PROFESSIONAL DIGITAL TWO-WAY RADIO SYSTEM & SMARTNET® AND PRIVACY PLUS™ TRUNKED MOBILE RADIOS

MOTOTRBO™ PORTABLE BASIC SERVICE MANUAL XPR™ 6580 DISPLAY PORTABLE XPR™ 6380 NON-DISPLAY PORTABLE XPR™ 6580 IS DISPLAY PORTABLE

i

Foreword This manual covers all models of the XPR™ series Portable Radios, unless otherwise specified. It includes all the information necessary to maintain peak product performance and maximum working time, using levels 1 and 2 maintenance procedures. This level of service goes down to the board replacement level and is typical of some local service centers, self-maintained customers, and distributors.

Product Safety and RF Exposure Compliance

! Caution

Before using this product, read the operating instructions 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 6881095C98) 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.motorolasolutions.com/governmentandenterprise

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, modified, 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.

Document Copyrights No duplication or distribution of this document or any portion thereof shall take place without the express written permission of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Motorola.

Disclaimer The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.

Trademarks MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M logo are trademarks or registered trademarks of Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective owners. © 2011–2012 Motorola Solutions, Inc. All rights reserved.

ii

Notes

iii

Document History The following major changes have been implemented in this manual since the previous edition: Edition

Description

Date

68009271001-A

Initial release

Dec. 2009

68009271001-B

Added IECEx/CSA 800/900 info

Jan. 2011

68009271001-C

Added CSA 157 800/900 info

Feb. 2012

iv

Notes

Table of Contents

v

Table of Contents Foreword ..........................................................................................................i Product Safety and RF Exposure Compliance .............................................................................................i Computer Software Copyrights ....................................................................................................................i Document Copyrights ...................................................................................................................................i Disclaimer.....................................................................................................................................................i Trademarks ..................................................................................................................................................i

Document History ........................................................................................ iii Commercial Warranty .................................................................................xiii Limited Warranty ...................................................................................................................................... xiii MOTOROLA COMMUNICATION PRODUCTS ............................................................................ xiii I. What This Warranty Covers And For How Long ................................................................... xiii II. General Provisions ............................................................................................................... xiv III. State Law Rights ................................................................................................................ xiv IV. How To Get Warranty Service ............................................................................................ xiv V. What This Warranty Does Not Cover................................................................................... xiv VI. Patent And Software Provisions ..........................................................................................xv VII. Governing Law....................................................................................................................xv

Battery and Charger Warranty ...................................................................xvi Workmanship Warranty ............................................................................................................................ xvi Capacity Warranty .................................................................................................................................... xvi

Chapter 1 1.1 1.2

1.3 1.4 1.5

Notations Used in This Manual .................................................................................................... 1-1 Radio Description ........................................................................................................................ 1-1 1.2.1 Display Model .................................................................................................................. 1-2 1.2.2 Display Model .................................................................................................................. 1-2 1.2.3 Non-Display Model .......................................................................................................... 1-4 Portable Radio Model Numbering Scheme ................................................................................. 1-4 Model Charts ............................................................................................................................... 1-5 1.4.1 800/900 Band Model Chart.............................................................................................. 1-5 Specifications............................................................................................................................... 1-6

Chapter 2 2.1 2.2 2.3

Introduction ......................................................................... 1-1

Test Equipment and Service Aids ..................................... 2-1

Recommended Test Equipment .................................................................................................. 2-1 Service Aids ................................................................................................................................. 2-2 Programming, Testing and Alignment Cable ............................................................................... 2-3

vi

Table of Contents

Chapter 3 3.1 3.2 3.3

3.4

General ........................................................................................................................................ 3-1 Setup............................................................................................................................................ 3-1 Display Model Test Mode ............................................................................................................ 3-3 3.3.1 Entering Display Radio Test Mode .................................................................................. 3-3 3.3.2 RF Test Mode .................................................................................................................. 3-3 3.3.3 Display Test Mode ........................................................................................................... 3-7 3.3.4 LED Test Mode................................................................................................................ 3-7 3.3.5 Backlight Test Mode ........................................................................................................ 3-7 3.3.6 Speaker Tone Test Mode ................................................................................................ 3-7 3.3.7 Earpiece Tone Test Mode ............................................................................................... 3-7 3.3.8 Audio Loopback Earpiece Test Mode.............................................................................. 3-7 3.3.9 Battery Check Test Mode ................................................................................................ 3-8 3.3.10 Button/Knob/PTT Test Mode ........................................................................................... 3-8 Non-Display Model Test Mode................................................................................................... 3-10 3.4.1 Entering Non-Display Radio Test Mode ........................................................................ 3-10 3.4.2 RF Test Mode ................................................................................................................ 3-10 3.4.3 LED Test Mode.............................................................................................................. 3-10 3.4.4 Speaker Tone Test Mode .............................................................................................. 3-10 3.4.5 Earpiece Tone Test Mode ............................................................................................. 3-11 3.4.6 Audio Loopback Earpiece Test Mode............................................................................ 3-11 3.4.7 Battery Check Test Mode .............................................................................................. 3-11 3.4.8 Button/Knob/PTT Test Mode ......................................................................................... 3-11

Chapter 4 4.1 4.2 4.3 4.4

5.3 5.4 5.5 5.6

5.7

5.8

Radio Programming and Tuning ....................................... 4-1

Introduction .................................................................................................................................. 4-1 Customer Programming Software Setup ..................................................................................... 4-1 AirTracer Application Tool............................................................................................................ 4-1 Radio Tuning Setup ..................................................................................................................... 4-2

