FCC ID: AZ489FT3799 Hand Held Transmitter

 

Digital XTS 3500 Portable Radios Basic Service Manual 1 Foreword This manual covers all models of the ASTRO Digital XTS 3500 specied. It includes all the information necessary to maintain peak product performance and maximum working time, using the pass/fail service approach. This basic level of service is typical of some local service centers, self-maintained customers, and some distributors. Portable Radio, unless otherwise Included in this manual are: radio specications for the VHF and UHF frequency bands; a general description of ASTRO Digital XTS 3500 models; recommended test equipment, service aids, and tools;

radio alignment procedures; fundamental disassembly/reassembly procedures; and general maintenance recommendations. For details on the operation of the radio, or board or component-level troubleshooting, refer to the applicable manuals, available separately. To help you with your selection, a list is provided under Related Publications at the front of this manual. Safety Before operating an ASTRO XTS 3500 Radio, please read the Safety Information section in the front of this manual. Manual Revisions Changes which occur after this manual is printed are described in FMRs. These FMRs provide complete information on changes, including pertinent parts list data. 2 Table of Contents Foreword

. inside front cover List Of Figures. ii List of Tables. ii Related Publications . iii Portable Radio Model Numbering System. iv Specifications for VHF Radios. v Specifications for UHF Radios. vi Glossary . vii Safety Information . x 1 - Introduction . 1 General . 1 Notations Used in This Manual . 1 Radio Description . 2 FLASHport. 2 2 - Basic Maintenance . 3 Introduction to This Section . 3 Preventive Maintenance . 3 Handling Precautions . 4 3 - Recommended Test Equipment and Service Aids . 5 Recommended Test Equipment . 5 Service Aids . 5 Field Programming Equipment . 6 4 - Performance Checks . 7 Introduction to This Section . 7 Setup . 7 Display Radio Test Mode . 7 Non-Display Radio Test Mode . 10 5 - Radio Alignment Procedures . 15 Introduction to This Section . 15 General . 15 Reference Oscillator Alignment . 17 Transmit Power Alignment. 18 Transmit Deviation Balance (Compensation) Alignment . 19 Transmit Deviation Limit Alignment. 20 Front End Filter Alignment. 21 A

, Motorola, ASTRO, and Private-Line are registered trademarks of Motorola, Inc. XTS 3500, FLASHport, and Digital Private-Line are trademarks of Motorola, Inc. 1999, 2000 by Motorola Inc. Commercial, Government and Industrial Solutions Sector 8000 W. Sunrise Blvd., Ft. Lauderdale, FL 33322 Printed in U.S.A. 3/00 Basic Service Manual 68P81089C80-A i 6 - Basic Removal/Installation Procedures . 23 Introduction to This Section. 23 Antenna. 23 Battery . 23 Belt Clip. 24 Universal Connector Cover . 25 Frequency Knob . 25 Volume Knob . 26 7 -Basic Theory of Operation . 29 General Overview . 29 Analog Mode of Operation . 29 ASTRO Mode of Operation . 30 RF Board Basic Theory of Operation. 30 VOCON Board Basic Theory of Operation . 31 8 - Radio-Level Troubleshooting. 33 Introduction to This Section. 33 Power-Up Error Codes. 33 Operational Error Codes . 34

. inside back cover Replacement Parts Ordering List Of Figures Figure 1. Radio Alignment Test Setup . 15 Figure 2. RSS Service Menu Layout . 16 Figure 3. Softpot Concept . 16 Figure 4. Reference Oscillator Alignment Screen. 17 Figure 5. Transmit Power Alignment Screen . 18 Figure 6. Transmit Deviation Balance (Compensation) Alignment Screen . 19 Figure 7. Transmit Deviation Limit Alignment Screen . 20 Figure 8. Front End Filter (VHF and UHF Only) Alignment Screen . 21 Figure 9. Partial Exploded View . 27 List of Tables Table 1. ASTRO XTS 3500 Basic Features. 2 Table 2. Recommended Test Equipment . 5 Table 3. Service Aids. 6 Table 4. Initial Equipment Control Settings . 7 Table 5. Front-Panel Access Test-Mode Displays . 8 Table 6. Test Frequencies . 9 Table 7. Test Environments . 9 Table 8. Receiver Performance Checks . 12 Table 9. Transmitter Performance Checks. 13 Table 10. Reference Oscillator Alignment . 18 Table 11. Transmit Power Settings. 19 Table 12. Transmit Deviation Limit. 20 Table 13. Partial Exploded View Parts List. 28 Table 14. Local Oscillator and First IF Frequencies . 30 Table 15. Power-Up Error Code Displays. 34 Table 16. Operational Error Code Displays . 34 Table 17. Receiver Troubleshooting Chart . 34 Table 18. Transmitter Troubleshooting Chart. 35 Table 19. Encryption Troubleshooting Chart . 35 ii Related Publications ASTRO Digital XTS 3500 Model I User Guide . 68P81089C77 ASTRO Digital XTS 3500 Model II User Guide . 68P81089C78 ASTRO Digital XTS 3500 Model III User Guide . 68P81089C79 ASTRO Digital XTS 3500 Detailed Service Manual . 68P81089C81 Computer Software Copyrights The Motorola products described in this manual may include copyrighted Motorola computer programs stored in semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the Motorola products described in this manual may not be copied, reproduced, modied, reverse-engineered, or distributed in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the sale of a product. iii Portable Radio Model Numbering System Typical Model Number:

Position:

H 2 T 1 4 0 4 2 3 F F 6 C L 5 S S 4 9 7 9 P W 7 P W 7 8 10 9 A A 11 S N N S 12 13 P 0 P 1 14 15 16 0 1 Position 1 - Type of Unit D = Dash-Mounted Mobile Radio H = Hand-Held Portable M = Motorcycle Mobile Radio T = Trunk-Mounted Mobile Radio Positions 2 & 3 - Model Series 24 = XTS 3500 04 = ASTRO

Less than 29.7MHz 29.7 to 35.99MHz 36 to 41.99MHz 42 to 50MHz 66 to 80MHz 74 to 90MHz Product Specific 136 to 162MHz 146 to 178MHz 174 to 210MHz 190 to 235MHz Position 4 - Frequency Band A P B Q C R D S F T G U H V J W K Y L Z M Values given represent range only; they are not absolute. 336 to 410MHz 403 to 437MHz 438 to 482MHz 470 to 520MHz Product Specific 806 to 870MHz 825 to 870MHz 896 to 941MHz 1.0 to 1.6GHz 1.5 to 2.0GHz

Position 5 - Power Level A

B

C

D

E F 0 to 0.7 Watts 0.7 to 0.9 Watts 1.0 to 3.9 Watts 4.0 to 5.0 Watts 5.1 to 6.0 Watts 6.1 to 10 Watts

10.1 to 15 Watts 16 to 25 Watts 26 to 35 Watts 36 to 60 Watts G H J K L

= 61 to 110 Watts Position 6 - Physical Packages A B C D E F G H J K L M N P Q R RF Modem Operation Receiver Only Standard Control; No Display Standard Control; With Display Limited Keypad; No Display Limited Keypad; With Display Full Keypad; No Display Full Keypad; With Display Limited Controls; No Display Limited Controls; Basic Display Limited Controls; Limited Display Rotary Controls; Standard Display Enhanced Controls; Enhanced Display Low Profile; No Display Low Profile; Basic Display Low Profile; Basic Display, Full Keypad

Position 7 - Channel Spacing 1 = 5kHz 2 = 6.25kHz 3 = 10kHz 4 = 12.5kHz 5 = 15kHz 6 = 20/25kHz 7 = 30kHz 9 = Variable/Programmable iv Positions 13 - 16 SP Model Suffix Position 12 -

Unique Model Variations C = Cenelec N = Standard Package Position 11 - Version Version Letter (Alpha) - Major Change Position 10 - Feature Level 1 = Basic 2 = Limited Package 3 = Limited Plus 4 = Intermediate 5 = Standard Package 6 = Standard Plus 7 = Expanded Package 8 = Expanded Plus 9 = Full Feature/

Programmable Position 9 - Primary System Type A B C D E F G H J K L M N P Q W X Y Conventional Privacy Plus Clear SMARTNET Advanced Conventional Stat-Alert Enhanced Privacy Plus Nauganet 888 Series Japan Specialized Mobile Radio (JSMR) Multi-Channel Access (MCA) CoveragePLUS MPT1327* - Public MPT1327* - Private Radiocom Tone Signalling Binary Signalling Phonenet Programmable Secure Conventional Secure SMARTNET

* MPT = Ministry of Posts and Telecommunications

Position 8 - Primary Operation A B C D E F G H J K L M P Conventinal/Simplex Conventional/Duplex Trunked Twin Type Dual Mode Trunked Dual Mode Trunked/Duplex Trunked Type I Trunked Type II FDMA* Digital Dual Mode TDMA** Digital Dual Mode Single Sideband Global Positioning Satellite Capable Amplitude Companded Sideband (ACSB) Programmable

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access 0.35V (typical) Usable Sensitivity

(12dB SINAD):

0.20V (typical) Frequency Stability (typical)

(30 to +60C; 25C ref.):

.0002%

Emission (Conducted and Radiated):

75dBc All specications are per Telecommunications Industries Association TIA-603 unless otherwise noted 12.5kHz 44dB 78dB (typical) Intermodulation:

SPECIFICATIONS FOR VHF RADIOS Selectivity (typical)

(Companion Receiver):

(25/30kHz Channel):

(12.5kHz Channel):

80dB 67dB FM Hum and Noise (typical) FCC Designation:

Temperature Range:

Operating:

Storage:

GENERAL Spurious Rejection:

RECEIVER 78dB AZ489FT3799 Frequency Stability Frequency Range:

(30+60C; 25C reference):

.0002%

30C to +60C 40C to +85C Rated Audio:

Bandwidth:

500mW Quieting Sensitivity (20dBQ):

Distortion:

Modulation Limiting:

136-174MHz 2% Typical TRANSMITTER 25kHz chnls 5.0kHz 12.5kHz chnls 2.5kHz Adjacent Channel Power Ratio:

38MHz 25kHz 73dBc 12.5kHz 63dBc Power Supply:

or Nickel-Cadmium Battery (NiCd) Nickel-Metal-Hydride Battery (NiMH) Lithium-Ion Battery (Li-Ion) or FM Hum and Noise (typical):

25kHz 50dB 12.5kHz 44dB Emissions Designators:

20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1E Battery Voltage:

Nominal:

Range:

Distortion (At Rated Audio):

1.5% Typical 7.5 Volts 6 to 9 Volts Channel Spacing:

