LBI-39175A
SERVICE SECTION
ORION™
136-174 MHz Dual Bandwidth
SYNTHESIZED TWO-WAY FM RADIO
TABLE OF CONTENTS
Page
DESCRIPTION ........................................................................................................................... 2
INITIAL MEASUREMENTS ..................................................................................................... 2
TRANSMITTER ........................................................................................................... 2
RECEIVER.................................................................................................................... 2
MAINTENANCE ........................................................................................................................ 3
PREVENTIVE MAINTENANCE ................................................................................ 3
DISASSEMBLY PROCEDURE................................................................................... 4
ALIGNMENT PROCEDURES................................................................................................... 7
INTRODUCTION......................................................................................................... 7
TRACKING DATA....................................................................................................... 9
TEST FREQUENCIES.................................................................................................. 9
SETTING TRACKING DATA.....................................................................................10
TRANSMITTER ALIGNMENT.................................................................................................11
PA TRANSISTOR REPLACEMENT...........................................................................11
RECEIVER ALIGNMENT .........................................................................................................12
TEST EQUIPMENT REQUIRED ................................................................................12
ADJUSTMENT PROCEDURES ..................................................................................12
SQUELCH ADJUSTMENT..........................................................................................13
TROUBLESHOOTING GUIDE .................................................................................................13
INTRODUCTION.........................................................................................................13
MICROPHONICS.........................................................................................................13
SERVICEABLE PARTS...............................................................................................14
DIAGNOSTIC PROCEDURES ..................................................................................................15
ADDITIONAL TOOLS REQUIRED............................................................................16
ERROR CODES............................................................................................................19
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LBI-39175A
MAINTENANCE
PREVENTIVE MAINTENANCE
NOTE
To ensure high operating efficiency, and to prevent mechanical and electrical failures from interrupting system
operations, routine checks should be made of all mechanical and electrical equipment at regular intervals. This
preventive maintenance should include the checks as listed in Table 1, Maintenance Checks.
Table 1 - Maintenance Checks
MAINTENANCE CHECKS
INTERVAL
CONNECTIONS - Ground connections and connections to the voltage source
should be periodically checked for tightness. Loose or poor connections to the
power source will cause excessive voltage drops and faulty operation. When
ground connections are not made directly to the battery, the connection from the
battery to vehicle chassis must be checked for low impedance. A high
impedance may cause excessive voltage drops and alternator noise problems.
Every
6
months
ELECTRICAL SYSTEM - Check the voltage regulator and alternator or
generator periodically to keep the electrical system within safe and economical
operating limits. Overvoltage is indicated when the battery loses water rapidly.
Usage of 1 or 2 ounces of water per cell per week is acceptable for batteries in
continuous operation. A weak battery will often cause excessive noise or faulty
operation.
As
Required
MECHANICAL INSPECTION - Since mobile units are subject to constant
shock and vibration, check for loose plugs, nuts, screws, and parts to make sure
that nothing is working loose. Be sure that all screws are properly torqued.
Every 6
months
ANTENNA INSPECTION - The antenna, antenna base, and all contacts should
be kept clean and free from dirt or corrosion. If the antenna or its base should
become coated or poorly grounded, loss of radiation and a weak signal will
result.
Every 6
months
ALIGNMENT - The transmitter and receiver measurements should be checked
periodically. Refer to the applicable Alignment Procedure and troubleshooting
sheet for typical voltage readings.
As
Required
FREQUENCY CHECK - Check transmitter frequency and deviation, as
required by the FCC. Normally, these checks are made when the unit is first put
into operation, after the first six months, and once a year thereafter.
As
Required
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LBI-39175A
DISASSEMBLY PROCEDURE
NOTE
The VCO/Synthesizer circuitry is exposed by
removing the screws from the shield casting, also
located on the bottom of the module. However,
this is not recommended, except on extreme
situations. If the shield is removed, it should be
replaced using the exact screw torque and
installation sequence given in LBI-38909.
To Remove the Unit from the Mounting Bracket
1. Remove Microphone, Power, and Accessory/Remote
Control Cables, as required.
2. Remove the lock screws at the side of the radio unit,
using a No. 20 TORX driver.
Control Unit (Front Mounted)
1. Expose the Logic/Audio/455 kHz IF circuitry
3. Pull the radio, and remove the mounting bracket.
according to Steps 1 and 2 in
Transceiver (TXRX)
section.
Module
2. Disconnect Flex Circuit PC2 from Connector J701,
by carefully disengaging the locking tab from each
side of the connector with a jeweler's screwdriver or
tweezers. Use extreme care to avoid damaging the
plating runs or surface-mounted components on the
printed wire board (PWB) during this procedure.
To Gain Access to the Circuitry for Servicing
RF Power Amplifier Module
1. Remove the waterproof cover on the bottom of the
module, using #20 TORX driver. Note that the four
mounting screws are captive.
3. Turn the radio upside down, and disengage the two
mounting screws, using a #10 TORX driver. Be
sure to engage the screws in the captivation threads
on the Transceiver chassis. Do this by pulling each
screw upwards with tweezers or needle nose pliers,
2. Remove the inner shield by pulling the attached
handle.
while
simultaneously
turning
the
screw
counterclockwise with the TORX driver. See LBI-
38909 for details.
Transceiver (TXRX) Module
1. Remove the waterproof top and bottom covers, using
4. Disengage the control unit from the Transceiver
chassis using a pivoting motion about the top edge of
the Transceiver chassis.
a #20 TORX driver. Four cover mounting screws
are located on the bottom of the module. The screws
on the bottom cover are captive.
5. Disengage the four captive screws on the rear cover,
2. To expose the Logic/Audio/455 kHz IF circuitry,
remove the shield on top of the module by pulling the
attached handle.
using a #10 TORX driver. Slide the rear cover off
the Front Panel Assembly, using care to avoid
damaging the black "O-Ring" moisture gasket
attached to the rear cover. Note that the Flex Circuit
PC2 slides through a slot opening on the rear cover.
