

CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are properly grounded. Take the following precautions when working on this unit:

• Store and transport all CMOS devices in conductive material so that all ex posed leads are shorted together. Do not insert CMOS devices into conventional plastic “snow” trays used for storage and transportation of other semiconductor devices.

• Ground the working surface of the service bench to protect the CMOS device. We recommend using the Motorola Static Protection Assembly (part number 0180386A82), which includes a wrist strap, t wo ground cords, a table mat, and a floor mat.

• Wear a conductive wrist strap in series with a 100k resistor to g round. (Replacement wrist straps that connect to the bench top covering are Moto ro la pa rt number RSX-

4015.)

• Do not wear nylon clothing while handling CMOS devices.

• Do not insert or remove CMOS devices with power applied. Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present.

• When straightening CMOS pins, provide ground straps for the apparatus used.

• When soldering, use a grounded soldering iron.

• If at all possible, handle CMOS devices by the pac kage and not b y the leads. Prior to touching the unit, touch an electrical ground to remove any static charge that you may have accumulated. The package and substrate may be electrically common. If so, the reaction of a discharge to the case would cause the same damage as touching the leads.

December 3, 2003 HKLN4215A

Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-3

6.4 Disassembling and Re-assembling the Radio — General

Since these radios may be disassemb led and r e-assemb led with the use of only f our (board to casting) screws, it is important to pay particular attention to the snaps and tabs, and how parts align with each other.

The following tools are required for disassembling the radio (see 3.2 for a list of service aids):

• Knob remover/chassis opener

• Penknife-size screwdriver

• TORX™ T6 screwdriver

• Scribe

If a unit requires more complete testing or service than is customarily per form e d at th e ba sic level, send this unit to a Motorola Aut horized Service Center . See Appen dix B f or a list of authoriz ed service centers.

The following disassembly procedures should be performed only if necessary:

• Chassis Disassembly

• Speaker Disassembly

• PTT Disassembly

6.4.1 Radio Disassembly — Detailed

6.4.1.1 Front Cover From Chassis Disassembly

1. Turn off the radio.

2. Remove the battery (Figure 6-1):

a. Slide the battery latch into the unlock position. Disengage by pushing downward and

holding the latch towards the front of the radio.

b. With the battery latch disengaged, slide the battery down from the top of the radio about

1/2 in. Once the battery is free from the battery rails, lift it directly away from the radio.

c. Remove the battery from the radio.

Lock

Unlock

Battery Latch

Figure 6-1. Battery Removal

HKLN4215A December 3, 2003

6-4 Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General

3. Remove the antenna.

4. Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis

opener tool (Motorola part # 6686533Z01). (Figure 6-2.)

Figure 6-2. Antenna and Knob Removal

Note:

Both knobs slide on and off. However the knobs are designed to fit very tightly on the shaft.

5. Separate the chassis from the fro nt housing as semb ly by using the knob remov e r/chassis ope ner too. Place the broad side of the ope ner in to the slots locate d at the ba se of the radio (Figure 6-3). Press the handle on the opener downward s. This pressing action forces the thin inner plastic wall

toward the base of the radio, releasing the two chassis base tabs..

Knob Remover/ Chassis Opener

Radio Chassis

Figure 6-3. Chassis Removal

CAUTION: Marring the front cover O-ring sealing area will prevent the radio from sealing properly. If the O-ring is damaged, replace it with a new one.

6. Pull the chassis assembly out of the front cover only until the volume and channel selectors shaft

just clear the top of the case. (Figure 6-4).

December 3, 2003 HKLN4215A

Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-5

Note:

The speaker wire assembly microphone wire assembly and keypad flex cable connector connecting the front housing assembly and the chassis prevent the two units from being completely separated

7. Rotate the bottom of the chassis up about 20° to disconnect the keyboard flex cable connector. Push down 2 end tabs to release flex connector at the bottom of the chassis.

Radio Chassis

Flex Connector

Figure 6-4. Keyboard Flex Connection

8. Rotate the chassis counterclockwise out of the housing and position next to the housing. Take care not to damage the speaker and microphone wires that are still connected to the chassis (Figure 6-5).

Speaker Connector

Microphone Connector

Figure 6-5. Microphone and Speaker Connections

9. Unplug the speaker wire assembly from the 2-pin connector on the chassis.

10. Unplug the microphone wire assembly from the soc ket on the chassis.

11. Move the chassis aw ay from the housing and place on a clean work surface.

HKLN4215A December 3, 2003

6-6 Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General

6.4.1.2 Dust Cover Disassembly

1. Gently pry the top of the dust cover away from the body of the radio. (See Figu re 6-6).

2. Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed.

3. Separate the dust cover away from the body of the r adio. The dust cover key is fr ag ile; a pply o nly

light pressure to the key while removing the dust cover.

key

a. Pry dust cover from body.

b. Rotate dust cover 90

allow key to be removed.

Figure 6-6. Dust Cover Disassembly

6.4.1.3 Speaker and Microphone Disassembly

Note:

1. Remove the screw from the speaker retainer using a T6 Torx screwdriver (Figure 6-7.

2. Lift the retainer off the speaker, sliding end of retainer out of corner slot on the housing.

3. Lift the speaker out from the front housing.

4. Carefully lift microphone assembly out of housing.

The speaker is held in place with a retainer bracket. Be careful not to damage the speaker when removing the retainer bracket.

Speaker

Speaker Connector

° to

Retainer Bracket

c. Separate dust cover from body.

Microphone

Radio Housing

icrophone Connector

Figure 6-7. Removal Speaker-Microphone Assembly

December 3, 2003 HKLN4215A

Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-7

6.4.1.4 Keyboard Removal

1. Carefully pry the four ke ypad retainer locking tabs free from the housing use a scribe.

Note:

2. Lift the keypad retainer up from the bottom and slide the top tabs out.

3. Slide keypad retainer out of chassis carefully to prevent damage to flex cable.

CAUTION: Refer to the CMOS CAUTION paragraph (6.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

4. Lift LCD ke ypad board out of housing (Figure 6-8).

5. Lift keypad out of housing.

Use care when removing the keypad retainer to prevent damage t o the keyboard flex cable.