Chapter 5 5.1 5.2

Transceiver Performance Testing ..................................... 3-1

Disassembly/Reassembly Procedures ............................. 5-1

Introduction .................................................................................................................................. 5-1 Preventive Maintenance .............................................................................................................. 5-1 5.2.1 Inspection ........................................................................................................................ 5-1 5.2.2 Cleaning Procedures ....................................................................................................... 5-1 Safe Handling of CMOS and LDMOS Devices ............................................................................ 5-2 Repair Procedures and Techniques – General............................................................................ 5-4 Disassembling and Reassembling the Radio — General ............................................................ 5-5 Radio Disassembly – Detailed ..................................................................................................... 5-5 5.6.1 Front Cover from Chassis Disassembly .......................................................................... 5-5 5.6.2 Chassis Disassembly....................................................................................................... 5-8 5.6.3 Speaker Disassembly .................................................................................................... 5-10 Radio Reassembly – Detailed.................................................................................................... 5-11 5.7.1 Speaker Reassembly..................................................................................................... 5-11 5.7.2 Chassis Reassembly ..................................................................................................... 5-12 5.7.3 Chassis and Front Cover Reassembly .......................................................................... 5-15 Ensuring Radio Immersibility ..................................................................................................... 5-16 5.8.1 Servicing ........................................................................................................................ 5-16 5.8.2 Accidental Immersion .................................................................................................... 5-17

Table of Contents

vii

5.8.3 5.8.4 5.8.5 5.8.6 5.8.7 5.8.8 5.8.9

5.9

Specialized Test Equipment .......................................................................................... 5-17 Vacuum Pump Kit NLN9839.......................................................................................... 5-17 Pressure Pump Kit NTN4265 ........................................................................................ 5-17 Miscellaneous Hardware ............................................................................................... 5-17 Vacuum Test ................................................................................................................. 5-18 Pressure Test ................................................................................................................ 5-18 Troubleshooting Leak Areas.......................................................................................... 5-20 5.8.9.1 Front Housing ................................................................................................. 5-20 5.8.9.2 Chassis (Main Seal O-ring) ............................................................................ 5-21 5.8.9.3 Battery Contact Seal....................................................................................... 5-21 5.8.9.4 Breathing Vent Membrane and Breathing Vent Label .................................... 5-22 5.8.10 Troubleshooting Charts ................................................................................................. 5-23 Radio Exploded Mechanical Views and Parts Lists ................................................................... 5-26 5.9.1 Display Model Exploded View and Parts List ................................................................ 5-26 5.9.2 Non-Display Model Exploded View and Parts List ........................................................ 5-28 5.9.3 Torque Chart ................................................................................................................. 5-30

Chapter 6 6.1 6.2 6.3 6.4

Introduction .................................................................................................................................. 6-1 Replacement Back Cover Kit Procedures ................................................................................... 6-1 Power-Up Error Codes (Display Model only) ............................................................................... 6-2 Operational Error Codes .............................................................................................................. 6-4

Chapter 7 7.1

Basic Troubleshooting ....................................................... 6-1

Accessories ......................................................................... 7-1

Introduction .................................................................................................................................. 7-1 7.1.1 Audio ............................................................................................................................... 7-1 7.1.2 Batteries .......................................................................................................................... 7-2 7.1.3 Chargers.......................................................................................................................... 7-2 7.1.4 Cables ............................................................................................................................. 7-3 7.1.5 Antennas ......................................................................................................................... 7-3 7.1.6 Carry Devices .................................................................................................................. 7-3 7.1.7 Service/Replacement Parts ............................................................................................. 7-4 7.1.8 CPS ................................................................................................................................. 7-4 7.1.9 Miscellaneous Accessories ............................................................................................. 7-4

viii

Table of Contents

Appendix A Replacement Parts Ordering..............................................A-1 A.1 A.2 A.3 A.4 A.5 A.6 A.7

Basic Ordering Information ..........................................................................................................A-1 Motorola Online............................................................................................................................A-1 Mail Orders ..................................................................................................................................A-1 Telephone Orders ........................................................................................................................A-1 Fax Orders ...................................................................................................................................A-1 Parts Identification .......................................................................................................................A-2 Product Customer Service ...........................................................................................................A-2

Appendix B Motorola Service Centers...................................................B-1 B.1 B.2 B.3 B.4

Servicing Information ...................................................................................................................B-1 Motorola Service Center ..............................................................................................................B-1 Motorola Canadian Technical Logistics Center ...........................................................................B-1 Motorola Federal Technical Center..............................................................................................B-1

Glossary ......................................................................................... Glossary-1

List of Figures

ix

List of Figures Figure 1-1. Figure 1-2. Figure 1-3. Figure 2-1. Figure 2-2. Figure 3-1. Figure 4-1. Figure 4-2. Figure 5-1. Figure 5-2. Figure 5-3. Figure 5-4. Figure 5-5. Figure 5-6. Figure 5-7. Figure 5-8. Figure 5-9. Figure 5-10. Figure 5-11. Figure 5-12. Figure 5-13. Figure 5-14. Figure 5-15. Figure 5-16. Figure 5-17. Figure 5-18. Figure 5-19. Figure 5-20.