3. To expose the Exciter/RX Front End circuitry,
remove the shield on the bottom of the module by
pulling the attached handle.
Control Head (Remote Mounting)
1.
Disconnect Remote Control and Accessory cables,
using a small flat bladed screwdriver.
2.
Remove the two side mounting screws from the
mounting bracket. Carefully remove the Control
Head assembly from the bracket.
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LBI-39175A
3.
4.
Disengage the four captive screws on the rear half
(also known as the Remote Interface Adapter, or
RIA) of the Control Head. Slide the two halves
apart, using care to avoid damaging the black "O-
Ring" moisture gasket attached to the RIA.
NOTE
For re-assembly of the Control Units (Front and
Remote Mounting) Revision "A" or later, be sure
the black "O-Ring" is lubricated properly with
"HIVAC-G" silicone grease. (See Figures 1A and
1B for intructions.)
Disconnect Flex Circuit PC2 from Connector J2, by
carefully disengaging the locking tab from each side
of the connector with a jeweler's screwdriver or
tweezers. Use extreme care to avoid damaging
plating runs or surface-mounted components in the
PWB during this procedure.
Steps:
1.
2
Remove dust and dirt from the black O-Ring gasket.
Apply proper amount of the silicone grease to cloth.
To Re-Assemble Unit after Servicing
3.
Put the silicone grease on throughout the surface of
the black O-Ring gasket evenly. (see Figures 1A and
1B)
Essentially follow the reverse of the preceding
instructions. However, in order to preserve moisture
seals, be sure to follow the EXACT torque and
sequencing specifications for screw engagement during re-
assembly. These specifications are given in LBI-38909.
CAUTION
No fibers of the cloth must remain on the gasket
after silicone is applied.
4.
Wipe out protruded silicone grease from the
Rear/RIA Cover.
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LBI-39175A
Figure 1A - Front Mount Control Unit "O-Ring" Lubrication
Figure 1B - Remote Mount Control Unit "O-Ring" Lubrication
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LBI-39175A
ALIGNMENT PROCEDURES
CAUTION
Before bench testing the radio, be sure of the output
voltage characteristics of your bench power supply.
INTRODUCTION
To protect the transmitter power output transistors
from possible instant destruction, the following input
voltages must not be exceeded
All operations of this radio are controlled by an
embedded digital computer, which is programmed with a
personality unique to the customer. In order to align and
test the radio, it must be programmed with a specific test
personality, which will allow conventional operation on
certain test frequencies. Furthermore, certain commands,
known as Test Mode Commands, cause the radio to
perform specific test functions. These will be noted as
required in the following alignment and troubleshooting
instructions.
Transmitter unkeyed:
Transmitter keyed
16.5 Volts
16.3 Volts
(50 ohms resistive load)
Transmitter keyed
14.0 Volts
(no load or non-resistive load):
These voltages are specified at the normal vehicle
battery terminals of the radio and take the voltage
drop of standard cables into account. The voltage
limits shown for a non-optimum load is for "worst
case" conditions. For antenna mismatches likely to
be encountered in practice, the actual limit will
approach the 16.3 Volt figure.
In order to program an ORION personality, the
radio and control unit must first be connected to a
Personal Computer via a PC Programming Cable and
hardware Programming Interface TQ3370 in one of the
configurations shown in Figures 2 and 3. Accessories
may be connected to the appropriate Accessory Cable
19B802554P1-P4 as needed.
Routine transmitter tests should be performed at EIA
Standard Test Voltages (13.6 VDC for loads of 6 to
16 amperes; 13.4 VDC for loads of 16 to 36
amperes). Input voltages must not exceed the limits
shown, even for transient peaks of short duration.
The PC must be equipped with the PC
Programming Software Version 4.0 or later. It is assumed
in this manual that the Service Technician is familiar with
the operation of the PC Programming Software Programs.
Consult the PC Programming Software manuals for
further details regarding this software.
Many commonly used bench power supplies cannot
meet these requirements for load regulation and
transient voltage suppression. Bench supplies which
employ "brute force" regulation and filtering (such as
Lapp Model 73) may be usable when operated in
parallel with a 12 Volt automotive storage battery.
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LBI-39175A
Figure 2 - ORION Programming Configurations (USA)
Figure 3 - ORION Programming Configurations (EURO)
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LBI-39175A
Furthermore, if the Tracking Data is lost, specialized
procedures are required to load new Tracking Data.
TRACKING DATA
therefore, it is
to establish a record
VERY IMPORTANT
of the Tracking Data of every radio as it is received from
the factory. The frequencies at which Tracking Data is
established are given in the "Test Frequencies" section.
The radio personality contains certain
information bytes known as Tracking Data, which allow
the radio computer to calibrate transmitter power,
modulation deviation, and squelch threshold. Normally,
no adjustments need be made to the radio to maintain
specified limits for the above parameters, since the radio
computer makes the necessary adjustments using the
Tracking Data established at the factory. However,
should Transmitter PA, Synthesizer, or Logic Circuit
boards be replaced, it may be necessary to alter the
Tracking Data to re-set these parameters properly.
