Motorola BPR40 Service Manual

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.

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. © 2006, 2007, 2011 Motorola Solutions, Inc. All rights reserved.

Document History

This manual has undergone several revisions. Key changes include:

• Edition 6816986H01-A (Mar. 2006): Initial edition.
• Edition 6816986H01-B (June 2007): Updated Radio Model Information in Section 1, updated mechanical parts list in Section 2, and updated accessories in Section 5. Added Appendices A (Replacement Parts Ordering) and B (Motorola Service Centers).
• Edition 6816986H01-C (Mar. 2011): Added Serial Number Programming to Section 4. Updated Safety Information section with new released version.

Safety Information

Product Safety and RF Energy Exposure Booklet for Portable Two-Way Radios

This document provides information superseding general safety guidelines published before February 2002. Before using this radio, read the following information which contains important operating instructions for safe usage, RF energy awareness and control, and compliance with applicable national and international standards. For intrinsically safe radios, also read specific instructions on page ix.

RF Energy Exposure Awareness and Control Information and Operational Instructions for Occupational Use

NOTICE: This radio is intended for use in occupational/controlled conditions only. It is not authorized for general population or consumer use. This two-way radio uses electromagnetic energy in the radio frequency (RF) spectrum for communication. RF energy, like other forms of electromagnetic energy, should be handled with care. Standards for safe RF exposure have been developed by experts, including substantial margins of protection. Motorola radios are designed, manufactured, and tested to meet government-established RF exposure levels and provide simple user procedures to control exposure.

For more information on RF energy exposure and control, refer to:

• http://www.fcc.gov/oet/rfsafety/rf-faqs.html
• http://www.osha.gov/SLTC/radiofrequencyradiation/index.html

Federal Communication Commission (FCC) Regulations

The FCC requires manufacturers to comply with RF energy exposure limits for portable two-way radios before marketing in the U.S. Users in occupational settings must be aware of and control their exposure to meet FCC requirements. Product labels and user manuals provide necessary information for RF exposure control.

Compliance with RF Exposure Standards

Your Motorola two-way radio complies with national and International standards and guidelines for human exposure to radio frequency electromagnetic energy. It meets IEEE (FCC) and ICNIRP exposure limits for occupational/controlled RF exposure environments at operating duty factors up to 50% talk/50% listen and is authorized by the FCC for occupational use only. The radio generates measurable RF energy only when transmitting. Approved batteries are rated for a 5-5-90 duty factor (5% talk, 5% listen, 90% standby), though the radio complies with FCC occupational exposure limits and may operate at up to 50% talk.

The radio complies with the following standards:

• FCC, Code of Federal Regulations; 47 CFR et seq.
• FCC, OET Bulletin 65
• Institute of Electrical and Electronic Engineers (IEEE) C95.1
• International Commission on Non-Ionizing Radiation Protection (ICNIRP)
• Ministry of Health (Canada) Safety Code 6
• Industry Canada RSS-102
• Australian Communications Authority Radiocommunications Standard et seq.
• ANATEL ANNEX to Resolution No. 303 et seq.

RF Exposure Compliance and Control Guidelines and Operating Instructions

To control exposure and ensure compliance:

• Do not remove the RF Exposure Label.
• User awareness instructions should accompany the device when transferred.
• Do not use the device if operational requirements are not met.

Operating Instructions:

• Transmit no more than 50% of the time. Push the Push-To-Talk (PTT) button to transmit; release to receive.
• Hold the radio vertically, at least one inch (2.5 cm) from the nose or lips, with the antenna kept away from the eye. RF exposure decreases with distance from the antenna.
• When worn on the body, use only Motorola-approved clips, holders, holsters, cases, or body harnesses. Non-approved accessories may exceed FCC/ICNIRP limits.
• If not using a body-worn accessory or the intended face-to-face position, keep the antenna and radio at least one inch (2.5 cm) from the body when transmitting.

Approved Accessories:

Use only Motorola-approved antennas, batteries, and accessories. Use of non-Motorola approved items may exceed RF exposure guidelines. A list of approved accessories is available at: http://www.motorolasolutions.com/governmentandenterprise

For additional information on exposure requirements or training, visit http://www.motorola.com/rfhealth.

Electromagnetic Interference/Compatibility

NOTE: Electronic devices can be susceptible to electromagnetic interference (EMI) if inadequately shielded or configured. Turn off your radio in facilities where posted notices instruct you to do so (e.g., hospitals, aircraft) as equipment may be sensitive to external RF energy.

Medical Devices

Pacemakers: Maintain a minimum separation of 6 inches (15 cm) between a handheld wireless radio and a pacemaker. Always keep the radio more than 6 inches from your pacemaker when ON. Do not carry the radio in a breast pocket. Use the ear opposite the pacemaker. Turn the radio OFF immediately if interference is suspected.

