Codan MT-4E Operating manual

www.codancomms.com
MT-4E Analog and
P25 Digital
Radio Systems
MAINTENANCE GUIDE

MT-4E ANALOG & P25 DIGITAL RADIO SYSTEMS | MAINTENANCE GUIDE
Page i
Codan MT-4E
Analog and
P25 Digital
Radio Systems
Maintenance Guide

MAINTENANCE GUIDE | MT-4E ANALOG & P25 DIGITAL RADIO SYSTEMS
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© 2013 Codan Limited.
No part of this guide may be reproduced, transcribed, translated into any
language or transmitted in any form whatsoever without the prior written
consent of Codan Limited.
CODAN™, NGT™, Easitalk™, CIB™ and CALM™ are trademarks of
Codan Limited. Other brand, product, and company names mentioned
in this document are trademarks or registered trademarks of their
respective holders.
The English version takes precedence over any translated versions.
NOTE
DOCUMENT REVISION
DEFINITION
Codan Communications
43 Erie Street, Victoria, BC
Canada V8V 1P8
www.codancomms.com
[email protected]
Toll Free Canada and USA:
Phone: [phone]
Fax: [phone]
International:
Phone: [phone]
Fax: [phone]
PRINTED IN CANADA
Document Number:
Revision:
Revision Date:
MG-001
6-0-0
September 2013
Documentation uses a three-level revision system. Each element of
the revision number signifi es the scope of change as described in the
diagram below.
Major Revisions:
The result of a major change to
product function, process or requirements.
Minor Revisions:
The result of a minor change to
product, process or requirements.
Editorial Revisions:
The result of typing corrections or
changes in formatting, grammar or wording.
1-0-0
Three-level revision numbers start at 1-0-0 for the fi rst release. The
appropriate element of the revision number is incremented by 1 for each
subsequent revision, causing any digits to the right to be reset to 0.
For example:
If the current revision = 2-1-1 Then the next major revision = 3-0-0
If the current revision = 4-3-1 Then the next minor revision = 4-4-0
If the current revision = 3-2-2 Then the next editorial revision = 3-2-3
Document revision history is provided at the back of the document.

MT-4E ANALOG & P25 DIGITAL RADIO SYSTEMS | MAINTENANCE GUIDE
Page iii
Codan Communications is a leading international designer and
manufacturer of premium communications equipment for High
Frequency (HF) and Land Mobile Radio (LMR) applications. We’ve
built our reputation for reliability and customer satisfaction over 50
years in radio communications, in some of the toughest conditions
on the planet.
For over 50 years Codan has provided customers in North America
and internationally with highly reliable Base Stations and Repeaters
that are environmentally robust to operate in rugged and extreme
temperature conditions where low current consumption (solar
powered) is a key requirement.
Codan is a pioneering member of the P25 Digital standard, for radio
system interoperability between emergency response governmental
organizations, providing enhanced functionality and encryption.
Our products operate between 29 - 960 MHz and are available in
a variety of Base Station and Repeater confi gurations for two way
voice and mobile data applications.
Our self-servicing customers range from Forestry and National Park
services through Police and Fire departments and on to Utility and
Transportation groups. Our products have been deployed in every
imaginable situation from the Antarctic to Hawaiian mountaintops to
Alaska, enabling respondents to Forest Fires, Ground Zero rescue
and routine patrols.
Codan is an industry leader in Analog and P25 radio systems design.
We off er modular rack-mounted Base Stations and Repeaters
capable of operating in Low Band VHF,VHF AM , VHF FM, UHF FM,
700 MHz, 800 MHz, 900 MHz
ABOUT CODAN
COMMUNICATIONS
On August 7th, 2012 - Codan Limited (ASX: “CDA”) announced
the acquisition of Daniels Electronics Limited, a leading designer,
manufacturer and supplier of land mobile radio communications
(LMR) solutions in North America. The acquisition of Daniels delivers
on Codan’s stated strategy of growing market share and diversifying
its radio communications product off ering. Codan Limited designs,
manufactures and markets a diversifi ed range of high value added
electronic products, with three key business divisions; radio
communications, metal detection and mining technology.
DANIELS ELECTRONICS
IS NOW CODAN
COMMUNICATIONS