TEST FREQUENCIES
The following frequencies are those for which
Tracking Data is established, and are used as Test
Frequencies:
Table 2 - Tracking Data Frequencies (Low Split)
RF Power Modulation
Parameter
Squelch Set
Deviation
136.0000
139.9950
140.0050
143.9950
144.0050
147.9950
148.0050
153.0000
f1L (MHz)
f1H (MHz)
f2L (MHz)
f2H (MHz)
f3L (MHz)
f3H (MHz)
f4L (MHz)
f4H (MHz)
136.0000
N/A
140.0050
N/A
144.0050
N/A
148.0050
153.0000
136.0000
N/A
140.0050
N/A
144.0050
N/A
148.0050
153.0000
Table 3 - Tracking Data Frequencies (High Split)
Parameter
RF Power
Modulation
Deviation
150.0000
155.4950
155.5050
161.4950
161.5050
167.4950
167.5050
174.0000
Squelch Set
f1L (MHz)
f1H (MHz)
f2L (MHz)
f2H (MHz)
f3L (MHz)
f3H (MHz)
f4L (MHz)
f4H (MHz)
150.0000
N/A
155.5050
N/A
161.5050
N/A
167.5050
174.0000
150.0000
N/A
155.5050
N/A
161.5050
N/A
167.5050
174.0000
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LBI-39175A
SETTING TRACKING DATA
Normally, Tracking Data is set at the factory, and need not be re-loaded. However, the following repair situations
require re-loading some or all of the Tracking Data:
SITUATION
Replace PA module
NEW TRACKING DATA
RF Power, Squelch (Check: Re-load if necessary.)
Replace TXRX module
RF Power, Modulation Deviation, Squelch, Feature
Encryption, and Data Offset
Replace Control Unit module
Replace Synthesizer PWB
Replace Logic PWB
None
Modulation Deviation and Data Offset
RF Power, Squelch, Modulation Deviation, Feature
Encryption, and Data Offset.
To re-load Tracking Data, connect the radio in
the appropriate configuration as shown in Figures 2 and 3,
and perform the following steps:
Parameter
Limit
TX Modulation Deviation
30 kHz channel spacing
12.5 kHz channel spacing
4.4 ±0.1 kHz
2.25 ±0.1 kHz
1. Using the PC Programming Software , make sure the
radio is programmed in the following sequence:
TX High Power 110 W Model
50 W Model
110 +4, -0 W
50 +2, -0 W
25 +0, -1 W
a. Customer Operational Software (if necessary)
25 W Model
b. Tracking Data (First Iteration -- Tracking Data
originally shipped with the radio is a good
starting point.)
TX Mid Power
25 W Model
15 +.5, -.5 W
TX Low Power 110 W Model
50 W Model
55 +2, -0 W
25 +1, -0 W
c. Feature Encryption File (if necessary). Note: In
order to load an Encryption File into a new
Logic PWB, After Market Services must first be
contacted at 1-800-368-3277 for authorization
code. Otherwise the file will not load.
25 W Model
6
+.5 -.5 W
RX Squelch Threshold
8 +1, -0 dB
SINAD
d. Personality, which contains
a
Conventional
System using the frequencies given in Tables 2
and 3.
3. If measurements are within the limits, the job is
complete. If the measurements are not within the
limits stated, re-connect the Programming
Maintenance Software "MRKMAINT." Display the
Tracking Data screen. For those frequencies where
measurements are not within the stated limits, enter
new Tracking Data, following instructions on the
screen. Program into the radio personality, and exit.
2. Connect the radio unit in the normal operating
configuration. Activate the radio unit, and, using a
Service Monitor HP8920A or equivalent, measure the
Transmitter Power, Modulation Deviation, and
Squelch Threshold for each of the applicable
frequencies given in Tables 2 and 3. Measurements
should be within the following limits:
4. Repeat Steps 2 and 3 until the measurements at every
frequency given in Tables 2 and 3 are within the
limits specified.
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LBI-39175A
TRANSMITTER ALIGNMENT
NOTICE
The components listed above have been set at the factory
and are NOT adjustable.
The Transmitter consists of synthesizer, exciter,
and power amplifier. These have been calibrated at the
factory so the radio computer automatically adjusts RF
power and modulation deviation, based upon Tracking
Data. The following adjustments can be made by EGE
PC Programming Software:
ANY RE-ADJUSTMENT OF THESE COMPONENTS WILL
VOID THE WARRANTY OF THIS PRODUCT.
1. Modulation Deviation -- Change Tracking Data using
"MRKMAINT" maintenance software. Follow the
procedure given in "TRACKING DATA" section.
Be sure to record the new Tracking Data and
modulation levels. DO NOT CHANGE TRACKING
DATA UNLESS THE LOGIC OR SYNTHESIZER
HAS BEEN REPLACED. DO NOT CHANGE
TRACKING DATA FOR ANY FREQUENCY
OTHER THAN THAT GIVEN IN TABLES 2 AND
3.
PA TRANSISTOR REPLACEMENT
WARNING
The RF Power Transistors used in the transmitter
contain Beryllium Oxide, a TOXIC substance. If
the ceramic or other encapsulation is opened,
crushed, broken, or abraded, the dust may be
hazardous if inhaled. Use care in replacing
transistors of this type.
2. RF Power -- Set RF power for system (EDACS) or
channel (CONVENTIONAL) in the radio personality,
using "EDACS3" programming software. DO NOT
CHANGE TRACKING DATA UNLESS THE PA
MODULE OR LOGIC PWB HAS BEEN
REPLACED. DO NOT CHANGE TRACKING
DATA FOR ANY FREQUENCY OTHER THAN
THAT GIVEN IN TABLES 2 AND 3.
To Replace the PA RF Transistors
1. Unsolder one lead at a time with a 50-watt soldering
iron. Use a scribe or X-acto knife to hold the lead
away from the printed circuit board until the solder
cools. Remove the mounting screws.
There are no other adjustments to be made on the
transmitter. However, there are components located on
the synthesizer and power amplifier, which appear to be
adjustable. These are summarized as follows:
2. Lift out the transistor. Remove any old solder from
the printed circuit board with a vacuum de-soldering
tool. Special care should be taken to prevent damage
to the printed circuit board runs because part of the
matching network is included in the base and
collector runs.
Synthesizer:
CV240, CV280, RV201
Power Amp - 25 W:
Power Amp - 50 and 110 W:
RV1
RV2
3. Trim the new transistor leads (if required) to the lead
length of the removed transistor.