Hearing Aids: Some digital wireless radios may interfere with hearing aids. Consult your hearing aid manufacturer for alternatives if interference occurs.

Other Medical Devices: Consult your physician or the device manufacturer to determine if your personal medical device is adequately shielded from RF energy.

Use of communication devices while driving

Always check local laws and regulations. Give full attention to driving. Use hands-free operation if available. Pull off the road and park before making or answering a call if conditions or regulations require.

Acoustic Safety

Prolonged exposure to loud noises can temporarily or permanently affect hearing. Use the lowest volume necessary. Turn up volume only in noisy surroundings. Turn down volume before adding headsets. Limit time using headsets at high volume. Do not place the radio's speaker directly against your ear.

Operational Warnings

For vehicle with air bags

Refer to the vehicle manufacturer's manual before installing electronic equipment. Do not place a portable radio in or near an air bag deployment area, as it could be propelled with great force and cause serious injury.

Potentially Explosive Atmospheres

Turn off your radio before entering areas with potentially explosive atmospheres (e.g., fueling areas, chemical storage, areas with dust/powders) unless it is specifically qualified as Intrinsically Safe. Do not remove, install, or charge batteries in such areas. Sparks can cause explosions or fire.

Blasting Caps And Blasting Areas

To avoid interference with blasting operations, turn off your radio when near electrical blasting caps, in a blasting area, or in areas posted: "Turn off two-way radio." Obey all signs and instructions.

Operational Cautions

Antennas

Do not use a portable radio with a damaged antenna. Contact with a damaged antenna can result in a minor burn.

Batteries

Batteries can cause property damage and/or bodily injury if conductive material (e.g., jewelry, keys) touches exposed terminals, causing a short circuit and heat. Handle charged batteries with care, especially when placed with metal objects.

Intrinsically Safe Radio Information

Intrinsically safe (IS) approval indicates a product meets specific safety standards for hazardous classified locations, certified by agencies like FM Approvals, CSA, UL, ATEX, IEC. An IS radio will have an approval label specifying the hazardous Class/Division/Group and the required battery part number. This label is located on the radio unit.

Operational Cautions for Intrinsic Safe Equipment

• Do not operate radios in hazardous atmospheres unless they are specifically qualified (e.g., FM, UL, CSA, ATEX, IEC approved).
• Do not operate an IS radio that has been physically damaged (e.g., cracked housing) in a hazardous atmosphere.
• Do not replace or charge batteries in a hazardous atmosphere, as contact sparking may occur.

Warnings for Radios Approved as Intrinsically Safe

Radios must be shipped from Motorola with intrinsic safety capabilities and labeling. These capabilities cannot be added or upgraded in the field. Modifications to the unit's hardware must be made only by the original product manufacturer.

• Do not replace or change accessories in a hazardous atmosphere.
• Turn the radio OFF before removing or installing a battery or accessory.
• Do not disassemble an IS product in a way that exposes internal circuits.
• Using non-approved batteries or accessories with an IS radio may create an unsafe condition.
• Unauthorized or incorrect modification of an IS product will void its approval rating.
• Incorrect repair or relabeling could adversely affect the approval rating.
• Using a non-IS radio in a hazardous atmosphere could result in serious injury or death.

Repair

Repairs for Motorola products with intrinsically safe approval are the responsibility of the user. Repairs for FM approved radios should only be done at FM-audited locations. Contact Motorola for assistance. A repair is defined as internal work requiring opening the casing; actions not requiring opening the casing are not considered repairs.

Do Not Substitute Options or Accessories

Motorola IS-certified equipment is tested as a complete system (portable, battery, accessories). The approved portable and battery combination must be strictly observed. Substitution of items, even if previously approved with other Motorola equipment, is not permitted. Approved configurations are listed by the Approving Agency (FM, UL, CSA, ATEX, IEC). The Intrinsically Safe Approval Label and the manual PN referenced on it identify the approved system components. Using non-Motorola IS batteries or accessories with an approved radio unit will void the IS approval.

Section 1: INTRODUCTION

1.0 Scope of Manual

This manual is intended for service technicians familiar with similar equipment. It contains service information for the Mag One™ by Motorola Series radio and is current as of the printing date. Changes may be incorporated via manual revisions or additions. Read the Safety Information Section before operating or testing.

2.0 Warranty and Service Support

Motorola offers long-term product support, including exchange/repair during warranty and service/repair or spare parts support out of warranty. Authorized Motorola Dealers require a Warranty Claim Form for returns. Warranty terms are defined in dealer/distributor contracts.

Before shipping a unit for warranty, check programming and ensure no damage outside warranty terms. Contact Customer Resources for return authorization and Warranty Claim Forms. Ship in original or protective packaging.

