Motorola Astro Digitalport Saber Troubleshooting 68p81076c10 A Manual

							 
10-11 
Chart 17 . 09/10, Secure Hardware Failure
Repair opens.
Fail 09/10
Secure Hardware
Failure
Verify connections
to secure module
through J801.
Connections
good?
No
Yes
Synopsis
This failure relates only to
secure equipped radios and
indicates a power up self-test
failure for the secure module.
More specifically this failure
indicates a failure in
communications between the
Host µC and secure module.
The secure module is not
considered field repairable so
troubleshooting is limited to
verifying a problem with the
module and replacing.  Typical
failure modes would be:
1) Open between secure module
and vocon board at J801.
2) The host µC communicates
with the secure module via the
SPI bus (Refer to Fig. S1).  A
failure of this bus.
3) Failure to get proper
supplies and grounds to J801.
Replace module
with known
good one and
retest.
Is known
good module
available?
No Yes
Radio
functions
with known
good 
module?
Replace secure
module.Yes
Use ohmmeter to electrically
verify following signal
connections to source IC:
Signal @ J801 Source
MOSI,MISO,SPI_SCK U204
EMC_WAKEUP* U206
EMC_EN* U206
EMC_REQ U206
Pins 6,21,22 GND
Verify bias of following signals
Signal@J801 Nominal Bias
UNSW_B+     7.5VDC±1.0VDC
SW_B+         7.5VDC±1.0VDC
GND GND
No
Connections
good?
Repair
connections.
YesNo
Verify electrical activity at the
following signals at power up:
Signal @ J801 Source
MOSI,MISO,SPI_SCK U204
EMC_WAKEUP* U206
EMC_EN* U206
EMC_REQ U206
Signals
good? NoYes
MAEPF-24411-A
Replace secure
module.
Replace
respective
source IC or
VOCON board.
 
Chart 18 . 09/90, Secure Hardware Failure
Signals
good? NoYes
Replace secure
module.
Replace
respective
source IC or
VOCON board.
Repair opens.
Fail 09/90
Secure Hardware
Failure
Verify connections
to secure module
through J801.
Connections
good?
No
Yes
Synopsis
This failure relates only to
secure equipped radios and
indicates a power up self-test
failure for the secure module.
More specifically this failure
indicates a failure in
communications between the
DSP and secure module.  The
secure module is not considered
field repairable so
troubleshooting is limited to
verifying a problem with the
module and replacing.  Typical
failure modes would be:
1) Open between secure module
and vocon board at J801.
2) The DSP communicates with
the secure module via the
SCI/SSI bus (Refer to Fig. S1).
A failure of this bus.
3) Failure to get proper
supplies and grounds to J801.
Replace module
with known
good one and
retest.
Is known
good module
available?
No Yes
Radio
functions
with known
good
module?
Replace secure
module.Yes
Use ohmmeter to electrically
verify following signal
connections to source IC:
Signal @ J801 Source
EMC_RXD U405
EMC_TXD U405
Pins 6,21,22 GND
Verify bias of following signals
Signal@J801 Nominal Bias
UNSW_B+     7.5VDC±1.0VDC
SW_B+         7.5VDC±1.0VDC
GND GND
No
Connections
good?
Repair
connections.
YesMAEPF-24412-A
No
Verify electrical activity at the
following signals at power up:
Signal @ J801 Source
EMC_RXD U405 
						