Keypad Retainer

Flex Cable

Keypad Board

Keypad

Figure 6-8. Keypad Removal

6.4.1.5 PTT Disassembly

1. If required, the PTT (Figure 6-9 can be disassembly using a small screwdriver, as follows:

a. Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab. b. Pry the PTT awa y from the radio housing. c. Inspect the two hooks. If bent or broken, the PTT must be replaced. d. Remove the PTT seal.

HKLN4215A December 3, 2003

6-8 Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General

Hooks

PTT Seal

6.4.1.6 Chassis Disassembly

CAUTION: Refer to the CMOS CAUTION paragraph (see 3.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

1. Remov e the O-ring.

2. Use a Torx™ screwdriver with a T6 bit to remove the four screws (Figure 6-10) holding the main

board to the chassis.

Tab

Figure 6-9. PTT Removal

Flat Blade Screwdriver

Audio Jack Shroud

Main Board

Radio Chassis

O-Ring

Figure 6-10. Removal of Main Board from Chassis

3. The audio jack shroud can be removed from the main board.

December 3, 2003 HKLN4215A

Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-9

4. Lift the main board from the chassis (Figure 6-10).

5. Remove the battery contact seal.

6.4.2 Radio Re-assembly - Detailed

6.4.2.1 Dust Cover Re-assembly

1. Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 6-11).

2. Press the dust cap until the tail is fully into the hole.

Note:

3. Twist the dust cap counter-clockwise until the cap is seated properly onto the recess.

4. Press the cap again to ensure it fully covers the opening for the audio jack.

Make sure the dust cap is placed between the keypad retainer mounting post and the side wall of the radio.

12 34

Figure 6-11. Dust Cap Re-assembly

6.4.2.2 Microphone and Speaker Re-assembly

1. Check that the mic and speaker felts are in positio n and not damaged. If damaged replace felts.

2. Insert the microphone sub-assembly into the microphone boot.

3. 3. Insert the Boot and microphone sub-assembly into the microphone recess in the housing and

route wires as shown in Figure 6-12.

HKLN4215A December 3, 2003

6-10 Display Model Disassembly and Re-assembly: Disassembling and Re-assembli ng the Radio — General

Microphone

Boot

Microphone Recess

Microphone Position

Figure 6-12. Microphone Re-assembly

4. Locate the speake r tab and align it with the tab opening in the front housing (Figure 6-13).

5. Insert the speaker tab into the speak er r ecess in the h ousin g. En sure t he speaker is seated flush

in the housing.

Note:

Make sure the speak er and microp hone wir es are rout ed tightly b etwe en the speaker basket and the housing post.

6. Insert one end of the speaker retainer into the slot in the front housing (See Figure 6-13).

Speaker Retainer

Speaker

Front Housing Slot

Speaker Tab

Tab Ope ning

Figure 6-13. Speaker Re-assembly

Note:

When fastening the speaker retainer screw, make sure the wires are out of the way to prevent pinching by the retainer.

7. Install the retainer screw using a T6 Torx screwdriver. To rque to 2.3 - 2.5 lb/in.

December 3, 2003 HKLN4215A

Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-11

6.4.2.3 Keypad and LCD/Keyboard Re-assembly

1. Attach the flex cable from the LCD module to the keyboard, if not already attached (Figure 6-15).

2. Remove protective mylar from window and from keypad, if present.

3. Install the new keypad into the housing. Use the two housing posts for keypad alignment

(Figure 6-14).

Full Keypad

Housing Posts

Figure 6-14. Keypad Re-assembly

4. Remove mylar from LCD if present.

CAUTION: Make sure the microphone and speaker wires are not trapped under the LCD module.

5. Install the LCD/K eypad sub-assembly into the housing (Figure 6-15).

Flex Cable from LCD Module

Flex Cable to Main PC Board

Figure 6-15. LCD/Keypad Board Re-assembly

HKLN4215A December 3, 2003

6-12 Display Model Disassembly and Re-assembly: Disassembling and Re-assembli ng the Radio — General

6. Attach the flex cable into the connector on the keypad board, if not already connected.

7. Bend the flex cable as shown (Figure 6-15)

6.4.2.4 Keyboard Retainer Re-assembly

1. Insert the flex cable thro ugh the slot at the bottom of the keyboard retainer (Figure 6-16).

Figure 6-16. Keyboard Retainer Re-assembly

2. Insert the two top tabs of the keyboard retainer into the two tab retainers located on each side of the speaker in the front housing (Figure 6-16).

3. Press the four keypad retainer locking tabs into the housing.

4. Push the speaker and microphone wires into the top left hand corner of the housing.

6.4.2.5 Chassis Assembly/Re-assembly

1. Replace the battery contact seal (if necessary) surrounding the battery contact (Figure 6-17).

2. Remove the old Interface Pad from the chassis by scr aping off the pad and adhesive with a

straight razor. Use rubbing alcohol and a cloth to completely remove the adhesive from the chassis surface. With the chassis clean and dry, add a new Interface Pad to the chassis.

3. Place the main circuit board straight down on top of the chassis with the frequency and volume switches facing down (Figure 6-17).

Note:

4. Use the T6 Torx screwdriver to fasten the screws holding the main board to the chassis. Tighten

5. Replace the O-ring by positioning it in the top groove by the volume/frequency switches. Stretch

6. Check that the O-ring is not twisted and being held by the top and bottom chassis groves.

Be sure the battery contact seal protrudes through the chassis and is not pinched under the chassis.

to 3.7 - 3.9 in/lb.

the O-ring to place it into the retaining groove at the bottom end of the chassis.

December 3, 2003 HKLN4215A

Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-13

Frequency & Volume Switches

Interface Pad

Battery Contact Seal

Figure 6-17. Main Board onto Chassis Re-assembly

6.4.2.6 Chassis and Front Cover Re-assembly

1. Dress and connect the speaker wires..

Note:

Care should be taken when dressing the speaker and microphone wires to avoid pinching them between the speaker magnet and shield, or between the accessory connector and housing.