12.5/25 kHz Transmit Current Drain (Typical):

Receive Current Drain (Rated Audio):

Standby Current Drain:

2100mA 240mA 80mA Recommended Battery:

NTN8294_ NTN8293_ NTN8610_ NTN8295_*

NTN8299_*

Ultra-HIgh-Capacity NiCd:

Extended-Capacity NiMH:

or Li-Ion:

or UltraHigh-Capacity NiCd FM:

or UltraHigh-Capacity NiMH FM:

or Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III, Division 1, Groups C, D,E, F, and G. FM Non-incendive:

Class 1, Division 2, Groups A, B, C, and D. Dimensions (H x W x D) Note: 2.44" = width at PTT; 2.34" = width at bottom; 1.83" = depth at speaker; 0.97" =

depth at keypad Less Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"

(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 24.56mm) With Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 1.65"

(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm) Weight: (w/Helical Antenna) Less Battery:

With Ultra-High Cap. NiCd:

With Li-Ion:

With Ultra-High Cap. NiMH:

With Extended- Cap. NiMH:

14.10oz. (383gm) 25.19oz. (693gm) 20.41oz. (583gm) 23.45oz. (644gm) 24.04oz. (682gm) Specifications subject to change without notice v SPECIFICATIONS FOR UHF RADIOS All specications are per Telecommunications Industries Association TIA-603 unless otherwise noted GENERAL RECEIVER TRANSMITTER FCC Designation:

Temperature Range:

AZ489FT4828 Frequency Range:

450-520MHz RF Power:

Operating:

Storage:

30C to +60C 40C to +85C Bandwidth:

70MHz Quieting Sensitivity (20dBQ):

0.35V (typical) Usable Sensitivity

(12dB SINAD):

0.20V (typical) Intermodulation:

78dB (typical) Power Supply:

or Nickel-Cadmium Battery (NiCd) Nickel-Metal-Hydride Battery (NiMH) Lithium-Ion Battery (Li-Ion) or Battery Voltage:

Nominal:

Range:

7.5 Volts 6 to 9 Volts Transmit Current Drain (Typical):

Receive Current Drain (Rated Audio):

Standby Current Drain:

2000mA 240mA 80mA Selectivity (typical)

(25/30kHz Channel):

(12.5kHz Channel):

Spurious Rejection:

450-520MHz:

1 Watt/5 Watts Frequency Range:

450-520MHz Frequency Stability (typical)

(30 to +60C; 25C ref.):

.0002%

Emission (Conducted and Radiated):

75dBc 78dB 70dB 80dB FM Hum and Noise (typical)

(Companion Receiver):

25kHz 48dB 12.5kHz 42dB Distortion:

2% Typical Modulation Limiting:

25kHz chnls 5.0kHz 12.5kHz chnls 2.5kHz Recommended Battery:

Frequency Stability

(30+60C; 25C reference):

.0002%

Rated Audio:

FM Hum and Noise (typical):

Emissions Designators:

500mW 20K0F1E, 16K0F3E, 11K0F3E, 8K10F1D, and 8K10F1E 25kHz 48dB 12.5kHz 43dB Distortion (At Rated Audio):

1.5% Typical Channel Spacing:

12.5/25 kHz Specifications subject to change without notice NTN8294_ NTN8293_ NTN8610_ NTN8295_*

NTN8299_*

Ultra-HIgh-Capacity NiCd:

Extended-Capacity NiMH:

or Li-Ion:

or UltraHigh-Capacity NiCd FM:

or UltraHigh-Capacity NiMH FM:

or Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III, Division 1, Groups C, D,E, F, and G. FM Non-incendive:

Class 1, Division 2, Groups A, B, C, and D. Dimensions (H x W x D) Note: 2.44" = width at PTT; 2.34" = width at bottom; 1.83" = depth at speaker; 0.97" =

depth at keypad Less Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 0.97"

(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 24.56mm) With Battery:

6.58" x 2.44" x 1.83"/6.58" x 2.34" x 1.65"

(167.13mm x 61.90mm x 46.42mm/

167.13mm x 59.49mm x 41.97mm) Weight: (w/Helical Antenna) Less Battery:

With Ultra-High Cap. NiCd:

With Li-Ion:

With Ultra-High Cap. NiMH:

With Extended- Cap. NiMH:

14.10oz. (383gm) 25.19oz. (693gm) 20.41oz. (583gm) 23.45oz. (644gm) 24.04oz. (682gm) vi GLOSSARY A/D Analog-to-Digital converter; converts an instantaneous dc voltage level to a corresponding digital value. ABACUS IC Custom integrated circuit providing a digital receiver IF backend. ADDAG APCO CODEC D/A DTMF DPL DSP DSPS IC Firmware FGU FLASHport Host Host Port IC IMBE MCU MDC Analog-to-Digital/Digital-to-Analog Glue IC Association of Public Safety Communication Ofcers Coder/Decoder IC for analog-to-digital and digital-to-analog conversion. Digital-to-Analog converter; converts a digital value to a corresponding dc voltage value. Dual-Tone Multi-Frequency Digital Private-Line Digital Signal Processor; microcontroller specically tailored for signal processing computations. In this case refers specically to Motorola DSP56603. Digital Signal Processor Support IC. Generates processor clocks and provides peripheral functions for the DSP. Software or a software/hardware combination of computer programs and data, with a xed logic conguration stored in a read-only memory; information can not be altered or reprogrammed. Frequency Generation Unit A Motorola term that describes the ability of a radio to change memory. Every FLASHport radio contains a FLASHport EEPROM memory chip that can be software written and rewritten to, again and again. Motorola HC12A4 microcontrol unit U204 (see MCU). Parallel memory mapped interface consisting of eight registers in the DSP56603. Integrated Circuit Improved Multi-Band Excitation: a sub-band, voice encoding algorithm used in ASTRO digital voice. MicroControl Unit Motorola Digital Communications vii MISO MOSI OMPAC Master In Slave Out; used by the slave device to send data to the master device. Master Out Slave In; used by the master device to send data to the slave device. Over-Molded Pad-Array Carrier; a Motorola custom IC package, distinguished by the presence of solder balls on the bottom pads. Open Architecture A controller conguration that utilizes a microprocessor with extended ROM and RAM. PC Board Printed Circuit board PCIC PL PLL PTT Registers Repeater RESET RF PA RSS RPT/TA RX DATA Power Control IC Private-Line tone squelch; a continuous sub-audible tone that is transmitted along with the carrier. Phase-Locked Loop; a circuit in which an oscillator is kept in phase with a reference, usually after passing through a frequency divider. Push-To-Talk; the switch located on the left side of the radio which, when pressed, causes the radio to transmit. Short-term data-storage circuits within the microcontrol unit or programmable logic IC. Remote transmit/receive facility that re-transmits received signals in order to improve communications coverage. Reset line; an input to the microcontroller that restarts execution. Radio Frequency Power Amplier Radio Service Software RePeaTer/Talk-Around Recovered digital data line. Signal Qualier Mode An operating mode whereby the radio is muted but still continues to analyze receive data to determine RX signal type. SCI IN Softpot Software SPI viii Serial Communication Interface INput line Software potentiometer; a computer-adjustable electronic attenuator. Computer programs, procedures, rules, documentation, and data pertaining to the operation of a system. Serial Peripheral Interface; how the microcontroller communicates to modules and ICs through the CLOCK and DATA lines. Squelch SRAM SSI Standby Mode System Select TOT TSOP UART C VCO VCOB IC Vocoder VOCON VSWR Muting of audio circuits when received signal levels fall below a pre-determined value. Static-RAM chip used for volatile, program/data memory. Synchronous Serial Interface on the DSP56603 to the CODEC, DSPS IC, and ADDAG. An operating mode whereby the radio is muted but still continues to monitor data. The act of selecting the desired operating system with the system-

select switch (also, the name given to this switch). Time-Out Timer; a timer that limits the length of a transmission. Thin Small-Outline Package Universal Asynchronous Receiver Transmitter. Microcontrol unit (see MCU). Voltage-Controlled Oscillator; an oscillator whereby the frequency of oscillation can be varied by changing a control voltage. Voltage-Controlled Oscillator Buffer IC VOice enCODER; the DSP-based system for digitally processing the analog signals, includes the capabilities of performing voice compression algorithms or voice encoding. VOcoder/CONtroller board Voltage Standing Wave Ratio ix Safety Information Safe And Efcient Operation Of Motorola Two-Way Radios For information regarding radio use in hazardous areas, please refer to the Factory Mutual (FM) approval manual supplement that is included with radio models that offer this capability. Exposure To Radio Frequency Energy National and International Standards and Guidelines Your Motorola Two-Way Radio, which generates and radiates radio frequency (RF) electromagnetic energy (EME), is designed to comply with the following National and International Standards and Guidelines regarding exposure of human beings to radio frequency electromagnetic energy:

Federal Communications Commission Report and Order No. FCC 96-326 (August 1996) American National Standards Institute (C95.1 - 1992) National Council on Radiation Protection and Measurements (NCRP - 1986) International Commission on Non-Ionizing Radiation Protection (ICNRP - 1986) European Committee for Electrotechnical Standardisation (CENELEC):

ENV. 50166-1 1995 E ENV. 50166-2 1995 E Proceedings of SC211/8 1996 Human Exposure to Electromagnetic Fields Low Frequency (0Hz to 10kHz) Human Exposure to Electromagnetic Fields High Frequency (10kHz to 300GHz) Safety Considerations for Human Exposure to E.M.F.s from Mobile Telecommunications Equipment (M.T.E.) in the Frequency Range 30MHz - 6 GHz (E.M.F. - Electromagnetic Fields) To assure optimal radio performance and that human exposure to radio frequency electromagnetic energy is within the guidelines set forth in the above standards, always adhere to the following procedures:

Portable Radio Operation and EME Exposure When transmitting with a portable radio, hold the radio in a vertical position with its microphone 1 to 2 inches (2.5 to 5 centimeters) away from your mouth. Keep the antenna at least 1 inch (2.5 centimeters) from your head and body. If you wear a portable two-way radio on your body, ensure that the antenna is at least 1 inch (2.5 centimeters) from your body when transmitting. MAN WITH R Electromagnetic Interference/Compatibility Note Nearly every electronic device is susceptible to electromagnetic interference (EMI) if inadequately shielded, designed, or otherwise congured for electromagnetic compatibility. To avoid electromagnetic interference and/or compatibility conicts, turn off your radio in any facility where posted notices instruct you to do so. Hospitals or health care facilities may be using equipment that is sensitive to external RF energy. When instructed to do so, turn off your radio when on board an aircraft. Any use of a radio must be in accordance with airline regulations or crew instructions. x