							 
10-12 
Chart 19 . Key Load Fail
Replace U206.
Repair
connection.
Verify and repair
connection of
OPT_SEL2/KEYLOAD*
from KVL to Universal
connector to J206.
Verify the use of the correct keyloader per the following table:
Secure Module Kit(s) KVL Kit(s) Encryption
NTN7770 T3010DX DVP
NTN7771 T3011DX DES/DES-XL
NTN7772 T3011DX DES/DES-XL
NTN7773 T3012DX DVI-XL
NTN7774 T3014DX DVP-XL
NTN7329 T3012DX & T3010DX DVI-XL & DVP
NTN7332 T3011DX & T3010DX DES-XL & DVP
NTN7331 T3011DX & T3014DX DES-XL & DVP-XL
NTN7330 T3014DX & T3010DX DVP-XL & DVP
NTN7370  T3014DX & T3012DX DVP-XL & DVI-XL
NTN8967 All except DVPKVL3000
Verify the use of the correct KVL cable as a TKN8506.
With KVL attached to
radio and radio on,
verify display
message KEYLOAD
Obtain correct
KVL and cable.
Keyload
Failure
No
Synopsis
This failure relates only to
secure equipped radios and
indicates a failure to load key
with the KVL indicated by the
message x FAIL and key fail
tone.  Typical failure modes
would be:
1) Open between Pin 10 of the
universal connector  C which
places radio in Keyload mode.
2) Use of wrong KVL or KVL
cable for ASTRO Digital Saber
radio.
3) Failure of secure module.
KEYLOAD
message
displayed?Correct
equipment?
Yes
No
With KVL attached to
radio and radio on,
inititate a keyload by
pressing P-T-T on the
keyloader and look for
activity on J801-15.
Activity? Yes
Verify connection of
RTSIN*/KEYFAIL*
from the universal
connector pin 9
and from J206 to
J801-15.
Verify
connection
across J801.
Good
connection?
Good
connection?Repair
connection.Replace
secure module.
Yes No
No YesYes
No
MAEPF-27147-O
 
Chart 20 . Button Test
Refer to
appropriate
troubleshooting
chart.
                 Button Table
Button Code
Chart
C.24
C.24
C.24
C.24
C.24
C.24
C.23
C.22 PTT 1/  0-1
Top Button 3/  0-1
Top Side Button 96/  0-1
Side Button 1 97/  0-1
Side Button 2 98/  0-1
A/B Switch 65/  A=0, B=1
Zone/Channel Select 4/  0-15
Volume Control Knob 2/  0-255
Synopsis
This chart relates to a failure
in the button functions. Basic
Failure modes are as follows:
1) Failure in  control top/ptt or
    Spkr/mic flex circuit.
2) Bad connection.
3) Defective switches or pads.
4) Defective A/D port in host
    µC.
Button
Test
Place radio in Test
Mode.  Press Top
Side Button so
display reads CH.
This places radio in
button test mode.
Verify key codes
displayed per Button
Table.
Keys
correct?
No Yes
End
1 2ABC 3DEF
4GHI 5JKL
6MNO
7PRS 8TUV 9XYZ*
0
#
HOME
131/1 132/1 133/1
128/1 129/1 130/1
49/1 50/1 51/1
52/1 53/1 54/1
55/1 56/1 57/1
58/1 48/1 59/1Keypad TableSee Chart C.21
MAEPF-24397-O 
						

							 
10-13 
Chart 21 . Keypad Error
PJ6 PJ1 PJ0
PL7
PL6
PL5
PL4
PL3
PL2
1
2ABC 3DEF
4GHI 5JKL 6MNO
7PRS8TUV
9XYZ*
0
#
HOME
R0W1
R0W2
ROW3
ROW4
ROW5
ROW6COL1 COL2 COL3 U206
Verify keypad
model with RSS.
If model checks
good replace
U206.
Synopsis
This chart relates to a failure
in reading the keypad.  Basic
Failure modes are as follows:
1) Failure in flex circuit.
2) Bad connection.
3) Defective keypad.
4) Defective port in SLIC.
Keypad
Error.
Verify operation of
keypad per Button
Check flow chart C.20.
Signals
check good
at U206?
No
MAEPF-24398-O
By studying the
adjacent chart against
the keys which have
errors, one signal maybe determined to be in
error or verify logic
levels at U206
PJ0,PJ1,PJ6, and
PL2-PL7 for each
channel noting that the
key pressed provides a
logic low at on COLx
and one ROWx.
YesReplace keypad module
if J701 checks good.
 
