Motorola MOTOTRBO DR 3000 User Manual
Professional Digital Two-Way Radio System
MOTOTRBO™ Repeater
Basic Service Manual
DR 3000 Repeater
Title Page
M
DR 3000
UHF Range 1
MOTOTRBO
™
Repeater
Basic Service Manual
6866576D03-A
Foreword
This manual covers all models of the MOTOTRBO Repeater, unless otherwise specified. It includes all the information
necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance
procedures. This level of service goes down to the board replacement level and is typical of some local service centers,
Motorola Authorized Dealers, self-maintained customers, and distributors.
For details on repeater operation or component-level troubleshooting, refer to the applicable manuals available separately.
Product Safety and RF Exposure Compliance
Before using this product, read the operating instructions
for safe usage contained in the Product Safety and RF
!
C a u t i o n
This repeater is restricted to occupational use only to satisfy ICNIRP/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 product (Motorola
Publication part number 6866537D37) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, and other accessories, visit the following web site which
lists approved accessories: http://www.motorola.com/governmentandenterprise
Computer Software Copyrights
The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the
sale of a product.
Exposure booklet enclosed with your product.
ATTENTION!
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written permission
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA and the Stylized M logo are registered in the U.S. Patent & Trademark Office. All other product or service
names are the property of their respective owners.
© 2007 by Motorola, Inc.
All rights reserved.
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
6866576D03-A Initial Release Feb. 2007
iii
6866576D03-A February 21, 2007
iv
Notes
February 21, 2007 6866576D03-A
Table of Contents v
Table of Contents
Foreword.........................................................................................................ii
Product Safety and RF Exposure Compliance ............................................................................................ ii
Computer Software Copyrights ...................................................................................................................ii
Document Copyrights ..................................................................................................................................ii
Disclaimer....................................................................................................................................................ii
Trademarks ................................................................................................................................................. ii
Document History ........................................................................................ iii
Chapter 1 Introduction ......................................................................... 1-1
1.1 Notations Used in This Manual .................................................................................................... 1-1
1.2 Repeater Description ................................................................................................................... 1-1
1.3 MOTOTRBO Repeater Model Numbering Scheme..................................................................... 1-2
1.4 UHF1 High Power MOTOTRBO Repeater (403-470 MHz) Model Chart ..................................... 1-3
1.5 Specifications............................................................................................................................... 1-4
Chapter 2 Test Equipment and Service Aids ..................................... 2-1
2.1 Recommended Test Equipment .................................................................................................. 2-1
2.2 Service Aids ................................................................................................................................. 2-2
2.3 Programming Cables .................................................................................................................. 2-2
Chapter 3 Transceiver Performance Testing ..................................... 3-1
3.1 General ........................................................................................................................................ 3-1
3.2 Setup ........................................................................................................................................... 3-1
Chapter 4 Repeater Tuning and Programming .................................. 4-1
4.1 Introduction .................................................................................................................................. 4-1
4.2 Customer Programming Software Setup ..................................................................................... 4-1
4.3 Repeater Tuning Setup................................................................................................................ 4-2
Chapter 5 Disassembly/Reassembly Procedures ............................. 5-1
5.1 Introduction .................................................................................................................................. 5-1
5.2 Preventive Maintenance .............................................................................................................. 5-1
5.2.1 Inspection ........................................................................................................................ 5-1
5.2.2 Cleaning Procedures ....................................................................................................... 5-1
5.3 Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2
5.4 Repair Procedures and Techniques — General.......................................................................... 5-3