4. Apply a coat of silicone grease to the transistor
These components have been set at the factory, and
mounting surface.
mounting hole. Align the leads as shown on the
Outline Diagram. Then replace the transistor
Place the transistor in the
are NOT ADJUSTABLE. ANY RE-ADJUSTMENT OF
THESE
COMPONENTS
WILL
VOID
THE
WARRANTY OF THIS PRODUCT.
mounting screws using moderate torque (9.4 kg.cm).
5. Solder the leads to the printed circuit pattern. Start
at the inner edge of the mounting hole and solder the
remaining length of transistor lead to the board. Take
care not to use excessive heat that causes the printed
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LBI-39175A
wire board runs to separate from the board. Check
for shorts and solder bridges before applying power.
NOTE
Before aligning the receiver or making any
adjustments to the radio, be sure that the outputs
of the 9 Volt Regulators IC230, IC503, and
IC481 are 9.0 ±0.2 VDC.
CAUTION
Failure to solder the transistor leads as directed
may result in the generation of RF loops that
could damage the transistor or may cause low
power output.
ADJUSTMENT PROCEDURES
Receiver Frequency Adjustment
No receiver frequency adjustment is required.
2nd Receiver Oscillator
RECEIVER ALIGNMENT
Alignment of the Front End and Local Injection
circuits are not required because band-pass filters are
employed in the ORION wide-band synthesized radio
receiver.
Using a frequency counter to monitor Terminal TP5,
set L521 for a frequency of 44.645 MHz ±200 Hz.
TEST EQUIPMENT REQUIRED
IF/FM Detector Alignment
•
•
•
Distortion Analyzer
AC Voltmeter
Apply a 1000 microvolt, on-frequency test signal
modulated by 1000 Hz with standard deviation to antenna
jack J1.
Connect a 4-ohm, 25-watt resistor in place of the
speaker. Connect the isolation transformer input across
the resistor. Connect the isolation transformer output to
the Distortion Analyzer (see Figure 4).
RF Signal Generator
•
•
•
Frequency Counter (136-174 MHz)
4-Ohm, 25 Watt Resistor
Adjust the VOLUME control for 15 watts output
(7.75 VRMS) using the Distortion Analyzer as a
voltmeter.
Audio Isolation Transformer (1:1)
19A116736P1 or equivalent **
Set the output signal level of the RF signal generator
so as to obtain 12 dB SINAD at the audio output.
These four items can be replaced with a Service
Monitor HP8920A or its equivalent.
** See Figure 4. This is not needed if instrument
input is unbalanced with respect to ground.
Adjust coils L502, L504, L505, and L507 to obtain
minimum 12 dB SINAD.
Set the output signal level of the RF generator to
1000 microvolts.
Adjust L523 for maximum audio output.
Adjust RV501 for XTONEDEC output at ORCC to
500 mVRMS.
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LBI-39175A
ISOLATION
TRANSFORMER
Not required if instrument
input is balanced with respect
to ground.
DISTORTION
ANALYZER
OR
4-OHM
LOAD
AC VOLTMETER
1 : 1
Figure 4 - Audio Isolation Transformer
SQUELCH ADJUSTMENT
MICROPHONICS
Squelch threshold has been set at the factory to 8 dB
SINAD. Adjustment of the threshold requires changing
the Tracking Data. To change the Squelch Tracking Data,
follow the iterative procedure set forth in the
"TRACKING DATA" section, except let the desired
squelch threshold level replace the 8 +1, -0 dB SINAD
level set at the factory. BE SURE TO CHANGE THE
TRACKING DATA FOR ALL FREQUENCIES GIVEN
IN TABLES 2 AND 3. Otherwise the level will not be
consistent across the frequency band.
Synthesized radios tend to be sensitive to shock and
vibration, creating microphonics. The construction of the
ORION radio with its die-cast aluminum frame, cast
shield, and multiple board-mounting screws, provides a
high degree of immunity. When removing printed circuit
boards or shields, note the location of all mounting
hardware.
When servicing the radio be sure that no solder build-
up has occurred on the chassis or shield.
To assure a high degree of resistance to microphonics
be sure to replace exactly, all hardware removed. Be sure
that all mounting screws are properly torqued and shields
are in place. Refer to the Mechanical Layout Diagram
found in LBI-38909.
TROUBLESHOOTING GUIDE
INTRODUCTION
NOTE
Loose or rubbing parts, especially in the VCO
area, are particularly sensitive and can cause
microphonics. Again, be certain all hardware is
properly installed and torqued.
This radio is designed to be serviced by replacement
of modules and/or circuit boards. As such, there are very
few serviceable component parts contained on any of the
circuit boards within the radio. Normally, defective
boards should be replaced, and returned to an Authorized
Service Center. A list of serviceable parts is given in the
next section.
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LBI-39175A
Radio Unit - Power Amplifier 110 Watts
CAH-515H
SERVICEABLE PARTS
Control Unit - Switch Circuit CDF-368B/M
C25
C25
C26
C26
C27
C28
C33
C33
HC1
HC1
TR2
TR3
Capacitor, 270 pF (136-153 MHz)
Capacitor, 220 pF (150-174 MHz)
Capacitor, 270 pF (136-153 MHz)
Capacitor, 200 pF (150-174 MHz)
Capacitor, 200 pF (150-174 MHz)
Capacitor, 220 pF (150-174 MHz)
Capacitor, Mica, 47 pF
B19/5CAAA05042
B19/5CAAA03175
B19/5CAAA05042
B19/5CAAA05122
B19/5CAAA05122
B19/5CAAA03175
B19/5CMAB01252
B19/5CMAB01252
B19/5DHAA00049
B19/5DHAA00050
B19/5TCAF00510
B19/5TCAF00510
No serviceable parts.