Audio Jack Shroud (Replace after Plugging in Speaker and Mic)

Main Board

Flex Cable Connector

Radio Chassis

O-Ring

Note:

Ensure that the plug orientation is correct with the exposed pins in the wire casing facing upward and fully plugged in.

a. Connect the speaker wire assembly into the 2-pin connector on the main board and

bend the wires at the board connector so the wires are positioned toward the top of the radio (Figure 6-18).

b. Connect the microphone wire assembly into the two hole socket on the main board and

bend the wires at the board connector so the wires are positioned toward the top of the radio (Figure 6-18).

c. Slide the audio jack shroud onto accessory connector (Figure 6-17).

HKLN4215A December 3, 2003

6-14 Display Model Disassembly and Re-assembly: Disassembling and Re-assembli ng the Radio — General

Microphone Connector

Speaker Connector

Shroud

Figure 6-18. Microphone and Speaker W ires Re-assembly

2. Position the radio (Figure 6-19), and reconnect the flex connector from the keyb oard into the con- nector located on the bottom of the main board, pushing up the 2 end tabs.

3. Slide the volume po tentiometer a nd frequency switch shafts into their respective holes in the front cover. Look through the accessory connector opening to make certain that the wires are not pinched, between shroud and housing.

Radio Chassis

End Tabs

Flex Cable Connector

Figure 6-19. Keyboard Flex Cable Connection

4. Push the topside of the board chassis upward until it touches the housing end. Before snapping the board into the housing, perform the following checks:

a. Open the dust cap and ensure the wires are not pinched betwe en the shroud and housing. b. Ensure the O-ring is seated in the groove. c. Ensure that the bottom side of the dust cap is fully pressed into the housing before the

snapping the board into place.

December 3, 2003 HKLN4215A

Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 6-15

5. Snap chassis assemb ly completely into the top of the front cover (Figure 6-20) until it settles in

place.

Radio Chassis

Figure 6-20. Fastening the Chassis

6. Make sure the 0-ring is properly seated. If the O-ring seal is pinched, separate the chassis from the housing using the knob remov al/chassis opener and dress O-ring properly.

7. Snap the bottom of the chassis into the front cover.

8. Check that O-ring is visible at the corners.

9. After closing the radio, verify that the O-ring is not visible; if visible, re-assemble properly.

10. Re-assemble the knobs, antenna, and battery.

6.4.2.7 PTT Re-assembly

1. Place the PTT seal over the ridge around the top hole. Press down to seat the seal around the ridge.

2. Place the bottom tab in the slot inside the f ront housing PT T opening. Slightly slide do wn the PTT and bow it by placing one finger under the middle of the PTT, so that the top tab can be aligned and inserted into the top slot (Figure 6-21a).

3. Press the PTT assembly against the front cover opening (Figure 6-21b).

a. Place bottom tab into bottom slot.

Place top tab into top slot.

b. Push down on PTT toward bottom of radio so hooks do not get crushed.

Figure 6-21. PTT Re-assembly

HKLN4215A December 3, 2003

6-16 Display Model Disassembly and Re-assembly: Mechanical View and Parts List

6.5 Mechanical View and Parts List

6.5.1 EP450 Display Exploded View and Parts List

33 32 31

2 3

Figure 6-22. EP450 Display Radio Exploded View

December 3, 2003 HKLN4215A

Mechanical View and Parts List 6-17

Motorola

Item

Part

Description

Number

2 3680530Z02 Knob, Frequency 3 1386440Z01

4 5886627Z01 Antenna Adaptor/Seal

5 1586391Z03 Housing, Full, with Lens 6 3586621Z01 Speaker, Felt 7 3886489Z01 PTT, Rubber 8 4586439Z01 PTT, Plastic 9 5085738Z08 Speaker 10 4286620Z01 Retainer Speaker 11 3586621Z02 Felt, Microphone 12 0780608V01 Boot, Microphone 13 5085880L01 Microphone 14 5104949J16 Display, LCD Module

See Section 6 Antenna

Escutcheon, Top; 4 Ch.

1386440Z02

Escutcheon, Top; 16 Ch.

(Optional)

Item

Motorola

Part

Description

Number

NON-REFERENCED ITEMS

3386625Z01 Nameplate, Motorola

Nameplate, EP450

15 0104017J18 Keypad Board Assy 16 1586437Z01 Shroud, Audio Jack 17 3286431Z02 Seal, Main O-ring 18 7586436Z01 Pad, PA Interface 19 2786389Z01 Chassis 20 3286435Z01 Seal, Battery Contact Block 21 0304726J05 Screws, Chassis; 4 Used 22 4286648Z01 Plate, Retainer 23 0909059E19 Connector, 28-pin 24 0986632Z02 9 Pin Connector 25 7586654Z03 Keypad, Full 26 5586445Z02 Latch Assembly 27 4105944K01 Spring, Latch; 2 Used 28 3886441Z01 Cap, Dust 29 3286432Z01 Seal, Control Shaft 30 0386434Z01 Screw , Speaker Retainer 31 3386443Z01 Label, Escutcheon Seal 32 6186446Z02 Lightpipe 33 3680529Z01 Knob, Volume

6-18 Display Model Disassembly and Re-assembly: Mechanical View and Parts List

Notes:

December 3, 2003 HKLN4215A

Chapter 7 Non-Display Model Disassembly and

Re-assembly

7.1 Introduction

This section provides details about the following:

• Preventive maintenance (inspection and cleaning)

• Safe handling of CMOS and LDMOS devices

• Disassembly and re-assembly of the radio

• Repair procedures and techniques

7.2 Preventive Maintenance

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

7.2.1 Inspection

Check that the e xternal surf aces of the ra dio are clean, and that all external controls and switches are functional. It is not recommended to inspect the int erior electronic circuitry.

7.2.2 Cleaning Procedures

Note:

CAUTION: The effects of certain chemicals and their vapors can have harmful results on certain plastics. Avoid using aerosol sprays, tuner cleaners, and other chemicals.

Cleaning External Plastic Surfaces

Internal surfaces should be cleaned only when the radio is disassembled for service or repair.

7-2 Non-Display Model Disassembly and Re-assembly: Safe Handling of CMOS and LDMOS Devices

Cleaning Internal Circuit Boards and Components

Note:

Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material (from previous usage).