5.5 Disassembling and Reassembling the Repeater — General ...................................................... 5-4
6866576D03-A February 21, 2007
vi Table of Contents
5.6 Disassembly Procedures — Detailed .......................................................................................... 5-4
5.6.1 Disassembly of Cover...................................................................................................... 5-4
5.6.2 Disassembly of Repeater Indicator Board ....................................................................... 5-5
5.6.3 Disassembly of Fan .........................................................................................................5-6
5.6.4 Removing Transmit Radio ............................................................................................... 5-7
5.6.4.1 Removing Thermal Pad and Heatsink .............................................................. 5-8
5.6.5 Removing Receive Radio, Power Supply and Connector Board Assembly .................... 5-8
5.6.5.1 Disassembly of Receive Radio ....................................................................... 5-10
5.6.5.2 Disassembly of Connector Board Assembly ................................................... 5-10
5.6.5.3 Disassembly of Power Supply ........................................................................ 5-10
5.7 Transmit and Receive Radio Disassembly — Detailed ............................................................. 5-11
5.7.1 Transceiver Board and Receiver Board Removal ......................................................... 5-11
5.8 Transmit and Receive Radio Reassembly — Detailed .............................................................. 5-14
5.8.1 Transceiver Board and Receiver Board Reassembly.................................................... 5-15
5.8.2 Thermal Pad Replacement Procedure .......................................................................... 5-19
5.8.3 Reassembly of Receive Radio, Power Supply and Connector Board Assembly........... 5-21
5.8.3.1 Reassembly of Power Supply ......................................................................... 5-21
5.8.3.2 Reassembly of Receive Radio........................................................................ 5-21
5.8.3.3 Reassembly of Connector Board Assembly ................................................... 5-21
5.8.3.4 Reassembly of the Receive Bracket Assembly to the Enclosure ................... 5-21
5.8.4 Reassembly of Transmit Radio...................................................................................... 5-22
5.8.4.1 Replacing the Thermal Pad and Heatsink ...................................................... 5-22
5.8.4.2 Reassembly of the Transmit Bracket Assembly to the Enclosure .................. 5-22
5.8.5 Reassembly of Fan........................................................................................................ 5-23
5.8.6 Reassembly of Repeater Indicator Board...................................................................... 5-23
5.8.7 Reassembly of Cover .................................................................................................... 5-23
5.9 Repeater Exploded Mechanical Views and Parts Lists.............................................................. 5-24
5.10 Torque Chart.............................................................................................................................. 5-27
Chapter 6 Basic Troubleshooting ....................................................... 6-1
6.1 Introduction .................................................................................................................................. 6-1
6.1.1 High Power RF Precaution ..............................................................................................6-1
6.2 Replacement Service Kit Procedures .......................................................................................... 6-1
6.3 LED Indicator Descriptions .......................................................................................................... 6-2
Appendix A EMEA Regional Warranty, Service and Support ..............A-1
A.1 Warranty and Service Support .....................................................................................................A-1
A.2 European Radio Support Centre (ERSC) ....................................................................................A-2
A.3 Piece Parts...................................................................................................................................A-2
A.4 Technical Support ........................................................................................................................A-3
A.5 Further Assistance From Motorola...............................................................................................A-3
Glossary ......................................................................................... Glossary-1
February 21, 2007 6866576D03-A
viii List of Figures
List of Figures
Figure 1-1. Repeater Model Numbering Scheme................................................................................... 1-2
Figure 2-1. Mobile & Repeater Rear Programming Cable PMKN4010_ ................................................ 2-2
Figure 2-2. Mobile & Repeater Rear Programming, Testing & Alignment Cable PMKN4016_............... 2-3
Figure 4-1. Customer Programming Software Setup from Rear Accessory Connector ......................... 4-1
Figure 4-2. Repeater Tuning Equipment Setup ......................................................................................4-2
Figure 5-1. Removing Top Cover of Repeater Enclosure....................................................................... 5-4
Figure 5-2. Disconnecting Ethernet Cable and Flex Cable .................................................................... 5-5
Figure 5-3. Repeater Indicator Board Disassembly................................................................................ 5-6