Capacitor, Mica, 47 pF
Power Module (136-153 MHz)
Power Module (150-174 MHz)
Transistor, NPN
Control Unit - Panel Control CMC-638
Transistor, NPN
No serviceable parts.
Radio Unit - Power Amplifier 55 Watts CAH-515L
Remote Control Unit - RIA NQZ-4882
C8
C8
C9
Capacitor, 270 pF (136-153 MHz)
Capacitor, 220 pF (150-174 MHz)
Capacitor, 270 pF (136-153 MHz)
Capacitor, 220 pF (150-174 MHz)
Capacitor, Mica, 47 pF
Power Module, (136-153 MHz)
Power Module, (150-174 MHz)
Transistor, NPN
B19/5CAAA05042
B19/5CAAA03175
B19/5CAAA05042
B19/5CAAA03175
B19/5CMAB01252
B19/5DHAA00051
B19/5DHAA00052
B19/5TCAF00510
J2
Connector, 18 Pin
B19/5JBAX00020
C9
C159
HC1
HC1
TR1
Radio Unit - System Control CMC-682
F601
IC604
J701
Fuse, 5 Amp
AF Power Amplifier
Connector, 18 Pin
B19/5ZFAP00008
B19/5DAAA00350
B19/5JDAG00315
Radio Unit - Power Amplifier 25 Watts CAH-515E
Radio Unit - IF CMF-135
HC1
HC1
Power Module, (136-153 MHz)
Power Module, (150-174 MHz)
B19/5DHAA00049
B19/5DHAA00050
No serviceable parts.
Radio Unit - Synthesizer/Receiver/Exciter
CMN-352
No serviceable parts.
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LBI-39175A
possible to combine this test configuration with the PC
Programming configuration shown in Figures 2 and 3.
This usually results in increased efficiency, since the
service technician can alternate between programming and
hardware testing, as the need arises.
DIAGNOSTIC PROCEDURES
This product can be easily measured for maintenance
using a Communications Service Monitor, of which
several models are available. A typical test configuration
for the ORION product is shown in Figure 5. It is also
Figure 5 - Typical ORION Test Configuration
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LBI-39175A
ADDITIONAL TOOLS REQUIRED
•
RF Power Attenuator (30 dB, 150 watt, for transmitters with RF power beyond the capabilities of a Service
Monitor)
•
•
Digital Voltmeter
Oscilloscope (optional)
TRANSMITTER
DIAGNOSTIC PROCEDURE
SYMPTOM
No RF power output.
a. Program a Conventional System with frequencies given in Tables 2 and 3.
Use "EDACS3" PC Programming utility.
b. Check the RF Power Tracking Data, using "MRKMAINT" PC
Programming utility. The Data should be the same as that shipped with the
radio from the factory. I it has failed, re-enter the Tracking Data using the
procedure set forth in the "TRACKING DATA" section.
c. Check TP1 on the Power Amplifier PWB for A+. If it has failed, check the
power cable fuse.
d. Key the radio and measure the DC voltage at TP4 (9 VDC typical, when
keyed). If it has failed, trace TXENABLE signal back to Logic PWB.
e. Unscrew the PA module from the rest of the radio unit. Remove P1 from
J151, and connect an RF wattmeter to J151. Be sure to AC couple J151 to
the wattmeter. Key the radio and measure the exciter power at J151.
Power should be 400-700 mW. If it has failed, replace the Synthesizer
PWB, and reload the Modulation Tracking Data. If this passes, replace the
PA PWB.
Frequency too low/high.
Low or no modulation.
Adjust XU201 on the Synthesizer PWB. If the frequency is still out of
specification, replace the Synthesizer PWB.
a. Program a Conventional System with frequencies given in Tables 2 and 3.
Use "EDACS3" PC Programming utility.
b. Check the Modulation Tracking Data, using "MRKMAINT" PC
Programming utility. Data should be the same as that shipped with the radio
from the factory. If this has failed, re-enter the Tracking Data using the
procedure set forth in the "TRACKING DATA" section.
c. Apply a 1000 mVRMS, 1 kHz audio signal to the MIC connector Pin 1
(Pin 2 is ground reference). Key the radio (make sure the antenna
connector is connected to the proper 50 ohm load). Check for an audio
signal at TP202 on the Synthesizer PWB. If this has failed, replace the
Logic PWB. Be sure to perform the complete re-programming on the new
Logic PWB, If this passes, replace the Synthesizer PWB, and re-load the
Modulation Tracking Data.
16
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LBI-39175A
RECEIVER
DIAGNOSTIC PROCEDURE
SYMPTOM
Low RF sensitivity.
a. Program a Conventional System with frequencies given in Tables 2 and 3.
Use "EDACS3" PC Programming utility.
b. Unscrew the PA module from the TXRX module. Disconnect the coaxial
cable P2 from J401 on the Synthesizer PWB. Do not disconnect any other
cable.
c. Set the frequency of the RF signal generator to the middle of the split.
Apply a standard RF signal to J401, and measure 12 dB SINAD sensitivity.
Sensitivity should be better than 0.29 µV. If this passes, replace the PA
PWB.
d. If this fails, re-align the receiver, as instructed in the "ALIGNMENT"
section, and re-check the sensitivity at J401
e. If this passes, re-assemble with the PA module and re-check the sensitivity
at the antenna connector. If this passes, the job is complete
f. If the above fails, substitute a known good Synthesizer PWB, and re-check
the sensitivity. If this fails, replace the Logic PWB. Be sure to perform the
complete re-programming on the new Logic PWB. If this passes, replace
the synthesizer PWB, and re-load the Modulation Tracking Data.
High audio distortion
a. Program a Conventional System with frequencies given in Tables 2 and 3.
