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 Modelfields (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.
Copyright
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.
Test facilities ...................................................................................................................................... A-10
IS PCB servicing requirements ........................................................................................................... A-11
FM approval ....................................................................................................................................... A-11
FM approved products ....................................................................................................................... A-11
FM approved accessories ................................................................................................................... A-11
Synthesiser and VCO .......................................................................................................................... B-14
Power supplies ................................................................................................................................... B-14
Test commands ..................................................................................................................................... C-5
Calculating the parameters required for test command 101 ................................................................. C-7
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
Battery shift life ..................................................................................................................................... E-3
Disposing of used nickel-cadmium batteries .........................................................................................E-4
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 ........................................................................................................
Installing a vehicle kit ..........................................................................................................................F-10
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.
IS PCB servicing requirements ............................................................................ A-11
FM approval ........................................................................................................ A-11
FM approved products ........................................................................................ A-11
FM approved accessories ..................................................................................... A-11
A - 2June 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: M5000-00-105Servicing 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-
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: M5000-00-105The 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 radiosJune 2003 IPN: M5000-00-105
Table A-1: Tait Orca 5000 accessories
Type of accessoryProduct codeDescription
AntennasTOPA-AN-101130-230 MHz 3" helical
TOPA-AN-102336-540 MHz 3" helical
TOPA-AN-201136-340 MHz 6" helical
TOPA-AN-212400-940 MHz 6" wave whip
TOPA-AN-203896-941MHz 7" gain
TOPA-AN-204806-870M 1/2 wave gain
TOPA-AN-205896-941M 1/2 wave gain
TOPA-AN-30166-88MHz 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 -008Speaker microphone, -30 to 60 °C, MIL spec, no function buttons, high/low vol-
ume*
TOPA-AA-0092-wire palm microphone and earphone, -30 to 75°C*
TOPA-AA-0103-wire lapel microphone and earphone, -30 to 75°C*
TOPA-AA-011Light weight single speaker headset with in-line PTT, -30 to 75°C*
TOPA-AA-012Over-the-head headset with noise cancelling boom microphone, -30 to 75°C*
TOPA-AA-013Behind-the-head headset with noise cancelling boom microphone, -30 to 75°C*
TOPA-AA-101GSpeaker 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)
Carrying accessoriesTOPA-CA-001Heavy duty carry case
T952-012Australia, New Zealand and China (230 V 50 Hz input; plug configuration:)
T952-022Singapore and Middle East (230 V 50 Hz input; plug configuration:)
T952-032Mainland Europe (230 V 50 Hz input; plug configuration:)
T952-042USA and Canada (115 V 60 Hz input; plug configuration:)
T952-052UK and Hong Kong (230 V 50 Hz input; plug configuration:)
TOPA-CA-002Heavy duty holster
TOPA-CA-00338 mm belt clip x 10
TOPA-CA-004Accessory port cover x 10
TOPA-CA-00555 mm belt clip
TOPA-CA-00655 mm belt clip x 10
TOPA-CA-101Heavy duty carry case (with D-Clip)
TOPA-CA-102Holster carry case (with D-Clip)
TOPA-CA-103Belt loop
TOPA-CA-104G D-Clip
TOPA-CA-105Handstrap
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 accessoryProduct codeDescription
Audio accessoriesTOPA-AA-001Speaker microphone, -10 to 60 °C, two function buttons
TOPA-AA -002Speaker microphone, -30 to 60°C, heavy duty, two function buttons
TOPA-AA-003Speaker microphone, -30 to 60°C, MIL spec
TOPA-AA-004Speaker microphone, -30 to 60°C, MIL spec, with antenna socket
TOPA-AA-0057.5 mm accessory adaptor
TOPA-AA-006Tait Orca accessory connector kit
TOPA-AA-007Tait Orca RF accessory connector kit
Do not
Do not Do not
A - 8 The Tait Orca 5000 series of portable radiosJune 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
1
2
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.
3
4
to building earth (not
1
mains earth) via 1 M
series resistor
conductive wrist strap
2
conductive rubber
3
bench mat
metal frame
4
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: M5000-00-105Important 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 informationJune 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: M5000-00-105Servicing 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
ApprovalClassDivisionGroupTemperature 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.
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
T3C:
160°C
A - 12 Servicing Intrinsically Safe radiosJune 2003 IPN: M5000-00-105
Radio specifications and circuit
B
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
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
ParameterPerformance
Supply voltage6.0 to 9.0 V
Standard test voltage7.5 V
Table B-2: Receiver performance
ParameterPerformance
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)