2.1 Warranty Period and Return Instructions

Warranty conditions are in Motorola contracts. Check product programming and condition before shipping. Contact Customer Resources for return authorization and forms. Ship in original or protective packaging.

2.2 After Warranty Period

Motorola continues support through:

• Motorola's Radio Parts and Service Group: Offers repair services at competitive prices.
• Motorola Customer Care and Services Division (CCSD): Supplies individual parts and modules for technically capable dealers.

2.3 Piece Parts

Refer to "Appendix A Replacement Parts Ordering" on page A-1 for ordering information.

2.4 Technical Support

Technical support is available to assist dealers with malfunctions. Contact the Service Depot in your area, your Business Development Manager, Distributor, or Motorola Technical Support. Be prepared to provide the product model number and serial number. Confirm returns before sending units to depots. For service, contact depots listed in "Appendix B Motorola Service Centers".

2.5 Further Assistance From Motorola

Contact the Customer Help Desk via: http://www.motorolasolutions.com/governmentandenterprise

NOTE: Only Motorola Service Centers or Approved Motorola Service Dealers can perform these functions. Tampering by non-authorized centers voids the warranty. Visit http://www.motorolasolutions.com/governmentandenterprise for more information.

Section 1: RADIO MODEL INFORMATION

3.0 Radio Model Information

The model and serial number are on a label attached to the back of the radio. The model number indicates RF output power, frequency band, protocols, and physical packages. An example is provided:

Table 1-1 Radio Model Number (Example: AAH84KDS8AA1AN)

Key: H = Portable, AA = Motorola Internal Use

4.0 Radio Features

The radio includes the following features:

• Normal Operation: Rx/Tx, Radio-CPS-Radio Cloning, Radio-to-Radio Cloning, Factory Reset, Low Battery Indication, Self Test.
• Programmable Button: High/Low Power, Volume Set, Monitor, Sticky Monitor, Scan Activate, Nuisance Channel Delete, Repeater/Talkaround, PL/DPL, Button Lock, Battery Save Mode, Squelch, Unassigned.
• CPS (Customer Programming Software): Rx Frequency, Tx Frequency, RX TPL/DPL/IDPL, TX TPL/DPL/IDPL, User Defined PL (TPL1, TPL2, TPL3), Squelch Type, Unmute/Mute Rules, Power Level (High/Low), TPL Reverse Burst, Turn Off Code, Rx Only, Busy Channel Lock Out (BCLO), Channel Spacing (22KHz / 12.5KHz), Talkaround, Time Out Timer, Battery Save Mode, Quick Key Override, Password Protection, Scan List, Normal Scan, Priority Scan, Talkback Scan.

Section 2: MAINTENANCE

1.0 Introduction

This chapter covers Preventive Maintenance, Safe Handling of CMOS and LDMOS Devices, General Repair Procedures and Techniques, and Disassembling and Reassembling the Radio.

2.0 Preventive Maintenance

Periodic visual inspection and cleaning are recommended.

2.1 Inspection

Check external surfaces for cleanliness and all external controls and switches for functionality. Interior electronic circuitry inspection is not recommended.

2.2 Cleaning Procedures

Recommended cleaning agents and methods for external and internal surfaces:

• External Surfaces (front cover, housing, battery case): Use a 0.5% solution of mild dishwashing detergent in water. Apply sparingly with a stiff, non-metallic, short-bristled brush. Remove solution and dry with a soft, absorbent, lintless cloth or tissue. Ensure no water remains in connectors, cracks, or crevices. Avoid aerosol sprays, tuner cleaners, and other chemicals that may harm plastics.
• Internal Circuit Boards and Components: Use isopropyl alcohol (100% by volume) with a stiff, non-metallic, short-bristled brush to dislodge embedded materials. Brush material away from the radio's interior. Avoid soaking controls or tunable components. Do not use high-pressure air for drying. Dry with a soft, absorbent, lintless cloth. Do not apply alcohol to the frame, front, or back cover. Always use fresh alcohol and a clean container.

NOTE: Internal surfaces should only be cleaned when the radio is disassembled for service or repair.

3.0 Safe Handling of CMOS and LDMOS Devices

CMOS devices are susceptible to damage from electrostatic or high voltage charges, which can cause latent failures. Special precautions are mandatory, especially in low humidity conditions:

• Store and transport CMOS devices in conductive material, with exposed leads shorted together. Do not use conventional plastic "snow" trays.
• Ground the service bench working surface. Use a Motorola Static Protection Assembly (wrist strap, ground cords, table mat, floor mat) or equivalent.
• Wear a conductive wrist strap connected in series with a 100kΩ resistor to ground. (Replacement wrist straps: Motorola part number 4280385A59).
• Do not wear nylon clothing.
• Do not insert or remove CMOS devices with power applied. Check power supplies for voltage transients.
• Provide ground straps for apparatus used when straightening CMOS pins.
• Use a grounded soldering iron.
• Handle CMOS devices by the package, not the leads. Touch an electrical ground before handling the unit to discharge static charge. The package and substrate may be electrically common.