Use "EDACS3" PC Programming utility.
b. Apply a standard 1000 µV RF signal [with 1 kHz audio modulation at 3
kHz deviation (1.5 kHz for 12.5 kHz channel spacing)] at one of the
programmed RF frequencies in the center of the split to J1001. Set the
volume control to produce 15 watts at the 4-ohm speaker load
c. Measure the audio distortion at the "VOL HI" output (J1003 Pin 13
referenced to Pin 12). If this passes (3% THD), replace IC604 Audio
Power Amplifier on the Logic PWB.
d. If this fails, re-align the receiver per alignment procedure. Re-check the
distortion at the speaker load or "VOL HI."
e. If this fails, replace the Logic PWB. If this passes, the job is finished.
17
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LBI-39175A
CONTROL UNIT
DIAGNOSTIC PROCEDURE
SYMPTOM
Radio dead at power-on
(display dark and no
lighted indicators)
a. Check the battery connections and the Red lead A+ fuse on the power
cable.
b. Turn the unit "OFF," then simultaneously press and hold the
"EMERGENCY" and "OPTION" buttons, while turning the unit "ON."
All indicator lights and all display dots should light. Release the buttons
and the display should show the following message:
- 1993
EGE
or
- 1994
EGE
This indicates the Control Unit is functioning correctly. If this passes,
check programming and feature encryption, using "EDACS3" PC
Programming utility.
c. If this fails, measure A+ voltage at MIC connector Pin 6 (referenced to
ground at Pin 7). If this fails, check fuse F601 on the Logic PWB for A+
on each side of the part. Replace the PWB if it is open circuited.
d. If the fuse is OK, check the connection of the Flex Circuit PC2 with J701
on the Logic PWB. If this fails, reconnect PC2, making sure the side tabs
are locked. Re-check the MIC connector Pin 6 for A+.
e. If this passes, check the programming and feature encryption, using
"EDACS3" PC Programming utility. If this symptom persists, substitute a
known good Logic PWB, and re-program.
f. If no A+ is present at MIC Pin 7, check for A+ on the Logic PWB J704 Pin
3. If this fails, check the J704/J1004 connection. If this fails, replace the
PA module. If this passes, replace the Logic PWB.
The Display lights, then
goes dead.
a. Turn the unit "OFF," then simultaneously press and hold the
"EMERGENCY" and "OPTION" buttons, while turning the unit "ON."
All the indicator lights and all display dots should light. Release the buttons
and the display should show the following message:
- 1993
EGE
or
- 1994
EGE
This indicates the Control Unit is functioning correctly. If this passes,
check programming and feature encryption, using "EDACS3" PC
Programming utility.
b. If this passes, check the connection of the Flex Circuit PC2 with J701 on
the Logic PWB. If this passes re-connect it making sure the side tabs are
locked.
18
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LBI-39175A
GENERAL
DIAGNOSTIC PROCEDURE
SYMPTOM
Any hardware malfunction
PWB substitution is a valid technique for service and repair of the ORION
product, since there are only a few circuit boards in the product:
1. RF Power Amplifier
2. Logic/IF/Audio
3. Synthesizer/Exciter/RX Front End
4. Control Unit Panel Control
5. Control Unit Switching
6. Control Unit RIA (Remote Only)
7. DSP (AEGIS Only)
The service shop should be equipped with a set of the above PWB's which can
be used for substitution. Defective PWB's can be isolated simply by substituting
one at a time. It is recommended that the Logic PWB used for substitution be
pre-programmed with a conventional system and frequency set given in Tables
2 and 3.
All System Groups ORION
ERROR CODES
System Errors
Fatal system errors will cause the radio to display an
error message/code and then reset the radio to its starting
operation. The reset condition will remain until the fatal
error(s) is corrected.
This section lists all the ORION radio errors and
warnings. Each error code in the list includes an
explanation of what went wrong and what action to take to
correct the problem. The error codes are divided into three
different categories:
1. Fatal Operational Error Codes - These are errors that
are displayed during the radio normal operation or on
the radio power-up (Fatal System Errors). These
errors will cause the radio to reset.
Non-Fatal errors are displayed for a short period
(about 2 seconds) then normal radio operation will
resume.
The errors are displayed on the radio as shown in
Figure 6.
2. Non-Fatal Operational Error Codes - These are errors
that are displayed during the radio normal operation
or on the radio power-up. The radio will not reset.
3. Radio Programming Errors - These are errors that are
displayed on the radio or the programming PC
display during radio programming.
19
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LBI-39175A
message
ERR = xxxx
where xxx is the error code and the message is
one of the messages listed below
Figure 6 - Error Message/Code Display
FATAL ERRORS
NON-FATAL ERRORS
ERROR MESSAGE
DESCRIPTION
ERROR MESSAGE
DESCRIPTION
HARDWARE
SOFTWARE
TRACKING
NO LOCK
FREQDATA
PERSDATA
ROM errors
UNKNOWN
FEAT ERR
DSP ERR
General software failure
Tracking data fatal error
Synthesizer not locking
Frequency data fatal error
Personality errors
Feature encryption error
DSP error
20
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LBI-39175A
ROM Fatal Systems Errors
ROM fatal errors may be corrected by cycling the radio power (turn it off then on). When the power cycle does not
correct the problem the radio must be serviced.
ERROR NAME
MESSAGE
CODE
DESCRIPTION
FATAL_SYS_TRAP
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
HARDWARE
0
1
2
3
4
Fatal system error trap number.
NMI occurred outside of sleep.
8K RAM test error.
32K ROM checksum test error.
Flash checksum test error.
ASIC driver failed initialization.
ICP driver failed initialization.
ASP driver failed initialization.
FATAL_NMI_ERROR
FATAL_RAM_ERROR
FATAL_ROM_CHKSUM
FATAL_FLSH_CHKSUM
FATAL_ASIC_LOAD
FATAL_ICP_LOAD
10
11
12
13
14
15
16
17
18
19
20
21
30
31
40
41
50
60
70
80
90
91
92
FATAL_ASP_LOAD
FATAL_EE_LOAD
EEPROM driver failed initialization.
