PRO2150 Portable Radio Detailed Service Manual
Contents
1. 2 2 2 4 1 Parts Replacement and Substitution eem 2 2 2 4 2 Rigid Circuit Boards des tte deed e ecce d a ated dd eee ed ed deed 2 2 2 48 Flexible Circults o onte e de tea i dete eee etu e 2 3 244 Chip Components ice ne eite nte E Vt ed ees aedi e ada d ao eae d n 2 3 2 4 5 Shields idee eno oe de ei odere id ett eae p 2 4 25 Disassembling and Reassembling the Radio General seen 2 4 2 6 Radio Disassembly Detailed 2 5 2 6 1 Front Cover from Chassis Disassembly sss eee 2 5 2 6 2 Control Board Disassembly 2 7 26 3 RF Board Disassembly rinisin ei E ea Eaa i EN ea eaa 2 7 2 7 Radio Reassembly 2 8 2 7 1 RF Board 5 2 8 2 7 2 Control Board Reassembly cece nennen 2 8 2 7 3 Chassis and Front Cover Reassembly 2 8 28 Mechanical View and Parts Listi nennen 2 12 2 8 4 Exploded View and Parts List eene 2 12 2 9 Service eit menn M ES 2 14 2 10 Test Equipment iie edenda ts ed olus Lee dete LL ee ode eodd 2 15 2 11 Programming Cable DSKO01C706 2 16 2 12 IF Test2. CAE SEE resi det eet 4 3 441 PL Frequencies and Codes sss eene neret nnne 4 3 44 2 iDPEGOdeS oec dte t de t etd ehe d I eiat Ree cides RR adage 4 4 4 4 3 oet oe cen e te tete re red aed ike oh ae 4 4 Chapter 5 Error Code Displays 5 5 1 zoe 14 5 m 5 1 Chapter 6 JACCOSSO IOS deux ett cuo URN VERE YE 6 1 OMEN 6 1 0 2 Cairylhig ACCOSSOTIGS Phu rto E eret EE ER CER 6 1 CEN GI TESCO 6 1 04 che e i aene qtd re eter n Le Rd 6 1 6 5 Batteries use oeste died idit Loci hi Bote e dads ode eode deed udo 6 1 6 6 550 65 6 1 6 7 ir ede e LA Le A ee eee ee EE 6 2 Mo 6 2 August 30 2002 99R85452E01 O Table of Contents iii Chapter 7 VHF Band Information 7 1 1 Model Chart ict edt te tea dee e t t Tetas 7 1 7 2 Specifications ee ede pian cupere Teu ure ede eel A lee 7 2 To Theory of Operation cscs side imet dee ee eet le eee atre ERRARE 7 3 7 3 1 General Information tee De on ti oco eet dud t te eae eee and 7 3 7 3 2 PowerDistribUtlon nea dete ip n s RR Peces teen veatae 7 3 7 3 3 Po
3. Board to board connector Figure 2 5 2 6 3 RF Board Disassembly 1 Remove the screws and the stud which hold the RF board to the rear diecast with the Phillips head screwdriver and socket wrench respectively 2 Gently remove the RF board from rear diecast The completely disassembled radio is shown in Figure 2 6 Figure 2 6 NOTE The Control and RF boards are mounted with cross recess screws meeting the Phillips Cross Slot number 1 standard Using a Phillips 0 will damage the screw recesses as will a poorly fitting Phillips 1 screwdriver One example of a correct fitting screwdriver is manufactured by PB Baumann http www pbtools ch index_e html and is available from many electronic tool dealers The PB Baumann item number is 121 1 70 Other high quality manufacturer s pruducts meeting the Phillips 1 standard are also acceptable 99R85452E01 O August 30 2002 2 8 Maintenance Radio Reassembly Detailed 2 7 Radio Reassembly Detailed 2 7 1 RF Board Reassembly 1 Place the RF board on the rear diecast 2 Tighten the screws and the stud 2 7 2 Control Board Reassembly 1 Place the control board on the RF board 2 Connect the control board to the RF board by pressing it firmly downwards at the board to board connector See Figure 2 7 Board to board Connector Figure 2 7 3 Tighten the screws using a screwdriver to hold the control board in place 2 7 3 Chassis and Front Cover Reassembly
4. Scan Lower Limit Scan Upper Limit Freq Step Size Rx Freq Tx Freq Offset Freq Repeater Offset Rx PL DPL Tx PL DPL TOC Power Level BCL Ch Spacing PTT ID On Off Radio Information Radio Configuration Conventional Personality VFO Status Scan List Phone Information Signalling Programmable Button x x x Reverse Burst X X X X X X X X X X X X X X X X X X X X X X X X X X X 99R85452E01 O X Indicates available Blank Indicates unavailable August 30 2002 1 6 Introduction Radio Features This Page Intentionally Left Blank August 30 2002 99R85452E01 O Chapter 2 Maintenance 2 1 2 2 2 2 1 2 2 2 2 2 2 1 2 2 2 2 Introduction This chapter provides details about the following Preventive Maintenance Safe Handling of CMOS and LDMOS Devices General Repair Procedures and Techniques Disassembling and Reassembling the Radio Preventive Maintenance The radio does not require a scheduled preventive maintenance program however periodic visual inspection and cleaning is recommended Inspection Check that the external surfaces of the radio are clean and that all external controls and switches are functional It is not recommended to inspect the interior electronic circuitry Cleaning Procedures The follow
5. 1 Remove the metal retainer with a small flat head screwdriver See Figure 2 11 Housing tab meaner Figure 2 8 August 30 2002 99 85452 01
6. Radio Disassembly Detailed 2 5 26 Radio Disassembly Detailed 2 6 1 Front Cover from Chassis Disassembly 1 Turn off the radio 2 Remove the battery a Slide the battery clasp away from the radio See Figure 2 1 Figure 2 1 b Slide battery down and away from radio 3 Remove the antenna 4 Pull the On Off Volume knob off of its shaft 5 Remove the two screws at the back of the rear chassis See Figure 2 2 Insert screwdriver here to remove chassis Figure 2 2 6 Insert a small flat head screwdriver at the bottom of the radio between the chassis and housing location marked in Figure 2 2 and lift the chassis gently Be careful not to damage the housing or the O ring underneath 99R85452E01 O August 30 2002 2 6 Maintenance Radio Disassembly Detailed 7 Lift the rear chassis away from the front cover See Figure 2 3 Be careful not to damage the speaker wire underneath Figure 2 3 8 Slide the rear chassis downwards and away from the front cover 9 Remove the speaker connector which connects between RF Board and the internal speaker on the front cover See Figure 2 4 Figure 2 4 August 30 2002 99R85452E01 O Maintenance Radio Disassembly Detailed 2 7 2 6 2 Control Board Disassembly Remove the screws which hold the control board to the RF board 2 Remove the control board which is connected to the RF board through a board to board connector See Figure 2 5
7. Box DSK001C702 2 eiae e diee te tape a a 2 17 99R85452E01 O August 30 2002 ii Table of Contents Chapter 3 Radio Tuning 3 1 S ME ee E 3 1 3 2 Software Tuning ene Ide cece d ela dene sae cin eee a dave a ene det e ee 3 1 3 3 Affixing Antenna Ground Plate sssssssssssseeeeen e een eene nnn nnne 3 2 3 4 Hardware Tuning Setup and Procedure 3 3 3 4 1 Audio Modulation TUNNG sireisas nnne nnn 3 3 34 2 Sub Audio Modulation Tuning esssseeeeeeneenn m eene eene nnns 3 4 343 Tunng reet eb t a LE EAE urit nt ipod ae 3 4 Chapter 4 Radio 4 1 4 4 Introduction eec eer 4 1 4 2 Programming Your Radio ei ree eese Pri LE eee ee ete R Ato ps 4 1 4 2 1 Overview of the Programming Process 4 1 4 2 2 Cloning Radio Parameters to User 05 4 1 4 2 3 Parameters Which are 4 1 4 2 4 Parameters Which are Not Cloned 4 1 425 To Clone a Radio dete ede end ecd Le dede ese dete ta dene Sedo Lect 4 1 4 2 6 Eror Conditions Te UP E RR STE 4 2 4 9 CPS Programming dte ne ee ice e edu dre neigen dees andi dee 4 2 4 4 Programimitig i
8. Level LA 49 K D H 8 AA 9 136 174 SW Full Keypad 12 5 25K Conventional Full A A MHz with Display Keypad Q C 403 440 4w MHz R 435 480 MHz 99R85452E01 O Portable Motorola Internal Use August 30 2002 1 4 Introduction Radio Features 1 4 Radio Features PRO2150 Feature CPS User Accessibility Yes Yes Normal Operation Rx Tx Cloning Factory Reset VFO Squelch Level Scan List 1 Scan List 2 Scan List 3 Special PL 1 2 3 Norm Inv DPL TOT x x Battery Saver Battery Type Alert Tone Volume Prime Ch x XxX KL Prime Ch Return Hang Time PTT ID OFF PRE POST BOTH PTT ID Sidetone PTT Short Sidetone Tx Pretime Backlight Status PTT ID Button Programmability Access Deaccess Code Telephone No PL DPL Type Scan Interval Timer Scan Hang Timer Channel On Off Rx Freq Tx Freq Rx PL DPL X X X X X X X X X X X X X X X X X X X X X X X X X X X X X August 30 2002 99R85452E01 O Introduction Radio Features 1 5 Feature Tx PL DPL PRO2150 U o User TOC Power Level BCL Ch Alias Ch Spacing PTT ID On Off PL Required for Selcall Scan Type Select Scan List Select Copy Ch
9. MOTOROLA intelligence everywhere PRO2150 Portable Radio Detailed Service Manual Table of Contents i User Safety Training and General Information V Chapter 1 Introduction No d 1 1 14 Scope of niae ote ae ee deed clan ede eee e ER 1 1 1 2 Warranty and Service Support 1 1 1 2 1 Warranty Period and Return Instructions sssssee m emm 1 1 1 2 2 After Warranty Period eise erret ate acaba pene id en LR R RR ERE deua 1 1 1 2 3 Piece Parts reed de eet ee idee ee en dee ie Ran dd due ae 1 2 1 2 4 Technical SUpport iode bee e et e DO er petto 1 2 1 2 5 Parts Identification eee nde edet amaba die lla 1 2 1 3 Radio Model aaan reee eraa nen nnns nennen nnn 1 3 1 4 Radio Features rne re antes eed e ge e Pe nl nee dl Ha eee 1 4 Chapter 2 Maintenance 2 1 271 zminene aa a e 2 1 22 Preventive Maintenance 2 1 22 1 Inspection re 2 1 2 2 2 Cleaning edes eee oe a d te ed dde dd v eod 2 1 2 3 Safe Handling of CMOS and LDMOS 5 2 2 24 Repair Procedures and Techniques
10. air of tweezers and turn off the vacuum pump Remove the circuit board from the R 1070 s circuit board holder To replace the shield add solder to the shield if necessary using a micro tipped soldering iron Next rub the soldering iron tip along the edge of the shield to smooth out any excess solder Use solder wick and a soldering iron to remove excess solder from the solder pads on the circuit board Place the circuit board back in the R1070 s circuit board holder Place the shield on the circuit board using a pair of tweezers Position the heat focus head over the shield and lower it to approximately 1 8 above the shield Turn on the heater and wait for the solder to reflow Once complete turn off the heat raise the heat focus head and wait approximately one minute for the part to cool Remove the circuit board and inspect the repair No cleaning should be necessary Disassembling and Reassembling the Radio General Since these radios may be disassembled and reassembled with the use of only four board to casting screws it is important to pay particular attention to the snaps and tabs and how parts align with each other The following tools are required for disassembling the radio Phillips screwdriver 4mm socket wrench If a unit requires more complete testing or service than is customarily performed at the basic level send this unit to a Motorola Authorized Service Center August 30 2002 99R85452E01 O Maintenance
11. all CMOS devices in conductive material so that all exposed leads are shorted together Do not insert CMOS devices into conventional plastic snow trays used for storage and transportation of other semiconductor devices Ground the working surface of the service bench to protect the CMOS device We recommend using the Motorola Static Protection Assembly part number 0180386A82 which includes a wrist strap two ground cords a table mat and a floor mat Wear a conductive wrist strap in series with a 100k resistor to ground Replacement wrist straps that connect to the bench top covering are Motorola part number RSX 4015 Do not wear nylon clothing while handling CMOS devices Do not insert or remove CMOS devices with power applied Check all power supplies used for testing CMOS devices to be certain that there are no voltage transients present When straightening CMOS pins provide ground straps for the apparatus used When soldering use a grounded soldering iron If at all possible handle CMOS devices by the package and not by the leads Prior to touching the unit touch an electrical ground to remove any static charge that you may have accumulated The package and substrate may be electrically common If so the reaction of a discharge to the case would cause the same damage as touching the leads Repair Procedures and Techniques General Parts Replacement and Substitution When damaged parts are replaced identical par
12. ing procedures describe the recommended cleaning agents and the methods to be used when cleaning the external and internal surfaces of the radio External surfaces include the front cover housing assembly and battery case These surfaces should be cleaned whenever a periodic visual inspection reveals the presence of smudges grease and or grime NOTE Internal surfaces should be cleaned only when the radio is disassembled for service or repair The only recommended agent for cleaning external radio surfaces is a 0 596 solution of a mild dishwashing detergent in water The only factory recommended liquid for cleaning printed circuit boards and their components is isopropyl alcohol 7095 by volume CAUTION The effects of certain chemicals and their vapors can have harmful results on certain plastics Avoid using aerosol sprays tuner cleaners and other chemicals Cleaning External Plastic Surfaces Apply the 0 595 detergent water solution sparingly with a stiff non metallic short bristled brush to work all loose dirt away from the radio Use a soft absorbent lintless cloth or tissue to remove the solution and dry the radio Make sure that no water remains entrapped near the connectors cracks or crevices Cleaning Internal Circuit Boards and Components Apply Isopropyl alcohol 7096 with a stiff non metallic short bristled brush to dislodge embedded or caked materials located in hard to reach areas The brush stroke should direct the di
13. io aa E ea erede tas 8 4 8 3 3 Power up Sequence eicere needing dokn gite dde eaa eu a ke ee dd ele adu aa 8 4 9 3 4 CPU Gontrol Sectlori 5 et pre Ee tr pet he tbe HUE egeo tee don 8 5 8 3 5 VCO Synthesizer Section essaiar 8 5 8 3 6 Transmitter tna toc e ER e 8 6 8 3 7 Receiver Section eed ae ed hid de eo a hn Ra ada 8 7 8 3 6 Battery Section eee e ue eit et e eed e a s 8 8 8 4 Block Diagrams tete e teret vali etie e tea deae aud sila dd eed need dee edd decia 8 9 8 4 1 Complete rene 8 9 8 4 2 Controller ERO RDUM een 8 10 VCO cutem ta etapa E 8 10 8 4 4 Transmitter ice eret eo qe te erede epe Te re Baws Eo Ce 8 11 8 4 5 RECCIVEM onore eire o tatis eoe deeds 8 11 8 5 Troubleshooting Charts ehe been n a e e hn du da a 8 12 99R85452E01 O August 30 2002 iv Table of Contents This Page Intentionally Left Blank August 30 2002 99R85452E01 O User Safety Training and General Information Product Safety and RF Exposure Compliance CAUTION Before using this product read the operating i
14. is not normally available from Motorola If the part number is appended with an asterisk the part is serviceable by Motorola Depot only If a parts list is not included this generally means that no user serviceable parts are available for that kit or assembly All orders for parts information should include the complete Motorola identification number All part orders should be directed to your local AAD office Please refer to your latest price pages To order parts in Latin America and the Caribbean 7 00 a m to 7 00 p m Central Standard Time Monday through Friday Chicago USA 1 847 538 8023 Motorola Parts Accessories and Aftermarket Division AAD Attention Order Processing 1313 E Algonquin Road Schaumburg IL 60196 1 2 4 Technical Support https businessonline motorola com Select Contact Us 1 2 5 Parts Identification 1 847 538 0021 Voice 1 847 538 8194 Fax August 30 2002 99R85452E01 O Introduction Radio Model Information 1 3 Radio Model Information The model number and serial number are located on a label attached to the back of your radio You can determine the RF output power frequency band protocols and physical packages The example below shows one portable radio model number and its specific characteristics Table 1 1 Radio Model Number Example LAH49KDH8AAQ Type Model Frequency Power Physical Channel Feature of Protocol Unit Series Band Level Packages Spacing
15. ng the warranty period and service repair or spare parts support out of warranty Motorola de Colombia Service Center Carrera 7 No 71 52 Torre B Piso 13 Oficina 1301 Bogota Colombia Phone 571 376 6990 Motorola de Mexico Service Center Bosques de Alisos 125 Col Bosques de las Lomas CP 05120 Mexico D F Phone 525 257 6700 Warranty Period and Return Instructions Where the product is covered under warranty a check of the product should be performed prior to shipping the unit This is to ensure that the product has been correctly programmed or has not been subjected to damage outside the terms of the warranty Products should be shipped back in the original packaging or correctly packaged to ensure no damage occurs in transit After Warranty Period After the Warranty period Motorola continues to support its products in two ways 1 Motorola s authorized service centers offer a repair service to both end users and dealers at competitive prices 2 AAD supplies individual parts and modules that can be purchased by dealers who are technically capable of performing fault analysis and repair 1 2 Introduction Warranty and Service Support 1 2 3 Piece Parts Some replacement parts spare parts and or product information can be ordered directly If a complete Motorola part number is assigned to the part it is available from Motorola s Accessories and Aftermarket Division AAD If no part number is assigned the part
16. nstructions for safe usage contained in the Product Safety and RF Exposure booklet enclosed with your radio ATTENTION This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements Before using this product read the RF energy awareness information and operating instructions in the Product Safety and RF Exposure booklet enclosed with your radio Motorola Publication part number 68P81095C98 to ensure compliance with RF energy exposure limits For a list of Motorola approved antennas batteries and other accessories visit the following web site which lists approved accessories http www motorola com cgiss index shtml vi Product Safety and RF Exposure Compliance This Page Intentionally Left Blank August 30 2002 99R85452E01 O Chapter 1 Introduction 1 1 1 2 1 2 1 1 2 2 Scope of Manual This manual is intended for use by service technicians familiar with similar types of equipment It contains service information required for the equipment described and is current as of the printing date Changes which occur after the printing date may be incorporated by a complete Manual revision or alternatively as additions NOTE Before operating or testing these units please read the User Safety Training and General Information Section in the front of this manual Warranty and Service Support Motorola offers long term support for its products This support includes repair of the product duri
17. o be applied to the circuit To replace a component on a flexible circuit 1 Grasp with seizers hemostats the edge of the flexible circuit near the part to be removed 2 Pull gently 3 Apply the tip of the soldering iron to the component connections while pulling with the seizers NOTE Do not attempt to puddle out components Prolonged application of heat may damage the flexible circuit Chip Components Use either the RLN 4062 Hot Air Repair Station or the Motorola 0180381B45 Repair Station for chip component replacement When using the 0180381B45 Repair Station select the TJ 65 mini thermojet hand piece On either unit adjust the temperature control to 700 degrees F 370 degrees C and adjust the airflow to a minimum setting Airflow can vary due to component density To remove a chip component select a hot air hand piece and position the nozzle of the hand piece approximately 1 8 above the component to be removed Begin applying hot air Once the solder reflows remove the component using a pair of tweezers Using solder wick and a soldering iron or a power desoldering station remove the excess solder from the pads To replace a chip component using a soldering iron select the appropriate micro tipped soldering iron and apply fresh solder to one of the solder pads Using a pair of tweezers position the new chip component in place while heating the fresh solder Once solder wicks onto the new component remove the heat from
18. slodged material out and away from the inside of the radio Make sure that controls or tunable components are not soaked with alcohol Do not use high pressure air to hasten the drying process since this could cause the liquid to collect in unwanted places After completing the cleaning process use a Soft absorbent lintless cloth to dry the area Do not brush or apply any isopropyl alcohol to the frame front cover or back cover 2 2 2 3 Maintenance Safe Handling of CMOS and LDMOS Devices NOTE Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved material from previous usage Safe Handling of CMOS and LDMOS Devices Complementary metal oxide semiconductor CMOS devices are used in this family of radios and are susceptible to damage by electrostatic 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 CMOS circuits and are especially important in low humidity conditions DO NOT attempt to disassemble the radio without first referring to the following CAUTION statement 1 CAUTION This radio contains static sensitive devices Do not open the radio unless you 2 4 2 4 1 2 4 2 properly grounded Take the following precautions when working on this unit Store and transport
19. the solder Heat the remaining pad with the soldering iron and apply solder until it wicks to the component If necessary touch up the first side All solder joints should be smooth and shiny To replace a chip component using hot air select the hot air hand piece and reflow the solder on the solder pads to smooth it Apply a drop of solder paste flux to each pad using a pair of tweezers position the new component in place Position the hot air hand piece approximately 1 8 above the component and begin applying heat Once the solder wicks to the component remove the heat and inspect the repair All joints should be smooth and shiny 99R85452E01 O August 30 2002 2 4 Maintenance Disassembling and Reassembling the Radio General 2 4 5 Shields Removing and replacing shields will be done with the R 1070 station with the temperature control set to approximately 415 F 215 C 445 F 230 C max 2 5 To remove the shield place the circuit board in the R 1070 s holder Select the proper heat focus head and attach it to the heater chimney Add solder paste flux around the base of the shield Position the shield under the heat focus head Lower the vacuum tip and attach it to the shield by turning on the vacuum pump Lower the focus head until it is approximately 1 8 0 3cm above the shield Turn on the heater and wait until the shield lifts off the circuit board Once the shield is off turn off the heat grab the part with a p
20. ts should be used If the identical replacement part is not locally available check the parts list for the proper Motorola part number and order the part from the nearest Motorola Communications parts center listed in the Piece Parts section of this manual Rigid Circuit Boards This radio uses bonded multi layer printed circuit boards Since the inner layers are not accessible some special considerations are required when soldering and unsoldering components The printed through holes may interconnect multiple layers of the printed circuit Therefore exercise care to avoid pulling the plated circuit out of the hole August 30 2002 99R85452E01 O Maintenance Repair Procedures and Techniques General 2 3 2 4 3 2 4 4 When soldering near the 20 pin and 40 pin connectors Avoid accidentally getting solder in the connector Be careful not to form solder bridges between the connector pins Examine your work closely for shorts due to solder bridges Flexible Circuits The flexible circuits are made from a different material than the rigid boards and require different soldering techniques Excessive prolonged heat on a flexible circuit can damage the material Therefore avoid excessive heat and excessive bending For parts replacement use the ST 1087 Temperature Controlled Solder Station with a 600 700 degree F tip and use small diameter solder such as ST 633 The smaller size solder will melt faster and require less heat t
21. wer up Sequence 2200 see e ec ee cece cece etc eee ce ee ee eee 7 3 7 3 4 CPU Control Sectlori ote tete dle RH COR a eee anes 7 4 7 3 5 VCO Synthesizer Section eiti eaii A 7 4 1 3 6 6 ee Adee eg eh eed ated ate 7 5 7 3 7 Receiver Section e deat RE e Rau d de se eR do ine e ne 7 6 7 3 6 Battery Sectlon eedem ee e OG E ERE rere n TERR REL Enea 7 7 7 4 Block Diagrams ence cee el eed dud tee deuda ecd ded eodd dv eed 7 8 1 4 1 Complete 2 eet ERR ea ena 7 8 74 2 Controller arc rate et a TU 7 9 CALS NCO we T PEE LC I 7 9 TAA Dransmitter iet Maden nt econ Pe etes t eon e bee dee eines Let 7 10 45 ien end dei ee tee dues et iuret eter edades 7 10 7 5 Troubleshooting Charts iiie ced cesa cei use ed de LR EE Saee dk en eR LR E d a d eia 7 11 Chapter 8 UHF Band Information eese 8 1 8 1 iModel Charts oder dit ee nite ed cd sete Seeder es ea te Ree tta ke teu Hara 8 1 8 2 Specifications aee ee cete nae ee De aen rea a iade ans een ade ena 8 3 8 3 Theory of Operatlori ioter etel tee rete e t nee 8 4 8 3 1 General Informiation crine ere desi b eee va edat Da o qe dau ata 8 4 8 3 2 Power bDistribUtlon c reine ettet dit ge d
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