Chart 22 . Volume Set Error
Synopsis
This chart relates to a failure
in volume set knob. Basic
Failure modes are as follows:
1) Failure in  control top/ptt
flex circuit.
2) Bad connection.
3) Defective volume pot.
4) Defective A/D port in host
µC.
5) Problem in receive audio
circuit.
Volume Set
Error
Using voltmeter,
measure voltage at
U204-PE2 while
turning volume pot
from min to max.
Voltage should vary
from 0 to 5VDC.
Voltage
functional?
Verify connections
and control top/ptt
flex connections.NoYesMeasure resistance
from pin 3 of R901
to GND.  Value
should be 50K½.
Measure resistance
from pin 2 of R901
to GND while moving
volume pot through
range; vlaue should
vary from 50K½ to
0K½.
Volume pot?
Replace S901.No
Yes
MAEPF-24401-A
Replace U204.
Verify operation of
volume knob per
Button Check flow
chart C.20.
Refer to No
Receive Audio
flow chart C.29.Yes
No Volume checks
OK? 
						

							 
10-14 
Chart 23 . Zone/Channel Select Error
Verify codeplug
programming
with RSS.  If
codeplug checks
good replace
U206.
Channel          RTA3      RTA2    RTA1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
10
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1    RTA0
  10             0        
  2
0             0        
  3
0             0        
  4
0             0        
  5
0             1        
  6
0             1       
  7
0             1        
  8
0             1        
  9
1             0        
  10
1             0        
  11
1             0        
  12
1             0        
  13
1             1        
  14
1             1        
  15
1             1       
  16
1             1       
Synopsis
This chart relates to a failure
in reading the zone/channel
select knob.  Basic Failure
modes are as follows:
1) Failure in flex circuit.
2) Bad connection.
3) Defective switch.
4) Defective port in SLIC.
Zone/Channel Select
Error.Verify operation of
zone knob per Button
Check flow chart C.20.
Signals
check good
at U206?
No
By studying the
adjacent chart against
the channel numbers
which have errors,
one signal may be
determined to be in
error or verify logic
levels at PH3-PH0 at
U206 for each
channel..
YesVerify similar
operation directly at
S902.S902 checks
good?
Replace S902.
Repair flex or
connections as needed.
Yes
MAEPF-24402-A
No
 
Chart 24 . Top/Side Button Error
Synopsis
This chart relates to a failure
in reading the buttons: Top, Top
Side, Side Button 1, or Side
Button 2.  Basic Failure modes
are as follows:
1) Failure in flex circuit
consisting of R902, R903,
R904, R201.
2) Bad connection.
3) Defective switch.
4) Defective A/D port in host
µC.
Use RSS to
enable button.
Top/Side Button
Error
Using RSS, verify
problem button is
enabled for function.
Button
enabled?
YesNo
Using a voltmeter,
measure the voltage at
PE3 of U204 while
depressing the following
button:
Button Nom. VDC
Top 0.00
Top Side 2.38
Side 1 3.06
Side 2 3.77
Levels
correct?
Replace U204.
Verify connections
and control top/PTT
flex circuit
consisting of
R902, R903 ,R904,
R201 and repair as
necessary. NoYes
Verify
operation of buttons
S903, S905, S906,
and S907.
Buttons OK?
Replace frame
assembly.No
Yes
MAEPF-24400-A
Verify operation of
buttons per Button
Check flow chart C.20.
Buttons
check good? Yes
No 
						

							 
10-15 
Chart 25 . No Display
Replace U204.
Synopsis
This chart relates to a failure
in the display.  The display is
considered not field repairable
and must be replaced as a uint.
Basic Failure modes are as
follows:
1) Non-display model radio.
2) Bad connection.
3) Defective µC.
No Display.
Verify display model
with RSS.Verify signal activity on
J601-2 and J601-1
during mode select
changes.
Activity?Verify J601
connections and bias.Yes
Yes No
NoWrong model?
Fix with RSS.Yes
No
J601 checks?
Repair J601.
MAEPF-24403-A
Replace display
module. 
						