7.3 Safe Handling of CMOS and LDMOS Devices

CAUTION: This radio contains static-sensitive devices. Do not open the radio unless you are properly grounded. Take the following precautions when working on this unit:

• Wear a conductive wrist strap in series with a 100k resistor to g round. (Replacement wrist straps that connect to the bench top covering are Moto ro la pa rt number RSX-

4015.)

• Do not wear nylon clothing while handling CMOS devices.

• Do not insert or remove CMOS devices with power applied. Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present.

• When straightening CMOS pins, provide ground straps for the apparatus used.

• When soldering, use a grounded soldering iron.

December 3, 2003 HKLN4215A

Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-3

7.4 Disassembling and Re-assembling the Radio — General

Since these radios may be disassembled and re-assembled with the use of only four (board to casting) screws, it is important to pay particular attention to the snaps and ta bs, and how parts align with each other.

The following tools are required for disassembling the radio (see 3.2 for a list of service aids):

• knob remover/chassis opener

• penknife-size screwdriver

• TORX™ T6 screwdriver

The following disassembly procedures should be performed only if necessary:

• Chassis Disassembly

• Speaker Disassembly

• PTT Disassembly

7.4.1 Radio Disassembly — Detailed

7.4.1.1 Front Cover From Chassis Disassembly

1. Turn off the radio

2. Remove the battery (Figure 7-1):

a. Slide the battery latch into the unlock position. Disengage by pushing downward and

holding the latch towards the front of the radio.

b. With the battery latch disengaged, slide the battery down from the top of the radio about

1/2 in. Once the battery is free from the battery rails, lift it directly away from the radio.

c. Remove the battery from the radio.

Lock

Unlock

Battery Latch

Figure 7-1. Battery Removal

HKLN4215A December 3, 2003

7-4 Non-Display Model Disassembly and Re-as sembly: Disassembling and Re-assembling the Radio — General

3. Remove the antenna.

4. Pry off the volume and channel selector knobs from their shafts using the knob removal/chassis

opener tool (Motorola part # 6686533Z01). (Figure 7-2)

Figure 7-2. Antenna and Knob Removal

Note:

5. Separate the chassis from the fro nt housing as semb ly by using the knob remov e r/chassis ope ner

Both knobs slide on and off. However the knobs are designed to fit very tightly on the shaft.

too. Place the broad side of the ope ner in to the slots locate d at the ba se of the radio (Figure 7-3). Press the handle on the opener downward s. This pressing action forces the thin inner plastic wall

toward the base of the radio, releasing the two chassis base tabs..

Knob Remover/ Chassis Opener

Radio Chassis

Figure 7-3. Chassis Removal

CAUTION: Marring the front cover O-ring sealing area will prevent the radio from sealing properly. If the O-ring is damaged, replace it with a new one.

Note: The speaker wire assembly microphone wire assembly and keypad ribbon connector con-

necting the front housing assembly and the chassis prevent the two units from being completely separated

December 3, 2003 HKLN4215A

Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-5

6. Pull the chassis assembly out o f the front cover only until the volume and channel selectors shaft

just clear the top of the case. (Figure 7-4).

Rotate the chassis counterclockwise out of the housing and position next to the housing. Take care not to damage the speaker and microphone wires that are still connected to the chassis (Figure 7-4).

Speaker Connector

Shroud

Microphone Connector

Figure 7-4. Microphone and Speaker Connections

7. Unplug the speaker wire assembly from the 2-pin connector on the chassis.

8. Unplug the microphone wire assembly from the socket on the ch assis.

9. Move the chassis away from the housing and place on a clean work surface.

7.4.1.2 Dust Cover Disassembly

1. Gently pry the top of the dust cover away from the body of the radio. (See Figure 7-5).

2. Rotate the dust cover 90° in a counterclockwise direction to allow the key to be removed.

3. Separate the dust co ver away from the body of the radio. The du st cover key is fragile; apply only

light pressure to the key while removing the dust cover.

a. Pry dust cover from body.

Figure 7-5. Dust Cover Disassembly

b. Rotate dust cover 90 allow key to be removed.

° to

key

c. Separate dust cover from body.

HKLN4215A December 3, 2003

7-6 Non-Display Model Disassembly and Re-as sembly: Disassembling and Re-assembling the Radio — General

7.4.1.3 Speaker and Microphone Disassembly

Note:

The speaker is held in place with a retainer bracket. Be careful not to damage the speaker when removing the retainer bracket.

1. Remove the screw from the speaker retainer using a T6 Torx screwdriver (Figure 7-6).

2. Lift the retainer off the speaker, sliding end of retainer out of corner slot on the housing.

3. Lift the speaker out from the front housing.

4. Carefully lift microphone assembly out of housing.

Retainer Bracket

Speaker

Wire Connector

Radio Housing

Microphone Assembly

Figure 7-6. Removal Speaker-Microphone Assembly

7.4.1.4 PTT Disassembly

1. If required, the PTT (Figure 7-7) can be disassembly using a small screwdriver, as follows: a. Insert the tip of a small screwdriver underneath the PTT and unsnap the top tab.

b. Pry the PTT away from the radio housing. c. Inspect the two hooks. If bent or broken, the PTT must be replaced. d. Remove the PTT seal.

December 3, 2003 HKLN4215A

Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-7

Hooks

PTT Seal

7.4.2 Chassis Disassembly

CAUTION: Refer to the CMOS CAUTION paragraph (7.3) before removing the main board. Be sure to use Electrostatic Discharge protection when handling circuit boards.

1. Remove the O-ring.

2. Use a Torx™ screwdriver with a T6 bit to remove the four screws (Figure 7-8) holding the main

board to the chassis.