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Codan Communications provides many resources for the testing,
tuning, maintenance and design of your Codan MT-4E Analog and
P25 Digital Radio System.
Instruction Manuals
Codan instruction manuals are very comprehensive and include
information on:
Theory of operation
Detailed Specifi cations
Testing and tuning instructions
Component layout illustrations
Instruction manuals can be obtained from the factory.
Technical Notes
Technical notes outline key aspects of tuning, installing,
maintaining and servicing Codan Radio Systems.
Technical Notes can be found online at www.codancomms.com.
Codan MT-4R/D and IFR 2975 Test Procedures (TN950)
Technical Note TN950 is an aid to confi guring and testing Codan
MT-4R/D radios using an IFR 2975 Service Monitor by Aerofl ex.
TN950 is intended to be used with IFR 2975 Setup fi les that can be
loaded into the Service Monitor.
TN950 and Setup Files can be found online at www.codancomms.
com and can also be found on the Aerofl ex web page at www.p25.
com.
Application Notes
Application Notes provide an overview of the range of applications
in which Codan Radio systems can be used.
Application Notes can be found online at www.codancomms.com.
P25 Training Guide
The P25 Training Guide provides the reader with a simple, concise
and informative description of Project 25.
The P25 Training Guide can be found online at
www.codancomms.com.
MT-4E Analog and P25 Digital Radio Systems User Guide
The MT-4E User Guide provides an overview of the confi guration,
operation and programming of Codan MT-4E radios.
The MT-4E User Guide can be found online at www.codancomms.
com.
RESOURCES

MT-4E ANALOG & P25 DIGITAL RADIO SYSTEMS | MAINTENANCE GUIDE
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Contents
Chapter 1: Codan Radio Maintenance ...................................1
Introduction to Codan MT-4E .....................................................................1
Recommended Maintenance Schedule .....................................................2
Repair Note ................................................................................................2
ESD - Electrostatic Discharge ....................................................................2
Audio and Carrier Levels Reference ..........................................................3
Audio Levels ...................................................................................................3
Carrier Levels .................................................................................................3
Chapter 2: Installation ............................................................5
Installation of Codan Subracks .................................................................. 5
Chapter 3: Test Equipment and Spares .................................9
Recommended Test Equipment .................................................................9
Recommended Spares ............................................................................ 10
Recommended Maintenance Items ......................................................... 11
Chapter 4: Radio Site Survey .............................................. 13
Introduction to a Radio Site Survey ......................................................... 13
Codan Radio Site Checklist and Inventory ....................................................13
Preparation for a Site Survey ................................................................... 14
Exterior Site Survey ................................................................................. 15
Interior Site Survey .................................................................................. 15
Radio Site Inventory ................................................................................. 15
Radio System Testing .............................................................................. 16
Departure Checklist ................................................................................. 16

