Ericsson ORION Service manual

LBI-38993
SERVICE SECTION
136-174 MHz ORION
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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DESCRIPTION
This section contains the information required
to service the ORION VHF two-way FM radio. Included
are disassembly procedures, alignment procedures, and
troubleshooting information (see Table of Contents).
This radio is adjusted by setting personality
parameters stored in the radio's computer memory.
Therefore, all radio alignment procedures require the use
of a Personal Computer (IBM PC or equivalent), along
with an EGE Programming Interface TQ3370, and an
ORION PC Programming Cable TQ3377. EGE PC
Programming Software Version 3.00 or later is also
required.
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 EGE Service Center. Any serviceable parts
are listed in the troubleshooting guide for the individual
circuit boards.
INITIAL MEASUREMENTS
After the radio has been installed as described in
the Installation Manual, the following measurements
should be made by a certified electronics technician, and
recorded for future reference:
TRANSMITTER
•RF Power into 50 ohm resistive load
•Forward Power into antenna
•Reflected Power from antenna
•Carrier Frequency
•Modulation Deviation
RECEIVER
•12 dB SINAD Sensitivity from FM signal
generator
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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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DISASSEMBLY PROCEDURE
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.
3. Pull the radio, and remove the mounting bracket.
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.
2. Remove the inner shield by pulling the attached
handle.
Transceiver (TXRX) Module
1. Remove the waterproof top and bottom covers, using
a #20 TORXdriver. Four cover mounting screws
are located on the bottom of the module. The screws
on the bottom cover are captive.
2. To expose the Logic/Audio/455 kHz IF circuitry,
remove the shield on top of the module by pulling
the attached handle.
3. To expose the Exciter/RX Front End circuitry,
remove the shield on the bottom of the module by
pulling the attached handle.
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.
Control Unit (Front Mounted)
1. Expose the Logic/Audio/455 kHz IF circuitry
according to Steps 1 and 2 in Transceiver (TXRX)
Module section.
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.
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,
while simultaneously turning the screw
counterclockwise with the TORXdriver. See LBI-
38909 for details.
4. Disengage the control unit from the Transceiver
chassis using a pivoting motion about the top edge of
the Transceiver chassis.
5. Disengage the four captive screws on the rear cover,
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.
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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3. 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.
4. 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.
To Re-Assemble Unit after Servicing
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.
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.)
Steps:
1. Remove dust and dirt from the black O-Ring
gasket.
2 Apply proper amount of the silicone grease to cloth.
3. Put the silicone grease on throughout the surface of
the black O-Ring gasket evenly. (see Figures 1A
and 1B)
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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Figure 1A - Front Mount Control Unit "O-Ring" Lubrication
Figure 1B - Remote Mount Control Unit "O-Ring" Lubrication
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ALIGNMENT PROCEDURES
INTRODUCTION
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.
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.
The PC must be equipped with the EGE 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 "EDACS3" and "MRKMAINT."
Consult the PC Programming Software manuals for
further details regarding this software.
CAUTION
Before bench testing the radio, be sure of the output
voltage characteristics of your bench power supply.
To protect the transmitter power output transistors from
possible instant destruction, the following input voltages
must not be exceeded
Transmitter unkeyed: 16.5 Volts
Transmitter keyed 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.
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.
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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Figure 2 - ORION Programming Configurations (USA)