Tab

Figure 7-7. PTT Removal

Flat Blade Screwdriver

Audio Jack Shroud

Figure 7-8. Removal of Main Board from Chassis

3. The audio jack shroud can be removed from the main board.

4. Lift the main board from the chassis.

5. Remove the battery contact seal.

Main Board

Radio Chassis

O-Ring

HKLN4215A December 3, 2003

7-8 Non-Display Model Disassembly and Re-as sembly: Disassembling and Re-assembling the Radio — General

7.4.3 Radio Re-assembly - Detailed

7.4.3.1 Dust Cover Re-assembly

1. Insert the tail of the dust cap into the bottom hole of the audio jacks housing opening (Figure 7-9).

2. Press the dust cap until the tail is fully into the hole.

3. Twist the dust cap counter-clockwise until the cap is seated properly onto the recess.

4. Press the cap again to ensure it fully covers the opening for the audio jack.

12 34

Figure 7-9. Dust Cap Re-assembly

7.4.3.2 Microphone and Speaker Re-assembly

1. Check that the spea ker felt is in position and is not d amaged. If damaged replace felt.

2. Insert the microphone sub-assembly into the microphone boot.

3. Insert the Boot and microphone sub-assembly into the microphone recess in the housing and

route the wires as shown in Figure 7-10.

Microphone

Boot

Microphone Recess

Figure 7-10. Microphone Re-assembly

Microphone Position

4. Locate the speaker tab and align it with the tab opening in the front housing (Figure 7-11).

5. Insert the speaker tab into the speak er r ecess in the h ousin g. Ensure t he spe aker is seated flush

in the housing

December 3, 2003 HKLN4215A

Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-9

Note:

Make sure the speak er and microphone wire s are r outed tig htly bet we en the sp eak er ba sk et and the housing post

6. Insert one end of the speaker retainer into the slot in the front housing (See Figure 7-11)..

Speaker Retainer

Speaker Tab

Speaker

Tab Opening

Front Housing Slot

Figure 7-11. Speaker Re-assembly

Note:

When fastening the speaker retainer screw, make sure the wires are out of the way to prevent pinching by the retainer.

7. Install the retainer screw using a T6 Torx screwdriver. Torque to 2.3 - 2.5 lb/in.

7.4.3.3 Chassis Assembly/Re-assembly

1. Replace the battery contact seal (if necessary) surrounding the battery contact (Figure 7-12).

2. Remove the old Interface Pad from the chassis by scraping off the pad and adhesive with a

straight razor. Use rubbing alcohol and a cloth to completely remove the adhesive from the chassis surface. With the chassis clean and dry, add a new Interface Pad to the chassis.

3. Place the main circuit board straight down on top of the chassis with the frequency and volume switches facing down.

Note:

4. Use the T6 Torx screwdriver to fasten the screws holding the main board to the chassis. Tighten

5. Replace the O-ring by positioning it in the top groove by the volume/frequency switches. Stretch

6. Check that the O-ring is not twisted and is being held by the top and bottom chassis groves.

7. Replace the audio jack shroud.

Be sure the battery contact seal protrudes through the chassis and is not pinched under the chassis.

to 3.7 - 3.9 in/lb.

the O-ring to place it into the retaining groove at the bottom end of the chassis.

HKLN4215A December 3, 2003

7-10 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General

Frequency & Volume Switches

Interface Pad

Battery Contact Seal

Figure 7-12. Installation of Main Board onto Chassis

7.4.3.4 Chassis and Front Cover Re-assembly

8. Dress and connect the speaker wires .

Note:

Care should be taken when dressing the speaker and microphone wires to avoid pinching them between the speaker magnet and shield, or between the accessory connector and housing.

Audio Jack Shroud (Replace after Plugging in Speaker and Mic)

Main Board

Radio Chassis

O-ring

Note:

Ensure that the plug orientation is correct with the exposed pins in the wire casing facing upward and fully plugged in.

a. Connect the speaker wire assembly into the 10-pin connector on the main board and

bend the wires at the board connector so the wires ar e positioned toward the top of the radio (Figure 7-13).

b. Connect the microphone wire assembly into the two hole socket on the main board and

bend the wires at the board connector so the wires ar e positioned toward the top of the radio (Figure 7-13).

c. Slide the audio jack shroud onto accessory connecto r (Figure 7-12).

9. Slide the volume po tentiometer a nd frequency switch shafts into their respective holes in the front cover. Look through the accessory connector opening to make certain that the wires are not pinched.

10. Push the topside of the board chassis upward until it touches the housing end. Before snapping the board into the housing, perform the following checks.:

a. Open the dust cap and ensure the wires are not pinched betwe en the shroud and housing. b. Ensure the O-ring is seated in the groove.

11. c. Ensure that the bottom side of the dust cap is fully pressed into the housing before the snapping the board into place

December 3, 2003 HKLN4215A

Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General 7-11

Speaker Connector

Microphone Connector

Shroud

Figure 7-13. Microphone and Speaker Wires Re-assembly

Radio Chassis

12. Snap chassis assembly completely into the top of the front cover (Figure 7-14) until it settles in place.

13. Make sure the O-ring is proper ly sea ted . If th e O- ring seal is pinched, separate the chassis from the housing using the knob remov al/chassis opener and dress O-ring properly.

14. Snap the bottom of the chassis into the front cover.

15. Check that O-ring is visible at the corners.

16. After closing the radio, verify that the O-ring is not visible; if visible, re-assemble properly.

17. Re-assemble the knobs, antenna, and battery.

7.4.3.5 PTT Re-assembly

1. Place the PTT seal over the ridge around the top hole. Press down to seat the seal around the ridge.

Figure 7-14. Fastening the Chassis

HKLN4215A December 3, 2003

7-12 Non-Display Model Disassembly and Re-assembly: Disassembling and Re-assembling the Radio — General

3. Press the PTT assembly against the front cover opening (Figur e 7-15b).

a. Place bottom tab into bottom slot.

Place top tab into top slot.

Figure 7-15. PTT Re-assembly

b. Push down on PTT toward bottom of radio so hooks do not get crushed.