4.0 Repair Procedures and Techniques – General

NOTE: Environmentally Preferred Products (EPP) use environmentally friendly components and solder assembly techniques (complying with EU RoHS Directive 2002/95/EC and WEEE Directive 2002/96/EC). Use only Motorola-specified parts for product compliance and reliability.

Rework or repair on EPP products must use appropriate lead-free solder wire and paste:

• Lead Free Solder Wire: Motorola Part Number 1088929Y01 (Alloy 95.5Sn/3.8Ag/0.7Cu, RMA Flux, 2.7-3.2% Flux Content, 217°C Melting Point, Supplier Part 52171, 0.015" Diameter, 1lb spool).
• Lead Free Solder Paste: Motorola Part Number 1085674C03 (Manufacturer Part NC-SMQ230, 900-1000KCPs Viscosity, Type 3, 95.5%Sn-3.8%Ag-0.7%Cu Composition, 89.3% Metal, 217°C Liquid Temperature).

Parts Replacement and Substitution

Use identical replacement parts. If unavailable, order the correct Motorola part number from the list in "Appendix A Replacement Parts Ordering".

Rigid Circuit Boards

These radios use bonded, multi-layer PCBs. Inner layers are not accessible. Exercise care to avoid pulling plated circuits out of holes when soldering/desoldering. Avoid getting solder in connectors or forming solder bridges between connector pins.

Flexible Circuits

Flexible circuits require different soldering techniques. Excessive heat or bending can cause damage. Use the ST-1087 Temperature-Controlled Solder Station (600-700°F tip) and small diameter solder like ST-633. To replace a component, grasp the circuit edge, apply heat to connections while pulling with tweezers. Do not puddle-out components.

Chip Components

Use the RLN4062 Hot-Air Repair Station (370°C / 700°F, minimum airflow). To remove: apply hot air, then remove component with tweezers. Remove excess solder from pads using solder wick and iron or desoldering station. To replace using soldering iron: apply fresh solder to one pad, position new component with tweezers while heating, then heat remaining pad. Ensure all solder joints are smooth and shiny.

To replace using hot air: reflow pads, apply solder paste flux, position component with tweezers, apply heat with hot-air hand piece, and inspect repair.

5.0 Disassembling and Reassembling the Radio – General

Pay close attention to snaps, tabs, and part alignment during disassembly and reassembly. Required tools include Phillips screwdriver, flat head screwdriver, Chassis Opener, Crab Eye Nut Opener, and tweezers. For more complete testing or service, send the unit to a Motorola Authorized Service Center.

6.0 Radio Disassembly – Detailed

6.1 Front Cover from Chassis Disassembly

1. Turn off the radio.
2. Unlatch the battery latch at the bottom and remove the battery by gently lifting its hilt away from the housing and sliding it downwards.
3. Unscrew and remove the antenna.
4. Pull the On/Off Volume and Channel knobs off their shafts using the Chassis Opener.
5. Insert the Chassis Opener between the chassis and housing at the bottom and gently lift the chassis away from the front cover. Be careful not to damage the housing or the O-ring.
6. Lift the rear chassis away from the front cover, being careful of the speaker wire. Slide the rear chassis downwards and away.
7. Remove the speaker connector between the PC Board and the internal speaker on the front cover.
8. To replace the latch: Remove the latch pad from the right slot. Push the shaft in the housing slot to the right and slide the battery latch shaft out from the latch.
9. To replace the speaker, speaker bracket, or speaker felt: Unscrew the speaker bracket from the housing, remove the speaker from the speaker felt, and remove the speaker felt from the grille area.

6.2 PC Board Disassembly

1. Remove the audio jack seal.
2. Remove the 10 screws holding the PC board to the diecast.
3. Remove the 2 nuts on the On/Off Volume and Channel knobs shafts using the Crab Eye Nut Opener.
4. The PC board can now be removed from the rear diecast.
5. A completely disassembled PC board view shows components like the Radio Chassis, POGO Pin Seal, Thermal Pad, PTT Insulation Tape, Crab-eye Knob Nut, Antenna Bracket, O-ring, Nameplate Label, Shield, Stickers for Tuning Holes, Thermal Paste, POGO Pin Housing, Audio Jack Seal, Audio Bracket, PCB-Chassis Tape, PCB Microphone Boot.