Operational Warnings Vehicles With an Air Bag W A R N I N G Do not place a portable radio in the area over an air bag or in the air bag deployment area. Air bags inate with great force. If a portable radio is placed in the air bag deployment area and the air bag inates, the radio may be propelled with great force and cause serious injury to occupants of the vehicle. Potentially Explosive Atmospheres Turn off your two-way radio when you are in any area with a potentially explosive atmosphere, unless it is a radio type especially qualied for use in such areas (for example, Factory Mutual or CENELEC approved). Sparks in a potentially explosive atmosphere can cause an explosion or re resulting in bodily injury or even death. Batteries Do not replace or recharge batteries in a potentially explosive atmosphere. Battery contact sparking may occur while installing or removing batteries and may cause an explosion. Blasting Caps and Blasting Areas To avoid possible interference with blasting operations, turn off your radio when you are near electrical blasting caps, in a blasting area, or in areas posted: Turn off two-way radio. Obey all signs and instructions. Note The areas with potentially explosive atmospheres referred to above include fueling areas such as: below decks on boats; fuel or chemical transfer or storage facilities; areas where the air contains chemicals or particles, such as grain, dust, or metal powders; and any other area where you would normally be advised to turn off a vehicle engine. Areas with potentially explosive atmospheres are often but not always posted. Operational Cautions Antennas

C a u t i o n Do not use any portable two-way radio that has a damaged antenna. If a damaged antenna comes into contact with your skin, a minor burn can result. Make sure you have the correct antenna installed for your radios frequency band. Ask your dealer for details. Batteries All batteries can cause property damage and/or bodily injury such as burns if a conductive material such as jewelry, keys, or beaded chains touch exposed terminals. The conductive material may complete an electrical circuit (short circuit) and become quite hot. Exercise care in handling any charged battery, particularly when placing it inside a pocket, purse, or other container with metal objects. Battery Information Charging Batteries This product is powered by a nickel-cadmium (Ni-Cd), nickel-metal-hydride (NiMH), or lithium-ion rechargeable battery. Charge the battery before use to ensure optimum capacity and performance. The battery was designed specically to be used with a Motorola charger. Charging in non-Motorola equipment may lead to battery damage and void the battery warranty. Note When charging a battery attached to a radio, turn the radio off to ensure a full charge. The battery should be at about 77F (25C) (room temperature), whenever possible. Charging a cold battery (below 50 F [10C]) may result in leakage of electrolyte and ultimately in failure of the battery. Charging a hot battery (above 104F [40C]) results in reduced discharge capacity, affecting the performance of the radio. Motorola rapid-rate battery chargers contain a temperature-sensing circuit to ensure that batteries are charged within the temperature limits stated above. xi Recycling of Nickel-Cadmium Batteries Nickel-cadmium (Ni-Cd) rechargeable batteries can be recycled. However, recycling facilities may not be available in all areas. Under various U.S. state laws and the laws of several other countries, Ni-Cd batteries must be recycled or disposed of properly and cannot be disposed of in landlls or incinerators. Contact your local waste management agency for specic requirements and information in your area. Motorola fully endorses and encourages the recycling of Ni-Cd batteries. In the U.S. and Canada, Motorola participates in the nationwide Rechargeable Battery Recycling Corporation (RBRC) program for Ni-Cd battery collection and recycling. Many retailers and dealers participate in this program. For the location of the drop-off facility closest to you, access RBRC's Internet website at www.rbrc.com or call 1-800-

8-BATTERY. This internet site and telephone number also provide other useful information concerning recycling options for consumers, businesses, and governmental agencies. Intrinsically Safe Radio Information FMRC Approved Equipment Anyone intending to use a radio in a location where hazardous concentrations of ammable materials exist

(hazardous atmosphere) is advised to become familiar with the subject of intrinsic safety and with the National Electric Code NFPA 70 (National Fire Protection Association) Article 500 (hazardous [classied] locations). An Approval Guide, issued by Factory Mutual Research Corporation (FMRC), lists manufacturers and the products approved by FMRC for use in such locations. FMRC has also issued a voluntary approval standard for repair service

(Class Number 3605). FMRC Approval labels are attached to the radio to identify the unit as being FM Approved for specied hazardous atmospheres. This label species the hazardous Class/Division/Group along with the part number of the battery that must be used. Depending on the design of the portable unit, this FM label can be found on the back or the bottom of the radio housing. The FM Approval mark is shown below:

FM APPROVED

W A R N I N G WARNINGS Do not operate radio communications equipment in a hazardous atmosphere unless it is a type especially qualied (for example, FMRC Approved) for such use. An explosion or re may result. Do not operate an FMRC Approved Product in a hazardous atmosphere if it has been physically damaged (for example, cracked housing). An explosion or re may result. Do not replace or charge batteries in a hazardous atmosphere. Contact sparking may occur while installing or removing batteries and cause an explosion or re. Do not replace or change accessories in a hazardous atmosphere. Contact sparking may occur while installing or removing accessories and cause an explosion or re. Do not operate an FMRC Approved Product unit in a hazardous location with the accessory contacts exposed. Keep the connector cover in place when accessories are not used. Turn a radio off before removing or installing a battery or accessory. Do not disassemble an FMRC Approved Product unit in any way that exposes the internal electrical circuits of the unit. Radios must ship from the Motorola manufacturing facility with the hazardous atmosphere capability and FM Approval labeling. Radios will not be upgraded to this capability and labeled in the eld. A modication changes the units hardware from its original design conguration. Modications can only be made by the original product manufacturer at one of its FMRC-audited manufacturing facilities. xii WARNINGS Failure to use an FMRC Approved Product unit with an FMRC Approved battery or FMRC Approved accessories specically approved for that product may result in the dangerously unsafe condition of an unapproved radio combination being used in a hazardous location. Unauthorized or incorrect modication of an FMRC Approved Product unit will negate the Approval rating of the product. Repair of FMRC Approved Products

W A R N I N G REPAIRS FOR MOTOROLA PRODUCTS WITH FMRC APPROVAL ARE THE RESPONSIBILITY OF THE USER. You should not repair or relabel any Motorola- manufactured communication equipment bearing the FMRC Approval label (FMRC Approved Product) unless you are familiar with the current FMRC Approval standard for repairs and service (Class Number 3605). You may want to consider using a repair facility that operates under 3605 repair service approval. WARNINGS Incorrect repair or relabeling of any FMRC Approved Product unit could adversely affect the Approval rating of the unit. Use of a radio that is not intrinsically safe in a hazardous atmosphere could result in serious injury or death.

W A R N I N G FMRCs Approval Standard Class Number 3605 is subject to change at any time without notice to you, so you may want to obtain a current copy of 3605 from FMRC. Per the December 1994 publication of 3605, some key denitions and service requirements are as follows:

Repair A repair constitutes something done internally to the unit that would bring it back to its original condition Approved by FMRC. A repair should be done in an FMRC Approved facility. Items not considered as repairs are those in which an action is performed on a unit which does not require the outer casing of the unit to be opened in a manner which exposes the internal electrical circuits of the unit. You do not have to be an FMRC Approved Repair Facility to perform these actions. Relabeling The repair facility shall have a method by which the replacement of FMRC Approval labels are controlled to ensure that any relabeling is limited to units that were originally shipped from the Manufacturer with an FM Approval label in place. FMRC Approval labels shall not be stocked by the repair facility. An FMRC Approval label shall be ordered from the original manufacturer, as needed, to repair a specic unit. Replacement labels may be obtained and applied by the repair facility, provided there is satisfactory evidence that the unit being relabeled was originally an FMRC Approved unit. Verication may include, but is not limited to: a unit with a damaged Approval label, a unit with a defective housing displaying an Approval label, or a customer invoice indicating the serial number of the unit and purchase of an FMRC Approved model. Do Not Substitute Options or Accessories The Motorola communications equipment certied by Factory Mutual is tested as a system and consists of the FM Approved portable, FM Approved battery, and FM Approved accessories or options, or both. This FM Approved portable and battery combination must be strictly observed. There must be no substitution of items, even if the substitute has been previously Approved with a different Motorola communications equipment unit. Approved congurations are listed in the FM Approval Guide published by FMRC, or in the product FM Supplement. This FM Supplement is shipped from the manufacturer with the FM Approved radio and battery combination. The Approval Guide, or the Approval Standard Class Number 3605 document for repairs and service, can be ordered directly from Factory Mutual Research Corporation located in Norwood, Massachusetts. xiii Notes xiv Introduction 1 General This manual covers information needed for level one troubleshooting. Level one troubleshooting consists of radio programming, radio alignment, knobs replacement, and installation and removal of antenna, belt clip, battery, and universal connector cover. Included in this manual are radio specications for the VHF and UHF frequency bands, a general description of XTS 3500 models, recommended test equipment, service aids, radio alignment procedures, general maintenance recommendations, and procedures for basic assembly and disassembly. Notations Used in This Manual Throughout the text in this publication, you will notice the use of warnings, cautions, and notes. These notations are used to emphasize that safety hazards exist, and care must be taken and observed. NOTE: An operational procedure, practice, or condition, etc., which is essential to emphasize.

C a u t i o n

W A R N I N G

D A N G E R CAUTION indicates a potentially hazardous situation which, if not avoided, may result in equipment damage. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury. 1 Radio Description The ASTRO Digital XTS 3500 radios are among the most sophisticated two-

way radios available. The radios are available in the VHF and UHF R2 bands. One of the newest in a long line of quality Motorola products, the ASTRO Digital XTS 3500 radio provides improved voice quality across more coverage area. The digital process, called embedded signalling, intermixes system signalling information with digital voice, resulting in improved system reliability, and the capability of supporting a multitude of advanced features. Such features add up to better, more cost-effective two-way radio communications. ASTRO Digital XTS 3500 radios are available in three basic models. Table 1 describes their basic features. Table 1 ASTRO XTS 3500 Basic Features Model I None None 48 No No Model II LCD 4 lines/

Model III LCD 4 lines/

12 characters per line 12 characters per line 3 x 2 button 3 x 6 button 255 Yes Yes 255 Yes Yes The ASTRO Digital XTS 3500 radio utilizes Motorolas revolutionary FLASHport technology. FLASHport makes it possible to add software that drives the radios capabilities both at the time of purchase and later on. Previously, changing a radios features and capabilities meant signicant modications, or buying a new radio. But now, similar to how a computer can be loaded with different software, the radios features and capabilities can be upgraded with FLASHport software. Feature Display Keypad Channel Capability Dialing from Prestored List Programmable Softkeys FLASHport 2 Basic Maintenance 2 Introduction to This Section This section of the manual describes preventive maintenance and handling precautions. Each of these topics provides information vital to the successful operation and maintenance of your radio. Preventive Maintenance The ASTRO Digital XTS 3500 radios do not require a scheduled preventive maintenance program; however, periodic visual inspection and cleaning is recommended. Inspection Cleaning Check that the external surfaces of the radio are clean, and that all external controls and switches are functional. A detailed inspection of the interior electronic circuitry is not needed. The following procedures describe the recommended cleaning agents and the methods to be used when cleaning the external surfaces of the radio. External surfaces include the housing assembly and battery case. These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime. The only recommended agent for cleaning the external radio surfaces is a 0.5%

solution of a mild dishwashing detergent, such as JOY, in water.