December 3, 2003 HKLN4215A

Non-Display Model Disassembly and Re-assembly: Mechanical View and Parts List 7-13

7.5 Mechanical View and Parts List

7.5.1 EP450 Non-Display Exploded View and Parts List

26 25 24

2 3

4 5

Figure 7-16. EP450 Non-Display Radio Exploded View

HKLN4215A December 3, 2003

7-14 Mechanical View and Parts List

Motorola

Item

Part

Description

Number

1 See Section 6 Antenna 2 3680530Z02 Knob, Frequency 3 1386440Z02 Escutcheon, Top; 16 Ch. 4 5886627Z01 Antenna Adaptor / Seal 5 1586391Z01 Housing, ELP+, Plain 6 3586621Z01 Felt, Speaker 7 3886489Z01 PTT , Rubber 8 4586439Z01 PTT , Plastic 9 5085738Z08 Speaker 10 4286620Z01 Retainer, Speaker 11 3586621Z02 Felt, Microphone 12 0780608V01 Boot, Microphone 13 5085880L01 Microphone 14 3286431Z02 Seal, Main O-ring 15 7586436Z01 Pad, PA Interface 16 2786389Z01 Chassis 17 3286435Z01 Seal, Battery Contact Block 18 0304726J05 Screws, Chassis; 4 Used 19 1586437Z01 Shroud, Audio Jack 20 5586445Z02 Latch Assembly 21 4105944K01 Spring, Latch; 2 Used 22 3886441Z01 Cap, Dust 23 3286432Z01 Seal, Control Shaft 24 3386443Z01 Label, Escutcheon Seal 25 6186446Z02 Lightpipe 26 3680529Z01 Knob, Volume 27 0386434Z01 Screw, Speaker Retainer

NON-REFERENCED ITEMS

3386625Z01 Nameplate, Motorola

Nameplate, EP450

Chapter 8 Troubleshooting Tables

8.1 Power-Up Error Codes

During radio power-up, the radio perf orms dynamic tests to determine if the radio is working pr operly. Problems detected during these tests are presented as an error code on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Table 8-1 to aid in understanding particular operational error codes.

Table 8-1. Power-Up Error Code Display

Error Code Possible Causes Corrective Action

RAM ERR RAM Test Failure Retest radio by turning if off and tuning it on again. If

message reoccurs, replace main board or send radio to depot.

ROM ERR ROM checksum is wrong Reprogram FLASH memory and retest. If message reoc-

curs, replace main board or send radio to depot.

EPRM ERR

EEPROM Hardware Error – Codeplug structure mismatch or non-existence of codeplug or, EEPROM Checksum Error – Codeplug checksum is wrong

Reprogram codeplug with correct codeplug and retest. If message reoccurs, replace main board or send radio to depot.

8.2 Operational Error Codes

During radio operation, the radio perfor ms dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as an error code on the radio’s display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Table 8-2 to aid in understanding particular operational error codes.

Table 8-2. Operational Error Code Display

Error Code Possible Causes Corrective Action

SYN UNLK Synthesizer Out-of-Lock Verify codeplug and reprogram if necessary. If message

reoccurs, replace main board or send radio to depot.

8-2 Troubleshooting Tables: Troubleshooting Table for Receiver

8.3 Troubleshooting Table for Receiver

Table Table 8-3 lists the possible causes of, and corrections for, receiver problems.

Table 8-3. Receiver Troubleshooting Table

Symptom Possible Causes

Radio Dead; Display Does Not Turn On

Radio Dead; Display Turns OnTransceiver Board Send radio to depot.

No Receive Audio, or Receiver Does Not Unmute

Audio Distorted or Not Loud Enough

RF Sensitivity Poor

1. Dead Battery. Replace with charged battery.

2. Blown Fuse Send radio to depot.

3. On/Off Switch

4. Regulators

5. Regulator fault

Programming 1. Does the transmitted signal match the receiver configu-

Synthesizer Not On Frequency

1. Synthesizer Not on Frequency

2. Antenna Switch/Connector

(Measurements at Room Temperature)

ration (PL, DPL, etc.)?

2. With the monitor function enabled, can the radio be unmuted?

Check synthesizer frequency by measuring the transmitter frequency; realign it off by more than ±150 Hz (VHF), ±500 Hz (UHF)

Send radio to depot.

Corrective or Test

3. Receiver Front End Tuning

Radio Will Not Turn Off Transceiver Board Send radio to depot.

Check RF front-end tuning for optimum sensitivity using the tuner.

December 3, 2003 HKLN4215A

Troubleshooting Tables: Troubleshooting Table for Transmitter 8-3

8.4 Troubleshooting Table for Transmitter

Table Table 8-4 lists the possible causes of, and corrections for, transmitter problems.

Table 8-4. Transmitter Troubleshooting Table

Symptom Possible Causes

No RF Power Out 1. Tx Power Level or Fre-

quency

2. No Injection To Power Amplifier

Antenna Switch/Connector

No Modulation; Distortion Modulation

Bad Microphone Sensitivity 1. Check Deviation and

No/Low Signaling (PL, DPL, MDC)

Cannot Set Deviation Balance

1. Programming Check deviation and compensation settings using th e

2. Transceiver Board Send radio to depot.

Compensation

2. Microphone Send radio to depot.

1. Programming Check programming.

2. Transceiver Board Send radio to depot. RF Board Send radio to depot.

Corrective or Test

(Measurements at Room Temperature)

Check Tx power level and frequency programming (from tuner).

Send radio to depot.

tuner.

Realign if necessary.

HKLN4215A December 3, 2003

8-4 Troubleshooting Tables: Troubleshooting Table for Transmitter

Notes:

December 3, 2003 HKLN4215A

Appendix A Accessories

Antennas

NAD6502_R VHF Heliflex Antenna 14cm (146-174 MHz) HAD9742 VHF Stubby Antenna, 9cm (146-162 MHz) HAD9743 VHF Stubby Antenna, 9cm (162-174 MHz) NAE6522_R UHF Heliflex Stubby Antenna 9cm (438-470 MHz) NAE6483_R Flexible Whip Antenna (403-520 MHz) 8505816K26 UHF Heliflex Stubby (470-520 MHz)

Carrying Accessories

RLN5498 Hard Leather Case, Full DTMF with Belt Loop RLN5496 Hard Leather Case, Full DTMF with 3 inch Swivel Belt Loop RLN5497 Hard Leather Case, Full DTMF (attaches to D-Shaped Rings on case) RLN5644 2.5 inch Spr ing Action Belt Clip NTN5243 Shoulder Strap for Hard Leather Cases (attaches to D-Shaped Rings on

case) HLN9985 Waterproof Bag RLN5383 Nylon Case with Belt Loop Non-Display models HLN9701 Leather Case with Belt Loop RLN5384 Leather Case with 2-1/2 inch Swivel Belt Loop Non-Display models RLN5385 Leather Case with 3 inch Swivel Belt Loop Non-Display models