7.0 Radio Reassembly – Detailed

7.1 PC Board Reassembly

1. Place the PC board on the rear diecast.
2. Tighten the screws and nuts on the two knobs.

7.2 Chassis and Front Cover Reassembly

1. For speaker replacement: Place the speaker felt onto the grille area, place the speaker on top of the felt, stick the speaker poron pad onto the back of the speaker magnet, and screw the speaker bracket to the housing.
2. For latch replacement: Slot the battery latch shaft into the latch. Place the latch onto the housing with the shaft protruding. Push the shaft in the housing slot to the left and place the small latch pad onto the right slot space.
3. Connect the internal speaker connector to the PC board.
4. Place the diecast into the front housing.
5. Snap the front housing cover firmly into place on the rear diecast.
6. Attach the battery.
7. Attach the On/Off Volume Knob, Channel Knob, and Antenna.

8.0 Mechanical View and Parts List

8.1 Exploded View and Parts List

Figure 2-14 shows an exploded view of the radio, illustrating how the components assemble. Table 2-1 lists the parts with their reference numbers, part numbers, names, and quantities.

Notes: Items marked “” are also available as PMDN4051_R. Non-EPP compliant boards must be used with PMDN4011_R and PMDN4024_R. EPP compliant boards must be used with PMDN4067_R and PMDN4068_R.

9.0 Service Aid

Table 2-2 lists recommended service aids for working on Mag One by Motorola Radios. Equivalent items may be substituted.

10.0 Test Equipment

Table 2-3 lists test equipment required for servicing Mag One by Motorola Radios and other two-way radios.

Programming Cable (PMDN4043_R) Schematic: Figure 2-15 shows the schematic for the programming cable.

Cloning Cable (PMDN4060_R) Schematic: Figure 2-16 shows the schematic for the cloning cable.

Test Box (PMDN4040_R) Schematic: Figure 2-17 shows the schematic for the test box.

Section 3: RADIO TUNING

1.0 Introduction

This chapter details hardware tuning for the Mag One by Motorola Series radio. No software tuning is required. The radio must be disassembled to the PC Board level for manual tuning procedures. Parameters that can be tuned include Transmitter Tuning (High Power, Low Power, Frequency, Modulation Balancing, Maximum Modulation, Subtone Modulation), Receiver Tuning (Wide Band Sinad, Narrow Band Sinad), and PLL Synthesizer Tuning (Rx PLL Frequency, Tx PLL Frequency). Refer to Table 2-2 for required Service Aids.

2.0 Hardware Tuning Setup and Procedure

2.1 Tuning Frequency

Table 3-1 lists the frequencies used for tuning:

2.2 Preparation Before Tuning (refer to Figure 3-1)

1. Set Power Supply to 7.5V and connect it to the radio.
2. Connect the connector and ground plate to the radio's antenna port.
3. Connect the radio to the test equipment.

Figure 3-1 illustrates the Radio Tuning Setup, showing connections from the Radio's Antenna Port and Acc Jack to the Test Box and then to Test Equipment. It also shows the Ground Contact Finger.

NOTE: Select 8 ohm resistance on the Test Box for PMUD2086A_ and PMUE2386A_. Select 24 ohm resistance for all other kits. The radio may need to be disassembled to the PC board level to access certain tuning ports (refer to "Radio Disassembly – Detailed" on page 2-6).

2.3 Transmitter Tuning

2.3.1 High Power

Connect the radio to a power meter. Set the radio to the appropriate tuning frequency. Key up the radio and adjust R425 (refer to Figure 3-2) using a ceramic tool to tune high power.

2.3.2 Low Power

Connect the radio to a power meter. Set the radio to the appropriate tuning frequency. Key up the radio and adjust R426 (refer to Figure 3-2) using a ceramic tool to tune low power.

2.3.3 Frequency Tuning

Set the radio to the appropriate tuning frequency. Adjust FL701 (refer to Figure 3-2) using a ceramic tool to tune the frequency.

2.3.4 Modulation Balancing

Set the radio to the appropriate tuning frequency. Configure test equipment for Audio bandwidth: 0.25Hz to 15,000Hz, De-emphasis: Off, FM: Peak negative. Inject a 1 kHz tone via the test box. Key up the radio. Set the desired modulation balance at the Audio Analyzer output. Adjust R174 (refer to Figure 3-3) using a ceramic tool to tune to 100% of the maximum deviation.

2.3.5 Maximum Modulation

Set the radio to the appropriate tuning frequency. Configure test equipment for Audio bandwidth: 0.25Hz to 15,000Hz, De-emphasis: Off, FM: Peak negative. Input a 1 kHz tone + 67Hz subtone, 120mV to the radio via the test box. Key up the radio. Adjust R159 (refer to Figure 3-3) using a ceramic tool to tune maximum modulation between 2.4±0.02KHz for narrow band or under 5KHz for wide band.