							 
10-16 
Chart 26 . No TX Modulation
Replace U406 if
continuity of
signals
EXT/INT_SPKR
and MICEN from
U401 to U406
verifies and PTT
was initiated
from external.
*Note: Q401 ia a
non-inverting
transistor buffer.
Synopsis
This failure indicates a lack of
transmit modulation with the
fault lying with the vocoder.  It
assumes no power up fail codes
were displayed.  Since all
modulation modes occur
through the same path, this
failure applies to digital/
PL,DPL, etc.  Failure modes are
as follows:
1) Error with host µC in which
PTT is not detected.
2) Missing DSP IRQB interrupt.
3) Missing clock or data on SSI
port from/to ADSIC.
4) Non functional control of or
faulty Audio PA.
5) Damaged microphone or flex.
6) Faulty ADSIC IC.
Isolate and
repair problems.
See chart C.5.
No TX Modulation
(Vocoder Failure)
Set radio to test mode CSQ.
Connect radio to R4005B test box
or equivalent and inject a 1KHz
mic signal with amplitude
sufficient to provide 3KHz
deviation (about 11mV RMS).
Standard
bias OK?
Verify standard bias
per Table 3.
YesVerify signals per Figs. W8
and W10.
All signals
present?Replace
Speaker/Mic/Flex
assembly after
verifying continuity
of signal paths.
1
1 NoFig. W8-
Trace 1
present?
Replace U406. No
Fig. W8-
Trace 3
present?Yes
Yes Yes
Fig. W8-
Trace 4
present?
Yes No
Verify signals at U401 are:
Signal Logic
EXT/INT_SPKR 0
MICEN 1
Control
signals
correct?Verify 1KHz
signal at U401-
EXTMICIN.Yes No
Replace U401.
Audio signal
present at
input to
U401? Yes
No
Verify MUX control
voltages:
Signal Logic
U408-4 0
U412-4 1MUX control
voltages
check?
Check and repair
Q402 inverter
circuit as
necessary.No
Yes
MAEPF-24418-A
Verify operation
of MUXs U408 and
U412.MUXs verify?
Replace as
necessary.No
Yes
Repair limiter
circuit comprised
of U411 and
associated
circuitry.
If signal is present
during this test, but
not under normal
conditions (internal
mic.) check MUX
circuitry of U408
and U412 and
microphone bias
elements
R434/R406 and
R430/R408. Maybe
Fig. W8-Trace 2
present?Yes
Fault lies with
transceiver board.
Refer to appropriate
chart. No Transmit
Deviation V/U - C.28
800MHz - C.27
No
Verify signals per
Fig. W3 at indicated
points.Fig. W3-Trace 2
present?No
Fig. W3-
Traces 1 and
3 present?
Replace U406.Replace U405. No
Yes
Yes
PTT radio using external
PTT switch.  Verify signals
per Figs. W8 and W10.
Verify LED on
top of radio is
lit RED.
Trace PTT (int/ext)
from switch to
U206 and correct
opens.  If no
problems found,
replace U206.
YesNo
Replace U406.
Fault lies with
transceiver board.
Refer to appropriate
chart. No Transmit
Deviation V/U - C.28
800MHz - C.27 
						

							 
10-17 
Chart 27 . 800MHz No TX Deviation
Replace J401
header.
No TX Deviation
800MHz TransceiverAudio at pin
15 of J1?
Set radio to test mode CSQ.
Connect radio to R4005B test box
or equivalent and inject a 1KHz
mic signal with amplitude
sufficient to provide 3KHz
deviation (about 11mV RMS).PTT radio using external
PTT switch.  Verify signals
per Figs. W8 and W10.
No
Yes
Check
continuity
between pin
15 of J1 and
pin 5 of U302. No
NoMAEPF-24405-O
YesYes Audio at pin 5
of U302?
Audio at pin 30
of U302?Replace U302.
Check components
C316,
C315,R305,C324,
and R314.
 