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Chapter 5: Codan Radio System Testing ............................. 17
MT-4E Testing with the IFR 2975 by Aerofl ex .......................................... 17
General Set-Up and Connections ............................................................ 18
Uploading Codan Confi gurations to the IFR 2975 .........................................18
Radio Service Software (RSS) ......................................................................19
Control Cards ................................................................................................19
Adapters, Cables and Extender Cards ..........................................................19
Codan MT-4E Radio System Test Sheet .......................................................19
Turning OFF the MT-4E Receiver and Transmitter Modules .........................20
Audio Connections ........................................................................................21
System Regulator Testing ........................................................................ 22
System Voltage Testing .................................................................................22
Receiver Testing ....................................................................................... 23
Receiver Analog Testing ................................................................................23
Receiver Digital Testing .................................................................................28
Receiver Bit Error Rate Testing .....................................................................30
Receiver RF Preselector Alignment and Tuning ............................................32
Receiver Reference Oscillator Adjustment ....................................................34
Transmitter Testing ................................................................................... 37
Transmitter Analog Testing ............................................................................37
Transmitter CTCSS Testing ...........................................................................42
Transmitter Digital Testing .............................................................................45
Transmitter Modulation Fidelity Testing .........................................................47
Transmitter Reference Oscillator Adjustment ................................................49
System Testing ......................................................................................... 51
Duplex Analog Testing ...................................................................................51
Duplex Digital Testing ....................................................................................54
Chapter 6: Additional Radio System Tests ........................... 57
Radio System Testing Through Filtering Equipment ................................ 58
Radio System Testing with the Antenna Connected ................................ 59
VSWR ............................................................................................................59
Receiver Desense .........................................................................................60
RF Carrier Signal Levels on Links between Sites .........................................61
Spurious Signals over the Air ........................................................................62
Chapter 7: Blank Worksheets .............................................. 63

MT-4E ANALOG & P25 DIGITAL RADIO SYSTEMS | MAINTENANCE GUIDE
Chapter 1: Codan Radio Maintenance Page 1
CHAPTER 1: CODAN RADIO MAINTENANCE
This document is written as a maintenance guide to Codan MT-4E Analog and P25 Digital Radio Systems.
The document assumes the reader is familiar with conventional Two-Way Radio Communications
systems and general electronics maintenance practices. This document is a companion document to
the Codan Communications MT-4E Analog and P25 Digital Radio Systems User Guide.
INTRODUCTION TO CODAN MT-4E
Codan MT-4E radio systems are designed for operation in highly varied conditions. Your application
may require high performance radio systems (intermodulation and selectivity) for operation in congested
radio sites, operation over wide temperatures using battery solar powered systems (low current drain),
or a confi gurable system for emergency deployment in a transportable case. Codan manufactures a
diverse range of radio products tailored to the type of operation you need.
The MT-4E radio system is characterized by high performance and reliability, whether it is a remote,
low current repeater or a high performance base station. The total system is designed to provide
dependable, low maintenance performance and great fl exibility for expansion and servicing.
The MT-4E series of radio and control modules are packaged in the compact Eurostandard housing with
anodized aluminum front panels, and are ruggedly designed for remote or transportable applications.
All of the modules use high reliability components and corrosion resistant fasteners.
The MT-4E radio system is specifi cally designed to deliver high performance under adverse conditions.
Voltage stress testing and a 24 hour burn-in is performed on the radio system and performance of the
system at room temperature (25°C) is documented and measured. As an option, extensive environmental
testing can be conducted over the temperature range - 30°C to + 60°C and the performance measured
to ensure compliance with the design specifi cations.
A Codan MT-4E radio system consists of separate RF receiver and transmitter modules plugged into
a standard 19” subrack. Each subrack also requires a control card and system regulator. External
connections to the system (COR, PTT, audio, channel select, etc.) are made through an auxiliary
connector on the rear of the subrack. An optional cable or terminal strip connector is available to
connect externally through the auxiliary connector to the radio system.