Figure 5-4. Fan Orientation..................................................................................................................... 5-6
Figure 5-5. Tx Radio Disassembly ......................................................................................................... 5-7
Figure 5-6. Receive Radio Removal....................................................................................................... 5-9
Figure 5-7. Die Cast Cover Removal.................................................................................................... 5-11
Figure 5-8. Accessory Connector Removal..........................................................................................5-12
Figure 5-9. RF/DC Retention Clips Removal........................................................................................5-12
Figure 5-10. Transceiver Board Removal............................................................................................... 5-13
Figure 5-11. Thermal Pads and Shield Gasketing on Chassis and Die Cast Cover............................... 5-14
Figure 5-12. Transceiver Board with Thermal Pads ............................................................................... 5-14
Figure 5-13. Replacing GPS Plug .......................................................................................................... 5-15
Figure 5-14. Placing the Transceiver Board in the Chassis.................................................................... 5-15
Figure 5-15. Inserting RF/DC Retention Clips ........................................................................................ 5-16
Figure 5-16. Inserting Accessory Connector .......................................................................................... 5-16
Figure 5-17. Assembling of PA Pad and O-ring...................................................................................... 5-17
Figure 5-18. Assembling Die Cast Cover onto Chassis ......................................................................... 5-18
Figure 5-19. Screw Sequence to Tighten Die Cast Cover...................................................................... 5-19
Figure 5-20. Replacing Thermal Pads .................................................................................................... 5-19
Figure 5-21. Aligning Driver Pad on Chassis.......................................................................................... 5-20
Figure 5-22. Placing Thermal Pads on PA and Transistor Components ................................................ 5-20
Figure 5-23. Fan Orientation................................................................................................................... 5-23
Figure 5-24. Repeater Assembly Exploded View ................................................................................... 5-24
Figure 5-25. Receive Bracket and Radio Assembly Exploded View ...................................................... 5-25
Figure 5-26. Transmit Bracket and Radio Assembly Exploded View...................................................... 5-25
Figure 5-27. Front Panel Complete Assembly Exploded View ............................................................... 5-26
February 21, 2007 6866576D03-A
List of Tables ix
List of Tables
Table 1-1. Frequency Ranges and Power Levels ................................................................................. 1-1
Table 2-1. Recommended Test Equipment ........................................................................................... 2-1
Table 2-2. Service Aids ......................................................................................................................... 2-2
Table 3-1. Initial Equipment Control Settings ........................................................................................ 3-1
Table 3-2. Receiver Performance Checks ............................................................................................ 3-2
Table 4-1. Repeater Software Program Kits ......................................................................................... 4-1
Table 5-1. Lead Free Solder Wire Part Number List ............................................................................. 5-3
Table 5-2. Lead Free Solder Paste Part Number List ........................................................................... 5-3
Table 5-3. Repeater Exploded View Parts List.................................................................................... 5-26
Table 5-4. Torque Specifications for Nuts and Screws........................................................................ 5-27
Table 6-1. LED Indicator Descriptions................................................................................................... 6-2
6866576D03-A February 21, 2007
x Related Publications
February 21, 2007 6866576D03-A
Chapter 1 Introduction
1.1 Notations Used in This Manual
Throughout the text in this publication, you will notice the use of note and caution notations. These
notations are used to emphasize that safety hazards exist, and due care must be taken and
observed.
NOTE: An operational procedure, practice, or condition that is essential to emphasize.
!
C a u t i o n
CAUTION indicates a potentially hazardous situation which, if
not avoided, might
1.2 Repeater Description
The MOTOTRBO Repeater is Motorola’s newest two-way digital and analog repeater designed for
your organization’s most demanding needs. The repeater is available in the following frequency
ranges and power levels.
Table 1-1. Frequency Ranges and Power Levels
Frequency
Band
UHF R1 403–470 MHz 25-40 Watts
This repeater is among the most sophisticated two-way repeaters available. It has a new robust
design for users who need high performance, quality, and reliability in their daily communications.
This new architecture provides the capability of supporting a multitude of legacy and advanced
features resulting in a more cost-effective two-way repeater communications solution.
result in equipment damage.