Chart 28 . VHF/UHF No TX Deviation
No TX Deviation
VHF/UHF TransceiverAudio at pin
15 of J1?
Set radio to test mode CSQ.
Connect radio to R4005B test box
or equivalent and inject a 1KHz
mic signal with amplitude
sufficient to provide 3KHz
deviation (about 11mV RMS).PTT radio using external
PTT switch.  Verify signals
per Figs. W8 and W10.
No
Yes
Audio &
voltage at
U204-5?
Check C303 &
continuity of
J1. NoReplace U204.
No YesYes
Audio &
voltage at
U204-30?
Check
continuity of
J1.
Audio &
voltage
between C231
& C233?
Check solder
joint and for
broken runner.
YesNoSuspect R208.
VSF* at
R208?
Check U204. Voltage
between R207
& R208?*VSF = Voltage from Super Filter
(U204, pin 19) 4.6VDC.
YesNoYes
No
Voltage at
CR202? Audio between
R207 &
R208?Yes
No
MAEPF-24404-O
C225 OK?
Suspect R207
or C231.
Replace C225.
Suspect
L218. No
NoYes
Yes 
						

							 
10-18 
Chart 29 . No RX Audio
Synopsis
This failure indicates a lack of
received audio with the fault
lying with the vocoder.  It
assumes a functional
transceiver board and no power
up fail codes were displayed.
Since all received signal modes
occur through this same path,
this failure applies to digital/
PL,DPL, etc.  Failure modes are
as follows:
1) Missing DSP IRQB interrupt.
2) Lack of 2.4 REF clock and/or
data from ABACUS.
3) Missing clock or data on SSI
port from ADSIC.
4) Non functional control of or
faulty Audio PA.
5) Damaged speaker or speaker
flex.
6) Faultu ADSIC.
Isolate and
repair problems.
See chart C.5.
No Receive Audio
(Vocoder Failure)
Set radio to test mode
CSQ.  Inject a 1KHz
modulated signal at the
carrier frequency at
-60dBm level with
3KHz deviation.
Standard
bias OK?
Verify standard bias
per table Table 3.
Yes
NoVerify signals
present at ADSIC
(U406) per Fig. W10
and Fig. W5.  Note
DOUT and DOUT* are
low level voltage
signals.
Signals
present?
During a mode
change, verify an
ABACUS
programming
sequence occurs
per Fig. W4
probing on the
ABACUS carrier.ABACUS is
programmed
?
Verify SBI signal
connection
between ADSIC and
ABACUS ICs.
Repair as
necessary.  If
connection good,
replace U406. No
Yes
Fault lies with
transceiver board.
Refer to appropriate
section. Chart C.30
Verify signals per
Fig. W7 at points
indicated.
Signals
present?
Replace
Speaker/Flex
assembly after
verifying continuity
of signal paths.
Fig. W7-
Trace 1
present?
1Yes
No
1
Replace U406.
Fig. W7-
Trace 2
present? No
Yes
Verify signals per Fig.
W2 at points
indicated.
Signals
present?
No
No
Replace U406.Yes
YesFig. W7-
Trace 3 or 4 
not present or
 in phase?
Verify signals
EXT/INT_SPKR
and AMPEN at
U401 are logic
high.
Replace
Speaker/Flex
assembly after
verifying continuity
of signal paths. No
Yes
Control
signals
correct?
Replace U401. Yes
MAEPF-24406-A
No
Replace U406 if continuity
of signals EXT/INT_SPKR
and AMPEN from U401 to
U406 verifies.. At this point the fault
could lie with a faulty
ADSIC, or it could be
the DSP does not
see/service the IRQB
or SC1 interrupt from
ADSIC!
Check for continuity
between U405 and
U406 of the signals
depicted in Fig. W2
and the 8KHz IRQB.
Connections
good?
Repair
connections.
No
Yes
Perform radio
function which
causes an alert
tone to be
generated.
Alert tone
audible?Replace U405.Replace U406.
No YesMake sure no
external
mic/speaker is
attached to
universal
connector which
would cause the
radios to select
EXT_SPKR. No
Yes 
						