Figure 3 - ORION Programming Configurations (EURO)
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TRACKING DATA
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.
Furthermore, if the Tracking Data is lost, specialized
procedures are required to load new Tracking Data.
therefore, it is VERY IMPORTANT to establish a
record 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.
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)
Parameter RF Power
Modulation
Deviation
Squelch Set
f1L (MHz) 136.0000
136.0000
136.0000
f1H (MHz) N/A
139.9950
N/A
f2L (MHz) 140.0050
140.0050
140.0050
f2H (MHz) N/A
143.9950
N/A
f3L (MHz) 144.0050
144.0050
144.0050
f3H (MHz) N/A
147.9950
N/A
f4L (MHz) 148.0050
148.0050
148.0050
f4H (MHz) 153.0000
153.0000
153.0000
Table 3 - Tracking Data Frequencies (High Split)
Parameter RF Power
Modulation
Deviation
Squelch Set
f1L (MHz) 150.0000
150.0000
150.0000
f1H (MHz) N/A
155.4950
N/A
f2L (MHz) 155.5050
155.5050
155.5050
f2H (MHz) N/A
161.4950
N/A
f3L (MHz) 161.5050
161.5050
161.5050
f3H (MHz) N/A
167.4950
N/A
f4L (MHz) 167.5050
167.5050
167.5050
f4H (MHz) 174.0000
174.0000
174.0000
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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 NEW TRACKING DATA
Replace PA module 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 None
Replace Synthesizer PWB Modulation Deviation and Data Offset
Replace Logic PWB 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:
1. Using the EGE PC Programming Software , make
sure the radio is programmed in the following
sequence:
a. Customer Operational Software (if necessary)
b. Tracking Data (First Iteration -- Tracking Data
originally shipped with the radio is a good
starting point.)
c. Feature Encryption File (if necessary). Note: In
order to load an Encryption File into a new
Logic PWB, EGE Service Parts Department
must first be contacted at 1-800-368-3277 for
authorization code. Otherwise the file will not
load.
d. Personality, which contains a Conventional
System using the frequencies given in Tables 2
and 3.
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:
Parameter Limit
TX Modulation Deviation 4.4 ±0.1 kHz
TX High Power 110 W Model 110 +4, -0 W
50 W Model 50 +2, -0 W
25 W Model 25 +0, -1 W
TX Mid Power 25 W Model 15 +.5, -.5 W
TX Low Power 110 W Model 55 +2, -0 W
50 W Model 25 +1, -0 W
25 W Model 6 +.5 -.5 W
RX Squelch Threshold 8 +1, -0 dB
SINAD
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.
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4. Repeat Steps 2 and 3 until the measurements at
every frequency given in Tables 2 and 3 are within
the limits specified.
TRANSMITTER ALIGNMENT
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:
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.
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.
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:
Synthesizer: CV240, CV280, RV201
Power Amp - 25 W: RV1
Power Amp - 50 and 110 W: RV2
These components have been set at the factory, and
are NOT ADJUSTABLE. ANY RE-ADJUSTMENT
OF THESE COMPONENTS WILL VOID THE
WARRANTY OF THIS PRODUCT.
NOTICE
The components listed above have been set at the factory
and are NOT adjustable.
ANY RE-ADJUSTMENT OF THESE COMPONENTS WILL
VOID THE WARRANTY OF THIS PRODUCT.
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.
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.
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.
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
mounting surface. Place the transistor in the
mounting hole. Align the leads as shown on the
Outline Diagram. Then replace the transistor
mounting screws using moderate torque (9.4 kg.cm).
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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 wire board runs to separate from the board.
Check for shorts and solder bridges before applying
power.
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.
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.
TEST EQUIPMENT REQUIRED
•Distortion Analyzer∗
•AC Voltmeter∗
•RF Signal Generator∗
•Frequency Counter (136-174 MHz)∗
•4-Ohm, 25 Watt Resistor
•Audio Isolation Transformer (1:1)
19A116736P1 or equivalent **
∗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.
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.
ADJUSTMENT PROCEDURES
Receiver Frequency Adjustment
No receiver frequency adjustment is required.
2nd Receiver Oscillator
Using a frequency counter to monitor Terminal
TP5, set L521 for a frequency of 44.545 MHz ±200 Hz.