Chargers

WPLN4137 Desktop Rapid Charger Base Only w/NA LA Manual WPLN4138_R Rapid 90-Min. Desktop Charger w/US plug WPLN4139_R Rapid 90-Min. Desktop Charger w/Euro plug WPLN4142_R Rapid 90-Min. Desktop Charger w/Argentina plug WPLN4140_R Rapid 90-Min. Desktop Charger w/UK plug WPLN4161 Rapid 90-Min. Multi-Unit Charger w/US plug WPLN4162 Rapid 90-Min. Multi-Unit Charger w/Euro plug WPLN4163 Rapid 90-Min. Multi-Unit Charger w/UK plug WPLN4164 Rapid 90-Min. Multi-Unit Charger w/Argentina plug

Batteries

NNTN4496_R High Capacity Ni-Cd, 1100 mAH NNTN4497_R Ultra High Capacity Li-lon, 1800 mAH NNTN4851_R High Capacity NiMH, 1400 mAH NNTN4970 High Capacity Li-Ion, 1600 mAH

A-2 Accessories

Audio Accessories

HMN9752 Earpiece with Volume Control, 1-Wire (plastic earloop) (Beige) HMN9727 Earpiece without Volume Control, 1-Wire (plastic earloop) (Beige) RLN4894 Earpiece without Volume Control, 1-Wire (plastic earloop) (Black) HMN9754 Earpiece with Microphone & PTT Combined, 2-Wire (Beige) RLN4895 Earpiece with Microphone & PTT Combined, 2-Wire (Black) RLN5198_P Earpiece with Microphone & PTT Combined (Black) including Low Noise Kit,

2-Wire Surveillance Kit w/Clear Comfortable Acoustic Tube

(includes NTN8371) BDN6720 Flexible Ear Receiver (RX only) PMLN4443 Flexible Ear Receiver with Microphone & PTT Combined HMN9036 Earbud with Microphone & PTT Combined, 2-Wire (Black) PMLN4294 Earbud with Microphone & PTT Combined PMLN4442 Earbud with Microphone & PTT Combined HLN9132 Earbud Single Wire Receive Only (Black) NTN8370 Extreme Noise Kit 5080384T72 Replacement Noise Attenuating Plug for NTN8370 NTN8371 Low Noise Kit RLN4760 Small Custom Clear Earpiece, Right Ear RLN4763 Small Custom Clear Earpiece, Left Ear RLN4761 Medium Custom Clear Earpiece, Right Ear RLN4764 Medium Custom Clear Earpiece, Left Ear RLN4762 Large Custom Clear Earpiece, Right Ear RLN4765 Large Custom Clear Earpiece, Left Ear BDN6646 Standard 95 dB Ear Microphone with PTT Interface Module BDN6706 Standard 95 dB Ear Microphone with VOX & PTT Interface Module 0180358B38 Ring PTT Switch for Ear Microphone System 0180300E83 Body PTT Switch for Ear Microphone System RLN5500 Accessory Retainer RLN5317 2-Wire Comfort Earpiece wMic & PTT (Beige) RLN5318 2-Wire Comfort Earpiece w/Mic & PTT (Black) TDN9327 Portable Radio Hanger TDN9373 Portable Radio Hanger

Headsets

RLN5411 Ultra-Lite Breeze Behind the Head Headset PMMN4001 Ultra-Lite Earset with Mic and PTT HMN9013 Lightweight Headset w/o In-line PTT RMN4016 Lightweight Headset with In-line PTT RLN5238 Lightweight Headset with In-line PTT, NFL Style HMN9021 Medium Weight Over the Head Dual Muff Headset HMN9022 Medium Weight Behind the Head Dual Muff Headset

December 3, 2003 HKLN4215A

Accessories A-3

BDN6647 Medium Weight Single Speaker Headset BDN6648 Heavy Duty Dual Muff Headset with Noise Canceling Microphone 5080371E66 Replacement Ear Pad for BDN6647 RMN5015 Heavy Duty Dual Muff Racing Headset

(requires RKN4090 Headset Adapter Cable) REX4648 Ear Pad and Windscreen Kit RKN4090 Adapter Cable for use with RMN5015 Racing Headset RMN4051 2-Way Hard Hat Mount, Black, Noise Reduction Rating (22db)

(requires RKN4094 Adapter Cable) RMN4055 Receive-Only Headband Style Headset with 3.5mm Right Angle Plug HLN9133 VOX Adapter Kit (for use with Headsets only) RKN4094 In-Line PTT Adapter for use with headsets RMN4051, RMN4052, and

RMN4053 only) PMLN4445 Ultra-Light Headset with Boom Microphone

Remote Speaker Microphones

HMN9030 Remote Speaker Microphone RLN4904 Mic Jacket for HMN9030 Remote Speaker Microphone HKN9094 Replacement Cord for HMN9030 PMMN4008 Remote Speaker Microphone

Manuals

HKLN4212 E-Series User Guide HKLN4215 E-Series Basic Service Manual HKLN4216 E-Series Detailed Service Manual

HKLN4215A December 3, 2003

A-4 Accessories

December 3, 2003 HKLN4215A

Appendix B Warranty, Service Support, and

Replacement Parts

1.1 Scope of Manual

This manual is intended for use by service technicians familiar with similar types of equipment. It contains service information required for the equipment described and is current as of the printing date. Changes which occur after the printing date ma y be incorporated by a complete Manual re vision or alternatively as additions.

Notes:

Before operating or testing these units, please read the Product Safety and RF Exposure Compliance section in the front of this manual.

1.2 Warranty

Motorola offers long term support for its products. This support includes full e xchange and/or repair of the product during the warr anty period, and service/ repair or spare p arts support out of warranty. Any “return for exchange” or “return for repair” by an authorized Motorola Dealer must be accompanied by a Warranty Claim Form. Warranty Claim Forms are obtained by contacting an Authorized Motorola Dealer.

1.2.1 Warranty Period and Return Instructions

The terms and conditions of warranty are defined fully in the Motorola Dealer, Distributor, or Reseller contract. These conditions may change from time to time and the following notes are for guidance purposes only.