2.3.6 Subtone Modulation

Set the radio to the appropriate tuning frequency. Configure test equipment for Audio bandwidth: 0.25Hz to 15,000Hz, De-emphasis: Off, FM: Peak negative. Program the radio subtone to 67Hz (CTCSS). Key up the radio. Adjust R172 (refer to Figure 3-3) using a ceramic tool to tune subtone modulation between 0.42 ± 0.02KHz at narrow band.

2.4 Receiver Tuning

2.4.1 Wide Band Sinad Tuning

Set the radio to the appropriate tuning frequency. Set RF Signal Generator level to -47dBm with a 1 kHz tone, 60% deviation. Find the SINAD level 7 by decreasing the RF Signal Generator level. Adjust R215 clockwise (refer to Figure 3-2) to turn off the audio output, then adjust R215 counterclockwise to the point where the Audio Frequency signal appears.

2.4.2 Narrow Band Sinad Tuning

Set the radio to the appropriate tuning frequency. Set RF Signal Generator level to -47dBm with a 1 kHz tone, 60% deviation. Find the SINAD level 7 by decreasing the RF Signal Generator level. Adjust R216 clockwise (refer to Figure 3-2) to turn off the audio output, then adjust R216 counterclockwise to the point where the Audio Frequency signal appears.

2.4.3 PLL Synthesizer Tuning

Rx PLL Frequency Tuning: Set the radio to the appropriate tuning frequency. Detect output voltage at test point TP1 (refer to Figure 3-3). Adjust C710 (refer to Figure 3-4) using a ceramic tool to tune the voltage to 5.2V ±0.1V.

Tx PLL Frequency Tuning: Set the radio to the appropriate tuning frequency. Detect output voltage at test point TP1. Adjust C722 (refer to Figure 3-4) using a ceramic tool to tune the voltage below 5.0V ±0.1V.

Section 4: RADIO PROGRAMMING

1.0 Introduction

Radios can be programmed using the Customer Programming Software (CPS).

2.0 Programming Your Radio

2.1 Overview of the Programming Process

To prepare radios for customers, first program the radio with necessary parameters, then clone these parameters to all customer radios.

2.2 Cloning Radio Parameters to User Radios

Cloning duplicates the contents of a master radio (Radio 1) into a slave radio (Radio 2). Tuning and alignment information are not affected.

2.3 Parameters which are cloned

• Radio Configuration parameters
• Conventional Personality parameters

2.4 Parameters which are not cloned

• Unit Serial Number
• Model Number

2.5 To Clone a Radio

Cloning duplicates the master radio's contents into the slave radio.

2.5.1 Setting Up the Master Radio

1. Turn off the radio.
2. Press and hold Programmable Button 1 (top button) and turn on the radio.
3. Keep holding until two beeps are heard, then release. The LED changes to RED.

2.5.2 Setting Up the Slave Radio

1. Turn off the radio.
2. Press and hold Programmable Button 1 (top button) and turn on the radio.
3. Keep holding until three beeps are heard, then release. The LED changes to GREEN.

2.5.3 Radio to Radio Cloning Procedures

1. Connect the cloning cable to both Master and Slave radios.
2. Press and release Programmable Button 1 of the Slave radio.
3. Press and release Programmable Button 1 of the Master radio.
4. The LED on both radios flashes orange during cloning.
5. An 'Out Chirp' alert tone is heard from both radios upon completion.
6. Disconnect the radios.

2.6 Error Conditions

An error during cloning results in a Faulty Condition Alert tone and a momentary flashing orange LED. If the LED remains RED and the radio transmits after cloning, disconnect the cloning cable.

3.0 CPS Programming

The CPS is designed for Windows 98/NT/2000/XP and above. Installation instructions are in the CPS kit.

Description: Mag One Customer Programming Software (CD) - Kit Number RVN5081_

Figure 4-1 shows the CPS Programming Setup, illustrating the connection between the Radio, Programming Cable (PMDN4043_R), and Comm Port on a PC.

3.1 To Read Radio Data to a PC

1. Turn off the radio.
2. Connect the programming cable.
3. Press and hold Programmable Button 1, then turn on the radio. Release after one beep. The LED illuminates orange.
4. Click the 'Read' button on the CPS. A reading progress bar will be shown.

3.2 To Write Data to a Radio

1. Turn off the radio.
2. Connect the programming cable.
3. Press and hold Programmable Button 1, then turn on the radio. Release after one beep. The LED illuminates orange.
4. Click the 'Write' button on the CPS. A writing progress bar will be shown.

4.0 Serial Number Programming

A Serial Number can be reprogrammed into units with replacement boards using the Dealer Serial Number Programming tool (refer to Figure 4-1 CPS Programming Setup).