Bandwidth Power Level
1-2 Introduction: MOTOTRBO Repeater Model Numbering Scheme
A
A
1.3 MOTOTRBO Repeater Model Numbering Scheme
Model No.Example : AA M 2 7 Q P R 9 J A 7 A N
Position : 1 2 3 4 5 6 7 8 9 10 11 12
Z: Asia/Australia
LA: Latin America
A: North America (except Mexico)
MD: Europe/Middle East/Africa
Power Level
P: 25-40W
Repeater
MOTOTRBO Repeater
Model Series
Band
Q: 403-470MHz
Physical Packages
R: Repeater
Feature Level
1: Mini-U
2: BNC
7: Rack Mount
Primary System Type
A: Conventional
Primary Operation
J: w/o GPS
L: w/ GPS
Unique Model Variations
N: Standard Package
Version Letter
Channel Spacing
9: Variable/Programmable
Figure 1-1. Repeater Model Numbering Scheme
February 21, 2007 6866576D03-A
Introduction: UHF1 High Power MOTOTRBO Repeater (403-470 MHz) Model Chart 1-3
1.4 UHF1 High Power MOTOTRBO Repeater (403-470 MHz) Model
Chart
UHF1 403-470 MHz, 25-40W
Model Description
MDM27QPR9JA7AN 403-470 MHz, 25-40W, MOTOTRBO Repeater
Item Description
X PMLN4815_ Connector Board Assembly
X PMLN4814_ Repeater Indicator Board
X PMUE2390_S Repeater Service Kit
X 3002695D05
NNTN7373_R
NNTN7374_R
X 6866537D37 Product Safety and RF Exposure Booklet
X = Item Included
_ = the latest version kit. When ordering a kit, refer to your specific kit for the suffix number.
Power Supply UK
Power Supply US
Power Supply EU
6866576D03-A February 21, 2007
1-4 Introduction: Specifications
1.5 Specifications
General
Specification UHF1
Channel Capacity 1
Technical RF Output 25-40W
Frequency 403-470 MHz
Dimensions (HxWxL) 132.6 mm x 482.6 mm x 296.5 mm
Weight 14 kg
Voltage Requirements 100-240 V AC 47-63 Hz (13.6 V DC)
Current Drain: Standby
Transmit
Operating Temperature Range -30°C to +60°C
Max Duty Cycle 100%
Receiver
Specification UHF1
Frequency 403-470 MHz
Channel Spacing 12.5 kHz/25 kHz
Frequency Stability (-30°C to +60°C) ±0.5 ppm
Analog Sensitivity 0.30 µV (12 dB SINAD)
Digital Sensitivity 5% BER: 0.3 µV
Intermodulation 70 dB
0.5 A (1 A DC typical)
1.5 A (11 A DC typical)
0.22 µV (typical) (12 dB SINAD)
0.40 µV (20 dB SINAD)
Adjacent Channel Selectivity: 60 dB @ 12.5 kHz, 70 dB @ 25 kHz
Spurious Rejection 70 dB
Audio Distortion @ Rated Audio 3% (typical)
Hum and Noise -40 dB @ 12.5 kHz
-45 dB @ 25 kHz
Audio Response +1, -3 dB
Conducted Spurious Emission -57 dBm
February 21, 2007 6866576D03-A
Introduction: Specifications 1-5
Transmitter
Specification UHF1
Frequency 403-470 MHz
Channel Spacing 12.5 kHz/25 kHz
Frequency Stability (-30°C to +60°C) ±0.5 ppm
Power Output 25-40 W
Modulation Limiting ±2.5 kHz @ 12.5 kHz
±5.0 kHz @ 25 kHz
FM Hum and Noise -40 dB @ 12.5 kHz
-45 dB @ 25 kHz
Conducted/Radiated Emission -36 dBm < 1 GHz
-30 dBm > 1 GHz
Adjacent Channel Power 60 dB @ 12.5 kHz
70 dB @ 25 kHz
Audio Response +1, -3 dB
Audio Distortion 3%
Digital Vocoder Type AMBE++
Digital Protocol ETSI-TS102 361-1
Conforms to:
ETSI TS 102 361 (Parts 1, 2 & 3) - ETSI DMR Standard
1999/5/EC (R&TTE - Radio and Telecommunications Terminal Equipment)
2002/95/EC (RohS - Banned Substances)
2002/96/EC (WEEE - Waste Electrical and Electronic Equipment)
94/62/EC (Packaging and Packaging Waste)
Radio meets applicable regulatory requirements.