ICP digital I/O initialization failed.
Standard input/output driver failed initialization.
Standard input driver failed initialization.
RADIO driver failed initialization.
MODEM driver failed initialization.
External I/O driver failed initialization.
Serial communication interface driver failed initialization.
ICP prom checksum.
ADI did not respond to command.
ADI Rx circular queue underflowed.
LCD did not acknowledge message.
LCD hardware is invalid.
Serial communication interface out of heap (RAM memory) space.
ICP did not acknowledge message.
ICP failed in a fork.
Radio driver could not write to ASP.
Software memory error - ROM task.
Software memory error - Boot loader.
Boot loader could not attach to SCI.
FATAL_ICP_PORTNIT
FATAL_INTOUT_LOAD
FATAL_INTIN_LOAD
FATAL_RADIO_LOAD
FATAL_MODEM_LOAD
FATAL_EXTIO_LOAD
FATAL_SCI_LOAD
FATAL _ICP_CHKSUM
FATAL_ADI_NOACK
FATAL_ADI_QUNDERFLOW
FATAL_LCD_NOACK
FATAL_LCD_HARD_FAIL
FATAL_SCI_NOHEAP
FATAL_ICP_NOACK
FATAL_EXTIO_ICPFAIL
FATAL_RADIO_ASPWRT
FATAL_ROM_NOHEAP
FATAL_BL_NOHEAP
FATAL_BL_SCI_ATACH
Operational Software Non-Fatal System Errors
ERROR NAME
MESSAGE
CODE
DESCRIPTION
PIFEAT_SNR_ERROR
PIFEAT_READ_ERROR
PIFEAT_CRC_ERROR
RI_DSPDOWN_NOATTEMPT
AEGIS_ADIDOWN_
FEAT ERR
FEAT ERR
FEAT ERR
DSP ERR
550
551
552
850
851
Feature encryption - Can not read radio ROM serial number.
Personality feature encryption read failure or data not available.
Decryption failure. Personality feature encryption CRC failure.
DSP not found
DSP ERR
DSP file not found.
NOTFOUND
AEGIS_ADIDOWN_CRCFAIL
AEGIS_ADIDOWN_ENCERR
AEGIS_ADIDOWN_PMFAIL
DSP ERR
DSP ERR
DSP ERR
852
853
854
DSP file not found.
Radio feature encryption does not match DSP file.
DSP file is corrupted or hardware failure. RE-program radio or power cycle the
radio.
AEGIS_ADIDOWN_DMFAIL
AEGIS_ADIDOWN_BIOSERR
AEGIS_KEYLOAD_
NOBANKS
DSP ERE
DSP ERR
DSP ERR
855
856
860
DSP file is corrupted or hardware failure. Re-program radio or power cycle radio.
Hardware failure.
Personality did not assign banks for the keys.
AEGIS_PVT_NONE
FEAT ERR
870
Private is not feature encrypted.
21
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LBI-39175A
Operational Software Fatal System Errors
ERROR NAME
RADC_PITD_ERROR
RADC_PIHW_ERROR
RADC_FREQ_ERROR
RADC_PITD_MALLOC_ERROR
RADC_PITD_CKSUM_ERROR
DACS_NO_LOCK
MESSAGE
CODE
DESCRIPTION
TRACKING
PERSDATA
FREQDATA
SOFTWARE
SOFTWARE
NO LOCK
200
201
202
203
204
300
Personality tracking data error. Re-program the tracking data.
Personality hardware data error. Re-program the personality.
Personality frequency data error. Re-program the personality.
Personality tracking data malloc error. Re-program the tracking data.
Personality tracking data checksum error. Re-program the tracking data.
Synthesizer did not lock or became unlocked. Check the frequencies in the PC
programmer and re-program the radio personality.
Unable to correctly configure the modem for EDACS operation. Re-program
the personality.
DACS_MODEM_FATAL_ERROR
SOFTWARE
301
DACS_RADC_FAILURE
DACS_MODEM_RXOVR
DACS_MODEM_RXAVR
CONV_RADC_ERROR
CONV_NOLOCK_ERROR
SOFTWARE
SOFTWARE
SOFTWARE
SOFTWARE
NO LOCK
302
304
305
400
401
Power cycle the radio.
Hardware Modem overflow. Power cycle the radio.
Power cycle the radio.
Error calling RADC function. Power cycle the radio.
Synthesizer became unlocked. check the frequencies in the PC programmer
and re-program the radio personality.
CONV_PUT_UIMSG_ERROR
CONV_MODEM_RXOVR
CONV_MODEM_RXAVR
CONV_MODEM_FATAL_ERROR
CONV_PERS_ERROR
PI_NOPERS_ERROR
PI_CRC_ERROR
PI_DESC_CRC_ERROR
PI_MALLOC_ERROR
SOFTWARE
SOFTWARE
SOFTWARE
SOFTWARE
PERSDATA
PERSDATA
PERSDATA
PERSDATA
SOFTWARE
PERSDATA
SOFTWARE
402
403
404
405
407
500
501
502
503
600
601
UI message buffer not enabled. Power cycle the radio.
Conventional DIGV modem overflow.
Conventional DIGV modem underflow.
Unable to correctly configure the modem for conventional DIGV operation.
Conventional personality error.
Personality data is not present. Program the personality.
Flash personality CRC did not match EEPROM. Re-program the personality.
Crucial personality data has incorrect CRC. Re-program the personality.
Could not allocate memory to store crucial personality data.
Input/Output device error.
UI_FATAL_DEVICE_ERROR
UI_FATAL_SWTO_
Software memory error.