4.1 To read the Radio Serial Number to a PC

1. Turn off the radio.
2. Connect the programming cable.
3. Press and hold Programmable Button 1, then turn on the radio. Release after one beep. The LED illuminates orange.
4. Click the 'Read' button on the Dealer Serial Number Programming Tool. A reading progress bar will be shown.
5. The tool displays the serial number field. If it's empty or populated with the factory number, the board can be reprogrammed. If it's grayed/un-editable, it's already programmed with a 10-digit serial number and cannot be reprogrammed.

4.2 To Reprogram a Serial Number to a Radio

NOTE: Only radios with replacement service boards listed in Table 4-1 can have the serial number reprogrammed. Ensure the replacement board is reprogrammable by following the procedures in "To read the Radio Serial Number to a PC" on page 4-4.

1. Note the 10-digit serial number from the sticker on the radio's chassis (following "S/N").
2. Turn off the radio.
3. Connect the programming cable.
4. Press and hold Programmable Button 1, then turn on the radio. Release after one beep. The LED illuminates orange.
5. Enter the correct 10-digit serial number into the tool's serial number field. The tool requires a complete 10-digit number to allow writing.
6. Click the 'Write' button. A writing progress bar will be shown.

Table 4-1 Reprogrammable Service Boards: Lists boards like PMDD4000AR (136–150 MHz 5W PCB), PMDD4001AR (150–174 MHz 5W PCB (Non-EPP)), PMDD4005AR (150–174 MHz 5W PCB (EPP)), etc., for various frequency bands.

5.0 Factory Reset

This feature restores the radio to its factory default settings.

1. Press and hold both the PTT and Programmable Button 2 (lower button) while turning on the radio.
2. The radio emits a 'Good Key Chirp' tone upon completion of the factory reset.

Section 5: ACCESSORIES

The following accessories are available for the Mag One by Motorola Series radio:

1.0 Antennas

• PMAD4051_R: Mag One VHF Antenna, 150 – 174 MHz
• PMAE4020_R: Mag One UHF Antenna, 450 – 470 MHz

2.0 Carry Accessories

• PMLN4743_: Mag One Spring Belt Clip
• 4216586H02: Mag One T-Strap

3.0 Carry Cases

• PMLN4742_: Mag One Hard Leather Carry Case

4.0 Chargers

• PMLN5041_R: Mag One Tri-Chem Charger Base
• PMLN 5048_R: Mag One Tri-Chem SUC with Switching PS, US 2-pin
• EPNN9288_: 2-pin Switching Power Supply with AC Cord, US 2-pin, 90-264 VAC

5.0 Publications

• 6881098C61: BPR 40 User Guide (English/French Canadian)
• 6816986H01: Mag One by Motorola Series Radio Service Manual (English/French Canadian)
• 6871916T01: Mag One Tri-Chem Charger User Guide (English/Simplified Chinese/Bahasa Indonesia/French Canadian/Russian/Spanish/Portuguese)

6.0 Batteries

• PMNN4071_R: Mag One NiMH Battery, 1200 mAH
• PMNN4075_R: Mag One LiIon Battery, 1500 mAH

7.0 Audio Accessories

• PMMN4008_: Mag One Remote Speaker Switch
• PMLN4442_: Mag One Earbud with in-line Microphone and PTT/VOX* Switch
• PMLN4443_B: Mag One Ear Receiver with in-line Microphone and PTT/VOX* Switch
• PMLN4445_: Mag One Ultra Lightweight Headset with in-line PTT/VOX* Switch
• PMLN4294_: Earbud with Microphone and PTT Combined
• PMLN4605_: Clear Acoustic Tube (replacement kit)
• PMLN4606_: 2-Wire Surveillance Kit with Clear Acoustic Tube
• PMLN4658_: D-Shell Earset with Boom Microphone with PTT/VOX* Switch

*Caution: Your radio does not support the VOX feature. Please set the accessory switch to "PTT". If the accessory switch is set to "VOX", your radio transmits constantly and never receives.

8.0 Service Kits

• PMDN4038_R: Chassis Opener
• PMDN4039_R: Crab Eye Nut Opener
• PMDN4040_R: Test Box
• PMDN4041_R: RF Adapter
• PMDN4042_R: Battery Eliminator
• PMDN4043_R: Programming Cable
• PMDN4044_R: T-Head Ceramic Tuning Tool
• PMDN4054_R: Antenna Ground Plate
• PMDN4053_R: Flat Ceramic Tuning Tool (0.9 mm)
• PMDN4026_R: Flat Ceramic Tuning Tool (1.8 mm)
• PMDN4060_R: Cloning Cable

Appendix A: Replacement Parts Ordering

A.1 Basic Ordering Information

When ordering replacement parts or equipment, include the complete identification number. If the part number is unknown, provide the chassis or kit number and a sufficient description of the desired component.