Specifications subject to change without notice. All specfications shown are typical.
6866576D03-A February 21, 2007
1-6 Introduction: Specifications
Notes
February 21, 2007 6866576D03-A
Chapter 2 Test Equipment and Service Aids
2.1 Recommended Test Equipment
The list of equipment contained in Table 2-1 includes most of the standard test equipment required
for servicing Motorola repeaters.
Table 2-1. Recommended Test Equipment
Equipment Characteristic Example Application
Service Monitor Can be used as a
substitute for items
marked with an asterisk
(*)
Digital RMS
Multimeter*
RF Signal
Generator*
Oscilloscope* 2 Channel
Power Meter and
Sensor*
RF Millivolt Meter 100 mV to 3 V RF
100 µV to 300 V
5 Hz to 1 MHz
10 Meg Ohm Impedance
100 MHz to 1 GHz
-130 dBm to +10 dBM
FM Modulation 0 kHz to
10 kHz
50 MHz Bandwidth
5 mV/div to 20 V/div
5% Accuracy
100 MHz to 500 MHz
50 Watts
10 kHz to 1 GHz
Aeroflex 2975
(www.aeroflex.com), Motorola
R2670, or equivalent
Fluke 179 or equivalent
(www.fluke.com)
Agilent N5181A
(www.agilent.com), Ramsey
RSG1000B
(www.ramseyelectronics.com),
or equivalent
Leader LS8050
(www.leaderusa.com), Tektronix
TDS1001b
(www.tektronix.com), or
equivalent
Bird 43 Thruline Watt Meter
(www.bird-electronic.com) or
equivalent
Boonton 92EA
(www.boonton.com) or
equivalent
Frequency/deviation meter and
signal generator for wide-range
troubleshooting and alignment
AC/DC voltage and current
measurements. Audio voltage
measurements
Receiver measurements
Waveform measurements
Transmitter power output
measurements
RF level measurements
2-2 Test Equipment and Service Aids: Service Aids
2.2 Service Aids
Table 2-2 lists the service aids recommended for working on the repeater. While all of these items
are available from Motorola, most are standard workshop equipment items, and any equivalent item
capable of the same performance may be substituted for the item listed.
Table 2-2. Service Aids
Motorola
Part Number
RLN4460_ Test Set Enables connection to audio/accessory jack. Allows
GMVN5141_ Customer Programming Soft-
ware on CD-ROM
PMKN4016_ Mobile & Repeater Rear
Programming, Testing &
Alignment Cable
PMKN4010_ Mobile & Repeater Rear
Programming Cable
Description Application
switching for radio testing.
Allows servicer to program repeater parameters, tune
and troubleshoot repeaters.
Connects the radio’s rear connector to a USB port for
radio programming, data applications, testing and
alignment.
Connects the radio’s rear connector to a USB port for
radio programming and data applications.
2.3 Programming Cables
Figure 2-1. Mobile & Repeater Rear Programming Cable PMKN4010_
February 21, 2007 6866576D03-A
Test Equipment and Service Aids: Programming Cables 2-3
DB 25 CONNECTOR
1
14
915 15
CABLE
USB CONNECTOR
13
4
25
1455 24
CABLE
TO MOBILE RADIO
ACCESSORY
CONNECTOR
25
26
1
VIEWED FROM
FRONT (PIN END)
OF CONNECTOR
2
TABLE 2: WIRE DIAGRAM
26 PIN
ACCESSORY PORT
CONNECTOR
DESCRIPTION
PIN No.
VCC (5v)
3
22
DATA -
DATA +
1
4
9
11
17
16 16
10
GND
SPEAKER -
EXT MIC
DIGI IN 1
(EXT PTT)
GND
SPEAKER +
USB DB25P
1
3
7
17
20
1
Figure 2-2. Mobile & Repeater Rear Programming, Testing & Alignment Cable PMKN4016_
6866576D03-A February 21, 2007
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