Display Model ...................................................................................................................... 1-2 Non-Display Model............................................................................................................... 1-3 Portable Radio Model Numbering Scheme.......................................................................... 1-4 Programming, Testing and Alignment Cable........................................................................ 2-3 Pin Layout of Side Connector .............................................................................................. 2-4 Battery Check Test Mode Display ........................................................................................ 3-8 CPS Programming Setup..................................................................................................... 4-1 Radio Tuning Equipment Setup ........................................................................................... 4-2 Dust Cover removal. ............................................................................................................ 5-5 Battery and Antenna removal. ............................................................................................. 5-6 Knob removal. ...................................................................................................................... 5-6 Chassis removal. ................................................................................................................. 5-7 LCD Module removal. .......................................................................................................... 5-8 LCD Retainer removal.......................................................................................................... 5-8 Transmission and Interface Board removal. ........................................................................ 5-9 O-ring and Battery Contact Seal removal. ........................................................................... 5-9 Speaker removal. ............................................................................................................... 5-10 Speaker reassembly (Display Model). ............................................................................... 5-11 Speaker reassembly (Non-Display Model)......................................................................... 5-12 O-ring and Battery Contact Seal reassembly. .................................................................... 5-13 Secondary O-ring reassembly............................................................................................ 5-13 Transmission and Interface Board reassembly. ................................................................. 5-14 LCD Retainer and LCD Module reassembly. ..................................................................... 5-14 Back Cover Kit reassembly. ............................................................................................... 5-15 Chassis to Front Cover reassembly. .................................................................................. 5-16 Connector Fitting - Fitting Seal Pump Connector............................................................... 5-17 Display Model Exploded View............................................................................................ 5-26 Non-Display Model Exploded View .................................................................................... 5-28

x

List of Figures

Notes

Related Publications

xi

List of Tables Table 1-1. Table 2-1. Table 2-2. Table 2-3. Table 3-1. Table 3-2. Table 3-3. Table 3-4. Table 3-5. Table 3-6. Table 4-1. Table 5-1. Table 5-2. Table 5-3. Table 5-4. Table 5-5. Table 6-1. Table 6-2.

Radio Frequency Ranges and Power Levels....................................................................... 1-1 Recommended Test Equipment ........................................................................................... 2-1 Service Aids ......................................................................................................................... 2-2 Pin Configuration of Side Connector.................................................................................... 2-4 Initial Equipment Control Settings ........................................................................................ 3-2 Front Panel Access Test Mode Displays.............................................................................. 3-3 Test Environments................................................................................................................ 3-4 Test Frequencies.................................................................................................................. 3-4 Transmitter Performance Checks ........................................................................................ 3-5 Receiver Performance Checks ............................................................................................ 3-6 Software Installation Kits Radio Tuning Setup ..................................................................... 4-1 Lead Free Solder Wire Part Number List ............................................................................. 5-4 Lead Free Solder Paste Part Number List ........................................................................... 5-4 Display Model Exploded View Parts List............................................................................ 5-27 Non-Display Model Exploded View Parts List .................................................................... 5-29 Torque Specifications for Screws ....................................................................................... 5-30 Power-Up Error Codes......................................................................................................... 6-2 Operational Error Codes ...................................................................................................... 6-4

xii

List of Tables

Related Publications IMPRES Adaptive Single-Unit Charger User Manual ..................................................................6816787H01 IMPRES Adaptive Multi-Unit Charger User Manual.....................................................................6816789H01 IMPRES Adaptive Multi-Unit Charger Service Manual ................................................................ 6871357L01 Remote Speaker Microphone User Manual ................................................................................. 6871003L01 IMPRES Remote Speaker Microphone User Manual .................................................................. 6871004L01 Factory Mutual Approval Manual ................................................................................................. 6871532L01 *MOTOTRBO™ Portable User Guide CD ....................................................................................HKLN4282_ *CD consists of: XPR™ 6300/6350 User Guide XPR™ 6300/6350 Quick Reference Card XPR™ 6500/6550 User Guide XPR™ 6500/6550 Quick Reference Card Safety Leaflet **Portable User Guide CD Kit for SMARTNET® / Privacy Plus™ ................................................HKLN4409_ **CD consists of: XPR™ 6380/6580 User Guide in English and French Canadian XPR™ 6380/6580 Quick Reference Card in English and French Canadian Safety Leaflet

Commercial Warranty

xiii

Commercial Warranty

Limited Warranty MOTOROLA COMMUNICATION PRODUCTS I. What This Warranty Covers And For How Long MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication Products listed below (“Product”) against defects in material and workmanship under normal use and service for a period of time from the date of purchase as scheduled below:

XPR Series Digital Portable Radios

Two (2) Years

Product Accessories (Excluding Batteries and Chargers)

One (1) Year

The portables additionally ship with a standard 1-year Repair Service Advantage (RSA) (for U.S. customers) or 1-year Extended Warranty (for Canada customers). However, at the time of order, you may choose to omit these warranties. For more RSA or Extended Warranty information, please refer to the portable price pages or Motorola Online (https://businessonline.motorola.com) > Resource Center > Services > Service Product Offerings > Repair Service Advantage or Extended Warranty. Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts), replace it (with a new or reconditioned Product), or refund the purchase price of the Product during the warranty period provided it is returned in accordance with the terms of this warranty. Replaced parts or boards are warranted for the balance of the original applicable warranty period. All replaced parts of Product shall become the property of MOTOROLA. This express limited warranty is extended by MOTOROLA to the original end user purchaser only and is not assignable or transferable to any other party. This is the complete warranty for the Product manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or modifications to this warranty unless made in writing and signed by an officer of MOTOROLA. Unless made in a separate agreement between MOTOROLA and the original end user purchaser, MOTOROLA does not warrant the installation, maintenance or service of the Product. MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by MOTOROLA which is attached to or used in connection with the Product, or for operation of the Product with any ancillary equipment, and all such equipment is expressly excluded from this warranty. Because each system which may use the Product is unique, MOTOROLA disclaims liability for range, coverage, or operation of the system as a whole under this warranty.

xiv

Commercial Warranty

II. General Provisions This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product. Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW.

III. State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY. This warranty gives specific legal rights, and there may be other rights which may vary from state to state.

IV. How To Get Warranty Service You must provide proof of purchase (bearing the date of purchase and Product item serial number) in order to receive warranty service and, also, deliver or send the Product item, transportation and insurance prepaid, to an authorized warranty service location. Warranty service will be provided by Motorola through one of its authorized warranty service locations. If you first contact the company which sold you the Product, it can facilitate your obtaining warranty service. You can also call Motorola at 1-800-927-2744 US/Canada.

V. What This Warranty Does Not Cover A. Defects or damage resulting from use of the Product in other than its normal and customary manner. B. Defects or damage from misuse, accident, water, or neglect. C. Defects or damage from improper testing, operation, maintenance, installation, alteration, modification, or adjustment. D. Breakage or damage to antennas unless caused directly by defects in material workmanship. E. A Product subjected to unauthorized Product modifications, disassemblies or repairs (including, without limitation, the addition to the Product of non-Motorola supplied equipment) which adversely affect performance of the Product or interfere with Motorola's normal warranty inspection and testing of the Product to verify any warranty claim. F.

Product which has had the serial number removed or made illegible.

G. Rechargeable batteries if: - any of the seals on the battery enclosure of cells are broken or show evidence of tampering. - the damage or defect is caused by charging or using the battery in equipment or service other than the Product for which it is specified. H. Freight costs to the repair depot.

Commercial Warranty

xv

I.

A Product which, due to illegal or unauthorized alteration of the software/firmware in the Product, does not function in accordance with MOTOROLA’s published specifications or the FCC type acceptance labeling in effect for the Product at the time the Product was initially distributed from MOTOROLA.

J.

Scratches or other cosmetic damage to Product surfaces that does not affect the operation of the Product.

K. Normal and customary wear and tear.

VI. Patent And Software Provisions MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the extent that it is based on a claim that the Product or parts infringe a United States patent, and MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in any such suit which are attributable to any such claim, but such defense and payments are conditioned on the following: A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such claim; B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its settlement or compromise; and C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the subject of a claim of infringement of a United States patent, that such purchaser will permit MOTOROLA, at its option and expense, either to procure for such purchaser the right to continue using the Product or parts or to replace or modify the same so that it becomes noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and accept its return. The depreciation will be an equal amount per year over the lifetime of the Product or parts as established by MOTOROLA. MOTOROLA will have no liability with respect to any claim of patent infringement which is based upon the combination of the Product or parts furnished hereunder with software, apparatus or devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary equipment or software not furnished by MOTOROLA which is attached to or used in connection with the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of patents by the Product or any parts thereof. Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute copies of such Motorola software. MOTOROLA software may be used in only the Product in which the software was originally embodied and such software in such Product may not be replaced, copied, distributed, modified in any way, or used to produce any derivative thereof. No other use including, without limitation, alteration, modification, reproduction, distribution, or reverse engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent rights or copyrights.

VII. Governing Law This Warranty is governed by the laws of the State of Illinois, USA.

xvi

Battery and Charger Warranty

Battery and Charger Warranty

Workmanship Warranty The workmanship warranty guarantees against defects in workmanship under normal use and service.

All MOTOTRBO Batteries

Two (2) Years

IMPRES Chargers (Single-Unit and Multi-Unit, Non-Display)

18 Months

IMPRES Chargers (Multi-Unit with Display)

One (1) Year

Capacity Warranty The capacity warranty guarantees 80% of the rated capacity for the warranty duration.

Nickel Metal-Hydride (NiMH) or Lithium-Ion (Li-lon) Batteries

12 Months

IMPRES Batteries, When Used Exclusively with IMPRES Chargers

18 Months

Introduction: Notations Used in This Manual

1-1

Chapter 1 Introduction

1.1

Notations Used in This Manual Throughout the text in this publication, you will notice the use of note and caution notations. These notations are used to emphasize that safety hazards exist, and due care must be taken and observed. NOTE An operational procedure, practice, or condition that is essential to emphasize.

! Caution

CAUTION indicates a potentially hazardous situation which, if not avoided, might result in equipment damage.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

1-2

1.2

Introduction: Radio Description

Radio Description The XPR series portable radios are available in the following frequency ranges and power levels. Table 1-1. Radio Frequency Ranges and Power Levels Frequency Band

Bandwidth

Power Level

800/900 RX/TX Talk Around

851–870MHz 935–941MHz

1 Watt or 2.5 Watt

800/900 TX Trunking

806–825MHz 896–902MHz

1 Watt or 2.5 Watt

IECEx/CSA 800/900 RX/TX Talk Around

851–870MHz 935–941MHz

1 Watt

IECEx/CSA 800/900 TX Trunking

806–825MHz 896–902MHz

1 Watt

CSA 157 800/900 RX/TX Talk Around

851–870MHz 935–941MHz

1 Watt or 2 Watt

CSA 157 800/900 Tx Trunking

806–825MHz 896–902MHz

1 Watt or 2 Watt

These digital radios are among the most sophisticated two-way radios available. They have a robust design for radio users who need high performance, quality, and reliability in their daily communications. This architecture provides the capability of supporting a multitude of legacy and advanced features resulting in a more cost-effective two-way radio communications solution.

Introduction: Radio Description

1.2.1

1-3

Display Model

Channel Selector Knob

Antenna

On/Off/Volume Control Knob

LED Indicator Side Button 1 PUSH-TO-TALK(PTT) Button Side Button 2 Side Button 3 Front Button P1 Microphone

Emergency Button Universal Connector for Accesories Display Menu Navigation Keys Keypad Front Button P2 Speaker

Figure 1-1. Display Model • ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counterclockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate counter-clockwise to decrease volume level. • LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status. • LCD (Liquid Crystal Display) – 132x34 full dot matrix display provides visual information about many radio features. • MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface. • KEYPAD – Twelve keys that allows the user to input characters for various text based operations. • FRONT BUTTONS and SIDE BUTTONS – These five buttons are field programmable using the CPS. • CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to decrement the channel. • PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call). • ANTENNA – Provides the needed RF amplification when transmitting or receiving. • MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated. • UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be used with the radio. It has twelve points to which specific accessories will connect and be activated.

1-4

1.2.2

Introduction: Radio Description

Display Model (IECEx/CSA 800/900 & CSA 157 800/900) Channel Selector Knob Antenna On/Off/Volume Control Knob Emergency Button LED Indicator Side Button 1 Speaker PUSH-TO-TALK (PTT) Button Side Button 2 Side Button 3

Microphone Display Menu Navigation Keys Keypad

Figure 1-2. Display Model (IECEx/CSA 800/900 & CSA 157 800/900) • ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counterclockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate counter-clockwise to decrease volume level. • LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status. • LCD (Liquid Crystal Display) – 132x34 full dot matrix display provides visual information about many radio features. • MENU NAVIGATION KEYS – Five keys to provide menu navigation and selection interface. • KEYPAD – Twelve keys that allows the user to input characters for various text based operations. • FRONT BUTTONS and SIDE BUTTONS – These five buttons are field programmable using the CPS. • CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to decrement the channel. • PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call). • ANTENNA – Provides the needed RF amplification when transmitting or receiving. • MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated. • UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be used with the radio. It has twelve points to which specific accessories will connect and be activated.

Introduction: Radio Description

1-5

• EMERGENCY BUTTON – Turns on and off the Emergency Operations. • SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like keypad tones and voice audio).

1.2.3

Non-Display Model

Channel Selector Knob

Antenna

On/Off/Volume Control Knob

LED Indicator Side Button 1 PUSH-TO-TALK (PTT) Button

Emergency Button Universal Connector for Accesories Speaker Microphone

Side Button 2 Side Button 3

Figure 1-3. Non-Display Model • ON/OFF/VOLUME KNOB – Rotate clockwise until click is heard to turn on radio; rotate counterclockwise until click is heard to turn off radio. Rotate clockwise to increase volume level; rotate counter-clockwise to decrease volume level. • LED INDICATORS – Red, green and orange light-emitting diodes indicate operating status. • SIDE BUTTONS – These 3 buttons are field programmable using the CPS. • CHANNEL SELECTOR KNOB – Rotate clockwise to increment and counter clockwise to decrement the channel. • PUSH-TO-TALK (PTT) – Press to execute voice operations (e.g. Group call and Private Call). • ANTENNA – Provides the needed RF amplification when transmitting or receiving. • MICROPHONE – Allows the voice to be sent when PTT or voice operations are activated. • UNIVERSAL CONNECTOR FOR ACCESSORIES – Interface point for all accessories to be used with the radio. It has twelve points to which specific accessories will connect to and be activated. • EMERGENCY BUTTON – Turns on and off the Emergency Operations. • SPEAKER – Outputs all tones and audio that are generated by the radio (e.g. features like keypad tones and voice audio).

1-6

1.3

Introduction: Portable Radio Model Numbering Scheme

Portable Radio Model Numbering Scheme

Model No.Example : Position

AZ

:

H

5

5

Q

D

H

9

L

A

1

A

N

1

2

3

4

5

6

7

8

9

10

11

12 N: Standard Package

AZ: Asia/Australia LA: Latin America AA: North America (except Mexico) MD: Europe/Middle East/Africa

Version Letter

H: Portable 55: MOTOTRBO Portable Model Series

Feature Level 1: Standard 3: CSA IECEx ATEX

800/900 Band U: 806 – 941MHz Primary System Type A: Conventional B: Trunking C: Analog

Power Level C: 1.0-2.5 W Physical Packages C: Non-Display Model H: Display Model

Primary Operation J: w/o GPS L: w/ GPS

Channel Spacing 9: Variable/Programmable

Figure 1-4. Portable Radio Model Numbering Scheme

Introduction: Model Charts

1-7

1.4

Model Charts

1.4.1

800/900 Band Model Chart

XPR 6000 Series, 800/900 MHz Model AAH55UCH9LB1AN AAH55UCC9LB1AN

Description 806–941MHz 2.5W, Display Portable with GPS 806–941MHz 2.5W, Non-Display Portable with GPS

Item X

Description

PMLF4063_

Back Cover Kit, MOTOTRBO Display Portable with GPS, Digital

PMLF4065_

Back Cover Kit, MOTOTRBO Non-Display Portable with GPS, Digital

PMLF4063_

Back Cover Kit, MOTOTRBO Display Portable with GPS, Digital (GOB)

X

PMLF4065_

Back Cover Kit, MOTOTRBO Non-Display Portable with GPS, Digital (GOB)

X

X

PMAF4003_

800/900 +GPS Helical Antenna (806–941MHz)

X

X

HKLN4409_

User Guide CD

X X

1.4.2

IECEx/CSA 800/900 & CSA 157 800/900 Band Model Chart

XPR 6000 Series, 800/900 MHz Model AAH55UCH9LB3AN AAH55UCH9LB3BN

Description 806–941MHz 1 W, Display Portable with GPS 806–941MHz 2 W, Display Portable with GPS

Item X X X X

Description

PMLN5583_

Front Cover Kit, MOTOTRBO Display Portable ATEX CSA with GPS

PMLF4081_

Back Cover Kit, MOTOTRBO Display Portable with GPS, Digital (GOB)

PMAF4005_

800/900 +GPS Helical Antenna (806–941MHz)

HKLN4883_

User Guide CD

1-8

1.5

Introduction: Specifications

Specifications General

Channel Capacity Frequency Dimensions (HxWxT) w/ NiMH battery

Weight (with LiIon FM battery) (with LiIon 2200 battery) (with LiIon 1750 battery) XPR 6580 IS Power Supply

Display XPR 6580/ XPR 6580 IS

Non-Display XPR 6380

160

32

800 Band: 851 – 870 MHz 900 Band: 935 – 941 MHz 5.18 x 2.40 x 1.38 in (131.5 x 61 x 35 mm) XPR 6580 IS 5.60 x 2.20 x 1.78 in (142.3x 56 x 45.3 mm) 13 oz (370 g) 12.7 oz (360 g) 18.70 oz (530 g)

11.1 oz (315 g) 10.75 oz (305 g)

7.5V nominal 7.4V nominal (XPR 6580 IS)

FCC Description

800/900 Band:ABZ99FT5011 IECEx/CSA 800/900: ABZ99FT5012 CSA 157 800/900: ABZ99FT5013

IC Description

800/900 Band: 109AB-99FT5011 IECEx/CSA 800/900: 109AB-FT5012 CSA 157 800/900: 109AB-99FT5013

Average battery life at 5/5/90 duty cycle without battery saver enabled in carrier squelch and transmitter in high power. IMPRES FM LiIon (FM battery approximate 7 hrs)

Analog: 5 satellites visible at a nominal -130 dBm signal strength)

Military Standards Applicable MIL–STD

810E

810F

Methods

Procedures

Methods

Procedures

Low Pressure

500.3

II

500.4

II

High Temperature

501.3

I/A, II/A1

501.4

I/Hot, II/Hot

Low Temperature

502.3

I/C3, II/C1

502.4

I/C3, II/C1

Temperature Shock

503.3

I/A, 1C3

503.4

I

Solar Radiation

505.3

I

505.4

I

Rain

506.3

I,II

506.4

I, III

Humidity

507.3

II

507.4

–

Salt fog

509.3

I

509.4

I

Dust

510.3

I

510.4

I

Vibration

514.4

I/10,II/3

514.5

I/24

Shock

516.4

I, IV

516.5

I, IV

1-14

Introduction: Specifications

Environmental Specifications *Operating Temperature

-30 °C to +60 °C (XPR 6550/6350 & CSA 157 800/900) -20 °C to +50 °C (For IECEx/CSA 800/900 Only)

Storage Temperature

-40 °C to +85 °C (XPR 6550/6350 & CSA 157 800/900) 0 °C to +30 °C (For IECEx/CSA 800/900 Only)

Thermal Shock

Per MIL-STD

Humidity

Per MIL-STD

ESD

IEC-801-2KV

Water Intrusion

IEC 60529 -IP57 IEC 60529 -IP67 (XPR 6580 IS)

Packaging Test

MIL-STD 810D and E

* –Operating temperature specification with LiIon battery is -10 °C to +60 °C. –Operating temperature specification with NiMH battery is -20 °C to +60 °C.

Chapter 2 Test Equipment and Service Aids

2.1

Recommended Test Equipment The list of equipment contained in Table 2-1 includes most of the standard test equipment required for servicing Motorola portable radios. Table 2-1. Recommended Test Equipment

Equipment

Characteristics

Example

Application

Service Monitor

Can be used as a substitute for items marked with an asterisk (*)

Aeroflex 2975 (www.aeroflex.com), Motorola R2670, or equivalent

Frequency/deviation meter and signal generator for wide-range troubleshooting and alignment

Digital RMS Multimeter *

100 µV to 300 V 5 Hz to 1 MHz 10 Mega Ohm Impedance

Fluke 179 or equivalent (www.fluke.com)

AC/DC voltage and current measurements. Audio voltage measurements

RF Signal Generator *

100 MHz to 1 GHz -130 dBm to +10 dBm FM Modulation 0 kHz to 10 kHz Audio Frequency 100 Hz to 10 kHz

Agilent N5181A (www.agilent.com), Ramsey RSG1000B (www.ramseyelectronics.com), or equivalent

Receiver measurements

Oscilloscope *

2 Channel 50 MHz Bandwidth 5 mV/div to 20 V/div

Leader LS8050 (www.leaderusa.com), Tektronix TDS1001b (www.tektronix.com), or equivalent

Waveform measurements

Power Meter and Sensor *

5% Accuracy 100 MHz to 500 MHz 50 Watts

Bird 43 Thruline Watt Meter (www.bird-electronic.com) or equivalent

Transmitter power output measurements

RF Millivolt Meter

100 mV to 3 V RF 10 kHz to 1 GHz

Boonton 92EA (www.boonton.com) or equivalent

RF level measurements

Power Supply

0 V to 32 V 0 A to 20 A

B&K Precision 1790 (www.bkprecision.com) or equivalent

Voltage supply

2-2

Test Equipment and Service Aids: Service Aids

2.2

Service Aids Table 2-2 lists the service aids recommended for working on the radio. While all of these items are available from Motorola, most are standard workshop equipment items, and any equivalent item capable of the same performance may be substituted for the item listed. Table 2-2. Service Aids

Motorola Part No.

Description

Application

RLN4460_

Portable Test Set

Enables connection to the audio/accessory jack. Allows switching for radio testing.

RVN5115_

Customer Programming Software on CD-ROM

Allows servicer to program radio parameters, tune and troubleshoot radios.

PMKN4012_

Portable Programming Cable

This cable connects the radio to a USB port for radio programming and data applications.

PMKN4013_

Portable Programming, Testing & Alignment Cable

This cable connects the radio to a USB port for radio programming, testing and alignment.

PMNN4076_

7.5V Universal Battery Eliminator

Connects to radio via battery eliminator cable.

5880348B33

DMR SMA to BNC RF Adaptor

Adapts radio’s antenna port to BNC cabling of test equipment.

PMHN4085_

Bench Test Housing Eliminator

Interconnects radio to power supply. Provides for troubleshooting of the radio when the housing is removed.

NLN9839_

Vacuum Pump Kit

Allows servicer to test for leakages.

NTN4265_

Pressure Pump Kit

Allows servicer to locate leakages.

5871134M01

Connector Fitting

This connector allows the vacuum hose to be connected to the radio chassis.

3271133M01

Fitting Seal

This seal secures the connector fitting to the radio chassis.

Test Equipment and Service Aids: Programming, Testing and Alignment Cable

2.3

2-3

Programming, Testing and Alignment Cable #25

P1

#14

#1 #13

#1

P2

P3 #1

#2

#11 #12

Figure 2-1. Programming, Testing and Alignment Cable

#4

2-4

Test Equipment and Service Aids: Programming, Testing and Alignment Cable

Table 2-3. Pin Configuration of Side Connector

CONNECTION P1

P2

Pin

Pin

Pin

1

3

VCC (5V)

3

4

DATA +

2

5

DATA -

16

6

GROUND

7

8

SPEAKER -

17

10

EXTERNAL MIC +

16

11

EXTERNAL MIC -

20

9

EXTERNAL PTT

1

7

SPEAKER +

4

P3

1 (Coax Connector)

Function

GROUND

slot for accessory connector hook

GPIO_0 1-Wire

Coaxial RF Connector

Vbus D+

2

1 3

D-

4 GND

6 Spkr +

8

5 7 9

Spkr -

10 11 GPIO_3

12

Mic + Mic GPIO_4

Figure 2-2. Pin Layout of Side Connector

Chapter 3 Transceiver Performance Testing

3.1

General These radios meet published specifications through their manufacturing process by utilizing highaccuracy laboratory-quality test equipment. The recommended field service equipment approaches the accuracy of the manufacturing equipment with few exceptions. This accuracy must be maintained in compliance with the manufacturer’s recommended calibration schedule. Although these radios function in digital and analog modes, all testing is done in analog mode.

3.2

Setup Supply voltage is provided using a 7.5 VDC power supply. The equipment required for alignment procedures is connected as shown in the Radio Tuning Equipment Setup Diagram, Figure 4-2.

Do NOT use any form of connector, e.g. wires, crocodile clips, and probes, to supply voltage to the radio, other than the Motorola approved battery eliminator. Initial equipment control settings should be as indicated in Table 3-1. The remaining tables in this chapter contain the following related technical data: Table Number

Title

3-2

Front Panel Access Test Mode Displays

3-3

Test Environments

3-4

Test Frequencies

3-5

Transmitter Performance Checks

3-6

Receiver Performance Checks

3-2

Transceiver Performance Testing Setup

Table 3-1. Initial Equipment Control Settings

Service Monitor

Power Supply

Test Set

Monitor Mode: Power Monitor

Voltage: 7.5Vdc

Speaker set: A

RF Attn: -70

DC on/standby: Standby

Speaker/load: Speaker

AM, CW, FM: FM

Volt Range: 10V

PTT: OFF

Oscilloscope Source: Mod Oscilloscope Horizontal: 10mSec/Div Oscilloscope Vertical: 2.5kHz/Div Oscilloscope Trigger: Auto Monitor Image: Hi Monitor Bandwidth: Narrow Monitor Squelch: Middle setting Monitor Vol: 1/4 setting

Current: 2.5A

Transceiver Performance Testing Display Model Test Mode

3.3

Display Model Test Mode

3.3.1

Entering Display Radio Test Mode

3-3

1. Turn the radio on. 2. Within 10 seconds after Self Test is complete, press Side Button 2 five times in succession. 3. The radio beeps and will show a series of displays that will give information regarding various version numbers and subscriber specific information. The displays are described in Table 3-2. Table 3-2. Front Panel Access Test Mode Displays

Name of Display

Description

Appears

Service Mode

The literal string indicates the radio has entered test mode.

Always

Host Version

The version of host firmware.

Always

DSP Version

The version of DSP firmware.

Always

Model Number

The radio’s model number as programmed in the codeplug.

Always

MSN

The radio’s serial number as programmed in the codeplug.

Always

FLASHCODE

The FLASH codes as programmed in the codeplug.

Always

RF Band

The radio’s band.

Always

NOTE The radio stops at each display for 2 seconds before moving to the next information display. If the information cannot fit into 1 line, the radio display scrolls automatically character by character after 1 second to view the whole information. If the Left Navigation Key (W) is pressed before the last information display, the radio shall suspend the information display until the user presses Right Navigation Key (X) to resume the information display. The radio beeps for each button press. After the last display, RF Test Mode will be displayed.

3.3.2

RF Test Mode When the radio is operating in its normal environment, the radio's microcontroller controls the RF channel selection, transmitter key-up, and receiver muting, according to the customer codeplug configuration. 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. In RF Test Mode, the display upon the first line is “RF Test”, together with the power level icon at the right end of the first line. The display upon the second line is the test environment, the channel number and channel spacing. The default test environment is CSQ. 1. Each short press of Side Button 2 changes the test environment (CSQ->TPL->DIG->USQ ->CSQ). The radio beeps once when radio toggles to CSQ, beeps twice for TPL, beeps three times for DIG and beeps four times for USQ. NOTE DIG is digital mode and other test environments are analog mode as described in Table 3-3.

3-4

Transceiver Performance Testing Display Model Test Mode

Table 3-3. Test Environments

No. of Beeps

Description

Function

1

Carrier Squelch (CSQ)

RX: if carrier detected TX: mic audio

2

Tone Private-Line (TPL)

RX: unsquelch if carrier and tone detected TX: mic audio + tone

3

Digital Mode (DIG)

RX: if carrier detected TX: mic audio

4

Unsquelch (USQ)

RX: constant unsquelch TX: mic audio

2. Each short press of Side Button 1 toggles the channel spacing between 25 kHz, 12.5 kHz. The radio beeps once for 25 kHz and beeps twice for 12.5 kHz. 3. Turning of the Channel Knob changes the test channel from 1 to 14 as described in Table 3-4. The radio beeps in each position. Table 3-4. Test Frequencies

Channel Selector Switch Position

Test Channel

800/900 MHz Band

1 Low Power 9 High Power

TX#1 or #9 RX#1 or #9

806.125 851.025

2 Low Power 10 High Power

TX#2 or #10 RX#2 or #10

824.975 855.225

3 Low Power 11 High Power

TX#3 or #11 RX#3 or #11

851.125 860.525

4 Low Power 12 High Power

TX#4 or #12 RX#4 or #12

869.975 865.025

5 Low Power 13 High Power

TX#5 or #13 RX#5 or #13

896.125 869.925

6 Low Power 14 High Power

TX#6 or #14 RX#6 or #14

901.975 935.025

7 Low Power 15 High Power

TX#7 or #15 RX#7 or #15

935.125 938.025

8 Low Power 16 High Power

TX#8 or #16 RX#8 or #16

940.975 940.925

Transceiver Performance Testing Display Model Test Mode

3-5

Table 3-5. Transmitter Performance Checks

Test Name

Communications Analyzer

Radio

Test Set

Comments

Reference Frequency

Mode: PWR MON 4th channel test frequency* Monitor: Frequency error Input at RF In/Out

TEST MODE, Test Channel 4 carrier squelch

PTT to continuously transmit (during the performance check)

+/- 100 Hz for GPS models and non GPS models

Power RF

As above

As above

As above

Low Power: 1W (800/900) High Power: 2.5– 2.8W (800/900)

Voice Modulation

Mode: PWR MON 4th channel test frequency* 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

As above

As above, meter selector to mic

Deviation: ≥ 4.0 kHz but ≤ 5.0 kHz (25 kHz Ch Sp).

Voice Modulation (internal)

Mode: PWR MON 4th channel test frequency* atten to -70, input to RF In/Out

TEST MODE, Test Channel 4 carrier squelch output at antenna

Remove modulation input

Press PTT switch on radio. Say “four” loudly into the radio mic. Measure deviation: ≥ 4.0 kHz but ≤ 5.0 kHz (25 kHz Ch Sp)

TPL Modulation

As above 4th channel test frequency* BW to narrow

TEST MODE, Test Channel 4 TPL

As above

Deviation: ≥500Hz but ≤1000Hz (25 kHz Ch Sp).

* See Table 3-4

3-6

Transceiver Performance Testing Display Model Test Mode

Table 3-6. Receiver Performance Checks

Communications Analyzer

Radio

Reference Frequency

Mode: PWR MON 4th channel test frequency* Monitor: Frequency error Input at RF In/Out

TEST MODE, Test Channel 4 carrier squelch output at antenna

PTT to continuously transmit (during the performance check)

+/- 100 Hz for GPS models and non GPS models

Rated Audio

Mode: GEN Output level: 1.0mV RF 4th channel test frequency* Mod: 1kHz tone at 3kHz deviation Monitor: DVM: AC Volts

TEST MODE Test Channel 4 carrier squelch

PTT to OFF (center), meter selector to Audio PA

Set volume control to 2.83Vrms

Distortion

As above, except to distortion

As above

As above

Distortion