MALLOC_ERROR
UI_FATAL_SWTO_MAX_ERROR
UI_FATAL_WINDOW_MAX_
ERROR
SOFTWARE
SOFTWARE
602
603
Software error, power cycle the radio.
Too many open windows.
UI_FATAL_WINDOW_MALLOC_
ERROR
UI_FATAL_MESSAGE_INVPARM
SOFTWARE
SOFTWARE
SOFTWARE
604
605
606
Software memory error.
Invalid parameter to UI_PUT_MESSAGE(). software error, report how error
was encountered.
UI Task message buffer full error. Software error, report how error was
encountered.
UI_FATAL_RI_MSGBUF_FULL
UI_FATAL_RISYS_MSGBUF_FULL
UI_FATAL_CI_MSGBUF_FULL
UI_FATAL_DEVICE_
SOFTWARE
SOFTWARE
PERSDATA
607
608
609
Radio Interface System (EDACS/CONV) task message buffer full.
CI Task message buffer full.
I/O device type (from personality) not supported.
NOTSUPPORTED
UI_FATAL_AUXIO_MALLOC_
ERROR
SOFTWARE
610
Software memory error.
UI_FATAL_NET_DEVICE_ERROR
UI_FATAL_INVALID_CUID
SOFTWARE
SOFTWARE
611
612
Network I/O device error
CU ID is invalid or CU not connected. Insure that CU ID is CUA and DUAL
is disabled in personality.
UI_FATAL_NO_TONE_DATA
UI_FATAL_UII0_MSGBUF_FULL
AEGIS_ADI_OVERFLOW
AEGIS_RXBUF_MALLOC_ERROR
AEGIS_KEYLOAD_MALLOC_
ERROR
SOFTWARE
SOFTWARE
SOFTWARE
SOFTWARE
SOFTWARE
613
614
801
802
803
No tone data is available in personality.
UI I/0 BBOS message buffer full.
ADI Transmit event not serviced in time and buffer has overflown.
No memory available.
No Keyloader table memory available.
AEGIS_KEYLOAD_ERROR
AEGIS_DATAMEM_MALLOC_
ERROR
SOFTWARE
SOFTWARE
804
805
General Keyload error has occurred.
No memory is allocated for data.
AEGIS_KEYLOAD_NOTABL
SOFTWARE
806
No key table was found in EEPROM.
22
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LBI-39175A
Radio Programming Errors
Programming errors are divided into three categories:
1. Protocol Errors - These are errors produced by the low level communication routines.
2. Radio Errors - These are errors that are returned from the radio ROM or operating software.
3. PC Errors - These are errors that are produced by the PC Programming software.
MESSAGE
CODE
DESCRIPTION
Successful
0
5
6
7
8
Command was performed successfully.
Protocol - Canceled by receiver
Protocol - Canceled by sender
Protocol - Terminate transmission
Protocol - Transmit error
x328 protocol received a cancel. The radio detected a cancel command.
x 328 protocol transmitted cancel. The radio is canceling the read command.
x328 protocol received an end of transmission.
x328 protocol could not transmit. Reliable communication cannot be established. It could be
the radio or PC hardware problems (programming cable, interface box, or radio hardware).
x328 protocol not initialized or failed to initialize.
Radio responded with a success. Radio acknowledged successful programming.
Radio could not configure its comport (hardware failure).
Radio failed to erase the flash memory. The radio flash memory part is unusable or it cannot
detect the 12 volts power. Check the programming box and cables.
Radio failed in writing to the flash memory. Retry the programming process (hardware
failure).
Protocol - Protocol initialization error
Radio - Programmed successfully
Radio - Comport configuration failed
Radio - Flash erase failed
9
10
11
12
Radio - Flash write failed
13
14
Radio - Flash code CRC did not match
Flash code not programmed correctly. CRC did not match. The operating software will not
execute. Re-program the radio.
Radio - Canceled by receiver
Radio - Canceled by sender
Radio - End of transmission received
Radio - Transmit error
15
16
17
18
The radio operating software received a cancel command.
The radio software received or sent an end of transmission.
Radio could not transmit the required data. Check all hardware connections and try
programming again.
Radio - Invalid command
Radio - No application code
19
20
Radio did not understand the received command.
No application code is loaded, the radio cannot accept personality commands. Re-program the
operating software (flash code) and re-program the personality.
The radio application code failed to perform the command.
Could not program the radio EEPROM part.
The radio acknowledged a successful baud communication baud rate change.
The PC programming software could not allocate adequate memory space to perform the
function.
Radio - Application code error
Radio - EEPROM programming error
Radio - Baud rate has changed
PC - Cannot allocate memory
21
22
23
50
PC - Cannot open data file
51
The specified file (code or personality) could not be opened (file does not exist or has access
protection).
PC - Cannot read data file
PC - Cannot write to file
PC - File not found
52
53
54
55
The specified file (code or personality) could not be read.
The specified file (code or personality) could not be written.
The specified file (code or personality) is not found in the current directory.
The radio flash part size is unknown or the operating software file size is larger than the radio's
flash memory size.
PC - File is larger than radio memory
PC - Incorrect Tracking Data RF band
split
57
Incorrect Tracking Data RF band split.
PC - Incorrect Tracking Data version
PC - Tracking Data checksum error
PC- Time-out, radio not responding
PC - Comport configuration error
PC - Abort, message canceled
PC - Requested personality data does
not exist
58
59
60
61
62
63
Incorrect Tracking Data version.
Tracking Data checksum error.
Radio is not connected or not turned on or the selected PC comport number is invalid.
Comport configuration error, cannot set comport.
Aborted by operator, message canceled.
The personality table does not exist (Tracking or Encryption table).
23
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Ericsson Inc.
Private Radio Systems
Mountain View Road
Lynchburg, Virginia 24502
1-800-592-7711 (Outside USA, 804-592-7711)
Printed in U.S.A.
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