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Chapter 1: Codan Radio MaintenancePage 2
RECOMMENDED MAINTENANCE SCHEDULE
Codan Communications does not recommend any specifi c maintenance schedule for our MT-4E
radio systems. Many organizations have annual preventative maintenance scheduled as part of their
standard maintenance procedures; other organizations will only maintain the radio system when a
system failure occurs; and other organizations will use a combination of preventative maintenance and
maintenance for failures.
REPAIR NOTE
The MT-4E Radio System employs a high percentage of surface mount components which should not
be removed or replaced using an ordinary soldering iron. Removal and replacement of surface mount
components should be performed only with specifi cally designed surface mount rework and repair
stations complete with Electrostatic Discharge (ESD) protection. When removing Surface Mount Solder
Jumpers, it is recommended to use solder wick braid in place of vacuum type de-soldering tools. This
will help prevent damage to the circuit boards.
ESD - ELECTROSTATIC DISCHARGE
Static Electricity can damage electronic equipment, causing it to stop functioning immediately, or
degrading it, leading to breakdown later. Static sensitive parts should be handled by technicians
grounded with wrist and/or two heel straps. Transferring of ESD sensitive components to or from
diff erent areas should be conducted in ESD safe bags, tote boxes or carts.

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Chapter 1: Codan Radio Maintenance Page 3
AUDIO AND CARRIER LEVELS REFERENCE
The following are conversions for both audio levels and RF carrier levels.
Audio Levels
2.500 Vrms 6.928 Vpp +10 dBm (@ 600 ohms)
0.975 Vrms 2.758 Vpp +2 dBm
0.775 Vrms 2.191 Vpp 0 dBm
0.388 Vrms 1.098 Vpp -6 dBm
0.308 Vrms 0.872 Vpp -8 dBm
0.245 Vrms 0.692 Vpp -10 dBm
0.098 Vrms 0.276 Vpp -18 dBm
0.077 Vrms 0.219 Vpp -20 dBm
Carrier Levels
70.71 uV -70 dBm (@ 50 ohms)
0.707 uV -110 dBm
0.398 uV -115 dBm
0.354 uV -116 dBm
0.316 uV -117 dBm
0.282 uV -118 dBm
0.251 uV -119 dBm
0.224 uV -120 dBm
0.199 uV -121 dBm
0.178 uV -122 dBm
0.158 uV -123 dBm

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Chapter 2: Installation Page 5
CHAPTER 2: INSTALLATION
INSTALLATION OF CODAN SUBRACKS
1. Ensure the 19” rack has enough room for the Codan subrack to be installed. Each Codan subrack
requires 5 1/4” height (3 RU) and 13.5” (maximum) depth clearances.
2. Install the subrack unit(s) in the 19” rack using four #10 x 3/4” screws as shown in Figure 2-1. Eight
screw holes are available, only four screws are required to mount the subrack properly. Use stainless
steel screws if the equipment is to be placed in a corrosive environment.
Figure 2-1: Subrack Installation
#10 x 3/4”
screws

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Chapter 2: InstallationPage 6
3. Connect the primary power (+10 Vdc to +17 Vdc, +13.8 Vdc nominal) to the Barrier Strip power input
on the rear of the subrack as shown in Figure 2-2. Ensure that the power source does not exceed +18
Vdc. Use a wire gauge suitable for delivering the power required by the subrack(s). If the subrack is
using a DC-DC or AC-DC Power Supply, refer to the specifi c manual supplied with the equipment for
installation instructions.
Reverse voltage protection and over voltage protection (transient suppressor) is provided at the main
power (+13.8 Vdc) input as well as the +9.5 Vdc line. The main power input is protected with a standard
fast-blow 15 amp fuse. These components may require replacing if the power supply is not connected
properly, or even after a power surge or a lightning strike. The two transient suppressors have diff erent
voltage ratings for the main power input and +9.5 Vdc lines.
4. Install the System Regulator, Receiver, Transmitter, Power Amplifi er and Control Card modules in to
the subrack using the proper guide rail slots if not already done. When installing modules, ensure the
quick release fasteners on the top and the bottom of the modules are in the unlocked (slot should be
horizontal) position before insertion to the guide rails. To lock the quick release fasteners, push and
turn the fastener 90 degrees clockwise with a fl at screwdriver.
Note: MT-4E modules may be removed or inserted from the subrack while power is supplied without
damaging the equipment.
5. Interconnect +9.5 Vdc and +13.8 Vdc power between subrack units if one of the subracks does
not include a system regulator (no system regulator is required for a second subrack with only power
amplifi ers mounted in it). If a CI-RC-4M Multiple Link Controller is part of the system, connect the
+9.5 Vdc from the subrack to the controller. Connect the audio, channel select and control signal lines
from a CI-RC-4M Multile Link Controller to the optional screw-type A-PNL-AUX96-3 auxiliary terminal
connector or use the DB25 connector to connect the to a CI-RC-4M-G2 Multiple Link Controller.
Figure 2-2: Subrack Power Connections
Power Input
+10 to +17 Vdc
+13.8 Vdc Nominal
+9.5 Vdc Regulated
Power Input / Output
(used for interconnecting
2 subracks or powering
CI-RC-4M)
P1 Auxiliary
Connector
Fuse Reverse and
Over Voltage
Protection
CI-RC-4M-G2
connector

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Chapter 2: Installation Page 7
6. If an external controller (eg. Telex tone-remote adapter) is to be connected to the system, all wiring
should be made to the DB25 connector or to the optional screw-type A-PNL-AUX96-3 auxiliary terminal
connector shown in Figure 2-3.
The female DB25 connector can be used for basic base connections to a Telex DSP-223 or IP-223,
using a standard straight-through male-to-male DB25 cable. The IP-223 also requires that 2 pins on the
DB25 (PTT COM - pin2 and MON COM - pin 16) are wired to ground for proper operation.
WARNING: JU108 must be confi gured correctly for DSP-223 or IP-223 or damage can occur.
JU108 A for +13.8 Vdc / DSP-223 or JU108 B for Rx A COR / IP-223
The plug in screw connectors on the A-PNL-AUX96-3 can be removed to allow for easy connection of
the wires.
For some applications, a cable, not a terminal strip connector, is used to connect to the auxiliary
connector. The cable must be plugged into the P1 auxiliary connector shown in Figure 2-2 on the rear
of the subrack. Ensure locking tabs on the connector are completely engaged.
Figure 2-3: Auxiliary Terminal Connector
7. Connect the RJ45 cables between the Receiver, Transmitter and Control Card for repeater
operation.
8. Connect the RF cables to the Receiver and Transmitter and ensure they are fi rmly screwed on.
Ensure the RF cables are properly connected to the Duplexer / Antenna Relay / Multicoupler / Combiner
and Antenna.
A-PNL-AUX96-3 optional
screw-type auxiliary
terminal connector
Telex CI-DSP-223
or CI-IP-223
connector

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Chapter 3: Test Equipment and Spares Page 9
CHAPTER 3: TEST EQUIPMENTAND SPARES
RECOMMENDED TEST EQUIPMENT
Codan Communications recommends the following test equipment for maintenance of an MT-4E radio
system:
+13.8 Vdc Power Supply Codan PSA-12-40-RB-00
(rated for current draw of equipment) (40 Amp rack-mounted power supply)
ICT ICT24012 (60 Amp desktop power supply)
ICT ICT12012 (10 Amp desktop power supply)
Current Meter / Multimeter Fluke 75 Multimeter
Communications Service Monitor Marconi Instruments 2965A
(Analog) Aerofl ex IFR 1200 (Super S)
Aerofl ex IFR COM-120
Communications Service Monitor Aerofl ex IFR 2975
(P25 Digital and Analog) Aerofl ex IFR 3920
Aerofl ex IFR 3500
Aerofl ex IFR 3550
General Dynamics R2670
General Dynamics R8000
Alignment Tools Codan A-TK-04
RF Signal Sampler Bird Model 4275 Variable RF Signal Sampler
Wattmeter Bird Model 43 Wattmeter
It is recommended that when in the shop / service area, the Communications Service Monitor be
frequency locked to an external reference (WWVH, GPS, Loran C) so that the high stability local
oscillator may be accurately set to within its ±1 ppm frequency tolerance.
The test equipment should be calibrated on an annual basis to ensure accurate measurements.