C a u t i o n The effects of certain chemicals and their vapors can have harmful results on certain plastics. Aerosol sprays, tuner cleaners, and other chemicals should be avoided. Cleaning External Plastic Surfaces The detergent-water solution should be applied sparingly with a stiff, non-

metallic, short-bristled brush to work all loose dirt away from the radio. A soft, absorbent, lintless cloth or tissue should be used to remove the solution and dry the radio. Make sure that no water remains entrapped near the connectors, cracks, or crevices. 3 Handling Precautions Complementary metal-oxide semiconductor (CMOS) devices, and other high-

technology devices, are used in this family of radios. While the attributes of these devices are many, their characteristics make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges. Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special precautions must be taken to prevent device damage during disassembly, troubleshooting, and repair. Handling precautions are mandatory for this radio, and are especially important in low-humidity conditions. 4 Recommended Test Equipment and Service Aids 3 Recommended Test Equipment Motorola Model Number R2600 Series The list of equipment contained in Table 2 includes all of the standard test equipment required for servicing two-way portable radios, as well as several unique items designed specically for servicing this family of radios. The Characteristics column is included so that equivalent equipment may be substituted; however, when no information is provided in this column, the specic Motorola model listed is either a unique item or no substitution is recommended. Table 2 Recommended Test Equipment Description Characteristics Application Communications System Analyzer This monitor will substitute for items with an asterisk (*). Fluke 8012 Digital Multimeter R1150_*

Code Synthesizer R1377_*

AC Voltmeter R1094_ Dual-Trace Oscilloscope 1mV to 300V, 10-Megohm input impedance 20MHz bandwidth 5mV to 5V/division S1350_*

ST1213_ (VHF)*

ST1223_ (UHF)*

Wattmeter Plug-In Element RF Dummy Load 50-ohm, 5% accuracy 10 watts, maximum 0-1000MHz, 300W Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment. Recommended for ac/dc voltage and current measurements Injection of audio and digital signalling codes Audio voltage measurements Waveform measurements Transmitter power output measurements R1065_ S1339_ R1013_*

S1347_ or S1348_

(programmable) Service Aids Load Resistor 10-watt Broadband For use with wattmeter RF Millivolt Meter 100V to 3V RF RF-level measurements SINAD Meter DC Power Supply 0-20Vdc, 0-5 Amps current limited Receiver sensitivity measurements Bench supply for 7.5Vdc Refer to Table 3, Service Aids, for a listing and description of the service aids designed specically for servicing this family of radios. These kits and/or parts are available from the Motorola Parts Division ofces listed in the Replacement Parts Ordering section located on the inside back cover of this manual. While all of these items are available from Motorola, most are standard shop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. 5 Motorola Part Number RKN-4035_ REX-4424_ RLN-4460_, or RTX-4005_, or both RTX-4005_ and RPX-4665_ Field Modication Kit RLN-1015_ or RLN-4008_ 01-80357A57 01-80358A56 Table 3 Service Aids Description Application RIB/Radio/Test Set Cable Connects radio to RTX-4005B Test Box and RIB. Battery Eliminator Interconnects radio to power supply. Portable Test Set Enables connection to the universal connector. Allows switching for radio testing. Radio Interface Box Enables communications between the radio and the computer's serial communications adapter. Wall-Mounted Power Supply Used to supply power to the RIB (120 Vac). Wall-Mounted Power Supply Used to supply power to the RIB (220 Vac). 30-80369B71 or 30-80369B72 Computer Interface Cables for RIB RLN4008_ 30-80390B48 or 30-80390B49 Computer Interface Cables for Smart RIB RLN1015_ Use B72 for 9-pin serial ports. All other models use B71

(25 pins). Connects the computer's serial communications adaptor to the RIB. Use B49 for 9-pin serial ports. All other models use B48

(25 pins). Connects the computer's serial communications adaptor to the RIB. RVN-4170_ Radio Service Software Software on 3-1/2 in. oppy disks. 58-80348B33 SMA to BNC Adaptor Adapts radios antenna port to BNC cabling of test equipment. Field Programming Equipment This family of radios can be aligned and programmed in the eld. This requires specic equipment and special instructions. Refer to the applicable Radio Service Software User's Guide for complete eld programming information. 6 Performance Checks 4 Introduction to This Section This section covers performance checks used to verify the radio meets published specications. The recommended test equipment listed in the previous section approaches the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the equipment must be maintained in compliance with the manufacturers recommended calibration schedule. Checks should be performed if radio performance degradation is suspected. Setup Display Radio Test Mode Entering Display Radio Test Mode Supply voltage can be connected from the battery eliminator. The equipment required for alignment procedures is connected as shown in the Radio Alignment Test Setup diagram (page 15, Figure 1). Initial equipment control settings should be as indicated in the following table, and should hold for all alignment procedures except as noted in Table 4. Table 4 Initial Equipment Control Settings System Analyzer Test Set Power Supply Monitor Mode: Pwr Mon Spkr Set: A Voltage: 7.5Vdc RF Attn: 70dB Spkr/Load: Speaker DC On/Standby: Standby AM, CW, FM: FM PTT: OFF (center) Volt Range: 10Vdc O'scope Source: Mod O'scope Horiz: 10mSec/Div O'scope Vert: 2.5kHz/Div O'scope Trig: Auto Monitor Image: Hi Monitor BW: Nar Monitor Squelch: Mid CW Monitor Vol: 1/4 CW Current: 2.5Amps 1. Turn the radio on. 2. Within 10 seconds after SSSSeeeellllffff TTTTeeeesssstttt is complete, press Side button 3 ve times in succession. 3. The radio will show a series of displays that will give information regarding various version numbers and subscriber specic information. The displays are described in Table 5 on page 8. 7 Table 5 Front-Panel Access Test-Mode Displays Name of Display Description Appears SSSSEEEERRRRVVVVIIIICCCCEEEE The literal string indicates the radio has entered test mode. Host Software Version The version of host rmware is displayed. DSP Software Version The version of DSP rmware is displayed. Always. Always. Always. EMC Secure Version Version of the encryption hardware. When the radio is secure equipped. Encryption Type 1 Type of encryption being used. When the radio is secure equipped. Encryption Type 2 Type of encryption being used. When the radio is secure equipped. Model Number Serial Number ROM Size FLASHcode The radios model number as programmed in the codeplug. Always. The radios serial number as programmed in the codeplug. Always. The memory capacity of the host FLASH part. Always. The FLASH codes as programmed in the codeplug. Always. Note: All displays are temporary and will expire without any user intervention. If information is longer than the physical length of the radios display, the information will wrap around to the next display. After the last display, RRRRFFFF TTTTEEEESSSSTTTT will be displayed. 4a. Press Side Button 1 to stop the displays and put the radio into the Control Top and Keypad test mode (display radio). The test mode menu CCCCHHHH TTTTEEEESSSSTTTT will be displayed. Go to the Control Top and Keypad Test Mode (Display Radio) section. NOTE: Each press of Side Button 1 will toggle between CCCCHHHH TTTTEEEESSSSTTTT and RRRRFFFF TTTTEEEESSSSTTTT. OR 4b. Press the Top Programmable Button (Emergency button) to stop the displays and put the radio into the RF test mode (display radio). The test mode menu 1111 CCCCSSSSQQQQ. will be displayed, indicating test frequency 1, Carrier SQuelch mode. Go to the RF Test Mode (Display Radio) section. When the ASTRO Digital XTS 3500 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug conguration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment via a special routine, called TEST MODE or air test. 1. Each additional press of Side Button 3 will advance to the next test channel. (Refer to Table 6.) 2. Pressing Side Button 2 will scroll through and access test environments as shown in Table 7. NOTE: Transmit into a load when keying a radio under test. RF Test Mode

(Display Radio) 8 Table 6 Test Frequencies Test Channel TX #1 RX #1 TX #2 RX #2 TX #3 RX #3 TX #4 RX #4 TX #5 RX #5 TX #6 RX #6 TX #7 RX #7 VHF 136.025 136.075 142.125 142.075 154.225 154.275 160.125 160.175 168.075 168.125 173.975 173.925 177.975 177.925 UHF Band 2 450.025 450.075 465.225 465.275 475.125 475.275 484.975 485.025 500.275 500.225 511.975 511.925 519.975 519.925 Table 7 Test Environments No. of Beeps Display Description Function 1 3 9 11 12 CSQ TPL Carrier Squelch Tone Private-Line SEC Secure***

AST ASTRO USQ Carrier Unsquelch RX: unsquelch if carrier detected TX: mic audio RX: unsquelch if carrier and tone (192.8 Hz) detected TX: mic audio + tone (192.8 Hz) RX: auto-coded clear TX: with key presentencrypted audio with key absentconstant unsquelch RX: none TX: 1200Hz tone **

RX: unsquelch always TX: mic audio

** All deviation values are based on deviation tuning of this mode

*** On radios equipped with secure option This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected. 1. Press and hold the Top Programmable Button; all segments on the display will light, and the LED on the control top will illuminate a red color. 2. Release the Top Programmable Button; 3333////0000 appears, which indicates that the Top Programmable Button is in the open condition. 3. Press the Top Programmable Button again; 3333////1111 appears, which indicates that the Top Programmable Button is in the closed condition. 4. Rotate the Mode/Zone Selector Switch; 4444////0000 through 4444////11115555 appears, which indicates that the selector switch is in mode/zone position 1 through 16. 9 Control Top and Keypad Test Mode

(Display Radio) 5. Rotate the Two-Position Concentric Switch; 66665555////0000 and 66665555////1111 appear. 6. Cycle through the Three-Position Programmable Switch; 66667777////0000, 66667777////1111, and 66667777////2222 appear. 7. Rotate the Volume Control; 2222////0000 through 2222////222255555555 appear. 8. Press Side Button 1; 99996666////1111 appears; release, 99996666////0000 appears. 9. Press Side Button 2; 99997777////1111appears; release, 99997777////0000 appears. 10. Press Side Button 3; 99998888////1111appears; release, 99998888////0000 appears. 11. Press the PTT Switch; 1111////1111 appears; release, 1111////0000 appears. 12. Keypad Checks:

Model III Only

Press 0, 44448888////1111 appears; release, 44448888////0000 appears. Press 1, 44449999////1111 appears; release, 44449999////0000 appears. Press 2, 55550000////1111 appears; release, 55550000////0000 appears. Press 3, 55551111////1111 appears; release, 55551111////0000 appears. Press 4, 55552222////1111 appears; release, 55552222////0000 appears. Press 5, 55553333////1111 appears; release, 55553333////0000 appears. Press 6, 55554444////1111 appears; release, 55554444////0000 appears. Press 7, 55555555////1111 appears; release, 55555555////0000 appears. Press 8, 55556666////1111 appears; release, 55556666////0000 appears. Press 9, 55557777////1111 appears; release, 55557777////0000 appears. Press *, 55558888////1111 appears; release, 55558888////0000 appears. Press #, 55559999////1111 appears; release, 55559999////0000 appears. All Display Models

Press <, 111122228888////1111 appears; release, 111122228888////0000 appears. Press O, 111122229999////1111 appears; release, 111122229999////0000 appears. Press >, 111133330000////1111 appears; release, 111133330000////0000 appears. Press the left-hand M key on the top row of keys, 111133331111////1111 appears;

release, 111133331111////0000 appears. Press the center N key, 111133332222////1111 appears; release, 111133332222////0000 appears. Press the right-hand M key, 111133333333////1111 appears; release, 111133333333////0000 appears.

Non-Display Radio Test Mode Entering Non-

Display Radio Test Mode 10 1. Turn the radio on. 2. Within 10 seconds after the top green LED turns off, press Side button 3 ve times in succession. RF Test Mode

(Non-Display Radio) Control Top and Keypad Test Mode

(Non-Display Radio) p p yp mode (non-display radio). Go to the Control Top and Keypad Test Mode

(Non-Display Radio) section. NOTE: Each press of Side Button 1 will toggle between Control Top and Keypad test mode (non-display radio) and RF test mode (non-display radio). OR 3b. Press the Top Programmable Button (Emergency button) to stop the displays and put the radio into the RF test mode (non-display radio). Go to the RF Test Mode (Non-Display Radio) section. When the ASTRO Digital XTS 3500 radio is operating in its normal environment, the radio's microcomputer controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug conguration. However, when the unit is on the bench for testing, alignment, or repair, it must be removed from its normal environment via a special routine, called TEST MODE or air test. 1. Each additional press of Side Button 3 will advance to the next test channel. (Refer to Table 6.) The channel number is represented by the number of beeps emitted by the radio after the button press (for example, ve beeps indicates channel 5). 2. Pressing Side Button 2 will scroll through and access test environments as shown in Table 7. The test environment is represented by the number of beeps emitted by the radio after the button press (for example, 11 beeps indicate AST). NOTE: Transmit into a load when keying a radio under test. This test mode is used to verify proper operation of all radio buttons and switches if a failure is suspected. 1. Press and hold the Top Programmable Button; the LED on the control top lights red, and the radio beeps. 2. Release the Top Programmable Button; the radio beeps again. 3. Press the Top Programmable Button again; the radio beeps, indicating that the Top Programmable Button is in the closed condition. 4. Rotate the Two-Position Concentric Switch; the radio beeps in each switch position. 5. Rotate the Mode/Zone Selector Switch; the radio beeps in each switch position. 6. Cycle through the Three-Position Programmable Switch; the radio beeps in each switch position. 7. Rotate the Volume Control; the radio beeps at each new volume setting. 8. Press Side Button 1; the radio beeps. 9. Press Side Button 2; the radio beeps. 10. Press Side Button 3; the radio beeps. 11 Test Name System Analyzer Radio Test Set Comments Table 8 Receiver Performance Checks Mode: PWR MON 4th channel test frequencyv Monitor: Frequency error. Input at RF In/Out Mode: GEN Output level: 1.0mV RF 4th channel test frequencyv Mod: 1kHz tone at 3kHz deviation Monitor: DVM: ac Volts As above, except to distortion As above, except SINAD;

lower the RF level for 12dB SINAD TEST MODE, 4 CSQ output at antenna PTT to continuous

(during the performance check) Frequency error to be 1.0kHz TEST MODE, 4 CSQ PTT to OFF (center);

meter selector to Audio PA Set volume control to 3.74Vrms As above As above Distortion < 3.0%

As above PTT to OFF (center) RF level set to 1mV RF As above As above, except change frequency to a conventional system. Raise RF level from zero until radio unsquelches. Out of TEST MODE; select a conventional system PTT to OFF (center);

meter selection to Audio PA; spkr/load to speaker As above RF input to be <

0.35V Set volume control to 3.74Vrms Unsquelch to occur at < 0.25V. Preferred SINAD =

5-8dB Reference Frequency Rated Audio Distortion Sensitivity

(SINAD) Noise Squelch Threshold (only radios with conventional system need to be tested) v See Table 7 12 Test Name System Analyzer Radio Test Set Comments Table 9 Transmitter Performance Checks Reference Frequency Mode: PWR MON 4th channel test frequencyv Monitor: Frequency error. Input at RF In/Out Power RF As above Voice Modulation Voice Modulation

(internal) PL Modu-

lation (radios with conven-

tional, clear mode, coded squelch oper-

ation only) Talkaround Modulation

(radios with conventional, clear mode, talk-around operation only) Talkaround Modulation

(radios with conventional, secure mode, talkaround operation only) v See Table 7 Mode: PWR MON 4th channel test frequencyv atten to 70, input to RF In/Out. Monitor: DVM, ac Volts. Set 1kHz Mod Out level for 0.025Vrms at test set, 80mVrms at ac/dc test set jack Mode: PWR MON 4th channel test frequencyv atten to 70, input to RF In/Out Change frequency to a conventional transmit frequency Change frequency to conventional talk-around frequency. Mode: PWR MON deviation, attenuation to 70, input to RF In/Out. Monitor: DVM, ac volts Set 1kHz Mod Out level for 25mVrms at test set. Change frequency to conventional talk-around frequency. Mode: PWR MON deviation, attenuation to 70, input to RF In/Out. Monitor: DVM, ac volts Mod: 1kHz out level for25mVrms at test set. Conventional coded squelch personality

(clear mode operation) 4 TPL Conventional talkaround personality

(clear mode operation) 1 CSQ Conventional talkaround personality

(secure mode operation) 1 SEC. Load key into radio. TEST MODE, 4 CSQ PTT to continuous

(during the performance check). Frequency error to be 1.0kHz. As above, 4 CSQ As above As above, 4 CSQ As above, meter selector to mic Refer to Maintenance Specications page in front of manual. Deviation: 4.1kHz but 5.0kHz TEST MODE, 4 CSQ, output at antenna Remove modulation input As above Press PTT switch on radio. Say four loudly into the radio mic. Measure deviation: 4.1kHz but 5.0kHz Deviation: 500Hz but 1000Hz As above Deviation: 4.1kHz but 5.0kHz As above Deviation: 3.7kHz but 4.3kHz 13 Notes 14 Radio Alignment Procedures 5 Introduction to This Section General This section describes both receiver and transmitter radio alignment procedures. A personal computer (PC) and radio service software (RSS) are required to align the radio. Refer to the applicable RSS manual for installation and setup procedures for the software. To perform the alignment procedures, the radio must be connected to the PC, radio interface box (RIB), and a universal test set as shown in Figure 1. 30 dB PAD SYSTEM ANALYZER OR COUNTER TRANSMIT 30 dB PAD WATTMETER SMA-BNC 58-80348B33 BNC RF GENERATOR RECEIVE BATTERY ELIMINATOR REX-4424 RTL-4224A RADIO TEST SET TEST SET RLN-4460_ or RTX-4005B RTX-4005_ SET TO APPROX. 450mV FOR Tx AUDIO IN TX AUDIO GENERATOR RX SINAD METER AC VOLTMETER MEASURE 80mV FOR Tx COMPUTER DATA BUSY GND COMPUTER INTERFACE CABLE 30-80369B71 30-80369B72 (IBM "AT" ONLY) 30-80369B71 (25 pins) 30-80369B72 (7 pins) PROGRAM/TEST CABLE RKN-4035_ RKN-4046A RIB RIB RLN-1015_ or RLN-4008B RLN-4008_ RIB POWER SUPPLY 01-80357A57 (120V) Figure 1 Radio Alignment Test Setup All service and tuning procedures are performed from the SERVICE menu, which is selected by pressing B from the MAIN MENU. Figure 2 illustrates how the RSS alignment SERVICE screens are organized. 15 SERVICE B F2 -

A F1 -

B F2 -

C F3 -

D F4 -

E F5 -

J F10 -

C F3 -

B F2 -

TRANSMITTER ALIGNMENT MENU HELP REFERENCE OSCILLATOR ALIGNMENT TRANSMIT POWER ALIGNMENT TRANSMIT DEVIATION BALANCE

(COMPENSATION) ALIGNMENT TRANSMIT DEVIATION LIMIT ALIGNMENT EXIT, RETURN TO SERVICE MENU RECEIVER ALIGNMENT MENU FRONT END BANDPASS FILTER ALIGNMENT Figure 2 RSS Service Menu Layout All SERVICE screens read and program the radio codeplug directly; you do NOT have to use the RSS GET/SAVE functions to use the SERVICE menus.

C a u t i o n Do NOT switch radios in the middle of any SERVICE procedure. Always use the EXIT key to return to the MAIN menu screen before disconnecting the radio. Improper exits from the SERVICE screens may leave the radio in an improperly congured state and result in seriously degraded radio or system performance. The SERVICE screens introduce the concept of the softpot, an analog SOFTware-controlled POTentiometer used for adjusting all transceiver alignment controls. Each SERVICE screen provides the capability to increase or decrease the softpot value with the keyboard UP/DOWN arrow keys respectively. A graphical scale is displayed indicating the minimum, maximum, and proposed value of the softpot, as shown in Figure 3. 0 Min. Value 15 Max. Value Figure 3 Softpot Concept 16 Reference Oscillator Alignment Adjusting the softpot value sends information to the radio to increase (or decrease) a dc voltage in the corresponding circuit. For example, pressing the UP arrow key at the Reference Oscillator screen instructs the radios microcomputer to increase the voltage across a varactor in the reference oscillator, which increases the frequency. In ALL cases, the softpot value is just a relative number corresponding to a digital-to-analog (D/A) generated voltage in the radio. Perform the following procedures in the sequence indicated. NOTE:

Some of the following screens may vary depending upon the radio under test and the version of radio service software you are using. Refer to your radio service software users guide. Adjustment of the reference oscillator is critical for proper radio operation. Improper adjustment will result not only in poor operation, but also in a misaligned radio that will interfere with other users operating on adjacent channels. For this reason, the reference oscillator should be checked every time the radio is serviced. The frequency counter used for this procedure must have a stability of 0.1 ppm (or better). 1. From the SERVICE MENU, press B to select the TRANSMITTER 2. Press B again to select the REFERENCE OSCILLATOR alignment screen. ALIGNMENT MENU. See Figure 4. MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDC9PW5AN MAIN:SERVICE:TX ALIGN:REF OSC REFERENCE OSCILLATOR

Frequency Current Value

519.975 150 New Softpot Value.....150 Transmitter..On 0 215 MIN |----+----+----+----+----+----+----+----+----+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE Figure 4 Reference Oscillator Alignment Screen 3. Press F to key the radio. The screen will indicate that the radio is transmitting. 4. Measure the transmit frequency on your service monitor. 5. Use the / arrow keys to adjust the reference oscillator softpot value. See Table 10. 17 Table 10 Reference Oscillator Alignment Band Target VHF or UHF 6. Press F again to dekey the radio. 7. Press H to program the new softpot value. 8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or 100 Hz press J twice to return to the SERVICE MENU. NOTES:

All power measurements are to be made at the antenna port. The transmitter power setting keeps the radiated power at or below the level specied in the exclusionary clause for low power devices of IEEE Standard C95.1-1991. 1. From the SERVICE MENU, press B to select the TRANSMITTER 2. Press C to select the TRANSMIT POWER alignment screen. The screen ALIGNMENT MENU. will indicate the transmit frequencies to be used. See Figure 5. MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDH9PW7AN MAIN:SERVICE:TX ALIGN:TX POWER TRANSMIT POWER

Current Value New Softpot Value Frequency High Pwr Mid Pwr Low Pwr High Pwr Mid Pwr Low Pwr

450.0250 65 25 25 65 25 25 465.2250 67 26 26 67 26 26 475.1250 68 27 27 68 27 27 484.9750 69 28 28 69 28 28 500.2750 72 29 29 72 29 29 511.9750 75 30 30 75 30 30 519.9750 59 31 31 59 31 31 Transmitter..Off 0 127 MIN |----+----+----+----+----+----X----+----+----+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE Figure 5 Transmit Power Alignment Screen 3. Press P (or Z or [RETURN]) to select a frequency eld (starting with the highest frequency shown). Then, press F to key the radio. The screen will indicate that the radio is transmitting. 4. Use the / arrow keys to adjust the transmit power per the values shown in Table 11. Transmit Power Alignment 18 Power Level Table 11 Transmit Power Settings Test Frequencies 136-174MHz 450-512MHz 512-520MHz 1 Watt 5 Watts 6 Watts 1.2W - 1.4W 6.2W - 6.5W 1.2W - 1.4W 5.2W - 5.4W 1.2W - 1.4W 3.2W - 3.4W 5. Press F to dekey the radio. 6. Press H to program the value. 7. Repeat steps 3-6 for the remaining frequencies. 8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU. Transmit Deviation Balance

(Compensation) Alignment Compensation alignment balances the modulation sensitivity of the VCO and reference modulation (synthesizer low-frequency port) lines. The compensation algorithm is critical to the operation of signalling schemes that have very-low-frequency components (for example, DPL) and could result in distorted waveforms if improperly adjusted. 1. From the SERVICE MENU, press B to select the TRANSMITTER 2. Press D to select the TRANSMIT DEVIATION BALANCE ALIGNMENT MENU.

(COMPENSATION) alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 6. MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDC9PW5AN MAIN:SERVICE:TX ALIGN:BAL ATTN TRANSMIT DEVIATION BALANCE (COMPENSATION)

Current Frequency Value New Softpot Value

450.025 30 30 465.225 30 30 475.125 30 30 484.975 45 45 500.275 45 45 511.975 45 45 519.975 45 Transmitter..Off 45 0 63 MIN |---+---+---+---+---+---+---+---+---+---+---+---+---+---+---+---| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE LOW TOGGLE HIGH PROGRAM EXIT TONE PTT TONE PTT VALUE Figure 6 Transmit Deviation Balance (Compensation) Alignment Screen 3. Press P (or Z or [RETURN]) to select a frequency eld (starting with 4. Press D. This will cause the radio to key and the radios DSP IC to inject the lowest frequency shown). an 80Hz tone into the RF board. 5. Measure the deviation and record this value. 19 6. Press D to dekey the radio. 7. Press F. This will cause the radios DSP IC to change the injection tone to 3kHz, 100mVrms. Use the / arrow keys to adjust the deviation to within 2% of the value recorded in step 5. tone deviation. 8. Repeat steps 4-7 until the 3kHz tone deviation is within 2% of the 80Hz 9. Press F again to dekey the radio. 10. Press H to program the new softpot value. 11. Repeat steps 3-10 for the remaining frequencies. 12. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU. Transmit Deviation Limit Alignment ALIGNMENT MENU. 1. From the SERVICE MENU, press B to select the TRANSMITTER 2. Press E to select the TRANSMIT DEVIATION LIMIT alignment screen. The screen will indicate the transmit frequencies to be used. See Figure 7. MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. XTS Model: H24SDC9PW5AN MAIN:SERVICE:TX ALIGN:DEV.LIMIT TRANSMIT DEVIATION LIMIT

Current Frequency Value New Softpot Value

450.025 24500 24500 465.225 24500 24500 475.125 24500 24500 484.975 24500 24500 500.275 24500 24500 511.975 24500 24500 519.975 24500 Transmitter..Off 24500 0 32767 MIN |----+----+----+----+----+----+----+----+X---+----+----+----| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP TOGGLE PROGRAM EXIT PTT VALUE Figure 7 Transmit Deviation Limit Alignment Screen 3. Press P (or Z or [RETURN]) to select a frequency eld (starting with 4. Press F to key the radio. Then use the / arrow keys to adjust for a the lowest frequency shown). deviation per the values shown in Table 12. Table 12 Transmit Deviation Limit Band Deviation (Hz) VHF or UHF 2785 - 2885 5. Press F again to dekey the radio. 6. Press H to program the softpot value. 7. Repeat steps 3-6 for the remaining frequencies. 20 8. Press J once to return to the TRANSMITTER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU. Front End Filter Alignment MENU. 1. From the SERVICE MENU, press C to select the RECEIVER ALIGNMENT 2. Press B to select the FRONT END FILTER (VHF AND UHF ONLY) screen. The screen will indicate the receive frequencies at which the lter is to be aligned. See Figure 8. MOTOROLA Radio Service Software Use UP/DOWN Arrows To Adjust Softpot. ASTRO Model: H09KDH9PW7AN MAIN:SERVICE:RX ALIGN:FE FL FRONT END FILTER (VHF AND UHF ONLY)

Current Frequency Value New Softpot Value RSSI....0

450.075 0 0 465.275 0 0 475.275 0 0 485.025 0 0 500.225 0 0 511.925 0 0 519.925 0 0 0 255 MIN |---+---+---+---+---+---+---+---+---+---+---+---+---+---+---+---| MAX F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 HELP READ PROGRAM EXIT RSSI VALUE Figure 8 Front End Filter (VHF and UHF Only) Alignment Screen 3. Press P (or Z or [RETURN]) to select a frequency eld. 4. Set the RF test generator to the rst receive frequency +150Hz. Set the RF level at the radio standard antenna port to 4.0V with no modulation. 5. Adjust the / arrow keys to obtain a peak value in the RSSI (receive signal strength indicator) eld. NOTE: D must be pressed to obtain each RSSI reading after adjustment. 6. Press H to program the new softpot value. 7. Repeat steps 3-6 for the remaining frequencies. 8. Press J once to return to the RECEIVER ALIGNMENT MENU, or press J twice to return to the SERVICE MENU. 21 Notes 22 Basic Removal/Installation Procedures 6 Introduction to This Section This section gives basic procedures for removing and installing the XTS 3500 radios:

Antenna, Battery, Belt Clip, Universal Connector Cover, Volume Knob, and Frequency Knob. Antenna Installing the Antenna Removing the Antenna Battery Screw the threaded end of the antenna into the antenna receptacle on the top of the radio. Rotate the antenna clockwise until it seats rmly against the bushing. Rotate the antenna counterclockwise until its threaded end unscrews from the radios antenna receptacle. NOTE:

The battery is shipped uncharged, and must be charged for at least 16 hours before use.

W A R N I N G

C a u t i o n To avoid a possible explosion:

DO NOT replace the battery in an area labeled hazardous atmosphere. DO NOT discard batteries in a re. If your radio is programmed with volatile-key retention

(consult your service technician), encryption keys will be retained for approximately 30 seconds after battery removal. 23 1. Turn off the radio and hold it with the back of the radio facing upward 2. Insert the top edge of the battery into the area at the top of the radio between the radios case and chassis. Make sure the three tabs on the radio chassis align with the three slots under the top edge of the battery. 3. Rotate the battery toward the radio, and squeeze the battery and radio together until the battery clicks in place. Radio Chassis 1. Turn off the radio and hold it so that the release button on the bottom of the battery is facing upward. 2. Press downward on the release button so the battery disengages from the radio. 3. Remove the battery completely away from the radio NOTE:

The battery must be removed from the radio before the belt clip can be installed or removed. 1. Hold the battery in one hand so that the top of the battery faces upward, and the back of the battery faces you. Slide Assembly 2. Holding the belt clip in the other hand with its top facing upward, align the slide assembly on the front of the belt clip with the slots on the back of the battery. 3. Slide the belt clip downward toward the bottom of the battery until the belt clip clicks in place. 1. Hold the battery (with belt clip installed) in one hand so that the top of the battery faces upward, and the front (radio side) of the battery faces you. 2. At the top of the battery, press down on the belt clips metal tab and slide the belt clip upward until it disengages from the battery. 3. Continue to slide the belt clip upward until it is free from the battery. Slots Press Down Release Button Belt Clip Battery Metal Tab Installing the Battery Removing the Battery Belt Clip Installing the Belt Clip Removing the Belt Clip 24 Universal Connector Cover Installing the Universal Connector Cover

C a u t i o n When the universal connector is not in use, keep it covered with the universal connector cover. 1. Looking at the antenna side of the radio, insert the top (at) hooked end of the cover into the slot on the top of the radio, above the universal connector. Press downward on the covers top to seat it in the slot. 2. While holding the cover seated in the top slot, insert the covers bottom (rounded) hooked end into the slot below the universal connector. Press rmly inward on the covers bottom until it snaps in place. Top Hooked End Top Slot Bottom Hooked End Bottom Slot Removing the Universal Connector Cover 1. Looking at the antenna side of the radio, insert a at-bladed screwdriver into the area between the lower end of the universal connector cover and the slot below the universal connector. 2. While holding the covers top (at) end in place with your thumb, pry upward on the covers lower end until it disengages from the radio. Frequency Knob Removing the Frequency Knob NOTES:

Refer to Figure 9, the Partial Exploded View, and Table 13, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 9 and Table 13. The battery (7) should be removed from the radio before installing or removing the frequency knob (1). In cases where the frequency insert (3) and escutcheon (2) must be removed, a new frequency insert and new escutcheon must be used for reassembly. 1. Hold the radio in one hand so that the top of the radio faces upward, and the front of the radio faces you. 2. With the other hand, grasp the frequency knob (1) and pull it upward, while rocking the knob back and forth, until it is free from the frequency insert (3) or the insert is free from the shaft. 3. If necessary, while pressing the inserts (3) two snap tabs away from the frequency control shaft so that the insert disengages from the shaft, use needle-nosed pliers to lift the insert up and off of the frequency control shaft. Discard the removed frequency insert. 4. Remove the secure lever (4) and the lightpipe (5). 25 Installing the Frequency Knob 1. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you. 2. Align the lightpipe (5) so that its straight tab is over the slot for the illuminated pointer. Push the tab down into the slot so that it is securely seated. 3. Place the secure lever (4) on the frequency control shaft, aligning it so that its pointer is at the front of the radio and its two inner slots line up with the two keys on the shaft. Slide the secure lever down to the bottom of the shaft. 4. If you are replacing the escutcheon (2):

a. Remove the backing paper from the escutcheon. b. Align the number 1 on the escutcheon with the alignment notch on the insert (3). c. Slide the escutcheon down over the insert until the alignment tabs on the escutcheon t inside the tab recesses on the insert. d. Adhere the escutcheon to the insert. 5. Place a new frequency insert (3) and new escutcheon (2) on the frequency control shaft, aligning the inserts D-shaped hole with the D-shaped shaft. Press downward rmly on the insert until it snaps in place on the shaft. 6. Place the frequency knob (1) on the frequency insert (3), aligning its pointer with the number 1 on the escutcheon (2). Press rmly downward on the knob until it seats securely in place. Volume Knob NOTES:

Refer to Figure 9, the Partial Exploded View, and Table 13, the Partial Exploded View Parts List. Numbers in parentheses ( ) refer to item numbers in Figure 9 and Table 13. The battery (7) should be removed from the radio before installing or removing the volume knob (8). In cases where the volume insert (9) must be removed, a new volume insert must be used for reassembly. 1. Hold the radio in one hand so that the top of the radio faces upward, and the front of the radio faces you. 2. With the other hand, grasp the volume knob (8) and pull it upward, while pushing it toward the back of the radio, until it is free from the volume insert (9). 3. While pressing the volume inserts (9) two snap tabs away from the volume control shaft so that the insert disengages from the shaft, use needle-nosed pliers to pull the insert up and off of the volume control shaft. Discard the removed volume insert. 4. Using needle-nosed pliers or some other pointed instrument, remove the o-ring (21). Removing the Volume Knob 26 Installing the Volume Knob 1. Place the o-ring (21) inside a new volume insert (9), and press it downward until it seats securely at the bottom of the insert. 2. Hold the radio so that the top of the radio faces upward, and the front of the radio faces you. 3. Place a new volume insert (9) on the volume control shaft, aligning the inserts D-shaped hole with the D-shaped shaft. Press downward rmly on the insert until it snaps in place on the shaft. 4. Place the volume knob (8) on the volume insert (9), aligning the two lugs on the inside of the knob with the inserts two snap tabs. Press rmly downward on the knob until it seats securely in place. 6 7 1 2 3 4 5 8 9 21 10 11 12 13 Alignment Tabs Alignment Notch Tab Recesses 15 16 17 18 A B C 20 XTS 3500 19 MNO DEF 3 6 WXY 9 JKL HOME ABC 2 5 8 0 TUV 1 4 7 GHI PRS 14 MAEPF-26563-B Figure 9 Partial Exploded View 27 Table 13 Partial Exploded View Parts List ITEM NO. MOTOROLA PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 3605370Z01 KNOB, Frequency 1305374Z01 ESCUTCHEON, Frequency 4305373Z01 INSERT RETAINER, Frequency Knob 4305375Z01 LEVER, Secure Frequency 6105376Z01 LIGHTPIPE INDICATOR/STOP, Frequency NTN8266_ CLIP, Belt NTN8923_ or NTN8294_ or NTN8295_ or NTN8299_ or NTN8610_ Battery, NiMH Extended Life Battery, NiCd Battery, NiCd FM Battery, NiMH FM Battery, Li-Ion 3605371Z01 KNOB, Volume 4305372Z01 INSERT RETAINER, Volume Knob 3305574Z03 LABEL, Motorola, Back

LABEL, Flashport

LABEL, Radio Serial Number

LABEL, Approval Agency 3305630Z02 or 3305630Z01 LABEL, Bottom LABEL, Bottom, FM NAD6563_ or NAD6566_ or NAD6567_ or NAD6568_ or NAE6547_ or NAE6548_ or NAE6549_ ANTENNA, Wideband Helical (136-174 MHz) ANTENNA, Helical (136-151 MHz) ANTENNA, Helical (151-162 MHz) ANTENNA, Helical (162-174 MHz) ANTENNA, Helical (430-470 MHz) ANTENNA, Helical (470-512 MHz) ANTENNA, Wideband Whip (403-512 MHz)

ESCUTCHEON, Concentric Switch (optional)

ESCUTCHEON, Toggle (optional) 1505579Z01 COVER, Dust, Universal Connector 3386139A01 LABEL, Motorola, Front 3505586Z01 Gortex 3205379W01 O-Ring 28 Basic Theory of Operation 7 General Overview Analog Mode of Operation The ASTRO Digital XTS 3500 radio is a wideband, synthesized, xed-tuned radio available in the VHF and UHF bands. All ASTRO Digital XTS 3500 radios are capable of both analog operation (12.5kHz or 25kHz bandwidths) and ASTRO mode (digital) operation (12.5kHz only). The ASTRO Digital XTS 3500 radio includes the following major assemblies:

VOCON Board - contains the microcontrol unit (MCU) and its associated memory and memory management integrated circuit (IC), the audio power amplier, and a switching regulator. The board also contains the digital signal processor (DSP) and its support IC and associated memories. RF Board - contains all transmit, receive, and frequency generation circuitry including the digital receiver back-end IC and the reference oscillator. Controls/Universal Flex - contains volume/on/off switch, frequency selector switch, push-to-talk (PTT) switch, monitor button, several function-selectable switches, universal connector, speaker, and microphone. Display (Models II and III Only) a four-line, 12-character liquid- crystal display (LCD). Keypad (Models II and III Only) Model II - a 3 x 2 keypad; Model III - a 3 x 6 keypad. When the radio is receiving, the signal comes from the antenna connector to the RF board, passes through the RX/TX switch and the receiver front end. The signal is then ltered, amplied, and mixed with the rst local-oscillator signal generated by the voltage-controlled oscillator (VCO). The resulting intermediate frequency (IF) signal is fed to the IF circuitry, where it is again ltered and amplied. This amplied signal is passed to the digital back-end IC, where it is mixed with the second local oscillator to create the second IF at 450kHz. It is then converted to a digital bit stream and mixed a third time to produce a baseband signal. This signal is passed to the VOCON board through a current-driven differential output. On the VOCON board, the digital-signal processor (DSP) support IC digitally lters and discriminates the signal, and passes it to the digital-signal processor

(DSP). The DSP decodes the information in the signal and identies the appropriate destination for it. For a voice signal, the DSP will route the digital voice data to the CODEC for conversion to an analog signal. The CODEC will then present the signal to the audio power amplier, which drives the speaker. 29 For signalling information, the DSP will decode the message and pass it to the microcontrol unit. When the radio is transmitting, microphone audio is passed through gain stages to the CODEC, where the signal is digitized. The CODEC passes digital data to the DSP, where pre-emphasis and low-pass (splatter) ltering are done. The DSP passes this signal to a digital/analog (D/A) converter, where it is reconverted into an analog signal and scaled for application to the voltage-

controlled oscillator as a modulation signal. Transmitted signalling information is accepted by the DSP from the microcontrol unit, coded appropriately, and passed to the D/A converter, which handles it the same as a voice signal. Modulation information is passed to the synthesizer along the modulation line. A modulated carrier is provided to the RF PA, which transmits the signal under dynamic power control. In the ASTRO mode (digital mode) of operation, the transmitted or received signal is limited to a discrete set of deviation levels, instead of continuously varying. The receiver handles an ASTRO-mode signal identically to an analog-

mode signal up to the point where the DSP decodes the received data. In the ASTRO receive mode, the DSP uses a specically dened algorithm to recover information. In the ASTRO transmit mode, microphone audio is processed identically to an analog mode with the exception of the algorithm the DSP uses to encode the information. This algorithm will result in deviation levels that are limited to discrete levels. The receiver front end consists of a preselector, an RF amplier, a second preselector, and a mixer. Both preselectors are varactor-tuned, two-pole lters, controlled by the microcontroller unit through the digital/analog (D/A) IC. The RF amplier is a dual-gate, gallium-arsenide-based IC. The mixer is a double-balanced, active mixer, coupled by transformers. Injection is provided by the VCO through an injection lter. See Table 14 for local oscillator (LO) and rst IF information. Table 14 Local Oscillator and First IF Frequencies VHF UHF LO Frequency Range 180.85-218.85MHz 376.65-446.65MHz First IF Frequency 44.85MHz 73.35MHz The frequency generation function is performed by three ICs and associated circuitry. The reference oscillator provides a frequency standard to the synthesizer/prescaler IC, which controls the VCOB IC. The VCOB IC actually generates the rst LO and transmit-injection signals and buffers them to the required power level. The synthesizer/prescaler circuit module incorporates frequency-division and comparison circuitry to keep the VCO signals stable. The synthesizer/prescaler IC is controlled by the microcontrol unit through a serial bus. Most of the synthesizer circuitry is enclosed in rigid metal cans on the RF board to reduce microphonic effects. ASTRO Mode of Operation RF Board Basic Theory of Operation 30 VOCON Board Basic Theory of Operation The receiver back end consists of a two-pole crystal lter, an IF amplier, a second two-pole crystal lter, and the digital back-end IC. The two-pole lters are wide enough to accommodate 4kHz modulation. Final IF ltering is done digitally in the DSP. The digital back-end IC consists of an amplier, the second mixer, an IF analog-to-digital converter, a baseband down-converter, and a 2.4MHz synthesis circuit to provide a clock to the DSP-support IC on the VOCON board. The second LO is generated by discrete components external to the IC. The output of the digital back-end IC is a digital bit stream that is current driven on a differential pair for a reduction in noise generation. The transmitter consists of an RF driver IC that gets an injection signal from the VCO and a nal-stage power amplier. Transmit power is controlled by a power-control IC that monitors the output of a directional coupler and adjusts PA control voltages correspondingly. The signal passes through a RX/TX switch that uses PIN diodes to automatically provide an appropriate interface to transmit or receive signals. Antenna selection is done mechanically in the control top. The vocoder and controller (VOCON) board contains the radios microcontrol unit with its memory and support circuits, the digital-signal processor (DSP), its memory devices, and the DSP-support IC, voltage regulators, audio, and power control circuits. Connected to the VOCON board are the display board, RF board, keypad board, controls/universal ex, and (optional) encryption module. The microcontrol unit controls receive/transmit frequencies, power levels, display, and other radio functions, using either direct logic control or serial communications paths to the devices.The microcontrol unit executes a stored program located in the FLASH ROM. Data is transferred to and from memory by the microcontrol unit data bus. The memory location from which data is read, or to which data is written, is selected by the address lines. The DSP-support IC is supplied with a 16.8MHz clock from the RF board. Both the DSP and the microprocessor have their clocks generated by the DSP-

support IC. They can both be adjusted so that the harmonics do not cause interference with the radios receive channel. The regulator and power-control circuits include 3.3-volt analog, 3.3-volt digital, and 5-volt regulators. The audio PA is sourced from 7.5V. The regulators power-down mode is controlled by the microcontrol unit, which senses the position of the on/off switch. The 5-volt regulator has an error pin for low-voltage resets. The DSP performs signalling and voice encoding and decoding as well as audio ltering and volume control. This IC performs Private-Line/Digital Private Line (PL/DPL) encode and alert-tone generation. The IC transmits pre-

emphasis on analog signals and applies a low-pass (splatter) lter to all transmitted signals. It requires a clock on the EXTAL pin. An 8kHz interrupt signal generated by the DSP-support IC is also required for functionality. It is programmed using parallel programming from the microcontrol unit. 31 The audio CODEC performs analog-to-digital and digital-to-analog conversions on audio signals. The DSP controls squelch, deviation, and executes receiver and transmitter ltering. The DSP-support IC receives a 2.4MHz clock, and receives data and formats it for the DSP. 32 Radio-Level Troubleshooting 8 Introduction to This Section Power-Up Error Codes This section of the manual contains troubleshooting charts and error codes that will help you to isolate a problem. Level one troubleshooting will support only radio alignment, programming, battery replacement, and knob replacement. If the radio needs further troubleshooting, it must be sent to the depot. Board- and component-level and service information can be found in the ASTRO Digital XTS 3500 Portable Radios Detailed Service Manual, Motorola publication number 68P81089C81. When the radio is turned on (power-up), the radio performs cursory tests to determine if its basic electronics and software are in working order. Problems detected during these tests are presented as error codes on the radios display. For non-display radios, the problem will be presented at power-up by a single, low-frequency tone. The radio should be sent to the depot if cycling power and reprogramming the code plug do not solve the problem. The presence of an error should prompt the user that a problem exists and that a service technician should be contacted. Self-test errors are classied as either fatal or non-fatal. Fatal errors will inhibit user operation; non-fatal errors will not. Use Table 15 to aid in understanding particular power-up error code displays. Table 15 Power-Up Error Code Displays Error Code Description Corrective Action FLASH ROM Codeplug Checksum Non-Fatal Error Internal EEPROM Codeplug Checksum Non-Fatal Error RF Deck Codeplug Checksum Non-Fatal Error FLASH ROM Codeplug Checksum Fatal Error RAM Fatal Error Note: not a checksum failure Internal EEPROM Codeplug Checksum Fatal Error RF Deck Codeplug Checksum Fatal Error 01/02 01/12 01/22 01/82 01/88 01/92 01/A2 02/10 DSP Support IC Checksum Non-Fatal Error 02/81 DSP ROM Checksum Fatal Error 02/88 DSP RAM Fatal Error Note: not a checksum failure 02/90 General DSP Hardware Failure (DSP startup message not received correctly) 09/10 09/90 Secure Hardware Error Secure Hardware Fatal Error Note: If the corrective action does not fix the failure, send the radio to the depot. Reprogram the codeplug. Reprogram the codeplug. Reprogram the codeplug. Reprogram the codeplug. Send radio to depot. Reprogram the codeplug. Reprogram the codeplug. Turn the radio off, then on. Send radio to depot. Turn the radio off, then on. Turn the radio off, then on. Turn the radio off, then on. Send radio to depot. 33 Operational Error Codes During radio operation, the radio performs dynamic tests to determine if the radio is working properly. Problems detected during these tests are presented as error codes on the radios display. The presence of an error code should prompt a user that a problem exists and that a service technician should be contacted. Use Table 16 to aid in understanding particular operational error codes. Table 16 Operational Error Code Displays Error Code Description Corrective Action FAIL 001 Synthesizer Out-of-Lock a. Reprogram codeplug b. Send radio to depot FAIL 002 Selected Mode/Zone Codeplug Checksum Error Reprogram codeplug Table 17 Receiver Troubleshooting Chart Symptom Possible Cause Correction or Test (Measurements Taken at Room Temperature) Radio Dead; Display Does Not Light Up 1. Dead Battery Replace with charged battery. 2. Blown Fuse Send radio to depot. 3. On/Off Switch 4. Regulators 1. VOCON Board Send radio to depot. Radio Dead; Display Lights Up No Receiver Audio or Receiver Does Not Unmute 2. RF Board Programming Audio Distorted or Not Loud Enough Synthesizer Not On Frequency a. Does the transmitted signal match the receiver conguration (PL, DPL, etc.)?

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

Check synthesizer frequency by measuring the transmitter frequency; if off by more than 1000Hz, realign. RF Sensitivity Poor 1. Synthesizer Not On Frequency Check synthesizer frequency by measuring the transmitter frequency; if off by more than 1000Hz, realign. 2. Antenna Switch Send radio to depot. 3. Receiver Front-

End Tuning Check RF front-end tuning for optimum sensitivity using the RSS. Radio Will Not Turn Off VOCON Board Send radio to depot. 34 Table 18 Transmitter Troubleshooting Chart Symptom Possible Cause No RF Power Out 1. TX Power Level or Frequency Correction or Test (Measurements Taken at Room Temperature) Check TX power level and frequency programming (from RSS). 2. No PTT From Control Top Send radio to depot. 3. No Injection To Power Amplier No Modulation;

Distorted Modulation 1. Programming Check deviation and compensation settings using the RSS. Bad Microphone Sensitivity 1. Check Deviation and Compensation Realign if necessary. 2. VOCON Board Send radio to depot. No/Low Signalling

(PL, DPL, MDC) 2. Microphone 1. Programming 2. VOCON Board Cant Set Deviation Balance RF Board Send radio to depot. Check Programming Send radio to depot. Send radio to depot. Table 19 Encryption Troubleshooting Chart Symptom Possible Cause Corrective Action No KKKKEEEEYYYYLLLLOOOOAAAADDDD on Radio Display When Keyloading Cable is Attached to the Radio Side Connector Keyloader Displays FFFFAAAAIIIILLLL. 1. Defective Keyload Cable Send radio to depot. 2. Defective Radio 1. Wrong Keyloader 2. Bad Keyloader 3. Defective Radio Make Sure the Keyloader is a T----CX or T----DX Keyloader. Try Another Keyloader Send radio to depot. Note: Keyloaders T----AX and T----BX must be upgraded to T----CX and T----DX in order to keyload an XTS 3500 radio. 35 36 REPLACEMENT PARTS ORDERING ORDERING INFORMATION When ordering replacement parts or equipment information, the complete identication number should be included. This applies to all components, kits, and chassis. If the component part number is not known, the order should include the number of the chassis or kit of which it is a part, and sufcient description of the desired component to identify it. Crystal and channel element orders should specify the crystal or channel element type number, crystal and carrier frequency, and the model number in which the part is used. MAIL ORDERS Send written orders to the following addresses:

Federal Government Orders:

International Orders:

Replacement Parts/

Test Equipment/Manuals/

Crystal Service Items:

Motorola Inc. United States and Canada Aftermarket Products Division Attention: Order Processing 1313 E. Algonquin Road Schaumburg, IL 60196 Motorola Inc. United States and Canada Aftermarket Products Division Attention: Order Processing 7230 Parkway Drive Landover, MD 21076 TELEPHONE ORDERS United States and Canada Aftermarket Products Division:

Call:

1-800-422-4210 1-800-826-1913 (For Federal Government Orders) 1-847-538-8023 (International Orders) FAX ORDERS United States and Canada Aftermarket Products Division:

FAX:

847-538-8198 (Domestic) 847-576-3023 (International) 847-538-8194 Parts ID:

Motorola Inc. United States and Canada Aftermarket Products Division Attention: International Order Processing 1313 E. Algonquin Road Schaumburg, IL 60196 Servicers Training (VHS Video Tapes):

Call:

847-576-2828 Federal Government Orders:

FAX:

International:

410-712-4991 410-712-6200 PARTS CUSTOMER SERVICE PRODUCT CUSTOMER SERVICE United States and Canada Aftermarket Products Division:

Call: 1-800-422-4210 Parts Identication:

Call: 847-538-0021 Customer Response Center

(Sales and Service Assistance):

Call: 1-800-247-2346 FAX: 1-800-232-9272 TEPF-9679-U 3

*6881089C80*

*6881089C80*

68P81089C80-A 4 Motorola 8000 West Sunrise Boulevard Fort Lauderdale, Florida 33322

 

 

MOTOROLA INC. FCC ID: AZ489FT3799 INSTRUCTION MANUAL x Preliminary Manual Attached. Complete Manual Attached. Note: See XTS3500bsm.pdf document to view XTS3500 Basic Service Manual information. EXHIBIT 8