							 
10-19 
Chart 30 . VHF/UHF/800MHz Receiver RF
Bad SINAD
Bad 20Db Quieting
No Recovered Audio
Spray or Inject 1st IF into 
XTAL Filter
FL1.
Audio
Heard?
Is
circuit 
from Q601 to
U401
good?
14.4MHz
at ABACUS
(U401) pin
15? Check 2nd LO
Cntrl Voltage
at R413 Inject RF
into J2
IF Signal
at L605?
RF
Signal
at T1 (VHF/
UHF), T202 
(800MHz)
?
RF
Signal
at L8 (VHF/
UHF), L180
(800MHz)
?
RF
Signal
at L6 (VHF/
UHF), L201
(800MHz)
?
RF
Signal at
CR109 (VHF/
UHF), CR102
(800MHz)
?
Check harmonic filter L126-127, 
ant. switch, CR109, J2 contact
(VHF/UHF). CR102, L105, L103,
L106, C101, C114 (800MHz)Program filter to 
schematic test freqs.
and check varactor
voltages.
If voltages OK check 
varactor filter. If voltages not 
OK, check U102. Check
also Q108, R115, U102 
voltages. Check U102 can 
be selected by MCU
before replacing U102.
Before replacing U401 check 2nd 
VCO Q1. Check VCO O/P level; 
C408, C425. Disconnect R416 and 
verify that a 0.5V to 5V ctrl voltage
VCO will sweep about the IF freq. Trace IF signal
from L605 to
Q601.
Check for bad
XTAL filter.VCO
Locked?
1st LO
O/P OK?
Locked?Check FGU
Chart C.31 -
VHF/UHF
C.32 -
800MHz
Check Mixer,
U2, T1 (VHF/UHF).
U205, T202
(800MHz)
Replace bad
components. Check filter between
U1 and U2 (VHF/UHF).
U202, U205 (800MHz)
Check U1 Stage.
U202 (800MHz)
Check U201 filter.
Before replacing U401, 
check U401 voltages. 
Check for no Rx audio
VOCON flowchart C.29. Q601
Collector
OK?
IF signal
present?2.1Mhz
Check
at Pin 19
U401?Check FGU,
Chart C.31 - VHF/
UHF C.32 -
800MHz
Activity
On U401
Sel Pin?Check J1. If
OK, Check No Rx
Audio Chart C.29
YES NO
NO
NONO YES YES
YES NONO
YES
YES NO
YES
YES NO
NO
YES
YES
YES NO
NO OR
WEAK RF
YES
VHF
UHF 800MHz
YESNO
NONOTE: INJECT MODULATED
ON CARRIER FREQUENCY
SIGNAL AS REQUIRED
MAEPF-24386-O
IF FREQS:
45.15 VHF
73.35 UHF/800MHz
Check
for
 3.0VDCCheck Q601
bias Circuitry
for Faults.Check R601,
R602NO YES
Check U401voltages
and programming &
14.4MHz VCO
components.
Rotate Freq. Knob
 
Chart 31 . VHF/UHF Frequency Generation Unit (FGU)
FGU No Lo Injection/TX
Unlock
Check continuity
between:
U204-2 & J401-9,
U204-3 & J401-10, 
U204-4 & J401-14.
If no fault found 
replace U204.
YES
MAEPF-24389-A
NO
VDC at
VCTRL (TP5),

						

							 
10-20 
Chart 32 . 800MHz Frequency Generation Unit (FGU)
FGU No Lo Injection/TX
Unlock
A
NO
MAEPF-24390-A
YES
VDC at
V Con Pin 1
U307