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Chapter 3: Test Equipment and SparesPage 10
RECOMMENDED SPARES
Codan Communications recommends one complete radio system spare for every ten radio systems
(or less) in operation to account for lightning damage or other maintenance issues. The amount of
spares could be dependant on the critical nature of the radio system and the availability of service for
the system. Codan recommends a complete radio system spare for every critical / essential site in
the system. The design of Codan MT-4E radio systems makes it easy to swap components of a radio
system and can save valuable time and eff ort during maintenance. The exact spares would depend on
the types of systems in operation, but would typically include:
Subrack / Motherboard SR-39-1
System Regulator SM-3-H0-014-00 (Standard)
SM-3-H0-014-01 (with main power switch)
SM-3-H0-R1N-00 (with single antenna relay)
SM-3-H0-R2N-00 (with dual antenna relays)
Control Card CI-RC-4L (Repeater Control Card)
CI-BC-4E (Base Control Card)
CI-RC-4M (Multiple Link Controller)
Receiver VR-4E150-A0-000 (136 - 174 MHz Class A)
UR-4E420-A0-000 (406 - 430 MHz Class A)
UR-4E460-A0-000 (450 - 470 MHz Class A)
VR-4E150-00-000 (136 - 174 MHz Class B)
UR-4E380-00-000 (380 - 406 MHz Class B)
UR-4E420-00-000 (406 - 430 MHz Class B)
UR-4E440-00-000 (430 - 450 MHz Class B)
UR-4E460-00-000 (450 - 470 MHz Class B)
UR-4E500-00-000 (470 - 520 MHz Class B)
UR-4E768-00-000 (768 - 776 MHz Class B)
UR-4E800-00-000 (798 - 824 MHz Class B)
UR-4E850-00-000 (851 - 869 MHz Class B)
UR-4E900-00-000 (896 - 902 MHz Class B)
UR-4E950-00-000 (930 - 960 MHz Class B)
Transmitter VT-4E150-00-800 (136 - 174 MHz)
UT-4E380-00-800 (380 - 406 MHz)
UT-4E450-00-800 (406 - 470 MHz)
UT-4E500-00-800 (470 - 520 MHz)
UT-4E850-00-300 (768 - 869 MHz)
UT-4E900-00-300 (896 - 960 MHz)
Amplifi er AMP-4-150-30-00 (136 - 174 MHz)
AMP-4-410-30-00 (380 - 430 MHz)
AMP-4-470-30-00 (450 - 470 MHz
Auxiliary Connector A-PNL-AUX96-3

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Chapter 3: Test Equipment and Spares Page 11
RECOMMENDED MAINTENANCE ITEMS
Codan Communications recommends the following maintenance items at each radio site:
A-TK-04 MT-4 Tool Kit
EC-48RD 48 pin Direct Connect Extender
EC-96D1 96 pin Direct Connect Extender
5059-TP110300 Test Points (included with all extender cards)
Additional extender kits can also be located at the radio shop:
EC-48RK-1.22 48 pin Extender Kit with cable
EC-96K-1.22 96 pin Extender Kit with cable
Items included in the MT-4 Tool Kit include:
5192-WJ01BJ01 SMB to BNC Jack Adapter
7910-WP0WP012 SMB to SMB Cable
2007-1N637500 10V Transient Suppressor
2007-1N637800 18V Transient Suppressor
2001-MR751000 Reverse Voltage Diode (Qty=2)
5604-5GAGC150 15 Amp Fast-Blow Fuse
CBLC46-12506050 50 cm RJ45 Cable
Radio Service Software (RSS)
APP-RSS03-WC-XX Radio Service Software for programming and service of the Receiver
and Transmitter modules.
CBLC44-20704305 type A to 5 pin mini-type B USB cable to connect from computer to
Receiver or Transmitter.

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