Motorola V300, V303, V400, V500, V525 Service Manual

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Consumer Solutions & Support
US Competency Center
600 North US Highway 45
Libertyville, Illinois 60048

Website: gs.mot.com

FIELD SERVICE BULLETIN

FSB Number: LVCCFSB2004-120
Author: Tony Bryan
Date: July 16, 2004
Total No. of Pages: 4
Subject: GSM Triplets - Flip Detect Switch
Model Affected: GSM V300, V303, V400, V500, V525, V600
Level of Repair: 2

Problem

Service is aware of an issue identified during NPI Analysis on all GSM Triplets models.
Some units, returned with a customer complaint of “Corrupt/Error CLI Display”, were
found to have intermittent operation of the Flip Detect Switch. As a result of the flip
switch not activating properly, the units would show the Carrier Logo upside down, on
the CLI Display with the flip closed, rather than showing the Time/Status. In some
cases, slight pressure applied to the top of the flip would allow the flip switch to activate
and the CLI Display to return to normal. The root cause of these failures was confirmed
to be a result of either foreign material or corrosion collecting on the PCB or Keypad,
which would interfere with the gold puck of the keypad making a good electrical
connection with the flip switch contacts (S550) on the PCB.

Foreign Material:
some excess material would extend over the cutout for the flip switch contacts (S550).
See diagram 1 below.

The main source of the foreign material was the side-key flex, where

Diagram 1.0 - Contamination from Side-Key Flex

Corrosion: The main source of the corrosion was isolated to the 3888844N01 keypad
supplied by Sinco. The gold pucks sourced by Sinco were sub-standard in quality and
had a high susceptibility to corrosion when exposed to environmental conditions in the
field. See diagram 2 below. In addition, the Sinco keypads had an additional air port
which directed air inward towards the contact increasing the opportunity for field failure.
The 3888844N01 keypad is used on V303, V400, V500 and V525.

MOTOROLA INTERNAL USE ONLY Page 1

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Consumer Solutions & Support
US Competency Center
600 North US Highway 45
Libertyville, Illinois 60048

Website: gs.mot.com

Diagram 2.0 - Corrosion caused by environments (3888844N01 Sinco Keypad)

Solution

Foreign Material: Supplier Process Improvements including the use of side-key flex with
a non-fiber based peelable paper. Factory Process Improvements including increased
inspection under magnification for foreign material.
Corrosion: The 3888844N01 Sinco keypad was redesigned to remove the extra air vent,
which was leading to a higher susceptibility to foreign material, completed 12/31/2003.
Sinco began sourcing higher quality gold pucks from Shin-Etsu on February 22, 2004.
Sinco obtained and crossed over to new supplier, with improved quality, for the gold
pucks as of March 31, 2004. Motorola changed the specification for the keypad where
an aggressive salt spray requirement was added.
Other: Product Development is evaluating a design change to the artwork of the PCB
contact and/or the mechanical design of the flip for further improvement of flip switch
performance.

Service Action

Customer Returns:

When servicing any GSM Triplet customer returns, with customer complaints of
“Corrupt/Error CLI Display”, then:

1. Test and evaluate the unit for proper performance of the Flip Switch
a. If Flip Switch operates normally, then follow normal troubleshooting

procedures to determine the fault per the customer complaint.

2. Dis-Assemble the unit and inspect the PCB contact and Keypad gold puck for

foreign material or corrosion, which may be interfering with the gold puck of the
keypad making a good electrical connection with the flip switch contacts (S550)
on the PCB.

3. Remove any foreign material found from PCB or keypad. IPA (Isopropyl Alcohol)

can be used to clean any remaining adhesive residue on the gold contacts.

4. Replace keypad or side-key flex if necessary to repair unit.

MOTOROLA INTERNAL USE ONLY Page 2