In instances where the product is covered under a “return for replacement” or “return for repair” warranty, a check of the product should be performed prior to shipping the unit back to Motorola. Th is is to ensure that the product has been correctl y programmed or has not been subjected to da mage outside the terms of the warranty.

1.2.2 After Warranty Period

After the Warranty period, Motorola continues to support its products in two ways.

1. Motorola's Radio Products Services Division (RPSD)* offers a repair service to both end users

and dealers at competitive prices.

2. Radio Products Services Division (RPSD) supplies individual parts and modules that can be pur-

chased by dealers who are technically capable of performing fault analysis and repair.

* The Radio Products Services Division (RPSD) was formerly knows as the Accessories and Aftermarket Division (AAD)

1.3 Replacement Parts Ordering

1.3.1 Basic Ordering Information

When ordering replacement parts or equipment information, the complete identification number should be included. This applied to all components, ki ts, 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, a sufficient description of the desired component to identify it.

Appendix B-2 Warranty, Service Support, and Replacement Parts: Replacement Parts Ordering

1.3.2 Motorola Online

Motorola online users can access our on-line catalog at: https://businessonline.motorola.com

1.3.3 Mail Orders

Send written orders to the following addresses:

International Orders:

Motorola, Inc. Customer Care and Services Division* Attention: Order Processing 2200 Galvin Dr. Elgin, IL 60123 U.S.A.

1.3.4 Telephone Orders

Radio Products Services Division (RPSD)* (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)

1.3.5 Fax Orders

Radio Products Services Division (RPSD) (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 Purchased Orders)

1.3.6 Parts Identification

Radio Products Services Division (RPSD) (United States and Canada) 1-800-422-4210, menu 3 1-847-538-0021(International) (voice)

* The Radio Products Services Division (RPSD) was formerly known as the Accessories and Aftermarket Division (AAD)

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Warranty, Service Support, and Replacement Parts: Technical Support Appendix B-3

1.4 Technical Support

Technical support is available to assist the dealer/distributor in resolving any malfunction which may be encountered. Initial contact sh ould be by telephone wherever possible. When contacting Motorola Technical Support (“contact us” MOL at https://businessonline.motor ola.com), be prep ared to provide the product model number and the unit’s serial number.

Motorola de Colombia Service Center

Carrera 7 No. 71-52 Torre B, Piso 13 Oficina 1301 Bogotá – Colombia 1-571-376-6990

Motorola de Mexico Service Center

Bosques de Alisos #125 Col. Bosques de las Lomas CP 05120 Mexico D. F. 1-525-257-6700

HKLN4215A December 3, 2003

Appendix B-4 Warranty, Service Support, and Replacement Parts: Technical Support

December 3, 2003 HKLN4215A

Glossary of Terms

Term Definition

ALC Automatic Level Control: a circuit in the transmit RF path that controls RF power

amplifier output, provides leveling over frequency and voltage, and protects

against high VSWR (voltage standing wave ratio). ASFIC Audio Signalling Filter Integrated Circuit BKC Bad Key Chirp CD Compact Disk CMP Compression CPS Customer Programming Software CSQ Carrier Squelch DTMF Dual-Tone Multifrequency DPL Digital Private-Line™ EEPROM Electronically Erasable/Programmable Read-Only Memory: used by the radio to

store its personality Firmware Software, or a software/hardware combination of computer programs and dat a,

with a fixed logic configur at ion stores in a read-o nly memory. Information cannot

be altered or reprogrammed. FGU Frequency Generation Unit GaAs Galli um Arsenide: a type of crystalline material used in some semiconductors. GKC Good Key Chirp ISW Inbound Signalling Word: data transmitted on the control channel from a sub-

scriber unit to the central control unit. LH DATA Longhorn Data: a bidirectional 0-5V, RS-232 line protocol that uses the micro-

controller’s integrated RS-232 asynchronous serial communications interface

(SCI) peripheral. LLE Low Level Expander: slight amount of volume expansion; used to improve the

signal to noise ratio. MCU Micro Controller Unit MRTI Motorola Radio-Telephone Interconnect: a system that provides a repeater con-

nection to the Public Switched Telephone Network (PSTN). The MRTI allows the

radio to access the telephone network when the pro pe r access code is re ce ived. OMPAC Over-Molded Pad-Array Carrier: a Motorola custom package, distinguished by

the presence of solder balls on the bottom pads. PC Board Printed Circuit Board PL Private-Line® tone squelch: a continuous sub-audible tone that is transmitted

along with the carrier.

G-2

Term Definition

PLL Phase-Locked Loop: a circuit in which an oscillator is kept in phase with a refer-

ence, usually after passing through a frequency divide r.

PTT Push-To-Talk: the switch located on the left side of the radio; when pre ssed,

causes the radio to transmit.

RAM Random Access Memory: the radio’s RAM is loaded with a copy of the EEPROM

data. Registers Short-term data-storage circuits within the microcontroller. RESET Reset line: an input to the microcontroller that restarts execution. RF PA Radio Frequency Power Amplifier RIB Radio Interface Box ROM Read Only Memory RSSI Received Signal-Strength Ind icator: a dc voltage p roportional to the receiv ed RF

signal strength. RPT/TA Repeater/Talk Around Softpot A computer-adjustable electronic attenuator Software Computer programs, procedures, rules, documentation, and data pertaining to

the operation of a system. SPI (clock and data

lines)

Serial Peripheral Interface: how the microcontroller communicates to modules

and ICs through the CLOCK and DATA lines. Squelch Muting of audio circuits when received signal levels fall below a pre-determined

value. Standby Mode An operating mode whereby the radio is muted but still continues to receive data TOT Time-Out Timer: a timer that limits the length of a transmission. TPL Tone Private-line µC Microcontroller UHF Ultra High Frequency µP Microprocessor VCO Voltage-Controlled Oscillator: an oscillator whereby the frequency of oscillation

can be varied by changing a cont rol voltage. VCOBIC Voltage-Controlled Oscillator Buffer Integrated Circuit VHF Very High Frequency VSWR Voltage Standing Wave Ratio

December 3, 2003 HKLN4215A

Motorola EP450 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual