Tait Orca 5000, Orca 5010, Orca 5011, Orca 5015, Orca 5020 Service Manual

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Tait Orca 5000 Portable Radios

Service Manual

June 2003

IPN: M5000-00-105

Preface

Contacting Tait Electronics Ltd

The contact details for your nearest Tait Electronics regional office, can be found on the Tait Website: http://www.taitworld.com/

Enquiries and comments

If you have any enquiries regarding this manual, or any comments, suggestions and notifications of errors, please contact Customer Support, Tait Electronics Ltd, Christchurch, New Zealand, or refer to the Tait Website.

Conventions

Throughout this manual, the following conventions are used:

■ Names of software screen, field and menu names are referred to in bold sans serif font. For

example:

Check that the information in the Radio Model fields (Specifications screen) is correct.

■ The xxxx-character is used as a wildcard in product codes and part numbers, to indicate unspec-

ified characters.

Disclaimer

There are no warranties extended or granted by this manual. Tait Electronics Ltd accepts no responsibility for damage arising from use of the information contained in the manual or of the equipment and software it describes. It is the responsibility of the user to ensure that use of such information, equipment and software complies with the laws, rules and regulations of the applicable jurisdictions.

Updating equipment and manuals

In the interests of improving performance, reliability or servicing, Tait Electronics Ltd reserve the right to update their equipment and/or manuals without prior notice.

All information contained in this manual is the property of Tait Electronics Ltd. All rights are reserved. This manual may not, in whole or in part, be copied, photocopied, reproduced, translated, stored, or reduced to any electronic medium or machine-readable form, without prior written permission from Tait Electronics Limited. All trade names referenced are the service mark, trademark or registered trademark of the respective manufacturers.

ii June 2003 IPN: M5000-00-105

Publication history

Publication Date Product Code

May 2001 M5000-00-100

June 2001 M5000-00-101

September 2001 M5000-00-102

May 2002 M5000-00-103

September 2002 M5000-00-104

June 2003 M5000-00-105

June 2003 IPN: M5000-00-105 iii

iv June 2003 IPN: M5000-00-105

Contents

Part A: Introduction

Servicing Tait Orca 5000 portable radios

Servicing Tait Orca 5000 portable radios .................................................................................

Servicing Tait Orca 5000 portable radios Servicing Tait Orca 5000 portable radios

WWW technical support ..................................................................................................................... A-3

What does this manual contain? .......................................................................................................... A-3

Calibration service kit .......................................................................................................................... A-3

Programming kit .................................................................................................................................. A-4

The Tait Orca 5000 series of portable radios

The Tait Orca 5000 series of portable radios ............................................................................

The Tait Orca 5000 series of portable radios The Tait Orca 5000 series of portable radios

The Tait Orca product code ................................................................................................................. A-5

Operating instructions ......................................................................................................................... A-5

Accessories ........................................................................................................................................... A-5

Important information

Important information .............................................................................................................

Important information Important information

Basic servicing precautions .................................................................................................................. A-9

Programming ....................................................................................................................................... A-9

............................................................................................................. A-9

..........................................................................................................................................................................................................................

................................................................................. A-3

..................................................................................................................................................................

............................................................................ A-5

........................................................................................................................................................

A-3

A-3A-3

A-5

A-5A-5

A-9

A-9A-9

Calibrating ......................................................................................................................................... A-10

Test facilities ...................................................................................................................................... A-10

Basic maintenance ............................................................................................................................. A-10

Servicing Intrinsically Safe radios

Servicing Intrinsically Safe radios ...........................................................................................

Servicing Intrinsically Safe radios Servicing Intrinsically Safe radios

Intrinsically Safe radios ...................................................................................................................... A-11

IS PCB servicing requirements ........................................................................................................... A-11

FM approval ....................................................................................................................................... A-11

FM approved products ....................................................................................................................... A-11

FM approved accessories ................................................................................................................... A-11

........................................................................................... A-11

......................................................................................................................................................................................

Part B: Radio specifications and circuit descriptions

Radio specifications

Radio specifications ..................................................................................................................

Radio specifications Radio specifications

General specifications ........................................................................................................................... B-3

Receiver performance ........................................................................................................................... B-3

Transmitter performance ..................................................................................................................... B-4

TOP-Axxxx 66-88MHz radio specifications.......................................................................................... B-5

.................................................................................................................. B-3

A-11

A-11A-11

B-3

B-3B-3

TOP-Bxxxx 136-174MHz radio specifications ...................................................................................... B-6

TOP-Cxxxx 174-225MHz radio specifications ...................................................................................... B-7

TOP-Gxxxx 336-400MHz radio specifications...................................................................................... B-8

TOP-Hxxxx 400-470MHz radio specifications...................................................................................... B-9

TOP-Ixxxx 450-530MHz radio specifications ..................................................................................... B-10

June 2003 IPN: M5000-00-105 v

TOP-Jxxxx 806-870MHz radio specifications...................................................................................... B-11

TOP-Kxxxx 896-941MHz radio specifications .................................................................................... B-12

Circuit descriptions

Circuit descriptions .................................................................................................................

Circuit descriptions Circuit descriptions

Transmitter ........................................................................................................................................ B-13

Transmit (Tx) audio ........................................................................................................................... B-13

Receiver .............................................................................................................................................. B-13

Receive (Rx) audio .............................................................................................................................. B-13

DSP .................................................................................................................................................... B-14

Synthesiser and VCO .......................................................................................................................... B-14

Power supplies ................................................................................................................................... B-14

Accessory connector interface ............................................................................................................ B-15

Universal band versus wideband IF filtering ...................................................................................... B-15

................................................................................................................. B-13

Part C: Diagnostics and fault finding

Test facilities

Test facilities .............................................................................................................................

Test facilities Test facilities

Error codes ........................................................................................................................................... C-3

............................................................................................................................. C-3

B-13

B-13B-13

C-3

C-3C-3

Test commands ..................................................................................................................................... C-5

Calculating the parameters required for test command 101 ................................................................. C-7

Fault finding charts

Fault finding charts ...................................................................................................................

Fault finding charts Fault finding charts

Radio cannot be switched on ................................................................................................................ C-9

Cannot change channel ...................................................................................................................... C-10

No serial communication ................................................................................................................... C-11

Receive faults ...................................................................................................................................... C-12

Cannot transmit ................................................................................................................................. C-13

No transmit audio .............................................................................................................................. C-14

...................................................................................................................C-8

Part D: Servicing the radio

Servicing the radio

Servicing the radio ...................................................................................................................

Servicing the radio Servicing the radio

Screw head types .................................................................................................................................. D-3

Disassembling the radio

Disassembling the radio ..........................................................................................................

Disassembling the radio Disassembling the radio

Removing the front panel from the chassis ..........................................................................................D-4

Removing the shield sub-assembly from the chassis ............................................................................ D-5

................................................................................................................... D-3

.......................................................................................................... D-4

C-8

C-8C-8

D-3

D-3D-3

D-4

D-4D-4

Removing the PCB from the chassis .....................................................................................................D-6

Removing the rear panel ......................................................................................................................D-7

Replacing key mechanical and ancillary devices

Replacing key mechanical and ancillary devices ......................................................................

Replacing key mechanical and ancillary devices Replacing key mechanical and ancillary devices

Replacing the lens (Orca 5015/2x/35/40) ...........................................................................................D-8

Replacing the PTT keypad ....................................................................................................................D-8

Replacing the speaker ........................................................................................................................... D-9

vi June 2003 IPN: M5000-00-105

...................................................................... D-8

............................................................................................................................................

D-8

D-8D-8

Replacing the LCD display (Orca 5015/2x/35/40) .............................................................................. D-9

Replacing the shield, user interface PCB and polyester dome (Orca 5015/2x/35/40) ....................... D-12

Replacing the antenna connector, channel selector switch and volume control switch ..................... D-12

Replacing the microphone .................................................................................................................D-12

Replacing the battery and speaker contacts .......................................................................................D-12

Replacing the tact switch ....................................................................................................................D-12

Replacing the chassis .......................................................................................................................... D-13

Reassembling the radio

Reassembling the radio ..........................................................................................................

Reassembling the radio Reassembling the radio

Rear panel reassembly and replacing the auxiliary flexible PCB ........................................................ D-14

Fitting the PCB to the chassis and replacing the RF out assembly ...................................................... D-15

Fitting the shield to the chassis .......................................................................................................... D-15

Fitting the front panel to the chassis .................................................................................................. D-16

Spares kits

Spares kits ..............................................................................................................................

Spares kits Spares kits

Information contained in the tables ................................................................................................... D-17

PCB Product Codes ............................................................................................................................ D-17

Orca 5010/11/30 spares kit (TOPA-SP-401G) .................................................................................. D-18

.............................................................................................................................. D-17

.......................................................................................................... D-14

D-14

D-14D-14

D-17

D-17D-17

Orca 5035 spares kit (TOPA-SP-402G) .............................................................................................. D-19

Orca 5015/2x/40 spares kit (TOPA-SP-403G)................................................................................... D-20

Orca 5010/11/30 re-skinning kit (TOPA-SP-404) ............................................................................. D-21

Orca 5035 Re-skinning kit (TOPA-SP-405)........................................................................................ D-21

Orca 5020/40 Re-skinning kit (TOPA-SP-406).................................................................................. D-21

Orca 5015/2x/35/40 User Interface PCB and Shield (TOPA-SP-407) ............................................... D-22

Orca 5015/21 Re-skinning kit (TOPA-SP-408).................................................................................. D-22

Part E: Battery packs and chargers

Battery packs

Battery packs .............................................................................................................................

Battery packs Battery packs

Battery shift life ..................................................................................................................................... E-3

Disposing of used nickel-cadmium batteries .........................................................................................E-4

Battery chargers

Battery chargers ........................................................................................................................

Battery chargers Battery chargers

Desktop fast charger

Desktop fast charger ..................................................................................................................

Desktop fast charger Desktop fast charger

Fast charger operation .......................................................................................................................... E-6

Using the fast charger ............................................................................................................................E-9

.............................................................................................................................E-3

........................................................................................................................E-5

..................................................................................................................E-6

E-3

E-3E-3

E-5

E-5E-5

E-6

E-6E-6

Repairing the fast charger ...................................................................................................................E-10

Desktop trickle charger

Desktop trickle charger ...........................................................................................................

Desktop trickle charger Desktop trickle charger

Trickle charger operation .................................................................................................................... E-12

Using the trickle charger .....................................................................................................................E-13

Repairing the trickle charger ...............................................................................................................E-13

June 2003 IPN: M5000-00-105 vii

...........................................................................................................E-12

E-12

E-12E-12

Troubleshooting ..................................................................................................................................E-14

Multi-charger

Multi-charger ..........................................................................................................................

Multi-charger Multi-charger

Multi-charger operation ......................................................................................................................E-15

Repairing the multi-charger ................................................................................................................E-15

Fuse replacement ................................................................................................................................E-16

.......................................................................................................................... E-15

Part F: Accessories

Tait Orca 5000 accessory connector

Tait Orca 5000 accessory connector .........................................................................................

Tait Orca 5000 accessory connector Tait Orca 5000 accessory connector

Screw head types ...................................................................................................................................F-3

Connecting an accessory .......................................................................................................................F-3

Connecting a headset ............................................................................................................................F-5

Accessory connector signal descriptions ...............................................................................................F-6

7.5 mm Accessory adaptor

7.5 mm Accessory adaptor ........................................................................................................

7.5 mm Accessory adaptor 7.5 mm Accessory adaptor

Tait Orca vehicle kit

Tait Orca vehicle kit ................................................................................................................

Tait Orca vehicle kit Tait Orca vehicle kit

Product codes ......................................................................................................................................F-10

Update to the vehicle kit ......................................................................................................................F-10

........................................................................................................ F-8

................................................................................................................ F-10

......................................................................................... F-3

..................................................................................................................................................................................

E-15

E-15E-15

F-3

F-3F-3

F-8

F-8F-8

F-10

F-10F-10

Installing a vehicle kit ..........................................................................................................................F-10

Vehicle kit operation ...........................................................................................................................F-10

Vehicle kit specifications .....................................................................................................................F-12

Servicing the vehicle kit ....................................................................................................................... F-13

Spares kits ...........................................................................................................................................F-14

Vehicle kit spares kit (TOPA-SP-301).................................................................................................. F-15

Vehicle kit reskinning kit (TOPA-SP-302)........................................................................................... F-16

Custom modifications ......................................................................................................................... F-17

Vehicle kit circuit descriptions ............................................................................................................F-19

Part G: Additional information

Glossary

Glossary ................................................................................................................................

Glossary Glossary

Accessory connector compatibility

Accessory connector compatibility ..........................................................................................

Accessory connector compatibility Accessory connector compatibility

...................................................................................................................................

.......................................................................................... G-8

....................................................................................................................................................................................

... G-3

......

G-3

G-3G-3

G-8

G-8G-8

viii June 2003 IPN: M5000-00-105

PART

Introduction

This part provides an introduction to servicing Tait Orca 5000 portable radios. It includes an outline of the Tait Orca 5000 range of products and precautions that should be taken before servicing Tait Orca 5000 portable radios.

Detailed servicing instructions and information about spare parts are found in Part D: Servicing the radio.

Contents

Servicing Tait Orca 5000 portable radios

Servicing Tait Orca 5000 portable radios ......................................................

Servicing Tait Orca 5000 portable radios Servicing Tait Orca 5000 portable radios

WWW technical support ...................................................................................... A-3

What does this manual contain? ........................................................................... A-3

...................................................... A-3

............................................................................................................

A-3

A-3A-3

Calibration service kit ........................................................................................... A-3

Programming kit ................................................................................................... A-4

Conventions .......................................................................................................... A-4

The Tait Orca 5000 series of portable radios

The Tait Orca 5000 series of portable radios .................................................

The Tait Orca 5000 series of portable radios The Tait Orca 5000 series of portable radios

The Tait Orca product code ................................................................................... A-5

Operating instructions .......................................................................................... A-5

Accessories ............................................................................................................ A-5

Important information

Important information .................................................................................

Important information Important information

Basic servicing precautions ................................................................................... A-9

Programming ........................................................................................................ A-9

Calibrating .......................................................................................................... A-10

Test facilities ....................................................................................................... A-10

Basic maintenance ............................................................................................... A-10

Servicing Intrinsically Safe radios

Servicing Intrinsically Safe radios ...............................................................

Servicing Intrinsically Safe radios Servicing Intrinsically Safe radios

Intrinsically Safe radios ....................................................................................... A-11

................................................................................. A-9

..................................................................................................................................................................

............................................................... A-11

..............................................................................................................................

................................................. A-5

..................................................................................................

A-5

A-5A-5

A-9

A-9A-9

A-11

A-11A-11

IS PCB servicing requirements ............................................................................ A-11

FM approval ........................................................................................................ A-11

FM approved products ........................................................................................ A-11

FM approved accessories ..................................................................................... A-11

A - 2 June 2003 IPN: M5000-00-105

Servicing Tait Orca 5000 portable radios

The Tait Orca 5000 series is a range of portable high performance, microprocessor-controlled radios manufactured using an RF-shielded PCB and high-density SMD components.

Servicing of Tait Orca 5000 portable radios is limited to key mechanical and ancillary devices. These include:

■ the front panel assembly;

■ the lens (Orca 5015/2x/35/40);

■ the PTT keypad;

■ the speaker;

■ the keypad;

■ the LCD display (Orca 5015/2x/35/40);

■ the shield, complete with user interface

PCB assembly and polyester dome (Orca 5015/2x/35/40);

■ the main PCB assembly;

■ the antenna connector;

■ the channel selector switch;

■ the volume control switch;

WWW technical support

Tait Electronics Ltd provides product support at the following address:

http://www.taitworld.com/support

What does this manual contain?

This manual is supplied as part of the Tait Orca 5000 service kit (TOPA-SV-117G), and provides the following:

■ general information and specifications on

the Tait Orca 5000 series of portable radios;

■ basic circuit descriptions;

■ information on finding and servicing non-

PCB-related faults;

■ information on Tait Orca 5000 battery

packs and chargers;

■ information on interfacing accessories to

Tait Orca 5000 portable radios; and

■ a glossary of key terms.

■ the microphone;

■ the speaker contacts;

■ the battery contacts;

■ the PTT tact switch;

■ the RF out assembly

■ the auxiliary flexible PCB

■ the rear panel; and

■ the chassis.

The repair of PCB-related faults is the responsibility of Technical Support at Tait Electronics Ltd. Detailed schematics and component location information for the main PCB may also be obtained from Technical Support. Contact your Tait dealer for more information.

Calibration service kit

The TOPA-SV-117G service kit contains:

■ calibration test unit (TOPA-SV-004);

■ radio calibration cable for connecting the

radio to the calibration test unit (TOPASV-007G);

■ 9 pin RS232 to modular phone jack

programming lead for connecting the calibration test unit to a PC (TOPA-SV-

019);

■ DC service adaptor (TOPA-SV-005);

■ SMA to N-type RF test lead for connecting

to the radio’s antenna connector (TOPASV-006);

June 2003 IPN: M5000-00-105 Servicing Tait Orca 5000 portable radios A - 3

■ T6 driver bit and 8 mm socket (TOPA-SV-

011);

■ this manual; and

■ TOP Programming Utilities (TPU) CD-

ROM (IPN 406-00003-xx).

Other items required for calibration but not included as part of the service kit are:

■ RF communications test set (e.g. HP8920,

MI2945/55, CMS52);

■ digital current meter capable of measur-

ing current up to 3 A, accurate to two decimal places.;

■ DC power supply, 7.5 V, 3 A for portable

radios; and

■ TOPA-SV-A07 if calibrating TOP-Axxxx-

xx 66 -88MHz product.

Programming kit

The TOPA-SV-116 kit for programming Tait Orca 5000 radios contains:

■ accessory connector to modular phone

socket programming cable for connecting the radio to the programming lead (TOPA-SV-003G); and

■ 9 pin RS232 to modular phone jack

programming lead for connecting the programming cable to a PC (TOPA-SV-

019); and

■ TOP Programming Utilities (TPU) CD-

ROM (IPN 406-00003-xx).

A - 4 Servicing Tait Orca 5000 portable radios June 2003 IPN: M5000-00-105

The Tait Orca 5000 series of portable radios

There are eight Tait Orca 5000 series portable radio products:

■ Orca 5010/11 - low tier conventional

■ Orca 5015 - mid tier conventional

■ Orca 5020/21 - high tier conventional

■ Orca 5030 - low tier trunked

■ Orca 5035 - mid tier trunked

■ Orca 5040 - high tier trunked

This manual includes information specific to all the Orca 5000 portable radios. As new features and enhancements occur, new revisions of this manual will be released.

The Tait Orca product code

The characters in the Tait Orca 5000 product code provide information about the radio’s functional parameters and various hardware options, according to the scheme outlined in Figure A-1. For more information on available products, contact your nearest Tait dealer.

technical support Website:

http://www.taitworld.com/support

2. In this manual, when the term TOP x is used (e.g. TOP A or TOP B), it indicates the specific frequency band. TOP A will therefore refer to an A band Orca, and TOP B to a B band Orca.

Operating instructions

A user’s guide is available for each radio. Copies can be obtained through Technical Support.

Accessories

Table A-1 shows the accessories available for Tait Orca 5000 portable radios. Of these accessories, only the chargers are serviceable.

For more information on chargers, see Part E: Battery packs and chargers. The battery packs available for Tait Orca 5000 portable radios are also described in Part E.

Figure A-1: Tait Orca 5000 Product Code Scheme

The Tait Orca Product Code has the following structure:

TOP-abcde-mn

where:

TOP - Family designator

a - Frequency band b - Channel spacing/IFBW c - User interface d - Air interface e - Compliance-relevant changes

m - Badging

n - Custom variations not affecting

radio/EMC compliance

Notes:

1. The complete Tait Orca product code standard can be downloaded from the

New chassis

A new chassis and accessory connector have been introduced in September 2002. This provides greater strength to the accessory connector. Old accessories are however no longer compatible with the new chassis, nor will the new accessories fit the old chassis. See “Accessory connector compatibility” on page G-8. Information specific to the old chassis or accessories can be found in version M5000-00-103 of the Tait Orca 5000 service manual.

The new accessory connectors have a different shape quarter turn tip, no hooks on the locating posts and a green dot on the outside at the lower left corner

The new chassis has a different shape hole for the connector’s quarter turn tip, and a green

June 2003 IPN: M5000-00-105 The Tait Orca 5000 series of portable radios A - 5

seal behind. Figure A-2 illustrates the difference. Radios factory fitted with the new chassis also have a product code with the format TOP-xxxxx-Bx.

need to remove the rear accessory cover. Remove the battery, then insert the end of a key underneath the bottom edge of the accessory cover. Lift to remove the cover.

Figure A-2: Changed chassis hole

Fitting an accessory

To fit some accessories to the radio, you will

When attaching or removing an accessory, ensure that the lever is in the upright position. Keeping the accessory connector parallel to the radio, engage the two posts at the base of the connector with the rear panel. Once the accessory is in position, rotate the lever 90 degrees counterclockwise to lock it in place. See Figure A-3.

Removing an accessory

When removing an accessory, press the lock spring tab before rotating the clip clockwise. See Figure A-4.

Fitting a non-Tait accessory

See Part F: Accessories for information on using non-Tait accessories with Tait Orca 5000 portable radios.

Figure A-3: Fitting an accessory with a D-Clip

Figure A-4: Removing an accessory with a D-Clip

A - 6 The Tait Orca 5000 series of portable radios June 2003 IPN: M5000-00-105

Table A-1: Tait Orca 5000 accessories

Type of accessory Product code Description

Antennas TOPA-AN-101 130-230 MHz 3" helical

TOPA-AN-102 336-540 MHz 3" helical

TOPA-AN-201 136-340 MHz 6" helical

TOPA-AN-212 400-940 MHz 6" wave whip

TOPA-AN-203 896-941MHz 7" gain

TOPA-AN-204 806-870M 1/2 wave gain

TOPA-AN-205 896-941M 1/2 wave gain

TOPA-AN-301 66-88MHz 10" helical

Audio accessories

TOPA-AA-001G Speaker microphone, -10 to 60°C, two function buttons

TOPA-AA -002G Speaker microphone, -30 to 60 °C, heavy duty, two function buttons

TOPA-AA -003G Speaker microphone, -30 to 60 °C, MIL spec

TOPA-AA-004G Speaker microphone, -30 to 60 °C, MIL spec, with antenna socket

TOPA-AA-005G 7.5 mm accessory adaptor

TOPA-AA-006G Tait Orca accessory connector kit

TOPA-AA-007G Tait Orca RF accessory connector kit

TOPA-AA -008 Speaker microphone, -30 to 60 °C, MIL spec, no function buttons, high/low vol-

ume*

TOPA-AA-009 2-wire palm microphone and earphone, -30 to 75°C*

TOPA-AA-010 3-wire lapel microphone and earphone, -30 to 75°C*

TOPA-AA-011 Light weight single speaker headset with in-line PTT, -30 to 75°C*

TOPA-AA-012 Over-the-head headset with noise cancelling boom microphone, -30 to 75°C*

TOPA-AA-013 Behind-the-head headset with noise cancelling boom microphone, -30 to 75°C*

TOPA-AA-101G Speaker microphone, -10 to 60 °C, two function buttons (with D-Clip)

TOPA-AA-102G Speaker microphone, -10 to 60 °C, heavy duty, two function buttons (with D-Clip)

TOPA-AA-103G Speaker microphone, -10 to 60 °C, MIL spec (with D-Clip)

TOPA-AA-104G Speaker microphone, -30 to 60°C, MIL spec, with antenna socket (with D-Clip)

TOPA-AA-106G Tait Orca 5000 accessory connector kit (with D-Clip)

TOPA-AA-107G Tait Orca 5000 RF accessory connector kit (with D-Clip)

* For use with

T952-051 Earphone kit with coil cord and 2.5 mm plug, -30 to 75 °C (for use with TOPA-

TOPA-AA-005G

Batteries TOPB100 1100 mAh NiCd battery pack

TOPB200 1500 mAh NiCd battery pack

TOPB200-IF 1500 mAh NiCd battery pack (intrinsically safe)

TOPB400 1500 mAh NiMH battery pack

TOPB500 2000 mAh NiMH battery pack

TOPB600 1100 mAh NiCd battery pack (slim)

TOPB700 1500 mAh NiMH battery pack (slim)

June 2003 IPN: M5000-00-105 The Tait Orca 5000 series of portable radios A - 7

AA-003G, TOPA-AA-004G, TOPA-AA-008, TOPA-AA-103G & TOPA-AA-104G)

Type of accessory Product code Description

Battery chargers TOPA-CH-100 Desktop trickle charger

TOPA-CH-200 Desktop fast charger

TOPA-CH-300 Six-way multi-charger

Plug packs (for TOPA-CH-200)

Carrying accessories TOPA-CA-001 Heavy duty carry case

T952-012 Australia, New Zealand and China (230 V 50 Hz input; plug configuration: )

T952-022 Singapore and Middle East (230 V 50 Hz input; plug configuration: )

T952-032 Mainland Europe (230 V 50 Hz input; plug configuration: )

T952-042 USA and Canada (115 V 60 Hz input; plug configuration: )

T952-052 UK and Hong Kong (230 V 50 Hz input; plug configuration: )

TOPA-CA-002 Heavy duty holster

TOPA-CA-003 38 mm belt clip x 10

TOPA-CA-004 Accessory port cover x 10

TOPA-CA-005 55 mm belt clip

TOPA-CA-006 55 mm belt clip x 10

TOPA-CA-101 Heavy duty carry case (with D-Clip)

TOPA-CA-102 Holster carry case (with D-Clip)

TOPA-CA-103 Belt loop

TOPA-CA-104G D-Clip

TOPA-CA-105 Handstrap

Warning!

The following accessories have the old accessory connector and are still available for

Tait Orca series portable radios. Do not attempt to fit to the

attempt to fit to the new chassis

attempt to fit to the attempt to fit to the

new chassis.

new chassisnew chassis

purchase. These accessories only fit the older

Table A-2: Tait Orca 5000 portable radio accessories with the old connector

Type of accessory Product code Description

Audio accessories TOPA-AA-001 Speaker microphone, -10 to 60 °C, two function buttons

TOPA-AA -002 Speaker microphone, -30 to 60°C, heavy duty, two function buttons

TOPA-AA-003 Speaker microphone, -30 to 60°C, MIL spec

TOPA-AA-004 Speaker microphone, -30 to 60°C, MIL spec, with antenna socket

TOPA-AA-005 7.5 mm accessory adaptor

TOPA-AA-006 Tait Orca accessory connector kit

TOPA-AA-007 Tait Orca RF accessory connector kit

Do not

Do not Do not

A - 8 The Tait Orca 5000 series of portable radios June 2003 IPN: M5000-00-105

Important information

Basic servicing precautions

Tait Orca 5000 portable radios require specialised servicing techniques and should only be serviced at an approved Tait service centre equipped with the necessary facilities.

Figure A-5: Typical anti-static bench setup

Warning!

Repairs attempted with incorrect equipment or by untrained personnel may result in permanent damage.

Standard anti-static procedures should be followed; a typical setup is shown in Figure A-5.

If in doubt, contact Tait Electronics Ltd or your nearest Tait dealer.

to building earth (not

mains earth) via 1 M series resistor

conductive wrist strap

conductive rubber

bench mat

metal frame

Torx head 1.8x5 mm screws should be removed using the supplied Torx T6 driver. When replacing these screws, set the driver to 2in.lb (0.23Nm).

Caution: CMOS devices

This equipment contains CMOS devices, which are susceptible to damage from static charges. Care when handling these devices is essential. For correct handling procedures, refer to manufacturers’ data books covering CMOS devices, such as Philips Data Handbook

Covering CMOS Devices or Motorola CMOS Data Book Section 5 (Handling Procedures).

Screw head types

Torx recess head screws and Pozidriv recess head screws require the correct sized driver to achieve best performance. Most of the screws in Tait Orca 5000 portable radios are Torx head screws, and so a Torx T6 driver bit is supplied as part of the service kit. Some earlier radios have Pozidriv screws.

Pan head Pozidriv M2x8 mm and M2x5 mm screws should be removed using a number 1 Pozidriver. When replacing these screws, set the driver to 2in.lb (0.23Nm).

Programming

For information on programming Tait Orca 5000 portable radios, refer to:

■ the Tait Orca Trunked Programming Appli-

cation User’s Manual or the online help;

■ the Tait Orca Conventional Programming

Application User’s Manual or the online

help.

The User’s Manuals are on the TOP Programming Utilities (TPU) CD-ROM, which is included, together with this manual, as part of the calibration service kit.

June 2003 IPN: M5000-00-105 Important information A - 9

Calibrating

For information on calibrating Tait Orca 5000 portable radios, refer to:

■ the Tait Orca Calibration Application User’s

Manual or the online help.

The User’s Manual is on the TOP Programming Utilities (TPU) CD-ROM, which is included, together with this manual, as part of the calibration service kit.

Test facilities

Standard test facilities provide a way of testing the radio’s functions independently of normal radio operation. See Part C: Diagnostics and fault finding for a description of the test facilities available for Tait Orca 5000 portable radios.

Troubleshooting

If you are experiencing difficulty operating your Tait Orca portable radio check the following items:

■ Is the battery firmly attached to the radio?

■ Is the battery sufficiently charged?

■ Is the battery charger working properly?

■ Is the antenna damaged?

If all appears to be in order but your radio still fails to operate properly, consult your local Tait dealer for assistance.

Basic maintenance

Your Tait Orca portable radio requires no regular maintenance other than ensuring that the battery has sufficient charge and that no damage has occurred to the antenna or the battery pack.

General care

■ Wipe the battery contacts, accessory

connector contacts and radio display with a dry lint-free cloth to remove any dirt, oil or grease.

■ Use a cloth dampened with clean water to

clean the radio’s case and display lens, but do not immerse the radio in fluids.

■ Do not allow the radio to come into

contact with detergents, alcohol, aerosol sprays or petroleum-based products as they may permanently damage the case.

■ Avoid high temperatures. If the radio

overheats, it will cease to function. You will hear two short high-pitched beeps.

A - 10 Important information June 2003 IPN: M5000-00-105

Servicing Intrinsically Safe radios

Intrinsically Safe radios

Intrinsically Safe (IS) radios are certified by a third party to be safe to use in particular hazardous locations.

Tait Orca 5000 IS portable radios can be identified by one or more of the following:

■ Yellow labels

■ IS circle logo

■ FM diamond logo

A radio with any of these features must only be serviced by an agency certified by both the approval authority and Tait Electronics Ltd. Any unauthorised repair or substitution of parts invalidates the intrinsic safety rating and the third party IS approval.

APPROVED

IS PCB servicing requirements

Tait Orca 5000 IS portable radios must be returned to an authorised Tait branch or subsidiary for servicing. Any unauthorised repair or substitution of parts invalidates the intrinsic safety rating.

FM approval

■ TOP-x25x0-B2

■ TOP-x25x0-T2

■ TOP-x26x0-B2

■ TOP-x26x0-T2

For more information about the Tait Orca product code, refer to page page A-5.

FM approved accessories

The following accessories are approved for use with the Tait Orca 5000 IS portable radios.

■ TOPB200-IF NiCd IS battery pack

■ TOPA-AA-003G rugged speaker-micro-

phone

■ TOPA-AA-004G RF speaker-microphone

■ TOPA-AA-005 adapter (required for use

with TOPA-AA-012/013)

■ TOPA-AA-012 heavy duty headset with

noise cancelling microphone (over the head)

■ TOPA-AA-013 heavy duty headset with

noise cancelling microphone (behind neck)

Tait Orca 5000 IS portable radios and accessories are approved by Factory Mutual Corporation (FM) to the following ratings:

■ IS/I/1/CD/T3C Ta=40°C

■ NI/I/2/ABCD/T3C Ta=40°C

See Table A-3 on page A-12 for more detail on these ratings.

FM approved products

Radios with the following product code have FM IS approval:

■ TOP-x24x0-B2

■ TOP-x24x0-T2

June 2003 IPN: M5000-00-105 Servicing Intrinsically Safe radios A - 11

■ T952-051 rugged earphone kit (optional

for use with TOPA-AA-003/004)

TOPB200-IF IS battery pack

The shift life of the TOPB200-IF IS battery pack may be reduced by up to 10 percent when compared to its non-IS equivalent.

The battery pack should not be charged in a hazardous location.

Table A-3: FM ratings

Approval Class Division Group Temperature Rating

Intrinsically Safe: The unit is unable to cause ignition under normal or abnormal operating conditions.

Incentive: The unit is unable to cause ignition under normal operating conditions.

Class I: Gas or petroleum type environment.

Division 1: Hazardous mixtures are normally present.

Division 2: Hazardous mixtures are present abnormally.

Groups C & D: Ethylene and propane gases.

Groups A, B, C & D: Acetylene, hydrogen, ethylene and propane gases.

T3C: 160°C

A - 12 Servicing Intrinsically Safe radios June 2003 IPN: M5000-00-105

Radio specifications and circuit

PART

descriptions

This part outlines the radio specifications and circuit descriptions for Tait Orca portable radios.

Contents

Radio specifications

Radio specifications ......................................................................................

Radio specifications Radio specifications

General specifications ............................................................................................ B-3

Receiver performance ............................................................................................ B-3

Transmitter performance....................................................................................... B-4

TOP-Axxxx 66-88MHz radio specifications ........................................................... B-5

TOP-Bxxxx 136-174MHz radio specifications ....................................................... B-6

TOP-Cxxxx 174-225MHz radio specifications ....................................................... B-7

TOP-Gxxxx 336-400MHz radio specifications ....................................................... B-8

TOP-Hxxxx 400-470MHz radio specifications....................................................... B-9

...................................................................................... B-3

............................................................................................................................................................................

B-3

B-3B-3

TOP-Ixxxx 450-530MHz radio specifications ...................................................... B-10

TOP-Jxxxx 806-870MHz radio specifications....................................................... B-11

TOP-Kxxxx 896-941MHz radio specifications ..................................................... B-12

Circuit descriptions

Circuit descriptions .....................................................................................

Circuit descriptions Circuit descriptions

Transmitter ..........................................................................................................B-13

Transmit (Tx) audio .............................................................................................B-13

Receiver ................................................................................................................B-13

Receive (Rx) audio ................................................................................................B-13

DSP ......................................................................................................................B-14

Synthesiser and VCO ............................................................................................B-14

Power supplies .....................................................................................................B-14

Accessory connector interface ..............................................................................B-15

Universal band versus wideband IF filtering ........................................................B-15

..................................................................................... B-13

..........................................................................................................................................................................

B-13

B-13B-13

B - 2 June 2003 IPN: M5000-00-105

Radio specifications

Tables B-1, B-2 and B-3 show information common to all the radios. For detailed information on each band, refer to the performance figures outlined in Tables B-4 to B-11.

The performance figures are typical figures, unless otherwise stated, for equipment operating at standard room temperature.

The test methods used to obtain these figures are those described in the European Telecommunication Standard ETS 300-086. Where applicable, the EIA figure is also given.

Details of test methods and the conditions that apply for type approval testing in all countries can be obtained from Tait Electronics Ltd.

Important notes for Tables B-4 to B-11

With regard to the typical performance figures, specifications are subject to change without notice and shall not form part of any contract. They are issued for guidance purposes only. For further information please check with your nearest Tait office or authorised dealer who can confirm that the radio meets applicable regulatory requirements.

* Tait Orca products have an intermediate

(universal) IF bandwidth and can be programmed per channel for 2.5, 4.0 or 5.0 kHz deviation to cover any channel spacing. See “Universal band versus wideband IF filtering” on page B-15.

Table B-1: General specifications

Parameter Performance

Supply voltage 6.0 to 9.0 V

Standard test voltage 7.5 V

Table B-2: Receiver performance

Parameter Performance

Audio

Minimum load impedance

Rated power

Distortion

Response

Spurious emissions

to 1 GHz

1 to 4 GHz (136-470 MHz)

1 to 12.75 GHz (>470 MHz)

Group delay variation ±50

13 Ω

500 mW (1kHz, 60% deviation into 16 Ω)

<5% (1kHz, 60% deviation at rated power into 16 Ω)

-6 dB/oct +1, -3 dB (relative to 1 kHz), 300-2550 Hz (narrowband) 300-3000 Hz (wideband)

-57 dBm (conducted and radiated)

-47 dBm (conducted and radiated)

-47 dBm (conducted only)

µs (at detected audio output) bandwidth 300-3000 Hz

† TOPB600 batteries are recommended for use

with conventional radios (Orca 501x/2x) only.

June 2003 IPN: M5000-00-105 Radio specifications B - 3

RSSI

range

slope

-120 to -40 dBm

29 mV/dB (typical)

Table B-3: Transmitter performance

Parameter Performance

Duty cycle 20%

(1 minute Tx, 4 minutes Rx at maximum temperature and voltage)

Group delay variation

bandwidth

Trunking data deviation (as per MPT1327)

narrowband

mediumband

wideband

Audio response

below limiting

in limiting

above 3 kHz

input for 60% deviation

distortion

µs (at mod audio out-

±50 put)

300-3000 Hz

1.5 kH z

2.4 kHz

3 kHz

6 dB/oct +1, -3 dB (relative to 1 kHz) 300-3000 Hz

0 dB +0, -4 dB (relative to maximum system deviation) 450-2550 Hz

-35 dB/oct min

5 mV

rms

<5% at 1 kHz

Ruggedness 2 minutes (into infinite

VSWR)

Stability 5:1 VSWR (all phase angles,

<-60 dBc)

B - 4 Radio specifications June 2003 IPN: M5000-00-105

Table B-4: TOP-Axxxx 66-88MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 66-88MHz

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-15ppm (-20 to -10°C); +/-10ppm (-10 to +60°C)

Current Consumption (Receiver Squelched) 80mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 800mA/1.6A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40mA N/A

Receiver

Measurements as per: ETS 300-086

Intermediate frequencies 21.4MHz and 455kHz

Sensitivity 12dB SINAD < -119dBm

Sensitivity 20dB SINAD < -114dBm

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 70dB (NB), 75dB (WB)*

Spurious Response 70dB

Intermodulation 65dB

Blocking 94dB

Ultimate Signal to Noise Ratio (EIA) 39dB (NB), 44dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

Rated Audio Output > 500mW nominal

Tra nsm itt er

Measurements as per: ETS 300-086

Power Output (Low/Mid/High) 1 / 2.5 / 5W

Spurious Emissions (Cond. & Rad.) < -36dBm (0-1GHz), < -30dBm (1-4GHz)

Hum and Noise (EIA) 38dB (NB), 43dB (WB)*

Modulation Type* narrowband

wideband

10K0F3E 16K0F3E

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

June 2003 IPN: M5000-00-105 Radio specifications B - 5

Table B-5: TOP-Bxxxx 136-174MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 136-174MHz

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-2.5ppm (-30 to +60°C)

Current Consumption (Receiver Squelched) 80mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 810mA/1.6A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40mA N/A

Receiver

Measurements as per: ETS 300-086

Intermediate frequencies 21.4MHz and 455kHz

Sensitivity 12dB SINAD < -119dBm

Sensitivity 20dB SINAD < -114dBm

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 70dB (NB), 75dB (WB)*

Spurious Response 70dB

Intermodulation 65dB

Blocking 94dB

Ultimate Signal to Noise Ratio (EIA) 37dB (NB), 42dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

Rated Audio Output > 500mW nominal

Transmitter

Measurements as per: ETS 300-086

Power Output (Low/Mid/High) 1 / 2.5 / 5W

Spurious Emissions (Cond. & Rad.) < -36dBm (0-1GHz), < -30dBm (1-4GHz)

Hum and Noise (EIA) 36dB (NB), 42dB (WB)*

Modulation Type* narrowband

wideband

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

10K 0F3 E 16K 0F3 E

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

B - 6 Radio specifications June 2003 IPN: M5000-00-105

Table B-6: TOP-Cxxxx 174-225MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 174-225MHz

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-2.5ppm (-30 to +60°C)

Current Consumption (Receiver Squelched) 80mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 800mA/1.5A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40mA N/A

Receiver

Measurements as per: ETS 300-086

Intermediate frequencies 21.4MHz and 455kHz

Sensitivity 12dB SINAD < -119dBm

Sensitivity 20dB SINAD < -114dBm

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 70dB (NB), 75dB (WB)*

Spurious Response 70dB

Intermodulation 65dB

Blocking 94dB

Ultimate Signal to Noise Ratio (EIA) 37dB (NB), 42dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

Rated Audio Output > 500mW nominal

Tra nsm itt er

Measurements as per: ETS 300-086

Power Output (Low/Mid/High) 1 / 2.5 / 4W

Spurious Emissions (Cond. & Rad.) < -36dBm (0-1GHz), < -30dBm (1-4GHz)

Hum and Noise (EIA) 36dB (NB), 42dB (WB)*

Modulation Type* narrowband

wideband

10K0F3E 16K0F3E

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

June 2003 IPN: M5000-00-105 Radio specifications B - 7

Table B-7: TOP-Gxxxx 336-400MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 336-400MHz

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-2.5ppm (-30 to +60°C)

Current Consumption (Receiver Squelched) 85mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 900mA/1.7A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40mA N/A

Receiver

Measurements as per: ETS 300-086

Intermediate frequencies 45.1MHz and 455kHz

Sensitivity 12dB SINAD < -119dBm

Sensitivity 20dB SINAD < -114dBm

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 66dB (NB), 72dB (WB)*

Spurious Response 70dB

Intermodulation 65dB

Blocking 94dB

Ultimate Signal to Noise Ratio (EIA) 36dB (NB), 42dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

Rated Audio Output > 500mW nominal

Transmitter

Measurements as per: ETS 300-086

Power Output (Low/Mid/High) 1 / 2.5 / 4W

Adjacent Channel Power 65dB (NB), 75dB (WB)*

Spurious Emissions (Cond. & Rad.) < -36dBm (0-1GHz), < -30dBm (1-4GHz)

Hum and Noise (EIA) 37dB (NB), 43dB (WB)*

Modulation Type* narrowband

wideband

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

10K 0F3 E 16K 0F3 E

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

B - 8 Radio specifications June 2003 IPN: M5000-00-105

Table B-8: TOP-Hxxxx 400-470MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 400-470MHz

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-2.5ppm (-30 to +60°C)

Current Consumption (Receiver Squelched) 80mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 780mA/1.5A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40mA N/A

Receiver

Measurements as per: ETS 300-086

Intermediate Frequencies 45.1MHz and 455kHz

Sensitivity 12dB SINAD < -119dBm

Sensitivity 20dB SINAD < -114dBm

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 66dB (NB), 72dB (WB)*

Spurious Response 70dB

Intermodulation 65dB

Blocking 94dB

Ultimate Signal to Noise Ratio (EIA) 34dB (NB), 40dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

Rated Audio Output > 500mW nominal

Tra nsm itt er

Measurements as per: ETS 300-086

Power Output (Low/Mid/High) 1 / 2.5 / 4W

Spurious Emissions (Cond. & Rad.) < -36dBm (0-1GHz), < -30dBm (1-4GHz)

Hum and Noise (EIA) 35dB (NB), 41dB (WB)*

Modulation Type* narrowband

wideband

10K0F3E 16K0F3E

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

June 2003 IPN: M5000-00-105 Radio specifications B - 9

Table B-9: TOP-Ixxxx 450-530MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 450-530MHz

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-2.5ppm (-30 to +60°C)

Current Consumption (Receiver Squelched) 80mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 870mA/1.7A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40mA N/A

Receiver

Measurements as per: ETS 300-086

Intermediate frequencies 45.1MHz and 455kHz

Sensitivity 12dB SINAD < -119dBm

Sensitivity 20dB SINAD < -114dBm

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 66dB (NB), 72dB (WB)*

Spurious Response 70dB

Intermodulation 65dB

Blocking 94dB

Ultimate Signal to Noise Ratio (EIA) 34dB (NB), 40dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Distortion (EIA) <5% @ 1kHz, 60% Deviation

Rated Audio Output > 500mW nominal

Transmitter

Measurements as per: ETS 300-086

Power Output (Low/Mid/High) 1 / 2.5 / 4W

Spurious Emissions (Cond. & Rad.) < -36dBm (0-1GHz), < -30dBm (1-4GHz)

Hum and Noise (EIA) 34dB (NB), 40dB (WB)*

Modulation Type* narrowband

wideband

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion <5% @ 1kHz, 60% Deviation

10K 0F3 E 16K 0F3 E

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

B - 10 Radio specifications June 2003 IPN: M5000-00-105

Table B-10: TOP-Jxxxx 806-870MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 806-870MHz Transmit

851-870MHz Receive

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-1.5ppm (-30 to +60°C)

Current Consumption (Receiver Squelched) 85 mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 780mA/1.3A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40 mA N/A

Receiver

Measurements as per: EIA

Intermediate frequencies 45.1MHz and 455kHz

Sensitivity 12dB SINAD < 0.25µV (-119dBm)

Sensitivity 20dB SINAD < 0.40 µV (-114dBm)

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 60dB (NB), 65dB (WB)*

Spurious Response 65dB

Intermodulation 65dB

Hum and Noise 32dB (NB), 38dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Rated Audio Output > 500mW nominal

Tra nsm itt er

Measurements as per: EIA

Power Output (Low/Mid/High) 1 / 2 / 3W

Spurious Emissions (Cond. & Rad.) - 65dB

Hum and Noise 38dB (NB), 42dB (WB)*

Modulation Type* narrowband

wideband

10K0F3E 16K0F3E

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion <5% @ 1kHz, 60% Deviation

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

June 2003 IPN: M5000-00-105 Radio specifications B - 11

Table B-11: TOP-Kxxxx 896-941MHz radio specifications

General Orca 501x/2x Orca 503x/40

Frequency Range 896-941MHz Transmit

935-941MHz Receive

Channel Spacing 12.5 / 20 / 25 kHz

Frequency Increments 5 or 6.25kHz

IF Bandwidth Universal Bandwidth (UB) 10kHz*

Frequency Stability +/-1.5ppm (-30 to +60°C)

Current Consumption (Receiver Squelched) 85 mA 100mA

Current Consumption (Standby with high economy duty cycle)

Current Consumption (Receiver Rated Audio) 300mA

Transmitter current (Low/High power) 750mA/1.3A

Size, incl. 1500mAh NiMH battery (WxHxD) 66 x 154 x 41mm

Weight Orca 5010/11/30 Orca 5035 Orca 5015/2x/40

With TOPB600 1100mAh NiCd† 490g 510g 515g

With TOPB200 1500mAh NiCd 525g 545g 550g

With TOPB700 1500mAh NiMH 510g 530g 535g

With TOPB500 2000mAh NiMH 550g 570g 575g

40 mA N/A

Receiver

Measurements as per: EIA

Intermediate frequencies 45.1MHz and 455kHz

Sensitivity 12dB SINAD <0.25µV (-119dBm)

Sensitivity 20dB SINAD <0.40µV (-114dBm)

Fixed Squelch Sensitivity 12dB SINAD or 16dB SINAD Nominal

Selectivity 60dB (NB), 65dB (WB)*

Spurious Response 60dB

Intermodulation 65dB

Hum and Noise 32dB (NB), 38dB (WB)*

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave De-emphasis

Rated Audio Output > 500mW nominal

Transmitter

Measurements as per: EIA

Power Output (Low/Mid/High) 1 / 2 / 3W

Spurious Emissions (Cond. & Rad.) -65dB

Hum and Noise 38dB (NB), 42dB (WB)*

Modulation Type* narrowband

wideband

Deviation Limiting Adjustable up to +/- 5kHz

Audio Response (300 Hz - 2.55 kHz) Within +1 / -3dB of 6dB / Octave Pre-emphasis

Distortion <5% @ 1kHz, 60% Deviation

10K 0F3 E 16K 0F3 E

*, † See “Important notes for Tables B-4 to B-11” on page B-3.

B - 12 Radio specifications June 2003 IPN: M5000-00-105

Circuit descriptions

Circuit interface diagrams for the Tait Orca portable radios are shown in Figure A-1 (TOP B, C, G, H, I, J and K) and Figure A-2 (TOP A only).

The Tait Orca portable radio has been designed to be totally electronically tuned using the Calibration Application. The titles of tests referred to below are tests available in the calibration system, e.g. Power Level test refers to the Power Level screen in the calibration system. Consult the Calibration Application online help or User’s Manual for more information on specific calibration tests.

Transmitter

The RF power amplifier amplifies transmit RF from the VCO to the output power level (3W 800/900 MHz, 4W UHF, 5W VHF). The PA output is fed to the PIN switch, which provides isolation between the transmit and receive paths.

An LPF follows the PIN switch and provides attenuation of unwanted high frequency signals.

Following the LPF, the signal is fed to the antenna.

Receiver

RF from the antenna is fed via the LPF and PIN switch into the receiver. The RF passes through the front end tuning circuit, which rejects unwanted frequencies. The front end is electronically tuned, and the front end tuning voltage that sets the centre of the bandpass filter is determined during calibration (Front End Tuning test).

The output of the front end tuning stage is fed to the first mixer, and the VCO provides the local oscillator input. The output of the mixer is at the first IF frequency (45.1 MHz UHF/

21.4 MHz VHF).

The IF signal passes through two crystal filters, separated by the IF amplifier.

In the Demod IC, the signal passes through the second mixer, producing the second IF (455 kHz). The second IF passes through a ceramic band pass filter and IF amp, which are external to the IC. The second IF is then fed back into the Demod IC for another amplification stage, then through another ceramic band bass filter. The final stage is the phase lock loop (PLL) discriminator in the Demod IC, which produces detected audio.

The output power level is controlled by the microprocessor and associated circuitry, and is initially set by calibrating the radio (Power

Level test).

Transmit (Tx) audio

Tx audio from the microphone is processed by the DSP and associated circuitry into two modulation signals, one required by the TCXO in the synthesiser and the other by the VCO.

A digital pot is used to set the overall deviation and modulation balance; these are controlled by calibration (Maximum Deviation and Modulation Balance tests).

June 2003 IPN: M5000-00-105 Circuit descriptions B - 13

A squelch detect circuit detects high frequency audio noise and compares it with a threshold (programmable as city or country for each channel), which is set up by the microprocessor. The squelch level can be set during calibration (Squelch Thresholds test).

The RSSI output of the detector circuit provides an analogue indication of the received signal strength. RSSI thresholds are set during calibration (RSSI Thresholds test).

Receive (Rx) audio

The detected audio is processed by the DSP, amplified and fed to an internal speaker,

whose selection is controlled by a line from the microprocessor. The speaker output is always available on the accessory connector to drive an external speaker.

The unprocessed audio from the output of the demodulator IC (RX-DET-AF) is also available at the accessory connector.

DSP

All signalling, such as Selcall, CTCSS, DCS, G-STAR, DTMF and FFSK, and all confidence tones are generated by the DSP. However, only Selcall, CTCSS, FFSK and Two-tone are decoded by the DSP.

The DSP operates in half-duplex mode. That is, its CODEC input and output is switched between the Tx and Rx audio paths, according to whether the radio is transmitting or receiving.

Synthesiser and VCO

The synthesiser receives channel frequency information from the microprocessor. It then sets the VCO to the required frequency and maintains its stability using a phase-locked loop. There are one or two VCOs, depending on the radio type. Some bands have one VCO that covers the whole tuning range of the radio plus the IF offset, with its output switched to Tx or Rx. Other bands have a dedicated Tx and Rx VCO.

A lock detect output from the synthesiser (LCK-DET) indicates whether the VCO is producing the correct frequency (the radio is in lock). If the frequency is incorrect, the lock detect status prevents the transmitter from operating, and informs the control microprocessor.

The reference frequency for the synthesiser is provided by the TCXO (temperature compensated crystal oscillator), which is initially set on frequency using a DC voltage at calibration (TCXO Calibration test).

Power supplies

+5V-DIG

The +5V-DIG supply provides a regulated 5 V to the microprocessor and its associated circuitry. It is controlled by the on/off switch and a line from the microprocessor.

It provides 5 V to all circuitry that requires power when the radio is in economy mode.

+5V-AN

The +5V-AN supply provides the power to all circuitry that requires 5 V when the radio is not in economy mode, mainly all analog circuitry in the receiver, synthesiser and audio modules. It is controlled by a line from the microprocessor and is a regulated supply.

+5V-TX

The +5V TX supply provides power for the exciter stage of the transmitter when the radio is in transmit mode. It is controlled by a line from the microprocessor and is a regulated supply.

+7V5-BATT

The +7V5-BATT supply is the unregulated voltage supplied to the radio from the battery.

+7V5-ACC

The +7V5-ACC supply is supplied to the accessory connector from the battery through a switch and a current limiter.

+7V5-SW

The +7V5-SW switched supply is an unregulated voltage supplied to the radio from the battery through a switch.

+14V

The +14V regulated supply provides the 14 V required by the loop filter in the synthesiser.

A switch mode regulator produces this voltage from the +7V5-SW and +5V-AN supplies.

B - 14 Circuit descriptions June 2003 IPN: M5000-00-105

+4V3-DEC

The +4V3-DEC supply is derived from the +5V-AN voltage. It is used to power the transmit and receive VCOs in conjunction with the transmit control line from the processor. It also provides the loop filter reference in the synthesiser.

Accessory connector interface

The accessory connector interface is described in Part F: Accessories.

Universal band versus wideband IF filtering

The IF filtering for the universal band is designed in such a way that it functionally meets specifications for both narrowband and wideband systems.

The Deviation and Receive Audio Processing are selectable per channel, which enables the radio to inter-operate between narrowband and wideband channels.

June 2003 IPN: M5000-00-105 Circuit descriptions B - 15

B - 16 Circuit descriptions June 2003 IPN: M5000-00-105

June 2003 IPN: M5000-00-105 Circuit diagrams B - 17

Figure B-1: Circuit interface diagram for Tait Orca portable radios (TOP B, C, G, H, I, J and K)

93 SHEET 2

POWER-AMP

TX-VCO

ANTENNA

RX-ANT

PWR-SET

GND

+7V5-BATT

+5V-AN

TX-INHIBIT PIN-SW

+7V5-SW

GATE-BIAS

+5V-TX

246

SHEET 3

RECEIVER

RX-ANT

SQL-DET SQL-SET FE-BIASRX-DET-AF RSSI

RX-LO

GND

+5V-AN

DCFB WB/NB

BATTERY+

SPRING PROBE

BATTERY-

SPRING PROBE

DSP AUDIO

252

PROCESSOR

RSSI

FE-BIAS

SQL-SET

SQL-DET

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DATPWR-SAVE

ACCESORY

TX-CNTRL

VCO-MOD

PWR-SET

DGND

GND

RADIO-TOPINTERFACE-PCB

RX-DET-AF

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

PIN-SW

TX-INHIBIT

+14V

GATE-BIAS

DCFB

WB/NB

+5V-TX

470

R10

150

PTT

TACT SWITCH

FUNC-2

TAC T

FUNC-1

TAC T

+SPKR

SPRING PROBE

-SPKR

SPRING PROBE

2922 SHEET 5

SYNTH-VCO

TX-VCO

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DAT VCO-MODPWR-SAVE

RX-LO

GND

TX-COM

+7V5-SW

+5V-AN

+14V

PL1

12 WAY SKT

INTER

22WAY SIDE ENTRY FLEXI BRD SKT

HEX

SWITCH

RSW1

16WAY BCD SW

124

BC847W

470R2470

100N

C11

10N

47N

1K0

10N

C10

10N

1N0

100N

LK1

LK2

BC857W

R16

R14

4K7

R13

47K

22K

DTC144W

R12

47K

R15

2K2

TP1

TP2

C15

1N0

C16

150P

TP3

TP4

TP5

TP6

TP7

TP8

TP9

TP10

TP11

TP12

TP13

TP14

SK3

SMA 90DEG SKT

SWITCH

1P1W

2K2

MIC

MICORPHONE

GND

GREEN

DUAL LED

RED

DUAL LED

RV1

10K LOG POT

RV1

10K LOG POT

TP15

TP17

TP16

R20

2K2

R17

180

330

LK3 LK4

+7V5-BATT

+7V5-ACC

PL1

+7V5-ACC

PL1

RXD

PL1

TXD

PL1

EXT-PTT

PL1

EXT-SPKR

PL1

GND

+5V-AN

+7V5-BATT

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

+5V-AN

PL1

EXT-MIC

INTER

+7V5-SW

INTER

KEY-LATCH

INTER

EXP-LATCH

INTER

KEY-D0

INTER

KEY-D1

INTER

KEY-D2

INTER

SDAT

INTER

SCLK

INTER

RESET

INTER

GND

+7V5-SW

+5V-DIG

PL1

MOD-AUDIO

+7V5-SW

PL1

SENSE-0

PL1

SENSE-1

PL1

RX-DET-AF

PL1

EXT+SPKR

INTER

+5V-DIG

INTER

DGND

+7V5-BATT

+7V5-SW

INTER

RX-DET-AF

INTER

VOL-MAX

INTER

MOD-AUDIO

INTER

PTT

INTER

MISO

INTERON2

INTER

TX-AUDIO

INTER

S-DATA-READY

+5V-DIG

+7V5-ACC

INTER

P37

+5V-DIG

INTER

GND

+5V-TX

Accesory Connector Interface PCB

link LK1 & LK2 if RV1 is not fitted

VOL-MAX

PTT

INT-MIC

RADIO-TOP

-SPKR

+SPKR

VOL-MIN

VOL-WIPER

VOL-MAX

KNOB3

KNOB2

KNOB1

KNOB0

RX-LED

TX-LED

ACCESORY

EXT-PTT

RXD

TXD

EXT-MIC

MOD-AUDIO

SENSE-0

SENSE-1

EXT+SPKR

EXT-SPKR

P37

INTERFACE

RESET

SCLK

SDAT

KEY-D2

KEY-D1

KEY-D0

EXP-LATCH

KEY-LATCH

TX-AUDIO

MISO

FN1

FN2

PTT

B - 18 Circuit diagrams June 2003 IPN: M 5000-00-105

June 2003 IPN: M5000-00-105 Circuit diagrams B - 19

Figure B-2: Circuit interface diagram for Tait Orca portable radios (TOP A only)

EV/ISS AMENDMENTS DATEAPVDD.O.CHKDDRAWN

NO.SHEETS:FILE NAME:

TAIT ELECTRONICS

IPN:

FILE DATE:

ISSUE: ID:.

2.SC.

PROJECT: DESIGNER:

ORCA : 66-88MHZ

SYSTEM DIAGRAM

161608a

220-01616-08

2-Au

-00

TAIT ORCA BRD

04A CLONED 220-01616-01 CCO 1616/006 BRD SP CK DW 24/11/99

06A CCO NO 1616-008 BRD 10-02-2K

06B CCO 1616-009 BRD 22-02-00

07A CCO NO. 1616-010 BRD 05-05-00

08A CCO NO.1616-011 BRD 27-07-00

93 SHEET 2

POWER-AMP

TX-VCO

ANTENNA

RX-ANT

PWR-SET

GND

+7V5-BATT

+5V-AN

TX-INHIBIT PIN-SW

+7V5-SW

GATE-BIAS

+5V-TX

246

SHEET 3

RECEIVER

RX-ANT

SQL-DET

SQL-SET

FE-BIASRX-DET-AF

RSSI

RX-LO

GND

+5V-AN

DCFB

WB/NB

BATTERY+

SPRING PROBE

BATTERY-

SPRING PROBE

DSP AUDIO

252

PROCESSOR

SHEET 4

RSSI

FE-BIAS

SQL-SET

SQL-DET

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DATPWR-SAVE

ACCESORY

TX-CNTRL

VCO-MOD

PWR-SET

DGND

GND

RADIO-TOPINTERFACE-PCB

RX-DET-AF

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

PIN-SW

TX-INHIBIT

+14V

GATE-BIAS

DCFB

WB/NB

+5V-TX

470

R10

150

PTT

TACT SWITCH

FUNC-2

TACT

FUNC-1

TACT

+SPKR

SPRING PROBE

-SPKR

SPRING PROBE

vco

sheet 6

2922 SHEET 5

SYNTH-VCO

TX-VCO

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DAT VCO-MODPWR-SAVE

RX-LO

GND

TX-COM

+7V5-SW

+5V-AN

+14V

PL1

12 WAY SKT

INTER

22WAY SIDE ENTRY FLEXI BRD SKT

HEX

SWITCH

RSW1

16WAY BCD SW

124

BC847W

470R2470

100N

C11

10N

47N

1K0

10N

C10

10N

1N0

100N

LK1

LK2

BC857W

R16

R14

4K7

R13

47K

22K

DTC144W

R15

2K2

TP1

TP2

C15

1N0

C16

150P

TP3

TP4

TP5

TP6

TP7

TP8

TP9

TP10

TP11

TP12

TP13

TP14

SK3

SMA 90DEG SKT

TACT

DOWN

TACT

SWITCH

1P1W

2K2

R6 10

MIC

MICORPHONE

GND

GREEN

DUAL LED

RED

DUAL LED

RV1

10K LOG POT

RV1

10K LOG POT

TP15

TP17

R20

2K2

R17

180

330

TP16

LK3

LK4

120NH

C18

18P

C17

0805

BLM11B102S

+7V5-BATT

+7V5-ACC

PL1

+7V5-ACC

PL1

RXD

PL1

TXD

PL1

EXT-PTT

PL1

EXT-SPKR

PL1

GND

+5V-AN

+7V5-BATT

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

+5V-AN

PL1

EXT-MIC

INTER

+7V5-SW

INTER

KEY-LATCH

INTER

EXP-LATCH

INTER

KEY-D0

INTER

KEY-D1

INTER

KEY-D2

INTER

SDAT

INTER

SCLK

INTER

RESET

INTER

GND

+7V5-SW

+5V-DIG

PL1

MOD-AUDIO

+7V5-SW

PL1

SENSE-0

PL1

SENSE-1

PL1

RX-DET-AF

PL1

EXT+SPKR

INTER

+5V-DIG

INTER

DGND

+7V5-BATT

+7V5-SW

INTER

RX-DET-AF

INTER

VOL-MAX

INTER

MOD-AUDIO

INTER

PTT

INTER

MISO

INTERON2

INTER

TX-AUDIO

INTER

S-DATA-READY

+5V-DIG

+7V5-ACC

INTER

P37

+5V-DIG

INTER

GND

+5V-TX

Accesory Connector Interface PCB

link LK1 & LK2 if RV1 is not fitted

SUB-VHF

Tait Orca

VOL-MAX

PTT

INT-MIC

RADIO-TOP

KNOB1

KNOB0

PTT

FN2

FN1

-SPKR

+SPKR

VOL-MIN

VOL-WIPER

VOL-MAX

KNOB3

KNOB2

KNOB1

KNOB0

RX-LED

TX-LED

EXT-SPKR

EXT+SPKR

SENSE-1

SENSE-0

MOD-AUDIO

EXT-MIC

TXD

RXD

EXT-PTT

ACCESORY

MISO

TX-AUDIO

KEY-LATCH

EXP-LATCH

KEY-D0

KEY-D1

KEY-D2

SDAT

SCLK

RESET

INTERFACE

P37

93 SHEET 2

POWER-AMP

TX-VCO

ANTENNA

RX-ANT

PWR-SET

GND

+7V5-BATT

+5V-AN

TX-INHIBIT PIN-SW

+7V5-SW

GATE-BIAS

+5V-TX

246

SHEET 3

RECEIVER

RX-ANT

SQL-DET

SQL-SET

FE-BIASRX-DET-AF

RSSI

RX-LO

GND

+5V-AN

DCFB

WB/NB

BATTERY+

SPRING PROBE

BATTERY-

SPRING PROBE

DSP AUDIO

252

PROCESSOR

RSSI

FE-BIAS

SQL-SET

SQL-DET

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DATPWR-SAVE

ACCESORY

TX-CNTRL

VCO-MOD

PWR-SET

DGND

GND

RADIO-TOPINTERFACE-PCB

RX-DET-AF

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

PIN-SW

TX-INHIBIT

+14V

GATE-BIAS

DCFB

WB/NB

+5V-TX

470

R10

150

PTT

TACT SWITCH

FUNC-2

TAC T

FUNC-1

TAC T

+SPKR

SPRING PROBE

-SPKR

SPRING PROBE

2922 SHEET 5

SYNTH-VCO

TX-VCO

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DAT VCO-MODPWR-SAVE

RX-LO

GND

TX-COM

+7V5-SW

+5V-AN

+14V

PL1

12 WAY SKT

INTER

22WAY SIDE ENTRY FLEXI BRD SKT

HEX

SWITCH

RSW1

16WAY BCD SW

124

BC847W

470R2470

100N

C11

10N

47N

1K0

10N

C10

10N

1N0

100N

LK1

LK2

BC857W

R16

R14

4K7

R13

47K

22K

DTC144W

R15

2K2

TP1

TP2

C15

1N0

C16

150P

TP3

TP4

TP5

TP6

TP7

TP8

TP9

TP10

TP11

TP12

TP13

TP14

SK3

SMA 90DEG SKT

SWITCH

1P1W

2K2

R6 10

MIC

MICORPHONE

GND

GREEN

DUAL LED

RED

DUAL LED

RV1

10K LOG POT

RV1

10K LOG POT

TP15

TP17

R20

2K2

R17

180

330

TP16

LK3

LK4

120NH

C18

18P

C17

0805

BLM11B102S

+7V5-BATT

+7V5-ACC

PL1

+7V5-ACC

PL1

RXD

PL1

TXD

PL1

EXT-PTT

PL1

EXT-SPKR

PL1

GND

+5V-AN

+7V5-BATT

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

+5V-AN

PL1

EXT-MIC

INTER

+7V5-SW

INTER

KEY-LATCH

INTER

EXP-LATCH

INTER

KEY-D0

INTER

KEY-D1

INTER

KEY-D2

INTER

SDAT

INTER

SCLK

INTER

RESET

INTER

GND

+7V5-SW

+5V-DIG

PL1

MOD-AUDIO

+7V5-SW

PL1

SENSE-0

PL1

SENSE-1

PL1

RX-DET-AF

PL1

EXT+SPKR

INTER

+5V-DIG

INTER

DGND

+7V5-BATT

+7V5-SW

INTER

RX-DET-AF

INTER

VOL-MAX

INTER

MOD-AUDIO

INTER

PTT

INTER

MISO

INTERON2

INTER

TX-AUDIO

INTER

S-DATA-READY

+5V-DIG

+7V5-ACC

INTER

P37

+5V-DIG

INTER

GND

+5V-TX

Accesory Connector Interface PCB

link LK1 & LK2 if RV1 is not fitted

VOL-MAX

PTT

INT-MIC

RADIO-TOP

PTT

FN2

FN1

-SPKR

+SPKR

VOL-MIN

VOL-WIPER

VOL-MAX

KNOB3

KNOB2

KNOB1

KNOB0

RX-LED

TX-LED

EXT-SPKR

EXT+SPKR

SENSE-1

SENSE-0

MOD-AUDIO

EXT-MIC

TXD

RXD

EXT-PTT

ACCESORY

MISO

TX-AUDIO

KEY-LATCH

EXP-LATCH

KEY-D0

KEY-D1

KEY-D2

SDAT

SCLK

RESET

INTERFACE

P37

93 SHEET 2

POWER-AMP

TX-VCO

ANTENNA

RX-ANT

PWR-SET

GND

+7V5-BATT

+5V-AN

TX-INHIBIT PIN-SW

+7V5-SW

GATE-BIAS

+5V-TX

246

SHEET 3

RECEIVER

RX-ANT

SQL-DET

SQL-SET

FE-BIASRX-DET-AF

RSSI

RX-LO

GND

+5V-AN

DCFB

WB/NB

BATTERY+

SPRING PROBE

BATTERY-

SPRING PROBE

DSP AUDIO

252

PROCESSOR

RSSI

FE-BIAS

SQL-SET

SQL-DET

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DATPWR-SAVE

ACCESORY

TX-CNTRL

VCO-MOD

PWR-SET

DGND

GND

RADIO-TOPINTERFACE-PCB

RX-DET-AF

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

PIN-SW

TX-INHIBIT

+14V

GATE-BIAS

DCFB

WB/NB

+5V-TX

470

R10

150

PTT

TACT SWITCH

FUNC-2

TAC T

FUNC-1

TAC T

+SPKR

SPRING PROBE

-SPKR

SPRING PROBE

2922 SHEET 5

SYNTH-VCO

TX-VCO

LCK-DET TCXO-MOD/SY-EN SY-CLK SY-DAT VCO-MODPWR-SAVE

RX-LO

GND

TX-COM

+7V5-SW

+5V-AN

+14V

PL1

12 WAY SKT

INTER

22WAY SIDE ENTRY FLEXI BRD SKT

HEX

SWITCH

RSW1

16WAY BCD SW

124

BC847W

470R2470

100N

C11

10N

47N

1K0

10N

C10

10N

1N0

100N

LK1

LK2

BC857W

R16

R14

4K7

R13

47K

22K

DTC144W

R15

2K2

TP1

TP2

C15

1N0

C16

150P

TP3

TP4

TP5

TP6

TP7

TP8

TP9

TP10

TP11

TP12

TP13

TP14

SK3

SMA 90DEG SKT

SWITCH

1P1W

2K2

R6 10

MIC

MICORPHONE

GND

GREEN

DUAL LED

RED

DUAL LED

RV1

10K LOG POT

RV1

10K LOG POT

TP15

TP17

R20

2K2

R17

180

330

TP16

LK3

LK4

120NH

C18

18P

C17

0805

BLM11B102S

+7V5-BATT

+7V5-ACC

PL1

+7V5-ACC

PL1

RXD

PL1

TXD

PL1

EXT-PTT

PL1

EXT-SPKR

PL1

GND

+5V-AN

+7V5-BATT

+5V-DIG +5V-AN +7V5-SW +7V5-BATT

+5V-AN

PL1

EXT-MIC

INTER

+7V5-SW

INTER

KEY-LATCH

INTER

EXP-LATCH

INTER

KEY-D0

INTER

KEY-D1

INTER

KEY-D2

INTER

SDAT

INTER

SCLK

INTER

RESET

INTER

GND

+7V5-SW

+5V-DIG

PL1

MOD-AUDIO

+7V5-SW

PL1

SENSE-0

PL1

SENSE-1

PL1

RX-DET-AF

PL1

EXT+SPKR

INTER

+5V-DIG

INTER

DGND

+7V5-BATT

+7V5-SW

INTER

RX-DET-AF

INTER

VOL-MAX

INTER

MOD-AUDIO

INTER

PTT

INTER

MISO

INTERON2

INTER

TX-AUDIO

INTER

S-DATA-READY

+5V-DIG

+7V5-ACC

INTER

P37

+5V-DIG

INTER

GND

+5V-TX

Accesory Connector Interface PCB

link LK1 & LK2 if RV1 is not fitted

VOL-MAX

PTT

INT-MIC

RADIO-TOP

PTT

FN2

FN1

-SPKR

+SPKR

VOL-MIN

VOL-WIPER

VOL-MAX

KNOB3

KNOB2

KNOB1

KNOB0

RX-LED

TX-LED

EXT-SPKR

EXT+SPKR

SENSE-1

SENSE-0

MOD-AUDIO

EXT-MIC

TXD

RXD

EXT-PTT

ACCESORY

MISO

TX-AUDIO

KEY-LATCH

EXP-LATCH

KEY-D0

KEY-D1

KEY-D2

SDAT

SCLK

RESET

INTERFACE

P37

B - 20 Circuit diagrams June 2003 IPN: M 5000-00-105

PART

Diagnostics and fault finding

This part provides information on diagnosing faults in Tait Orca 5000 portable radios.

The information in the fault finding charts should be used in combination with the test facilities, and it may also be helpful to examine the radio programming software data using the programming system for Tait Orca 5000 conventional or trunked radios.

Contents

Test facilities

Test facilities .................................................................................................

Test facilities Test facilities

Error codes ............................................................................................................ C-3

Test commands ...................................................................................................... C-5

................................................................................................. C-3

..................................................................................................................................................................................................

C-3

C-3C-3

Calculating the parameters required for test command 101 .................................. C-7

Fault finding charts

Fault finding charts .......................................................................................

Fault finding charts Fault finding charts

Radio cannot be switched on ................................................................................. C-9

Cannot change channel ....................................................................................... C-10

No serial communication .................................................................................... C-11

Receive faults ....................................................................................................... C-12

Cannot transmit .................................................................................................. C-13

No transmit audio ............................................................................................... C-14

....................................................................................... C-8

..............................................................................................................................................................................

C-8

C-8C-8

C - 2 June 2003 IPN: M5000-00-105

Test facilities

Standard test facilities provide a way of testing the radio’s functions independently of normal radio operation. A series of test commands can be sent to a radio in two ways:

■ using the TOP calibration application; or

■ using a terminal program.

See the Tait Orca Calibration Application: User ’s Manual or the program’s online help for infor-

mation on using the calibration system to send test commands to a radio.

When using a terminal program, use the following settings:

■ baud rate: 9600

■ number of data bits: 8

■ number of stop bits: 1

■ parity: none

■ flow control: none.

To put the radio into computer-controlled test mode, send ^ (Shift-6), wait for a return prompt (v), then immediately send % (Shift-5). A (-) appears. You can then begin sending test commands to the radio.

A full list of test commands is given in Table C-1. Table C-2 shows how to calculate the parameters necessary for test command

101.

{C01}

An invalid command code has been received. Try sending the command again.

{C02}

A (valid) command code has been received but with invalid parameters. Check the parameters and try sending the command again.

{C03}

A (valid) command code has been received but it cannot be processed at this time. Try sending the command again.

If the error persists, turn the radio off, then on again and put the radio into test mode. If the error still persists, contact your Tait dealer.

{C04}

An error occurred during the initialisation of test mode. Turn the radio off, then on again and put the radio into test mode.

If the error persists, contact your Tait dealer.

{X01}

EPROM checksum error. The software code in the flash has been corrupted. Re-download the radio software.

If the error persists, the flash needs to be replaced. Contact your Tait dealer.

If using the calibration system to send test commands to a radio, the parameters for command 101 are automatically calculated from the frequency value entered.

Error codes

The errors you may receive while the radio is in test mode are outlined below. If the radio must be returned for repair (e.g. the DSP needs to be replaced), contact your Tait dealer for more information.

June 2003 IPN: M5000-00-105 Test facilities C - 3

{X02}

Internal RAM failed. The RAM in the microprocessor is faulty and the microprocessor needs to be replaced. Contact your Tait dealer.

{X03}

External RAM failed. The RAM in the ASIC is faulty and the ASIC needs to be replaced. Contact your Tait dealer.

{X04}

{X36}

The DSP is not responding. Check the DSP for pin connections.

If the error persists, the DSP needs to be replaced. Contact your Tait dealer.

{X05}

The DSP version number is incorrect. The radio software and DSP software are incompatible. The DSP needs to be replaced with a later version. Contact your Tait dealer.

{X06}

The MCU internal configuration is incorrect. Contact your Tait dealer.

{X09}

The prototype timer has expired. This error will only occur on prototype software releases when the radio usage time has expired.

Temperature is above the T2 threshold and turn off of the transmitter is impending. Allow the radio to cool down before continuing.

{X37}

Voltage is less than the V1 threshold; the radio will give a low battery warning. Replace the battery or use a DC service adaptor.

{X38}

Voltage is less than the V2 threshold. The radio turns itself off after indicating this error and so will be unable to respond to the reset command character.

Replace the battery or use a DC service adaptor.

New radio software must be downloaded into the radio and the new software must have a different software version number.

{X31}

Model configuration checksum error. This error indicates that the radio’s model configuration checksum is incorrect. Contact your Tait dealer.

{X32}

Database checksum error. This error indicates that the radio’s database checksum is incorrect. Contact your Tait dealer.

{X33}

ESN error. The radio’s electronic serial number is incorrect. Contact your Tait dealer.

{X35}

Temperature is above the T1 threshold and turn down of transmit power is impending. Allow the radio to cool down before continuing.

C - 4 Test facilities June 2003 IPN: M5000-00-105

Table C-1: Test commands

Function Description CCTM code Parameters

Signalling Set modem to send zeros 10 None

Set modem to send ones 11 None

Set modem to send preamble 12 None

Disable modem signalling 13 None

Read modem receive string (continuous) 14 None

Disable all signalling 15 None

Enable subaudible signalling 16 None

Read subaudible signalling decode status 17 Returns: 0 = signal not detected,

1 = signal detected

Mute Force Rx audio muted 20 None

Force Rx audio unmuted 21 None

Mute DSP input 22 None

Unmute DSP input 23 None

Let squelch control Rx audio 24 None

Read RX_BUSY status 25 Returns: 0 = busy inactive,

1 = busy active

Relax Rx mute control 26 None

Rx/Tx Inhibit PA (transmit mode) 30 None

Enable PA (transmit mode) 31 None

Set radio to Rx 32 None

Set radio to Tx 33 None

Set transmit to low power 34 None

Set transmit to mid power 135 None

Set transmit to high power 35 None

Set transmit to max power 36 None

Set transmit to no power 137 None

Activate economy mode 42 None

Deactivate economy mode 43 None

Read battery level 46 Returns: 0 to 255

Read temperature level 47 Returns: 0 to 255

Set keypad test on 50 None

Set keypad test off 51 None

Set display test on 52 IN: 0, 1, 2 or 3

Set display test off 53 None

Read averaged RSSI level 63 Returns: 0 to 255

Read L1 threshold 64 Returns: 0 to 255

Read L2 threshold 65 Returns: 0 to 255

Miscellaneous Select normal micro clock 70 None

Select birdie micro clock 71 None

Read synth lock status 72 Returns: 0 = not in lock,

1 = in lock

Disable internal speaker 74

Enable internal speaker 75

Stop the MCU clock 79 None

Select wide band 84 None

Select medium band 85 None

Select narrow band 86 None

Select city squelch 88 None

Select country squelch 89 None

(continued on next page)

June 2003 IPN: M5000-00-105 Test facilities C - 5

Table C-1: Test commands (continued)

Function Description CCTM code Parameters

Radio info Read radio serial number 94/131 Returns: 6 digit number (hex)

Read radio software version number 96 Returns: 4 digit number

Read radio type 130 Returns: radio type (P or M),

frequency band (B-J), channel spacing (1 or 2)

Read DSP software version number 132 Returns: 4 digit number (hex)

Read radio hardware version number 133 Returns: 4 digit number

Read main database version 160 Returns: 4 digit number

Read calibration database version 160 Returns: 4 digit number

Read last system error 204 None

Synth Load absolute synth frequency 101 tttttt T rrrrrr R F (see Table C-2)

Load synth reference divider 102 8 to 16383

Load synth prescaler 103 0 = 64/65

1 = 128/129

Config Set volume pot 110 0 to 255

Set transistor gate bias 111 0 to 255

Set TCXO mod 112 0 to 255

Set VCO mod 113 0 to 255

Set Tx power level 114 0 to 255

Set TCXO coarse frequency 115 0 to 255

Set TCXO fine frequency 116 0 to 255

Set Rx front end tuning 117 0 to 255

Set squelch threshold 118 0 to 255

Set CTCSS modulation 120 0 to 32767

Set DCS modulation 121 0 to 32767

Set FFSK modulation 122 0 to 32767

Set Selcall modulation 123 0 to 32767

Set DTMF modulation 124 0 to 32767

Set voice modulation 125 0 to 32767

Force DCS signalling (023 tone) 126 None

Force CTCSS signalling (67.0 Hz) 127 None

Force Selcall signalling (2000 Hz for 2 seconds)

Force DTMF signalling (tone A) 129 IN: 1 = start encoding,

Read calibrated volume setting 136 Returns: 0 to 255

Select bottom microphone 138 None

Select top microphone 139 None

Disable both microphones 140 None

Enable both microphones 141 None

Set G-STAR modem to send zeros 150 None

Set G-STAR modem to send ones 151 None

Set G-STAR modem to send preamble 152 None

Send G-STAR message 153 None

Set ANR on 170 None

Set AN R o ff 171 No ne

Set reciprocal gain 172 0 to 32767

128 None

0 = stop encoding

C - 6 Test facilities June 2003 IPN: M5000-00-105

Table C-2: Calculating the parameters required for test command 101

)

Calculating parameters for test command 101

Enter the parameters in the format tttttt T rrrrrr R F

■ tttttt represents the transmit frequency

See Example 1

■ T and R represent channel spacing

0 = 5 kHz 1 = 6.25 kHz

■ rrrrrr represents the receive frequency

See Example 2

■ F indicates whether the test command changes

the calibration values 0 = do not change calibrated values 1 = recalculate the calibrated values based on new frequencies

Note: tttttt and rrrrrr may be up to 6 digits long.

Example 1: Calculating tttttt for an H band radio

transmit frequency (MHz)

tttttt =

channel spacing (MHz)

461.025 MHz

6.25 kHz

461.025 x 106 Hz

73764

6.25 x 10

Example 2: Calculating rrrrrr for an H band radio

receive frequency (MHz) - *IF (MHz

rrrrrr =

channel spacing (MHz)

461.025 MHz - 45.1 MHz

6.25 kHz

415.925 x 106 Hz

6.25 x 10

66548

Note: IF depends on the radio’s switching band.

■ For A, B, C and D bands radios, the IF is 21.4 MHz.

*(For A band, add the IF (MHz) in the formula (radio

uses high side injection).)

■ For E, F, G, H, I, J and K band radios, the IF is

45.1 MHz.

June 2003 IPN: M5000-00-105 Test facilities C - 7

Fault finding charts

The fault finding charts in Figures C-1 to C-6 address the faults you are most likely to find.

They are:

■ Radio cannot be switched on;

■ Cannot change channel;

■ No serial communication;

■ Receive faults;

■ Cannot transmit; and

■ No transmit audio.

If you experience other faults that do not fall into these categories, contact your Tait dealer.

C - 8 Fault finding charts June 2003 IPN: M5000-00-105

Figure C-1: Radio cannot be switched on

Radio cannot be switched on

Is the battery charged?

YES

Battery contacts clean and

unobstructed?

YES

Check on/off/volume

control switch.

Function for pins 1 to 4 OK?

YES

Return to nearest Tait Dealer

Charge the battery.

Clean battery contacts using

the graphite tip of a 4H (#4)

or harder pencil.

After charging battery, can

radio be switched on?

Replace on/off/volume

control switch.

Replace battery contacts.

June 2003 IPN: M5000-00-105 Fault finding charts C - 9

Figure C-2: Cannot change channel

Cannot change channel

Using the truth table

below, is channel selector

operation OK?

YES

Return to nearest

Tait Dealer

Antenna

connector 16-way

selector On/off/

123

654

Bottom of PCB

volume control

Replace channel

selector switch.

PINS

6341

20001

30010

50100

CHANNELS

91000

1 = S/C to GND 0 = O/C to GND

C - 10 Fault finding charts June 2003 IPN: M5000-00-105

Figure C-3: No serial communication

No serial communication

Are the physical connections

correct, e.g. battery charged,

comms lead inserted correctly

into the correct port on the PC,

flexible loom contacts clean, etc.?

YES

Make sure physical

connections are intact.

Is the software using the

correct serial port?

Change the ‘COMM Port’ using

Edit|Preferences or

Tools|Options.

YES

Leads OK? Replace or repair leads.

YES

Is the Tx/Rx

switch on the calibration

Set Tx/Rx switch to Rx.

test unit set to Rx?

YES

Is the flexible loom

inserted correctly?

Ensure loom is properly fitted

into the socket on the PCB.

YES

Is the flexible loom

end damaged?

YES

Replace flexible loom.

Is the PTT jammed on?

June 2003 IPN: M5000-00-105 Fault finding charts C - 11

YES

Return to nearest

Tait Dealer

Make sure PTT is released.

Figure C-4: Receive faults

Receive faults

Is the radio in lock

(command 72)?

YES

Is the radio programmed

correctly?

YES

Is receive sense

> -117 dBm

YES

Is squelch operating normally?

16 dB city, 12 dB country

YES

Does speaker Z = 16 ohms?

YES

Check programming. Are

channels programmed correctly?

Reprogram radio.

Recalibrate squelch.

Replace speaker.

YES

Is the frequency/band

information correct?

YES

Are the speaker contacts

functioning?

YES

Does on/off/volume pot vary

between 180 ohms to 10K

between pin 3 and GND and

between pin 2 and GND?

YES

Return to nearest

Tait dealer

Replace speaker contacts.

Replace on/off/volume

control switch.

C - 12 Fault finding charts June 2003 IPN: M5000-00-105

Figure C-5: Cannot transmit

Cannot transmit

Is the radio in lock

(command 72)?

YES

Is the radio programmed

correctly?

YES

Is current greater than 1.5 A (high

power) or 700 mA (low power)?

Is the transmit current

less than 400 mA?

Return to nearest

Tait Dealer

channels and frequency/band

information programmed

correctly?

Check programming. Are

YES

Reprogram radio.

Is RF switch functioning?

Check PTT switch.

YES

Is RF out assembly OK?

Replace RF out assembly.

YES

June 2003 IPN: M5000-00-105 Fault finding charts C - 13

Figure C-6: No transmit audio

No transmit audio

When an external accessory is

plugged in, is there microphone

audio for the accessory?

YES

Is the internal

microphone working?

YES

Return to nearest

Tait dealer

Is the flexible loom inserted correctly?

YES

Is the flexible loom damaged?

Replace internal microphone.

Ensure loom is properly fitted

YES

into the socket on the PCB.

Replace flexible loom.

C - 14 Fault finding charts June 2003 IPN: M5000-00-105

PART

Servicing the radio

This part describes the disassembly and reassembly of Tait Orca 5000 portable radios and the servicing of some key mechanical and ancillary devices.

Information is also provided on ordering spare parts for servicing portable radios.

Contents

Servicing the radio

Servicing the radio ........................................................................................

Servicing the radio Servicing the radio

Screw head types ................................................................................................... D-3

Disassembling the radio

Disassembling the radio ................................................................................

Disassembling the radio Disassembling the radio

Removing the front panel from the chassis ........................................................... D-4

........................................................................................ D-3

................................................................................................................................................................................

................................................................................D-4

................................................................................................................................................................

D-3

D-3D-3

D-4

D-4D-4

Removing the shield sub-assembly from the chassis ............................................. D-5

Removing the PCB from the chassis ...................................................................... D-6

Removing the rear panel ....................................................................................... D-7

Replacing key mechanical and ancillary devices

Replacing key mechanical and ancillary devices ...........................................

Replacing key mechanical and ancillary devices Replacing key mechanical and ancillary devices

Replacing the lens (Orca 5015/2x/35/40) ............................................................ D-8

Replacing the PTT keypad ..................................................................................... D-8

Replacing the speaker ............................................................................................ D-9

Replacing the LCD display (Orca 5015/2x/35/40) ............................................... D-9

Replacing the shield, user interface PCB and polyester dome

(Orca 5015/2x/35/40) ........................................................................................ D-12

Replacing the antenna connector, channel selector switch and volume control switch D-12

Replacing the microphone .................................................................................. D-12

Replacing the battery and speaker contacts ........................................................ D-12

Replacing the tact switch ..................................................................................... D-12

Replacing the chassis ........................................................................................... D-13

........................................... D-8

......................................................................................

D-8

D-8D-8

Reassembling the radio

Reassembling the radio ..............................................................................

Reassembling the radio Reassembling the radio

Rear panel reassembly and replacing the auxiliary flexible PCB ..........................D-14

Fitting the PCB to the chassis and replacing the RF out assembly .......................D-15

Fitting the shield to the chassis ............................................................................D-15

Fitting the front panel to the chassis ....................................................................D-16

Spares kits

Spares kits ..................................................................................................

Spares kits Spares kits

Information contained in the tables ....................................................................D-17

PCB Product Codes .............................................................................................. D-17

Orca 5010/11/30 spares kit (TOPA-SP-401G).................................................... D-18

Orca 5035 spares kit (TOPA-SP-402G) ............................................................... D-19

Orca 5015/2x/40 spares kit (TOPA-SP-403G).................................................... D-20

Orca 5010/11/30 re-skinning kit (TOPA-SP-404) .............................................. D-21

Orca 5035 Re-skinning kit (TOPA-SP-405) ......................................................... D-21

Orca 5020/40 Re-skinning kit (TOPA-SP-406) ................................................... D-21

Orca 5015/2x/35/40 User Interface PCB and Shield (TOPA-SP-407) ................ D-22

Orca 5015/21 Re-skinning kit (TOPA-SP-408) ................................................... D-22

.................................................................................................. D-17

....................................................................................................................................................................................................

.............................................................................. D-14

............................................................................................................................................................

D-14

D-14D-14

D-17

D-17D-17

D - 2 June 2003 IPN: M5000-00-105

Servicing the radio

Servicing of Tait Orca 5000 portable radios is limited to key mechanical and ancillary devices. These include:

■ the front panel assembly;

■ the lens (Orca 5015/2x/35/40);

■ the PTT keypad;

■ the speaker;

■ the keypad (Orca 5015/2x/35/40);

■ the LCD display (Orca 5015/2x/35/40);

■ the shield, complete with user interface

PCB assembly and polyester dome (Orca 5015/2x/35/40);

■ the main PCB assembly;

■ the antenna connector;

■ the channel selector switch;

■ the volume control switch;

A list of spares kits available for servicing Tait Orca 5000 portable radios is shown in Table D-1 on page D-17. These spares can be ordered from your local Tait dealer.

Screw head types

Most of the screws in Tait Orca 5000 portable radios are Torx head screws, and so a Torx T6 driver bit is supplied as part of the service kit. When removing screws be sure to use the correct driver.

Torx head 1.8x5 mm screws should be removed using the supplied Torx T6 driver. When replacing these screws, set the driver to 2in.lb (0.23Nm).

■ the microphone;

■ the speaker contacts;

■ the battery contacts;

■ the PTT tact switch;

■ the RF out assembly

■ the auxiliary flexible PCB

■ the rear panel; and

■ the chassis.

June 2003 IPN: M5000-00-105 Servicing the radio D - 3

Disassembling the radio

Removing the front panel from the chassis

Unscrew the antenna and detach the battery pack.

The channel selector and on/off/volume control knobs need to removed before separating the front panel and the chassis.

To remove the knobs, insert a side cutter at the base of each knob, flat side down (Figure D-2), making sure not to damage the knob label and the switch shaft. Squeeze lightly; the knobs should pop off. Discard the knobs.

Some earlier Tait Orca 5000 portable radios have the knobs glued on. If so, the knob’s metal insert will remain on the switch shaft. Remove the insert using a sharp scalpel blade.

Remove the two chassis screws at the base of the radio (Figure D-1), then reattach the battery and hold the base of the radio in one hand. With the other hand, pull the chassis from the front panel using the base of the battery as leverage (Figure D-3).

At this point you can replace the following:

■ the front panel assembly;

■ the PTT keypad (PTT key and function keys);

■ the speaker;

■ the lens;

■ the keypad; and

■ the volume plate and volume keypad.

Figure D-1: Removing the chassis screws

chassis

front panel

chassis screws

Note that you should not attempt to remove the PTT keypad before removing the front panel from the chassis. See “Replacing the PTT keypad” on page D-8 for more information.

Figure D-2: Removing the knobs

D - 4 Disassembling the radio June 2003 IPN: M5000-00-105

channel selector

on/off/volume control

knob label

insert side cutters here

Figure D-3: Removing the front panel from the chassis, using the battery as leverage

battery pack

front panel

chassis

shield

microphone grommet protruding from the shield

grip battery here, gently pull away from the front panel

pull radio out and away from the front panel at this point

Removing the shield sub-assembly from the chassis

Remove the plastic speaker pins. Place the radio’s internal assembly on a flat surface with the shield side facing up toward you. Press lightly down on the shield sub-assembly above the slot clip detail (shown in Figure D-4), which will slightly bow the shield away from

the chassis.

Maintain pressure and insert a flat bladed screwdriver (approximately 4 mm) in the gap between the shield and the chassis. Twist the screwdriver and the shield should rise up over the clip.

Figure D-4: Removing the shield sub-assembly from the chassis

remove speaker pins

shield

chassis

slot clip detail

apply pressure here

insert screw driver here and twist

June 2003 IPN: M5000-00-105 Disassembling the radio D - 5

Repeat this on the other side. Remove the microphone grommet by pulling upward (Figure D-5).

You can now see the bottom surface of the PCB. The basic layout of the PCB is shown in Figures D-8 and D-9. Refer to these diagrams for the placement of parts.

Note that on Orca 5015, Orca 502x, Orca 5035 and Orca 5040 radios, the user interface loom must be detached from the main PCB before the shield can be separated from the main PCB and chassis.

At this point you can replace:

■ the main PCB assembly;

■ the antenna connector;

■ the channel selector switch;

■ the volume control switch;

■ the microphone;

■ the speaker contacts;

■ the battery contacts;

■ the PTT tact switch; and

At this point you can replace:

■ the LCD display (Orca 5015, Orca 502x,

Orca 5035 and Orca 5040); and

■ the shield, complete with user interface

PCB assembly and polyester dome (Orca 5015, Orca 502x, Orca 5035 and Orca

5040).

Removing the PCB from the chassis

Remove the knob seal, which covers the antenna connector, channel selector switch and volume control switch.

Remove the screw through the PA shield. Remove the three nuts for the antenna connector and knobs using the supplied 8 mm long reach socket driver, then remove the three ribbed lock washers. Gently lift the PCB up to the angle shown in Figure D-5, then pull it away from the chassis.

■ the RF out assembly.

Figure D-5: Removing the PCB from the chassis

microphone grommet

PCB

chassis

D - 6 Disassembling the radio June 2003 IPN: M5000-00-105

Removing the rear panel

Follow the disassembly instructions and disassemble the radio to the PCB level. Refer to Figure D-10 for the details of the rear panel assembly.

Insert a small flat bladed screw driver under the auxiliary dummy rear cover and apply pressure to push the dummy rear cover lugs free of the holes in the rear panel. To remove the rear panel, insert a small flat-bladed screwdriver just under the notch in the base and twist.

Remove the rear panel seal. Note that the RF contact pin normally remains in the rear panel seal. Make sure that this is not lost during disassembly.

Using a calibration pin, lift the auxiliary flexible PCB contact area from the lower lefthand corner. Remove the flexible PCB with the seal from the chassis; they should come out as a unit.

You can now replace the auxiliary flexible PCB.

June 2003 IPN: M5000-00-105 Disassembling the radio D - 7

Replacing key mechanical

and ancillary devices

This section describes the replacement of key mechanical and ancillary devices. These include:

■ lens (Orca 5015/2x/35/40);

■ PTT keypad;

■ speaker;

■ LCD display (Orca 5015/2x/35/40);

■ shield, complete with user interface PCB

and polyester dome;

■ antenna connector;

■ channel selector switch;

■ volume control switch;

■ microphone;

■ speaker contacts;

■ battery contacts;

■ PTT tact switch; and

Press firmly into position, then remove the piece of clear plastic from the front of the lens.

Figure D-6: Replacing the lens

■ chassis.

Note that instructions for replacing the RF out assembly and the auxiliary flexible PCB are included as part of the reassembly instructions.

Refer to Figures D-8 and D-9 for the placement of parts. Once the required devices have been replaced, refer to the reassembly instructions on pages D-14 to D-16.

Replacing the lens (Orca 5015/2x/ 35/40)

You must disassemble the radio before gently prising the lens away from the front panel of the radio. Remove any adhesive remaining on the front panel.

Peel the paper from the back of the new lens, and place the lens in position on the front panel.

lens

front panel

gently prise the lens away from the front panel

Replacing the PTT keypad

Following the disassembly instructions, remove the front panel from the chassis.

To remove the PTT retaining plate, from the inside of the front panel, gently push the central latch that holds the retaining plate in place. Discard the PTT retaining plate. Be careful not to lose the two pins that act as actuators for the function keys.

To install the new PTT retaining plate, insert the bottom tab into the hole at the bottom of the PTT recess. Bend the PTT retaining plate very slightly so that the top tab slots easily into

D - 8 Replacing key mechanical and ancillary devices June 2003 IPN: M5000-00-105

the hole at the top of the PTT recess. Be sure not to split or otherwise damage it.

Replacing the LCD display (Orca 5015/2x/35/40)

Replacing the speaker

Following the disassembly instructions, remove the front panel from the chassis. The speakers sits in the inside of the front panel (see Figure D-7).

Using a scalpel and a flat screw driver, carefully remove the speaker from the front panel. Clean with alcohol any remaining adhesive from the speaker seating. Replace the adhesive ring and secure a new speaker in place. Be sure to align the tabs.

Following the disassembly instructions, remove the shield from the front panel and unplug the user interface loom from the main PCB.

Unplug the LCD display loom from the user interface PCB, remove the LCD display from the shield and discard the LCD display.

Position the new LCD display on the shield, pass the LCD loom through the gap in the shield and plug into the connector on the user interface PCB. Push down the two connector lugs to secure the loom.

Plug the user interface PCB loom onto the connector on the main PCB and push down the connector lugs to secure.

Refit the shield onto the chassis (refer to page D-15 for detailed instructions).

Place the LCD holder over the LCD, fitting the LCD holder locating blocks into the holes in the shield.

Figure D-7: Mounting the speaker in the front panel

Refit the front panel to the chassis (refer to page D-16 for detailed instructions).

front panel

adhesive

speaker

alignment tabs

June 2003 IPN: M5000-00-105 Replacing key mechanical and ancillary devices D - 9

Figure D-8: Bottom surface of the PCB, which is visible when the shield has been removed from the chassis

2 3

antenna connector

channel selector switch

on/off/volume control switch

antenna connector pin placement

(5 pins)

speaker contact pin placement

channel selector pin placement

(6 pins)

on/off/volume control pin

placement (5 pins)

PTT tact switch

PA can

PA screw

microphone placement

microphone grommet placement

user interface loom connector

D - 10 Replacing key mechanical and ancillary devices June 2003 IPN: M5000-00-105

Figure D-9: Top surface of PCB, which is visible only when the PCB has been removed from the chassis

123

antenna connector

channel selector switch

on/off/volume control switch

RF assembly placement

auxiliary flex socket

PTT tact pin placement (4 pins)

battery contact placement

battery contact seal placement

microphone pin placement (2 pins)

June 2003 IPN: M5000-00-105 Replacing key mechanical and ancillary devices D - 11

Replacing the shield, user interface PCB and polyester dome (Orca

edge of the PCB. Solder it in place using a lighttip soldering iron (e.g. Weller PTR7 tip).

5015/2x/35/40)

On Orca 5015/2x/35/40 radios the shield, user interface PCB and polyester dome are replaced as one complete assembly.

Following the disassembly instructions, remove the shield from the front panel and unplug the user interface loom from the user interface PCB.

Remove the LCD display assembly from the discarded shield, and fit to the replacement shield according to the instructions on page D-

Plug the user interface loom into the connector on the new user interface PCB, and reassemble the shield onto the chassis according to the instructions on page D-15.

Replacing the antenna connector, channel selector switch and volume control switch

Following the disassembly instructions, disassemble the radio to the PCB level. Remove the PCB from the chassis.

Replacing the battery and speaker contacts

Following the disassembly instructions, disassemble the radio to the PCB level. Remove the PCB from the chassis.

When replacing one of the battery or speaker contacts, replace the other contact, even if only one is faulty. If available, use solder paste to replace the contacts.

Note that the contacts are heat-sensitive and will fail if they are overheated.Low temperature solder must be used and the contacts must not be heated above 260°C.

Remove the contact with a soldering iron and discard. Refer to Figures D-7 and D-8 for the placement of the battery and speaker contacts.

Solder the replacement contact in place using a heavy-tip soldering iron (e.g. Weller 2PTCC8 tip). Hold onto the contact with a pair of pliers and apply large amounts of solder to the PCB, rather than to the contact, to avoid damaging the contact.

If any of the antenna connector, channel selector switch or volume control switch need to be replaced, remove them using a vacuumoperated solder station. Replace them according to the reassembly instructions on pages D14 to D-17.

Replacing the microphone

Following the disassembly instructions, disassemble the radio to the PCB level. Remove the PCB from the chassis.

Use a desoldering station to remove the microphone. Discard the microphone.

When replacing the microphone, make sure it is aligned with the marks on the PCB, since it is polarised. Refer to Figures D-8 and D-9 for the placement of the microphone.

The microphone should not hang over the

Replacing the tact switch

Following the disassembly instructions, disassemble the radio to the PCB level. Remove the PCB from the chassis.

Remove the PTT tact switch using a desoldering station or solderwick. Note that there is a lot of solder on both sides of the board, so be sure to remove it all.

Refer to Figures D-8 and D-9 for the placement of the PTT tact switch.

Place the new PTT on the board and solder it in place using a heavy-tip soldering iron (e.g. Weller 2PTCC8 tip).

D - 12 Replacing key mechanical and ancillary devices June 2003 IPN: M5000-00-105

Replacing the chassis

Following the disassembly instructions, fully disassemble the radio. Discard both the chassis and main seal.

Inspect a new main seal to determine orientation and top/bottom surfaces. The tab is located at the top of the radio. Note that the seal is not flat. Ensure that the orientation is such that the bends follow the groove on the new chassis.

Locate the tab in the hole at the top of the chassis groove. Place top corners. Smooth seal into position across the top of the chassis.

Place the seal in the groove at the bottom of the radio and locate the corners.

Starting at the corners and moving towards the middle, work the seal into place along both sides of the chassis. Be careful not to stretch the seal.

Ensure that the seal is fully inserted in the groove all the way around the chassis. Ensure that it is not pinched when the radio is reassembled.

June 2003 IPN: M5000-00-105 Replacing key mechanical and ancillary devices D - 13

Reassembling the radio

This section describes the reassembly of the radio once the required units have been serviced. Additional instructions for replacing the following mechanical and ancillary devices are also included:

■ auxiliary flexible PCB;

■ RF out assembly;

■ volume plate and volume keypad;

■ antenna connector;

■ channel selector switch; and

■ volume control switch.

Rear panel reassembly and replacing the auxiliary flexible PCB

Follow the instructions on page D-7 to access the auxiliary flexible PCB, and replace. Push the flexible PCB with seal firmly into the chassis, aligning the notch in the seal with the locating pin on the chassis (see Figure D-10).

The rubber must sit flush with the back of the chassis or the rear panel will not sit properly and the battery will not fit correctly.

Fold the flexible PCB over and fit the contact area on the chassis; it should fit snugly in place.

Replace the rear panel seal by tucking the two tags at the top of the seal under the lip on the chassis and folding it over the flexible PCB. Check that the RF contact pin is positioned correctly in the rear panel seal, and that the seal is flush with the chassis.

Slide the rear panel on from the top of the radio (Figure D-10). Force it into place by pressing the top edge of the cover against the edge of a table; it will clip home. Make sure the gap between the cover and the chassis is as small as possible. Refit the auxiliary dummy cover by pushing the lugs into the holes on the rear panel. Replace the chassis plug seal, pushing it onto the chassis boss.

Figure D-10: Rear panel assembly

auxiliary flexible PCB

auxiliary flex seal

end of auxiliary flex connector protruding

through the seal

make sure the seal and auxiliary flex

are firmly seated in the chassis here

rear panel seal

chassis

replace rear panel

RF contact pin

chassis plug seal

D - 14 Reassembling the radio June 2003 IPN: M5000-00-105

Fitting the PCB to the chassis and replacing the RF out assembly

Put the battery contact seal over the battery contacts rather than into the chassis. If you put the seal on the chassis, the contacts will squash the seal.

Fit the replacement RF out assembly as shown in Figure D-11.

If you have removed the antenna connector or either of the switches, fit them on the PCB (refer to Figures D-8 and D-9), but do not yet solder them in place. Align them with the holes in the chassis, and as you lower the PCB onto the chassis, make sure the accessory flex protruding from the chassis fits into the socket on the PCB. Lower the PCB onto the chassis, making sure it is firmly seated.

socket driver set to 10in.lb (1.1Nm). Then tighten the PA screw to 2in.lb (0.23Nm).

Using a heavy-tip soldering iron (e.g. Weller 2PTCC8 tip), solder the antenna connector and two switches in place, if required, taking care not to damage the surrounding components.

Replace the knob seal over the antenna connector and the two switches (see Figure D-12).

Fitting the shield to the chassis

Replace the microphone grommet over the microphone.

Replace the shield from the top of the radio, ensuring that the two pins on the chassis go into the two holes at the top of the shield.

Fit the PA screw loosely in place. Align the switches so they are centred, referring to Figures D-8 and D-9 for placement.

Figure D-12 shows the reassembly of the antenna and switches. Replace the washers, making sure the cone faces up. The nuts for the two switches are black.

Replace the nuts, making sure they are threaded correctly before using an 8 mm long reach

Figure D-11: Placing the RF out assembly

Replace the plastic speaker pins.

Should the main seal need replacing, place the new seal so that the notch at the top of the chassis (behind the channel selector switch) matches that on the seal and the profile matches the chassis.

Run your finger around the seal to ensure that it fits properly into the seal retaining well.

RF out assembly

insert here

antenna connector

auxiliary flex socket

June 2003 IPN: M5000-00-105 Reassembling the radio D - 15

Figure D-12: Assembly of the switches

shield

chassis

antenna connector

channel selector switch

on/off/volume control switch

ribbed lock washer (M6x10x0.7 mm)

SMA connector nut (¼x7.9x3 mm)

channel/volume control nut

(M6x7.9x3 mm)

knob seal

Fitting the front panel to the chassis

Place the radio into the front panel top first, inserting the antenna connector and knob switches through the holes. Gently ease the radio into the front panel until the edge of the chassis is flush with the edge of the front panel, while making sure that the seal is not pinched; using the battery as leverage as in radio disassembly may be helpful. Replace the two chassis screws at the base of the radio, tightening them to 2in.lb (0.23Nm).

Replace the two knobs on the radio with new knobs. Press each knob on firmly. There should be a small gap between the knob label and the base of the knob.

D - 16 Reassembling the radio June 2003 IPN: M5000-00-105

Spares kits

The following table shows a list of spares kits which are currently available for servicing Tait Orca 5000 portable radios. Spares kits are designed to service 100 radios, and can be ordered from your local Tait dealer.

Table D-1: Spares kits

Product code Description

TOPA-SP-401G Orca 5010/11/30 spares kit

TOPA-SP-402G Orca 5035 spares kit

TOPA-SP-403G Orca 5015/2x/40 spares kit

TOPA-SP-404 Orca 5010/11/30 re-skinning kit

TOPA-SP-405 Orca 5035 re-skinning kit

TOPA-SP-406 Orca 5020/40 re-skinning kit

TOPA-SP-407 Orca 5015/2x/35/40 U/I PCB +

shield

TOPA-SP-408 Orca 5015/21 re-skinning kit

TOPA-SP-504 Battery catch x 10

PCB Product Codes

Tait Orca 5000 main PCBs are available on an exchange basis from Technical Support at Tait Electronics Ltd. When ordering, use the following naming convention

TOP-XXXXX-KS.

For example, a replacement main PCB for a TOP-B2620-T0 is a TOP-B2620-KS.

The Tait Orca product code can be found on the chassis type approval label, which is visible when the battery is removed.

TOPA-SP-506 Orca 5000 series volume knobs x 10

TOPA-SP-507 Orca 5000 series channel knobs x 10

The contents of the Orca 5000 low, mid and high tier spares kits (TOPA-SP-401G, TOPA-SP-402G and TOPA-SP-403G) are shown in Tables D-2, D-3 and D-4. The contents of the Orca 5000 portable radio reskinning kits are shown in Tables D-5, D-6 and D-7.

Information contained in the tables

Note that the ‘IPN’ column is the ten digit ‘internal part number’ which uniquely identifies any component used in a Tait product.

The numbers in the ‘Reference’ column are Figure numbers in which the spares item is shown, and the number in brackets refers to the numbered legend within each figure.

June 2003 IPN: M5000-00-105 Spares kits D - 17

Table D-2: Orca 5010/11/30 spares kit (TOPA-SP-401G)

IPN Description Quantity Reference

040-05500-08 Volume Control Switch 10 D-8 (3), D-9 (3)

219-50029-00 RF out assembly 5 D-11 (1)

220-01414 -03 Au x Fl ex Connecto r PC B 5 D -10 ( 1) 231-00010-45 Channel Selector Switch 10 D-8 (2), D-9 (2) 232-00010-42 Switch PTT (Low Profile) 5 D-8 (8), D-9 (6) 240-02156-01 Antenna SMA Connector 10 D-12 (4) 252-00010-77 Speaker 40mm 0.5W 16E FST 5 — 252-00010-56 Microphone 5 D-8 (11)

303-10053-00 Radio Chassis 5 D-4 (2), D-5 (3)

303-30072-00 Battery Catch 20 — 30 8-01015-0 0 Hous ing Ac cess ory D umm y Co ver 20 —

311-01049-xx Channel Selector Knob 20 D-2 (1)

311- 03108 -00 PTT/ Funct ion Keyp ad 10 — 316-06763-00 Knob Label 5 D-2 (3) 316-06765-02 Rear Panel 10 D-10 (7) 316- 85133-0 0 PTT/ Fu n cti on Key Re t aini ng P lat e 10 — 319-0102 6-00 Main RF Shi eld 5 D-4 (1)

345-00020-09 PA Screw M2x5mm Pan Torx 10 D-8 (10)

345-00020-11 Chassis Screw M2x8mm Pan Torx 10 D-1 (3) 352-00010-52 Channel/volume Control Nut (M6x7.9x3mm) 20 D-12 (9) 352-01053-00 Antenna SMA Connector Nut 10 D-12 (8) 353-00010-42 Ribbed Lock Washer M6x10x0.7mm 30 D-12 (7) 360-01060-00 PTT/Function Key Actuator 40 — 360-02019-00 Microphone Grommet/Seal 10 D-5 (1) 365-01673-00 Insert Front Panel Logo Label 1 — 362-01035-01 Chassis Plug Seal (green) 10 D-10 (9) 362-01106-00 Rear Panel Seal 10 D-10 (5)

362--01089-01 Aux Flex Seal 10 D-10 (2)

362-01091-01 Knob Seal 10 D-12 (10) 362-01092-02 Main Seal 20 — 369-01039-00 Adhesive Ring 40mm (speaker) 5 D-7 (2)

304-07044-00 Speaker pin frame 20 —

316-85027-00 Pin External RF out assembly 10 — 356-01070-00 Speaker Contact Probe Spring 10 — 339-00010-53 Plastic bag, 150x250mm 11 — 399-00010-69 Plastic bag, 75x100mm Mini grip 23 —

311-01153-00 Package carton, T2000 SII, unprinted 1 — 365-01663-00 Warning Labels for Green D-Clips 1 —

OPP401 Front Panel Assembly. This comprises the following parts: 5 —

252-00010-77 Speaker 40mm 0.5W 16E FST 1 — 307-01022-00 Speaker cloth 1 — 316-06760-xx Front Panel 1 — 316-06763-00 Knob Label 1 D-2 (3) 354-01044-00 Bush M2 Threaded Brass 2 — 369-01039-00 Adhesive Ring 40mm (speaker) 1 D-7 (2) 316-85133-00 PTT/Function key retaining plate 1 — 311-03108-00 PTT/Function keypad 1 — 360-01060-00 PTT/Function key actuator 2 — 399-00010-91 Plastic bag, 96x225mm 1 —

D - 18 Spares kits June 2003 IPN: M5000-00-105

Table D-3: Orca 5035 spares kit (TOPA-SP-402G)

IPN Description Quantity Reference

040-05500-08 Volume Control Switch 10 D-8 (3), D-9 (3)

219-50029-xx RF out assembly 5 D-11 (1) 220-01414-03 Aux Flex Connector PCB 5 D-10 (1) 231-00010-45 Channel Selector Switch 10 D-8 (2), D-9 (2) 232-00010-42 Switch PTT (Low Profile) 5 D-8 (8), D-9 (6) 240-02156-01 Antenna SMA Connector 10 D-12 (4) 252-00010-77 Speaker 40mm 0.5W 16E FST 5 —

252-00010-56 Microphone 5 D-8 (11) 303-10053-00 Radio Chassis 5 D-4 (2), D-5 (3) 303-30072-00 Battery Catch 20 —

30 8-01015 -00 H ous ing Acc ess ory D umm y C ove r 20 —

311-01049-00 Channel Selector Knob 20 D-2 (1)

311-01050-00 Volume Knob 20 D-2 (2)

311-03108-00 PTT/Function Keypad 20 —

311-03110-00 Keypad 5 —

312-01087-00 Lens Coa ted 2 D -8( 1) 303-23098-00 Protective Lens Cover 5 —

316-06763-00 Knob Label 5 D-2 (3)

316-06765-02 Rear Panel 5 D-10 (7)

316- 85133- 00 P TT/Fun cti on Key R eta inin g P lat e 10 — 345-00020-09 Screw M2x5mm Pan Torx 10 D-8 (10) 345-00020-11 Chassis Screw M2x8mm Pan Torx 10 D-1 (3)

352-00010-52 Channel/volume Control Nut (M6x7.9x3mm) 20 D-12 (9)

352-01053-00 Antenna SMA Connector Nut 10 D-12 (8)

353-00010-42 Ribbed Lock Washer M6x10x0.7mm 30 D-12 (7)

360-01060-00 PTT/Function Key Actuator 40 —

360-02019-00 Microphone Grommet/Seal 10 D-5 (1) 362-01035-01 Chassis Plug Seal (green) 10 D-10 (9) 362-01087-00 Battery Contact Seal 10 D-9 (8) 36 2-0110 6-0 0 Rea r P ane l Se al 10 D-10 (5)

362--01089-01 Aux Flex Seal 10 D-10 (2)

36 2-010 91-01 Knob Sea l 10 D- 12 (10) 362-01092-02 Main Seal 20 — 369-01039-00 Adhesive Ring 40mm (speaker) 5 D-7 (2) 316-85027-00 Pin External RF out assembly 5 —

304-07044-00 Speaker pin frame 20 —

356-01070-00 Speaker Contact Probe Spring 10 — 339-00010-53 Plastic bag, 150x250mm 16 — 399-00010-69 Plastic bag, 75x100mm Mini grip 25 —

311-01153- 00 Pack age ca rton, T2 000 SI I, u npr inted 1 —

365-01663-00 Warning Labels for Green D-Clips 1 —

TOPA-SP-407 User Interface Kit, 5020/21/35/40, with PCB & Shield 5 —

OPP501 Front Panel Assembly. This comprises the following parts: 5 —

252-00010-77 Speaker 40mm 0.5W 16E FST 1 — 307-01022-00 Speaker cloth 1 — 316- 06761 -00 Fro nt Pan el 1 — 316-06763-00 Knob Label 1 D-2 (3) 354-01044-00 Bush M2 Threaded Brass 2 — 369-01039-00 Adhesive Ring 40mm (speaker) 1 D-7 (2) 360-01060-00 Preselect Actuator 2 — 311-03108-00 PTT/Function keypad 1 — 316-85133-00 PTT/Function key retaining plate 1 — 312-01087-00 Lens, Coated 1 D-8(1) 303-23098-00 Protective Lens Cover 1 — 399-00010-91 Plastic bag, 96x225mm 1 —

June 2003 IPN: M5000-00-105 Spares kits D - 19

Table D-4: Orca 5015/2x/40 spares kit (TOPA-SP-403G)

IPN Description Quantity Reference

008-36671-80 LCD Display 1 — 040-05500-08 Volume Control Switch 10 D-8 (3), D-9 (3)

219-50029-00 RF out assembly 5 D-11 (1)

220-01414 -03 Au x Fl ex Connecto r PC B 5 D -10 ( 1) 231-00010-45 Channel Selector Switch 10 D-8 (2), D-9 (2) 232-00010-41 Switch PTT (Low Profile) 5 D-8 (8), D-9 (6) 240-02156-01 Antenna SMA Connector 10 D-12 (4) 252-00010-77 Speaker 40mm 0.5W 16E FST 5 — 252-00010-56 Microphone 5 D-8 (11)

303-10053-00 Radio Chassis 5 D-4 (2), D-5 (3)

303-30072-00 Battery Catch 20 — 30 8-01015-0 0 Hous ing Ac cess ory D umm y Co ver 20 —

311-01049-00 Channel Selector Knob 20 D-2 (1)

311- 01050 -01 Volume Kn ob 2 0 D-2 (2 )

311-03108-01 PTT/Function Keypad 20 —

311-03109-00 Keypad TOP5020/5040 5 —

311-03113-00 Keypad TOP5021 5 —

312-01087-00 Lens Coated 2 D-6 (1)

303-23098-00 Protective Lens Cover 5 —

316-06763-00 Knob Label 5 D-2 (3) 316-06765-02 Rear Panel 5 D-10 (7) 316- 85133-0 0 PTT/ Fu n cti on Ret ain ing Pla te 10 —

345-00020-09 PA Screw M2x5mm Pan Torx 10 D-8 (10)

345-00020-11 Chassis Screw M2x8mm Pan Torx 10 D-1 (3)

349-00030-00 Speaker Screw 1.8x5mm Torx 10 D-7 (3)

352-00010-52 Channel/volume Control Nut (M6x7.9x3mm) 20 D-12 (9) 352-01053-00 Antenna SMA Connector Nut 10 D-12 (8) 353-00010-42 Ribbed Lock Washer M6x10x0.7mm 30 D-12 (7) 356-01070-00 Speaker Contact Probe Spring 10 — 360-01060-00 PTT/Function Key Actuator 40 — 360-02019-00 Microphone Grommet/Seal 10 D-5 (1) 362-01035-01 Chassis Plug Seal (green) 10 D-10 (9) 362-01087-00 Battery Contact Seal 10 D-9 (8) 362-01106-00 Rear Panel Seal 10 D-10 (5)

362--01089-01 Aux Flex Seal 10 D-10 (2)

362-01091-01 Knob Seal 10 D-12 (10) 362-01092-02 Main Seal 20 — 369-01039-00 Adhesive Ring 40mm (speaker) 5 D-7 (2)

304-07044-00 Speaker pin frame 20 —

316-85027-00 Pin External RF out assembly 20 —

311-01153-00 Package carton, T2000 SII, unprinted 1 — 339-00010-53 Plastic bag, 150x250mm 13 — 399-00010-69 Plastic bag, 75x100mm Mini grip 23 — 365-01663-00 Warning Labels for Green D-Clips 1 —

TOPA-SP-407 User Interface Kit, 5020/21/35/40, with PCB & Shield 5 —

OPP601 Front Panel Assembly. This comprises the following parts: 5 —

252-00010-77 Speaker 40mm 0.5W 16E FST 1 — 307-01022-00 Speaker cloth 1 — 316-06762-00 Front Panel 1 — 316-06763-00 Knob Label 1 D-2 (3) 369-01039-00 Adhesive Ring 40mm (speaker) 1 D-7 (2) 360-01060-00 Preselect Actuator 2 — 311-03108-00 PTT/Function keypad 1 — 316-85133-00 PTT/Function key retaining plate 1 — 312-01087-00 L ens , C oate d 1 D-8( 1) 303-23098-00 Protective Lens Cover 1 — 399-00010-91 Plastic bag, 96x225mm 1 —

D - 20 Spares kits June 2003 IPN: M5000-00-105

Table D-5: Orca 5010/11/30 re-skinning kit (TOPA-SP-404)

IPN Description Quantity

311-01049-01 Channel Knob 1 311- 01050 -01 Vol ume Kno b 1

316-06765-00 Rear Panel 1

345-00020-11 Screw M2x8mm SS Pan Torx Patch 2

36 2-0110 6-0 0 Rea r C ove r S eal 1 36 2-010 91-01 Knob Sea l 1 362-01092-02 Main Seal 1

OPP401 PHA Front Panel Assembly 1 399-00010-69 Plastic Bag 75x100mm Mini Grip 1 399-00010-53 Plastic Bag 150x250mm 1

410-01064-01 Packaging Header Card New Logo 1

316-0 676 5- 01 Rea r Pa nel 1

Table D-6: Orca 5035 Re-skinning kit (TOPA-SP-405)

IPN Description Quantity

311-01049-01 Channel Knob 1 311- 01050 -01 Vol ume Kno b 1 311-03110-00 Keypad 1

316-06765-00 Rear Panel 1

345-00020-11 Screw M2x8mm SS Pan Torx Patch 2

36 2-0110 6-0 0 Rea r C ove r S eal 1 36 2-010 91-01 Knob Sea l 1 362-01092-02 Main Seal 1

OPP501 PHA Front Panel Assembly 1 399-00010-69 Plastic Bag 75x100mm Mini Grip 1 399-00010-53 Plastic Bag 150x250mm 1

410-01064-01 Packaging Header Card New Logo 1

316-0 676 5- 01 Rea r Pa nel 1

Table D-7: Orca 5020/40 Re-skinning kit (TOPA-SP-406)

IPN Description Quantity

311-01049-01 Channel Knob 1

311- 01050 -01 Vol ume Kno b 1 311-03109-00 Keypad 1 316-06765-00 Rear Panel 1

345-00020-11 Screw M2x8mm SS Pan Torx Patch 2

36 2-0110 6-0 0 Rea r C ove r S eal 1 36 2-010 91-01 Knob Sea l 1 362-01092-02 Main Seal 1

OPP601 PHA Front Panel Assembly 1 399-00010-69 Plastic Bag 75x100mm Mini Grip 1 399-00010-53 Plastic Bag 150x250mm 1

410-01064-01 Packaging Header Card New Logo 1

316-0 676 5- 01 Rea r Pa nel 1

June 2003 IPN: M5000-00-105 Spares kits D - 21

Table D-8: Orca 5015/2x/35/40 User Interface PCB and Shield (TOPA-SP-407)

IPN Description Quantity

OPF200-B UI PCB SMT Subassembly 1 311-04005-00 Ins Poly Dome for 5015/2x/40 1 319-0102 6-00 Main Shi eld RF 1 399-00010-86 Static Shielding Bag 127x203mm 1

008-36671-80 LCD Display 12x2 Lines Flex 1 304-07043-00 LCD Frame Holder 1

220-01501-00 PCB Flexi User Interface 1 369-01044-00 Conductive Adhesive/Mylar 365-00011-38 Yellow Label Static Warning

Table D-9: Orca 5015/21 Re-skinning kit (TOPA-SP-408)

IPN Description Quantity

311- 01049 -01 Chan nel Kn ob 1 311- 01050 -01 Volume Kn ob 1

311-03113-00 Keypad 1 316-06765-00 Rear Panel 1 345-00020-11 Screw M2x8mm SS Pan Torx Patch 2 362-01106-00 Rear Cover Seal 1

362-01091-01 Knob Seal 1 362-01092-02 Main Seal 1

OPP601 PHA Front Panel Assembly 1 399-00010-69 Plastic Bag 75x100mm Mini Grip 1 399-00010-53 Plastic Bag 150x250mm 1

410-01064-01 Packaging Header Card New Logo 1 316- 0676 5-01 Rea r Pa nel 1

D - 22 Spares kits June 2003 IPN: M5000-00-105

PART

Battery packs and chargers

This part provides information on the battery packs and chargers available for Tait Orca 5000 portable radios.

The battery packs are not serviceable, and repair of chargers is limited to replacement of the spring contacts, the discharge tact switch and the DC jack.

Contents

Battery packs

Battery packs ..................................................................................................

Battery packs Battery packs

Battery shift life ......................................................................................................E-3

Disposing of used nickel-cadmium batteries ..........................................................E-4

Battery chargers

Battery chargers .............................................................................................

Battery chargers Battery chargers

Desktop fast charger

Desktop fast charger ......................................................................................

Desktop fast charger Desktop fast charger

..................................................................................................E-3

....................................................................................................................................................................................................

.............................................................................................E-5

..........................................................................................................................................................................................

......................................................................................E-6

............................................................................................................................................................................

E-3

E-3E-3

E-5

E-5E-5

E-6

E-6E-6

Fast charger operation ............................................................................................E-6

Using the fast charger ............................................................................................. E-9

Repairing the fast charger ....................................................................................E-10

Desktop trickle charger

Desktop trickle charger ................................................................................

Desktop trickle charger Desktop trickle charger

Trickle charger operation .....................................................................................E-12

Using the trickle charger ......................................................................................E-13

Repairing the trickle charger ................................................................................E-13

Troubleshooting ...................................................................................................E-14

Multi-charger

Multi-charger ...............................................................................................

Multi-charger Multi-charger

Multi-charger operation .......................................................................................E-15

Repairing the multi-charger .................................................................................E-15

Fuse replacement .................................................................................................E-16

...............................................................................................E-15

..............................................................................................................................................................................................

................................................................................E-12

................................................................................................................................................................

E-12

E-12E-12

E-15

E-15E-15

E - 2 June 2003 IPN: M5000-00-105

Battery packs

Six battery packs are available for Tait Orca 5000 portable radios. These battery packs are not serviceable, but their construction and expected life are described below.

The battery packs available are:

■ TOPB100 NiCD battery pack;

■ TOPB600 NiCD battery pack (slim, no belt

clip);

■ TOPB200 NiCD battery pack;

■ TOPB400 NiMH battery pack;

■ TOPB700 NiMH battery pack (slim, no belt

clip); and

■ TOPB500 NiMH battery pack.

The battery casing is constructed using a rugged resin material, and includes two pieces that are ultrasonically welded together.

Battery shift life

Battery shift life is outlined in Table E-1. Battery shift life for other models and circumstances can be calculated from the typical drain rates on page E-4.

For intrinsically safe batteries, see page A-11.

Preserving battery shift life

to preserve the shift life of the battery:

■ Charge or change the battery as soon as

the radio gives the ‘Low Battery’ warning.

■ Short condition the battery weekly.

■ Long condition the battery only for the

following reasons: on first use of new battery, if performance is poor, and after more than two weeks of storage.

■ Avoid leaving charged batteries in the

charger for more than a day.

■ Clean electrical contacts of the battery

using a fibre glass pencil, or the graphite tip of a type 4H (#4) or harder pencil.

■ Always store the battery detached from

the radio when storing for more than a few days.

■ Turn the radio off when it is unattended

for long periods.

■ Use only a Tait-recommended charger.

■ Maintain an ambient temperature of

between 5°C and 40°C during recharging. Optimum battery performance will be obtained between 15°C and 25°C.

■ Do not allow the battery pack contacts to

become short-circuited.

It is important that you follow the steps below

Ta ble E- 1 : Typ ical b atter y shif t life (in hou rs) b ased on a 5:5:9 0 duty cycle for a ne w cond ition ed bat tery p ack*.

Battery type

TOPB100/600 NiCD 8.5 7 6.5

TOPB400/700 NiMH 10.5 8.5 8

TOPB200 NiCD 11.5 9 8.5

TOPB500 NiMH 15 12 11

* Users should aim to have one hour spare capacity at the end of their shift to allow for battery ageing.

June 2003 IPN: M5000-00-105 Battery packs E - 3

Conventional -

Medium Economy

Radio type

Conventional -

No Economy

Tru nke d

Extending battery shift life

Battery shift life can be extended by activating economy mode (conventional radios) or by using dynamic power control (trunked radios).

During economy mode, the radio cycles between the normal receive state and a standby state, in which some of the radio’s circuitry is switched off or placed on standby mode. Dynamic power control optimises the radio’s power use by reducing the transmit power in high signal strength areas.

Typical drain rates for a conventional UHF radio are:

■ 1.5 A at high power transmit;

■ 300 mA in receive at rated audio;

■ 80 mA on standby (no audio);

■ 55 mA with low economy cycling enabled;

■ 45 mA with medium economy cycling

enabled; and

■ 40 mA with high economy cycling

enabled.

Economy cycling in conventional radios is programmed in the Power Save Features screen of the Tait Orca Portable Conventional Programming Application (TOPCPA). Dynamic power control in trunked radios is enabled in the User Selectable Parameters screen of the Tait Orca Portable Trunked Programming Application (TOPTPA).

Disposing of used nickel-cadmium batteries

NiCd batteries contain a small amount of the metal cadmium, which can produce potentially toxic waste if not disposed of properly. Contact your Tait dealer for recycling details.

E - 4 Battery packs June 2003 IPN: M5000-00-105

Battery chargers

Note:

Note: In order to charge TOPB700 NiMH

Note:Note: batteries, the charger must have firmware version 2.07 or greater. TOPB500 NiMH batteries can be charged on chargers with firmware version 2.05 or greater.

The trickle charger should not be used for NiMH battery packs as they can take up to 24 hours to charge fully and the overall lifetime of the battery may be reduced. NiMH battery packs should be charged using a fast charger.

Three battery chargers are available for Tait Orca portable radios:

■ desktop fast charger;

■ desktop trickle charger; and

■ six-way multi-charger.

The fast charger charges, conditions and analyses the battery. The trickle charger only charges the battery, and does not have a conditioning button but is otherwise identical in appearance to the fast charger. The multicharger is made up of six fast chargers, and

For details on charging intrinsically safe batteries, see page A-11.

Repair of chargers is limited to replacement of the spring contacts, the discharge tact switch and the DC jack.

The repair information provided for the fast charger also applies to repair of the trickle charger and multi-charger.

A spares kit is available for Tait Orca chargers (TOPA-SP-202). The contents of the spares kit is shown in Table E-2, and the assembly of these parts is shown in Figure E-3.

charging instructions for the fast charger also apply to the multi-charger.

Table E-2: Contents of the Tait Orca chargers spares kit (TOPA-SP-202)

IPN Description Quantity For charger

240-02020-07 Skt DC jack 10 All

232-00010-28 Tact switch 10 Desktop fast charger

Multi-charger

302-40054-01 Conditioning button 10 Desktop fast charger

Multi-charger

262-00001-00 Charger light pipe 10 Desktop fast charger

Multi-charger

312-0106 9-02 Ch arger top 10 All

312-01070-01 Charger base 10 All

365-01549-01 Charger logo label 10 All

365-01598-01 36 5-016 01-00

365-01597-00 36 5-016 01-02

369-00010-11 Rubber charger foot 40 All

360-01059-00 Trickle charger blanking label 10 Desktop trickle charger

356-01079-00 Spring probe charger bias-ball 40 All

Charger labels 10 Desktop fast charger

Multi-charger

Charger labels 5 Desktop trickle charger

June 2003 IPN: M5000-00-105 Battery chargers E - 5

Desktop fast charger

The Tait Orca desktop fast charger (Figure E-1) is an intelligent charger that can charge, condition and analyse both NiCd and NiMH batteries of varying capacities.

Fast charger operation

A circuit diagram of the fast charger is shown in Figure E-2. The fast charger operates using constant current charging and multiple criteria for end-of-charge detection. When a battery is inserted, the charger detects the type of battery, checks to see if it is working correctly, and then charges the battery.

If the conditioning button is pressed after inserting the battery, the charger will discharge the battery before charging. If the conditioning button is held down while the battery is being inserted, the charger will enter a long condition cycle that will charge and discharge the battery a number of times and, on the last cycle, check its capacity before recharging.

Multiple protection methods are employed to ensure safe operation.

Figure E-1: Tait Orca fast charger

LED

Conditioning button

sor, D1, in conjunction with PolySwitch™ PS1. Under reverse polarity conditions, D1 conducts, drawing the available short circuit current until PS1 trips. D1 also protects against any voltage spikes that may come through the AC to DC adaptor. The unit is designed for 10.5 - 14 V operation.

The +5V supply is produced by the regulator, IC1. A feature of this regulator is that it provides a RESET output to the microprocessor. This RESET output is used to delay startup of the microprocessor until the power supply has stabilised after turn-on. It also puts the microprocessor into reset if the input voltage falls too low. D2 sets this low voltage threshold to approximately 9.2 V.

The intelligence of the fast charger is provided by the microprocessor, IC2, which interfaces with the current source, the discharge circuit and the expanded battery voltage interface. The user can interact with the fast charger by pressing the conditioning button, SW1, and can observe the operational state on the tri-colour LED, D5.

The current source is based on a groundsensing linear topology. R1 and R2 are the current sense resistors. The power device is a P-channel MOSFET, Q4, which is controlled by an operational amplifier, IC3:A. The feedback path that controls the op amp, and hence the current, is through transistor Q5 and its resistor network. The grounding on R23 includes the ground sense resistors in the feedback path. The nominal output current is 800 mA.

Hardware operation

Power to the unit is provided from a 12 volt, 1 amp (nominal) wall-mounted AC to DC adaptor, through SK1. Reverse polarity protection is provided by the 22 V transient suppres-

E - 6 Desktop fast charger June 2003 IPN: M5000-00-105

+5V

R46

100K%05

R56

47K

27K 0.5%

G3 -

G3 O/P

CAP

3.9MM BASE DIA

C26

R50

R49

G3 +

IC3

LM324D

STP16NE06

R39

1K0

G1 O/P

IC3

LM324D

R37

100K%05

+BATT

R43

1K0

G1 -

10K 0.5%

+BATT

3.9MM BASE DIA

BLM41P800

TAN T

C54

4U7

C201

1N0

R40

R38

+5V

G2 O/P

IC3

LM324D

G2 +

G2 -

MTP2955

SGD

R17

1K0

G4 O/P

IC3

12V

G4 +

R16

BC847W

C16

1K0

C15

R15

10K 0.5%

LM324D

G4 -

18P

100N

+5V

R14

47K

R19

220K

R18

27K 0.5%

VCC

R21

R20

V+

IC3

1K0

100K%05

R22

LM324D

R23

10K 0.5%

C17

100N

10K 0.5%

GND

V-

R26

R25

BCW70

10K 0.5%

47K

R24

47K

HS1

R35

TO-220 HEATSINK

G1 +

100K%05

R36

R55

+5V

R411ER42

10K 0.5%

1M0

TEMP

3.9MM BASE DIA

BLM11B601SL3BLM11B601S

C25

100N

10K 0.5%

R45

1N0

10K 0.5%

100K%05

R48

100K%05

C20

100N

10K 0.5%

R47

C21

GND

100N

3.9MM BASE DIA

VCC

VIN

SK1

DC JACK 2.5MM

1APS1

+5V

BC847W

ANODE GR

VCC

1N0

TAN TC34U7

47K

VOUT

VS1CT

4V7

22V

IC1

L4949

VIN

D200

I/OPAD

RESET

C200

1N4001

GND

1N0

C10

100N

1N0

I/OPAD

+5V

C11

100N

-RESET

1K0

100N

-IRQ

IRQ

RESET

PA7

PA6

PA7

PA6

PC7/VRH

PC6/AN0

PC7/VRH

PC6/AN0

BC847W

PA5

PA4

PA5

PA4

PC5/AN1

PC4/AN2

PC5/AN1

PC4/AN2

+5V

SW1

PA3

PA2

PA3

PA2

IC2

PC3/AN3

PC2

PC3/AN3

RL-A

TAC T

PA1

PA0

PA1

PA0

MICRO

68HC05P6

PC1

PC0

PC1

PC0

ANODE RE D5

DUAL LED

CATHODE

DUAL LED

RED GREEN

CATHODE

PB5/SDO

PB6/SDI

PB5/SDO

TCMP

PD7/TCAP

RL-K

PB7/SCK

PB6/SDI

PB7/SCK

PD7/TCAP

PD5

R33

R32

47K

1N0

47K

GND

OSC1

OSC2

330

470

GND

OSC1

OSC2

33P

1M0

XTAL

33P

Figure E-2: Circuit diagram of the Tait Orca desktop fast charger

June 2003 IPN: M5000-00-105 Desktop fast charger E - 7

The discharge circuit is based around a constant current sink. This uses an N-channel MOSFET, Q6, controlled by an operational amplifier, IC3:B. R41 and R42 are the current sense resistors that allow the op amp to set the current. The nominal discharge current is 400 mA.

The microprocessor needs to be able to monitor the battery voltage. A coarse voltage is provided by the voltage divider R48, R49 and R50. This voltage divider brings the range of battery voltage into the same range as the microprocessor A/D input (0-5 V). This enables the microprocessor to monitor the general battery voltage. An expanded battery voltage interface is based around operational amplifier IC3:C. It expands a small window of battery voltage over the range of the microprocessor A/D input. This enables the microprocessor to detect small changes in battery voltage and accurately pick when the battery voltage drops below peak.

The interface to the battery is through four contacts, positive (+BATT), temperature (TEMP), capacity (CAP) and ground (GND). The positive and ground contacts are the main connections for charging. In the battery pack, the temperature contact is connected to ground via a thermistor. This allows the charger to monitor the temperature of the battery and if the battery temperature is outside the range +5°C to +40°C, the charger will not charge the battery. The charger also uses the temperature line for detecting the presence of a battery; for example, detecting whether the battery has been inserted or removed from the charger. In the battery pack, the capacity contact is connected to ground via a resistor. If there is a capacitor in parallel with the capacity resistor, then the resulting time constant indicates to the charger that the battery pack is NiMH. Consequently, battery packs that do not have a capacitor in parallel with the capacity resistor are considered to be NiCd.

Software operation

The charging sequence is as follows.

■ Battery discharge (optional);

■ Battery flat test;

■ Battery type detection;

■ Battery open circuit test;

■ Battery short circuit test;

■ Battery temperature test;

■ Rapid charge, with multiple end-of-charge

detection methods;

■ Rest;

■ Trickle charge (optional);

■ Standby charge;

■ Maintenance charge.

If during trickle or standby charge the battery voltage falls to the discharged battery threshold, the charger restarts the charge cycle as if the battery has just been inserted.

E - 8 Desktop fast charger June 2003 IPN: M5000-00-105

Using the fast charger

recharging (5°C to 40°C).

Fast charger indicators are described in Table E-3.

Table E-3: Fast charger indicators

Indicator Meaning

steady red battery charging

steady green battery charged

steady amber charge suspended until battery tem-

perature is within correct range

flashing red battery not seated properly in the

charger, contacts dirty or battery faulty

flashing green battery trickle charging

flashing amber battery being long or short condi-

tioned, or if flashing amber straight away, it may indicate a fault such as dirty contacts

Charging the battery using the fast charger

Charging using the fast charger involves three stages.

■ The fast charge stage quickly brings the

battery up to near its full capacity. The charger LED will glow red.

■ The trickle stage slowly tops up the battery

until it is at its full capacity, which is typically 1½ hours. The charger LED will flash green.

Approximate charge times are:

■ up to 1½ hours for TOPB100 and

TOPB600;

■ up to 2 hours for TOPB200, TOPB400 and

TOPB700; and

■ up to 2½ hours for TOPB500.

Once the battery has reached approximately 90% capacity, the indicator will flash green. At this point, it is recommended the battery be left in the charger for a further 1 to 2 hours, to ensure maximum battery charge. Once the battery is fully charged, the indicator will glow green.Avoid leaving charged batteries in the charger for more than a day.

Conditioning the battery with the fast charger

Two conditioning functions are available on the fast charger, a short conditioning cycle and a long conditioning cycle. The short cycle discharges the battery then charges it. Regularly recharging a battery that has not been completely discharged will eventually affect its ability to hold a full charge.

For best performance, the battery should be conditioned weekly using the fast charger. Conditioning the battery takes about four to eight hours, depending on how much use it has had.

■ The standby charge stage keeps the

battery at its full capacity, as long as the radio is turned off. The charger LED will glow green.

The battery can be charged separately or attached to the radio. The radio must be turned off to ensure a full charge.

Turn off the radio and insert the battery/radio into the charger. If the indicator does not glow red, make sure the battery/radio is seated properly and the charger is plugged in correctly. If the battery is too hot or too cold, the indicator will remain amber until the battery temperature is within the safe range for

June 2003 IPN: M5000-00-105 Desktop fast charger E - 9

Note

Note: Do not use the short conditioning cycle

NoteNote on a new battery without first fully charging it using a long conditioning cycle.

The long conditioning cycle is necessary:

■ before the battery is used for the first time;

■ if the battery performance has deteriorat-

ed; or

■ after the battery has been stored for longer

than two weeks.

To short condition the battery

Turn off the radio and insert the battery/radio into the fast charger. When the charger LED glows red, press the conditioning button until the indicator flashes amber. Release the conditioning button. The LED will flash amber while the battery is being discharged. Once the battery is discharged, it will charge normally. The battery is ready to be used again when the charger LED glows green.

To long condition the battery

Long conditioning the battery with the fast charger will put the battery through a number of conditioning cycles and will check the battery’s capacity on the last cycle.

The long condition cycle will take approximately 24 hours.

Once charged, the charger’s indicator will glow green if the battery is in good condition. The indicator will flash red if the battery is well below optimum capacity; consult your Tait dealer.

Repairing the fast charger

The assembly of the fast charger is shown in Figure E-3.

Depress the release tab in the base of the charger using the end of a flat-bladed screwdriver. Holding the lever in, gently pull the body away from the base. Lift out the PCB.

To long condition the battery, turn off the radio. Press and hold the conditioning button while inserting the battery/radio. Continue holding the conditioning button until the indicator flashes amber. When the indicator flashes amber, release the conditioning button.

Replace the battery contacts, the tact switch and the DC jack, if necessary.

Figure E-3: Assembly of the desktop fast charger

charger base

access to the release tab

PCB

DC jack

charger top

conditioning button

E - 10 Desktop fast charger June 2003 IPN: M5000-00-105

fit conditioning button here

light pipe

fit light pipe here

Replacing the spring contacts

t c

Reassembling the charger

Remove the faulty contacts with a soldering iron and discard.

If the replacement spring contacts have a larger diameter and will not fit through the PCB, the holes should be drilled out to 2.2mm.

When placing the replacement contact, it must not be bent or otherwise damaged. Solder the replacement contact in place using a heavy-tip soldering iron (e.g. Weller 2PTCC8 tip). Hold onto the contact with a pair of pliers and apply solder to the PCB, rather than to the contact, to avoid contact damage.

Figure E-4: The fast charger PCB

Capacity and

emperature

ontacts

Refer to Figure E-3.

Hold the body of the charger upside down and insert the conditioning button and the light pipe; both parts self-orient. Place the PCB so it rests on the location pins. Attach the base at the front edge, and clip it down at the back.

Table E-4: Charger Spares and Upgrade Kits:

Product code Description

TOPA-SP-202 Charger Spares Kit

TOPA-SP-203 Charger Upgrade Kit

TOPA-SP-205 Charger Software Upgrade Kit

–ve and +ve contacts

Replacing the discharge tact switch

Remove the tact switch using a desoldering station or solderwick. Place the new part on the board and solder it in place using a medium-tip soldering iron (e.g. Weller PTA7 tip).

Replacing the DC jack

Remove the DC jack using a desoldering station or solderwick. There is a lot of solder on both sides of the board, so be sure to remove it all.

Place the new part on the board and solder it in place using a heavy-tip soldering iron (e.g. Weller 2PTCC8 tip).

June 2003 IPN: M5000-00-105 Desktop fast charger E - 11

Desktop trickle charger

The Tait Orca desktop trickle charger can charge a 1100 mAh or 1500 mAh NiCd battery overnight. It is designed to provide approximately 1450 mAh of charge in a 16 hour period. Thus both 1100 mAh or 1500 mAh NiCd batteries can be charged. Simple protection of the radio is provided in the form of an open circuit voltage limit as well as short circuit protection.

Figure E-5 shows the charger current profile. Figure E-6 shows the circuit diagram for the trickle charger.

Trickle charger operation

When the battery voltage is above approximately 8 V, the charge current is inversely proportional to the battery voltage. This characteristic is produced by Q100, Q101 and Q102. The charge current is determined by the current through R104, which is set by Q102, its emitter resistors and the reference voltage. The slope of the curve is determined by Q101 and R106. The reference voltage is provided by an

8.2 V Zener diode (D100).

When the battery voltage is below approximately 8 V, the charge current is proportional to the battery voltage. This is accomplished by using Q103 to change the reference voltage in proportion to the battery voltage. This changes the current through R104, which changes the charge current, as desired.

The maximum voltage available from the trickle charger is limited to less than 10.5 V by R111, in conjunction with Q101, so that the radio can not be damaged if the battery goes open circuit. If the battery goes short circuit, then Q102 is held off by Q103 and thus Q100 is off, and there is negligible charge current.

emitter voltage of Q103 rises. However, the base of Q103 is still at zero volts, so Q103 starts to turn on. When Q103 is on, it will maintain Q102 off and hence Q100 will also stay off. Thus when V

IN has risen to its final value, the

circuit is in an off state, giving negligible output voltage and charge current.

In order to activate the circuit, a minimum voltage of approximately 2.6 V (a battery) must be connected to the circuit to charge C101 and turn Q103 off, thus turning on the charger.

The LED is on whenever there is sufficient charge current. Its brightness is proportional to the charge current profile, and its turn-on and turn-off thresholds are determined by R105. Thus the LED is on under normal charging, dims when the battery approaches full charge and is off under fault/no charge condiions.

Figure E-5: Tait Orca desktop trickle charger current charge profile

110

100

Charge current (mA)

234567891011

Battery voltage (V)

On startup, the state of the charger is similar to that when the charger output is shorted. When power is applied, V

E - 12 Desktop trickle charger June 2003 IPN: M5000-00-105

IN starts to rise and the

Figure E-6: Circuit diagram of the Tait Orca desktop trickle charger

Using the trickle charger

The trickle charger is not recommended for NiMH battery packs, as they can take up to 24 hours to charge fully and the overall lifetime of your battery may be reduced. Use a fast charger instead.

The battery can be recharged attached to the radio or as a separate unit. To charge the battery pack using the trickle charger, make sure the radio is turned off. Insert the battery/ radio into the charger. Make sure the indicator on the charger glows red. If the indicator does not glow red, check that the battery/radio is seated properly and the charger is plugged in correctly. The indicator will remain red until the radio is removed from the charger.

VIN = 12-18 VDC from T952-0X2 plug pack (12 VDC @ 1 A) Dropout voltage = 11.5 V

until you next need to use the radio. However, leaving the battery in the charger for longer than 24 hours is not recommended.

Repairing the trickle charger

For instructions on repairing the trickle charger, refer to those for repairing the desktop fast charger.

The battery will be fully charged in about 16 hours. You can leave the battery in the charger

June 2003 IPN: M5000-00-105 Desktop trickle charger E - 13

Troubleshooting

When inserting the battery/radio in the charger, there is no indication on the charger LED.

■ Check that the battery/radio is seated

properly in the charger.

■ Check that the charger is properly plugged

in and the correct plug pack is being used.

■ Check that the battery and charger

contacts are clean and not obstructed.

Clean the electrical contacts of the battery and charger using a fibre glass pencil, or the graphite tip of a type 4H (#4) or harder pencil.

■ May indicate a faulty plug pack or cable.

Contact your Tait dealer.

The charger LED flashes amber as soon as the radio is seated in the charger.

■ Check that the battery and charger

contacts are clean and not obstructed.

The charger LED glows amber.

■ Safe range for charging is 5°C to 40°C, and

optimum battery performance will be obtained between 15°C and 25°C. The charger will start charging when the battery temperature is within the range 5°C to 40°C.

The charger LED flashes red.

■ Check that the battery and charger

contacts are clean and not obstructed.

■ May indicate a more serious fault such as a

faulty battery. Contact your Tait dealer.

The battery contacts show corrosion.

■ Contact corrosion may start to be noticed

later in life, and will reduce battery cell capacity. If early signs of corrosion appear, then clean back and end contacts of the battery using a fibre glass pencil, or the graphite tip of a type 4H (#4) or harder pencil.

E - 14 Desktop trickle charger June 2003 IPN: M5000-00-105

Multi-charger

The multi-charger (TOPA-CH-300) is made up of six desktop fast chargers that operate independently of one another. Each multicharger PCB has an additional diode.

Repairing the multi-charger

Should one of the charger units be faulty, you can repair it according to the instructions for the desktop fast charger, or replace the faulty PCB with a fast charger PCB to which the diode (1N4001 or similar) has been added (refer to Figure E-8).

Multi-charger operation

The operation of the multi-charger is the same as that of the desktop fast charger.

Figure E-7: The Tait Orca six-way multi-charger

■ Gently pull the faulty charger away from

the multi-charger top. Turn the charger upside down so that the release tab is at the top.

■ Depress the release tab using the end of a

flat-bladed screwdriver and gently pull the base away from the body.

To remove a faulty charger from the multicharger:

■ Unplug the power cord.

■ Undo the 10 screws at the base of the radio

using a Pozi 1 driver.

■ Do not

Do not pull the top off the charger using

Do not Do not the housing of the individual chargers. Instead, from the side of the charger, lift the top cover up and gently fold back.

■ Unplug the red and black wires leading to

the faulty charger.

■ Remove the three screws holding the

faulty charger to the top of the multicharger.

June 2003 IPN: M5000-00-105 Multi-charger E - 15

■ Desolder both wires.

■ Repair the board or replace it with a new

one to which the required diode has been added.

■ Pass the wires through the charger base.

■ Solder the red wire to the positive terminal

on the PCB and the black wire to the negative terminal on the PCB.

■ Place the charger upside down and make

sure the conditioning button, the light pipe and the PCB are seated properly.

■ Attach the base at the front edge, and clip

it down at the back.

■ Gently pull the wires through the multi-

charger top while aligning the charger with the three screw holes.

■ Fasten the charger to the multi-charger

top using the three screws.

■ Close up the multi-charger, replacing the

10 screws using a Pozi 1 driver.

■ Reconnect the red and black wire to the

fuse connector. Ensure that the polarity is correct.

Figure E-8: The Tait Orca Fast Charger PCB. The inset shows where to place the diode (1N4001 or similar) for using the PCB in a multi-charger

Fuse replacement

Each charger is protected by a 3A fuse. To replace a fuse, open the multi-charger as described previously. The fuse must be replaced with a 12V 3A secondary fuse made from material with a Class V-2 flammability rating.

A suitable fuse can be ordered directly from

E - 16 Multi-charger June 2003 IPN: M5000-00-105

Technical Support, Tait Electronics (IPN 265-00010-64).

PART

Accessories

This part describes how to interface accessories with Tait Orca 5000 portable radios, using the Tait Orca accessory connector and the 7.5 mm accessory adaptor.

Detailed servicing information about the Tait Orca vehicle kit is also provided on page F-10.

A list of audio accessories currently available for use with Tait Orca 5000 portable radios is found in Table A-1, on page A-7.

Contents

Tait Orca 5000 accessory connector

Tait Orca 5000 accessory connector ...............................................................

Tait Orca 5000 accessory connector Tait Orca 5000 accessory connector

Screw head types .................................................................................................... F-3

............................................................... F-3

..............................................................................................................................

F-3

F-3F-3

Connecting an accessory ........................................................................................ F-3

Connecting a headset .............................................................................................F-5

Accessory connector signal descriptions ................................................................ F-6

7.5 mm Accessory adaptor

7.5 mm Accessory adaptor .............................................................................

7.5 mm Accessory adaptor 7.5 mm Accessory adaptor

Tait Orca vehicle kit

Tait Orca vehicle kit .....................................................................................

Tait Orca vehicle kit Tait Orca vehicle kit

Product codes .......................................................................................................F-10

Update to the vehicle kit .......................................................................................F-10

Installing a vehicle kit ........................................................................................... F-10

Vehicle kit operation ............................................................................................F-10

Vehicle kit specifications ......................................................................................F-12

Servicing the vehicle kit ........................................................................................ F-13

Spares kits ............................................................................................................F-14

Vehicle kit spares kit (TOPA-SP-301)................................................................... F-15

Vehicle kit reskinning kit (TOPA-SP-302)............................................................ F-16

Custom modifications .......................................................................................... F-17

Vehicle kit circuit descriptions .............................................................................F-19

............................................................................. F-8

..........................................................................................................................................................

.....................................................................................F-10

..........................................................................................................................................................................

F-8

F-8F-8

F-10

F-10F-10

F - 2 June 2003 IPN: M5000-00-105

Tait Orca 5000 accessory connector

The Tait Orca 5000 portable radio has a versatile accessory interface on the rear of the radio for connecting external accessories, such as speaker microphones and headsets.

There are four Tait accessory connector kits available for Tait Orca 5000 portable radios:

■ Accessory Connector Kit with green P-Clip

(TOPA-AA-006G);

■ RF Accessory Connector Kit with green P-

Clip (TOPA-AA-007G).

■ Accessory Connector Kit with D-Clip

(TOPA-AA-106G); and

■ RF Accessory Connector Kit with D-Clip

(TOPA-AA-107G)

These kits are for use with the new chassis only. See “New chassis” on page A-5 and “Accessory connector compatibility” on page G-8. For accessory connectors compatible with the old chassis, refer to issue M5000-00-103 of this service manual.

P-Clip connector, and a Hex 2 driver for the DClip connector. Additionally a Torx T6 driver is required.

Connecting an accessory

Check that your accessory is compatible with the accessory connector by referring to Table F-1 “Accessory connector signal specifications” on page F-5. If connecting a headset, refer to “Connecting a headset” on page F-5 for connection details.

Accessory connector PCB link options

There are two optional links on the accessory connector PCB.

To turn off the radio’s internal speaker, short link 1 (‘LINK1’, shown in Figure F-1).

If an external switch is to be used to control the EXT-PTT line, for example in a hands-free vehicle kit, short link 2 (‘LINK2’, shown in Figure F-1).

Each kit contains the accessory connector PCB with the required spring probes soldered on. The board supplied with the RF accessory connector kit has four additional probes for RF applications.

Figure F-1 shows the bottom side of the accessory connector PCB and a circuit diagram of the accessory connector is shown in Figure F-3.

Table F-1 shows the signals available at the accessory connector, and the signals are described in more detail in “Accessory connector signal descriptions” on page F-6.

Screw head types

Link1

Link2

The Tait Orca 5000 Accessory connector requires a

Pozi 1 driver for the green

Accessory connector PCB connections

Solder pads P1 to P16 are provided on the bottom side of the accessory connector PCB for connection to external accessories. The location of these pads is shown in Figure F-1.

This diagram also shows the locations of the spring probes 1 to 16, and links 1 and 2.

Figure F-1: Tait Orca accessory connector PCB bottom side

P10

P13

P14

P11

P12

P2P3P4

P16

P15

P5 P6

June 2003 IPN: M5000-00-105 Tait Orca 5000 accessory connector F - 3

Accessory connector assembly

Assemble the accessory connector as shown in Figure F-2.

The order of assembly is as follows.

Figure F-2: Accessory connector assembly diagram

1 Thread the cable from your accessory

through the accessory housing, making sure it goes through in the proper direction.

2 Slide a grommet of appropriate size onto

the cable and pull firmly so the cable and grommet fit in place.

3 Strip and tin the accessory signal wires.

4 Solder the accessory wires to the correct

pads on the accessory connector PCB (refer to Table F-2 for headset connections).

5 Fit the accessory connector PCB links, if

required.

6 Crimp the cable at an appropriate

distance along the cable, approximately in line with the edge of the PCB.

7 Use narrow-nose pliers to pull out the

appropriate plugs in the seal and fit it onto the PCB.

8 Fit the grommet and PCB/seal into the

housing and secure it with the supplied screw. Torque the screw to 3in.lb (0.34Nm).

Lock (a) green P-Clip or (b) D-Clip

9 Fit the lock to the accessory connector

housing.

10 Fit the quarter turn tip, and secure with

supplied screw. Torque the screw to 3in.lb (0.34Nm).

F - 4 Tait Orca 5000 accessory connector June 2003 IPN: M5000-00-105

Spring

accessory connector housing

grommet

accessory PCB, complete with pins

PCB seal

screw M2x5 Pan Torx

quarter turn tip (lugs)

screw M3x16 Pan Pozi (green P-Clip)

screw M3x20 Hex (with D-Clip)

Table F-1: Accessory connector signal specifications

Output

Signal Description Type Signal level

RX-DET-AF-ACC Unmuted receive audio Analogue audio

1.15-1.6 VD C

MOD-AUDIO Modulator input Analogue audio 0-4.8 V

ACC* Accessory power DC supply 7.0 V* nominal 20 mA (max) –

+7V5-

RXD-ACC Serial receive data CMOS high = 0

TXD-ACC Serial transmit data CMOS high = 0

SENSE-0-ACC Accessory sense

(internal speaker disable)

SENSE-1-ACC Accessory sense CMOS high = 1

EXT-MIC External microphone input

(electret)

EXT-PTT External press-to-talk input Analogue DC 0-5 V, PTT = 0 V – 27 kΩ

EXT-SPKR External speaker differential output Analogue audio ±6.5 V

CMOS high = 1

Analogue audio 11 mVpp (typical)

53-225 mV

DC coupled

differential

rms

2.4 VDC – 470 Ω

low = 1

low = 0

impedance

/current

2.2 kΩ –

––

1 mA (max) –

–1 kΩ

To drive 16 Ω

differentially

Input

impedance

–

EXT+SPKR External speaker differential output Analogue audio ±6.5 V

differential

RF Accessory antenna connection Radio frequency Tx: 5 W

* Dependent on battery charge level.

Connecting a headset

The headset must meet the following basic specifications:

Solder the headset wires onto the accessory connector PCB pads, as shown in Table F-2.

To turn the radio speaker off and only have the headset speaker on, short link 1 (LK1). This

■ speaker impedance: 32 Ω (16 Ω min);

■ speaker power: 1/4 W

rms

(min);

■ microphone: electret, approximately

1kΩ; and

■ PTT: switch not in line with microphone.

ties SENSE-0-ACC to GND, telling the radio to turn the speaker off.

Note that SPEAKER+ and SPEAKER– must not short to GND, or to any other signal.

Table F-2: Accessory connector headset connections

Note that if your headset has a PTT in line with the microphone, it can be connected with the 7.5 mm accessory adaptor. See “7.5 mm Accessory adaptor” on page F-8 for more information.

Solder to these pads Signal from headset

P1 MIC

P2 GND

P3 PTT

Determine the compatibility/suitability of your headset by checking Table F-1. If it is compatible, follow the assembly procedure

P6 SPEAKER–

P7 SPEAKER+

outlined previously, on page F-4.

(max) 50 Ω –

rms

To drive 16 Ω

differentially

–

June 2003 IPN: M5000-00-105 Tait Orca 5000 accessory connector F - 5

Accessory connector signal descriptions

RX-DET-AF-ACC

The RX-DET-AF-ACC line carries unprocessed receive audio from the output of the detector IC.

EXT-MIC

The EXT-MIC signal is an analogue input from the microphone of an accessory.

Connecting a microphone to EXT-MIC automatically turns off the radio’s internal microphone.

MOD-AUDIO

The MOD-AUDIO line is used during calibration to set up the modulation balance and by some accessories, such as modems.

+7V5-ACC

The +7V5-ACC line supplies +7.5 V to accessories and is limited to 20 mA maximum. The output voltage itself will change depending on the battery voltage level, and there will be some voltage differential between the battery voltage and 7V5-ACC, depending on the current drawn by the accessory.

RXD-ACC

The RXD-ACC line carries data from the accessory connector to the controller during tasks such as radio programming and calibration.

TXD-ACC

EXT-PTT

The EXT-PTT is an analogue signal from the accessory interface to the control area and indicates an external request for PTT and external function buttons.

GND

The GND pin is the ground point of the accessory connector.

BUTTON-1 and BUTTON-2

Two external accessory function buttons are available, BUTTON-1 and BUTTON-2.

The sensing of the external function buttons is determined by a voltage divider on EXT-PTT. This consists of a 27 kΩ pull up to 5 V inside the radio and a pull down resistor on the accessory PCB. The resistor pull downs for BUTTON-1 and BUTTON-2 are as follows:

The TXD-ACC line is a digital data line from the microprocessor and carries synchronous data from the controller to the accessory connector during tasks such as radio programming and calibration.

SENSE-0-ACC

SENSE-0-ACC is used to turn off the radio’s internal speaker. To turn off the internal speaker, tie SENSE-0-ACC to GND by shorting link 1 (LK1). The external speaker outputs are always active.

SENSE-1-ACC

On conventional radios, SENSE-1-ACC is an output which follows the squelch detect line.

On trunked radios, SENSE-1-ACC is a currently unused input.

■ PTT function: resistor pull down 0 Ω,

voltage level on EXT-PTT is 0 V;

■ BUTTON-1 function: resistor pull down

12 kΩ, voltage level on EXT-PTT is 1.5 V;

■ BUTTON-2 function: resistor pull down

27 kΩ, voltage level on EXT-PTT is 2.5 V.

These resistors are already fitted to the accessory PCB.

EXT SPKR +/–

The EXT SPKR +/– line can be used to drive an external speaker. Neither terminal should be grounded, as the output is differential.

This pin provides a connection for accessories requiring RF, such as the RF speaker microphone. When an RF accessory is connected, the main antenna is switched out.

F - 6 Tait Orca 5000 accessory connector June 2003 IPN: M5000-00-105

Figure F-3: Tait Orca accessory connector circuit diagram

June 2003 IPN: M5000-00-105 Tait Orca 5000 accessory connector F - 7

7.5 mm Accessory adaptor

You can connect non-Tait accessories that require a 7.5 mm adaptor to the Tait Orca portable radio using the 7.5 mm accessory adaptor (TOPA-AA-005G).

Such accessories use 3.5 mm and 2.5 mm phono plugs with 7.62 mm spacing between them. The speaker and microphone/PTT jacks for the 7.5 mm adaptor are shown in Figure F-4.

To connect an accessory to the Tait Orca portable radio that uses PTT in series with the microphone, wire the accessory to a 3.5 mm plug and 2.5 plug according to Figure F-4.

The 7.5 mm accessory adaptor differs from the standard accessory connector in that with the

7.5 mm adaptor, the PTT signal is in series with the microphone signal. The standard accessory connector has separate PTT and microphone signals. If the accessory has function buttons, they will not work with the

7.5 mm adaptor.

The main function of the 7.5 mm adaptor is to demultiplex the accessory’s MIC/PTT line into

two separate lines for the Tait Orca portable radio. The adaptor also detects the presence of the accessory speaker and turns off the radio’s speaker.

Figure F-5 shows the circuit diagram for the

7.5 mm accessory adaptor.

When the accessory PTT switch is pressed, it connects the microphone to the adaptor between ground and the base of Q3 (see Figure F-5). This pulls Q3 low turning it on. Q3 in turn pulls the base of Q2 high which pulls the EXT-PTT line low, enabling the transmitter. Audio from the accessory microphone passes through C4 to the radio’s EXT-MIC line.

When the accessory speaker is connected, the base of Q1 is pulled high via R3 and R1, turning it on. This pulls the SENSE-0-ACC line low, which tells the radio to turn off the internal speaker, and only the accessory speaker is operational. C1, C2 and C3 filter out the audio signal, so that the voltage swing of the signal will not turn off Q1.

Figure F-4: Plugs for the 7.5 mm accessory adaptor

Speaker jack

3.5 mm

SPK (-)

SPK (+)

7.62 mm

F - 8 7.5 mm Accessory adaptor June 2003 IPN: M5000-00-105

Mic/PTT jack

2.5 mm

GND

MIC/PTT

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