A.2 Motorola Online

Access the online catalog at http://motorola.com/businessonline. For online access registration, call 1-800-422-4210 (U.S. and Canada Service Centers only). International customers can get assistance at http://motorola.com/businessonline.

A.3 Mail Orders

Mail orders are accepted only by the U.S. Federal Government Markets Division (USFGMD): Motorola Inc., 7031 Columbia Gateway Drive, 3rd Floor - Order Processing, Columbia, MD 21046, U.S.A.

A.4 Telephone Orders

Radio Products and Solutions Organization* (United States and Canada): 7:00 AM to 7:00 PM (Central Standard Time) Monday through Friday. Call 1-800-422-4210 or 1-847-538-8023.

U.S. Federal Government Markets Division (USFGMD): 8:30 AM to 5:00 PM (Eastern Standard Time). Call 1-877-873-4668.

A.5 Fax Orders

Radio Products and Solutions Organization* (United States and Canada): Fax 1-800-622-6210 or 1-847-576-3023 (International).

USFGMD (Federal Government Orders): Fax 1-800-526-8641 (For Parts and Equipment Purchase Orders).

A.6 Parts Identification

Radio Products and Solutions Organization* (United States and Canada): Call 1-800-422-4210.

A.7 Product Customer Service

Radio Products and Solutions Organization (United States and Canada): Call 1-800-927-2744.

* The Radio Products and Solutions Organization (RPSO) was formerly known as the Radio Products Services Division (RPSD) and/or the Accessories and Aftermarket Division (AAD).

Appendix B: Motorola Service Centers

B.1 Servicing Information

For units requiring more extensive testing, component-level troubleshooting, or service beyond basic levels, send the radio to a Motorola Service Center listed below.

B.2 Motorola Service Center

45D Butterfield Trail, El Paso, TX 79906. Tel: 1-800-227-6772

B.3 Motorola Federal Technical Center

4395 Nicole Drive, Lanham, MD 20706. Tel: 1-800-969-6680, Fax: 1-800-784-4133

B.4 Motorola Canadian Technical Logistics Center

Motorola Canada Ltd., 8133 Warden Avenue, Markham, Ontario, L6G 1B3. Tel: 1-800-543-3222, Fax: 1-888-331-9872 or 1-905-948-5970

Glossary of Terms

Busy Channel Lockout (BCLO): Prevents transmission if the channel is active. Checks for carrier or coded squelch activity before transmitting.

Carrier: An electromagnetic signal transmitted on a selected frequency to carry voice or data.

CD: Compact Disk.

Channel: A single path separated by frequency or time divisions for transmitting and/or receiving voice and/or data.

Codeplug: A solid-state chip inside a radio storing personality data.

CPS: Customer Programming Software. Licensed Motorola software for programming two-way radios.

EPP: Environmentally Preferred Product.

Frequency: (a) Location of a channel's center in the radio spectrum (MHz). (b) Computer speed (MHz).

Model Number: Identifies the radio type, stored in the codeplug.

Normal Scan: Assigns equal priority to all channels in the Scan List. Scanning sequence includes all members and the Home Channel.

PLL: Phase-Locked Loop; a circuit that keeps an oscillator in phase with a reference.

Priority Scan: Assigns highest priority to the designated Priority Channel. Scans the Priority Channel 50% of the time.

Program: Transferring CPS information from computer memory to the radio.

PTT: Push-To-Talk; the switch on the radio's side that initiates transmission.

RESET: Reset line; an input to a microcontroller that restarts execution.

Reverse Burst / Turn Off Code: Transmits a Tone Private Line (TPL) or Digital Private Line (DPL) code at the end of a transmission to mute the receiving radio's speaker before carrier loss, eliminating squelch tail noise.

ROM: Read Only Memory.

Scan List: Determines which channels the radio scans in Scan Mode. Allows selection of channel groupings.

Scan List Member: A channel within a Scan List that can be scanned for transmission activity.

Scan Mode: Radio operates in Active Scan or Landed Scan states, initiated by the SCAN button.

Serial Number: Each radio has a unique serial number stored in its codeplug.

Software: Computer programs, procedures, rules, documentation, and data pertaining to system operation.

Squelch: Muting of audio circuits when received signal levels fall below a predetermined value.

Tone Private Line (TPL): Transmitted to ensure reception only from radios with specific TPL codes, creating communication groups and providing privacy on a frequency. Transmitted at a sub-audible frequency. Also known as CTCSS.

Tx Frequency: The designated frequency used when transmitting carrier for the current channel.

°C: Degrees Celsius.

UHF: Ultra High Frequency.

VHF: Very High Frequency.