IF/FM Detector Alignment
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).
Adjust the VOLUME control for 15 watts output
(7.75 VRMS) using the Distortion Analyzer as a
voltmeter.
Set the output signal level of the RF signal generator
so as to obtain 12 dB SINAD at the audio output.
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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4-OHM
LOAD
1 : 1
DISTORTION
ANALYZER
OR
AC VOLTMETER
ISOLATION
TRANSFORMER Not required if instrument
input is balanced with respect
to ground.
Figure 4 - Audio Isolation Transformer
SQUELCH ADJUSTMENT
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.
TROUBLESHOOTING GUIDE
INTRODUCTION
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
EGE Service Center. a list of serviceable parts is given
in the next section.
MICROPHONICS
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.
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.
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SERVICEABLE PARTS
Control Unit - Switch Circuit CDF-368B/M
No serviceable parts.
Control Unit - Panel Control CMC-638
No serviceable parts.
Remote Control Unit - RIA NQZ-4882
J2 Connector, 18 Pin B19/5JBAX00020
Radio Unit - System Control CMC-682
F601 Fuse, 5 Amp B19/5ZFAP00008
IC604 AF Power Amplifier B19/5DAAA00350
J701 Connector, 18 Pin B19/5JDAG00315
Radio Unit - IF CMF-135
No serviceable parts.
Radio Unit - Synthesizer/Receiver/Exciter
CMN-352
No serviceable parts.
Radio Unit - Power Amplifier 110 Watts
CAH-515H
C25 Capacitor, 270 pF (136-153 MHz) B19/5CAAA03092
C25 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03097
C26 Capacitor, 270 pF (136-153 MHz) B19/5CAAA03092
C26 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03097
C27 Capacitor, 270 pF (136-153 MHz) B19/5CAAA03092
C27 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03097
C28 Capacitor, 270 pF (136-153 MHz) B19/5CAAA03092
C28 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03097
C33 Capacitor, Mica, 47 pF B19/5CMAB01252
C33 Capacitor, Mica, 47 pF B19/5CMAB01252
HC1 Power Module (136-153 MHz) B19/5DHAA00049
HC1 Power Module (150-174 MHz) B19/5DHAA00050
TR2 Transistor, NPN B19/5TCAF00510
TR3 Transistor, NPN B19/5TCAF00510
Radio Unit - Power Amplifier 55 Watts CAH-515L
C8 Capacitor, 270 pF (136-153 MHz) B19/5CAAA03092
C8 Capacitor, 220 pF (150-174 MHz) B19/5CAAA03097
C9 Capacitor, 270 pF (136-153 MHz) B19/5CAAA01092
C9 Capacitor, 220 pF (150-174 MHz) B19/5CAAA01097
C159 Capacitor, Mica, 47 pF B19/5CMAB01252
HC1 Power Module, (136-153 MHz) B19/5DHAA00051
HC1 Power Module, (150-174 MHz) B19/5DHAA00052
TR1 Transistor, NPN B19/5TCAF00510
Radio Unit - Power Amplifier 25 Watts CAH-515E
HC1 Power Module, (136-153 MHz) B19/5DHAA00049
HC1 Power Module, (150-174 MHz) B19/5DHAA00050
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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
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.
Figure 5 - Typical ORION Test Configuration
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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
SYMPTOM DIAGNOSTIC PROCEDURE
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. Adjust XU201 on the Synthesizer PWB. If the frequency is still out of
specification, replace the Synthesizer PWB.
Low or no modulation. a. Program a Conventional System with frequecncies 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

LBI-3899
3
RECEIVER
SYMPTOM
DIAGNOSTIC PROCEDURE
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
µ
V. 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
µ
V RF signal (with 1 kHz audio modulation at 3
kHz deviation) 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

L
BI-38993
CONTROL UNIT
SYMPTOM DIAGNOSTIC PROCEDURE
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:
EGE- 1993
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:
EGE- 1993
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

LBI-3899
3
GENERAL
SYMPTOM
DIAGNOSTIC PROCEDURE
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.
ERROR CODES
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.
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.
All System Groups ORION
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.
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.
19

L
BI-38993
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 ROM errors UNKNOWN
SOFTWARE General software failure FEAT ERR Feature encryption error
TRACKING Tracking data fatal error DSP ERR DSP error
NO LOCK Synthesizer not locking
FREQDATA Frequency data fatal error
PERSDATA Personality errors
20