M/A-Com Orion User manual

Installation Manual
LBI-38901T
Orion™
Mobile Radio

2
CREDIT
M/A-COM and EDACS are registered trademarks and Orion, ProGrammer, and ProVoice are
trademarks of M/A-COM, Inc.
TORX is a registered trademark of CAMCAR/TEXTRON.
POZIDRIV is a registered trademark of Phillips International Company.
IBM is a registered trademark of IBM.
Windows is a registered trademark of Microsoft Corporation.
Molex is a registered trademark of Molex Company.
All other brand and product names are trademarks, registered trademarks or service marks of their
respective holders.
This manual is published by M/A-COM, Inc., without any warranty. Improvements and changes to this
manual necessitated by typographical errors, inaccuracies of current information, or improvements to programs
and/or equipment, may be made by M/A-COM, Inc., at any time and without notice. Such changes will be
incorporated into new editions of this manual. No part of this manual may be reproduced or transmitted in any
form or by any means, electronic or mechanical, including photocopying and recording, for any purpose,
without the express written permission of M/A-COM, Inc.
Copyright© 1993-2004, M/A-COM, Inc. All rights reserved.

TABLE OF CONTENTS Page
INTRODUCTION.............................................................................4
UNPACKING AND CHECKING EQUIPMENT ............................5
INSTALLATION (Single Control Unit)......................................... 11
STEP 1 – PLAN THE INSTALLATION ................................11
STEP 2 - LOCATE TOOLS REQUIRED................................ 12
Vehicles Powered By Liquefied (Lp) Gas ........................12
STEP 3 – INSTALL CABLES.................................................13
Power Cable ...................................................................... 13
Ignition Sense (All Applications)......................................14
Accessory Cable (Front Mount)........................................ 16
Accessory and Control Cable (Remote Mount) ................ 24
STEP 4 – MOUNT CONTROL UNIT AND RADIO .............34
Control Unit Mounting (Remote Applications Only)........34
Pigtail Bracket................................................................... 34
Radio Front Mount And Final Hook-Up........................... 37
Radio Remote Mount and Final Hook-Up........................38
Cassette Mounting (EURO Only) ..................................... 40
STEP 5 - INSTALL OPTIONS AND ACCESSORIES...........44
Speaker D2LS1F...............................................................44
Microphone Hanger and/or Hookswitch Mounting .......... 44
Siren and Light..................................................................45
INSTALLATION (Dual Control Units).......................................... 47
STEP 1 - PRE-INSTALLATION PROGRAMMING ............. 47
Front Mount Procedure ..................................................... 47
Remote Mount Procedure.................................................. 51
STEP 2 – INSTALL DUAL CONTROL UNITS .................... 55
Front Mount ...................................................................... 55
Remote Mount...................................................................58
DUAL RADIO UNITS.................................................................... 63
STEP 1 - PRE-INSTALLATION PROGRAMMING ............. 63
Master Radio Programming .............................................. 64
Slave Radio Programming................................................. 64
STEP 2 – INSTALL CABLES/EQUIPMENT.........................67
Front Mount ...................................................................... 67
Remote Mount...................................................................69
Keyloading the Radio........................................................ 74
Keyloading a Dual Radio..................................................75
TECHNICAL ASSISTANCE .........................................................78
3

INTRODUCTION
This manual contains installation instructions for the Orion™Mobile radio unit
and associated accessories. These instructions cover the mounting and
cabling of the radio. Interconnection and wiring diagrams are provided for
reference. Before the installation, program the radio using the following:
• IBM®compatible personal computer
• TQS3385 – ProGrammer™PC Software
or
TQS3389 - Conventional ProGrammer PC Software
• TQ3370 - Serial/Flash Programming Interface Module
(required with TQ3377 cable only)
• One of the following programming cables:
o TQ3377 (19B802554P15) – Shop Programming Cable (requires
TQ3370)
o TQ3409 (CA101288V15) - Shop Programming Cable (does not
require TQ3370)
o *TQ3410 (CA101287V1) - Field Programming Cable (does not
require TQ3370)
* The field programming cable must be used with one of the following
accessory cables:
CA101288V2, CA101288V4, CA101288V10
CAUTION
ORION UHF MOBILES
The PC programmer automatically defaults the receiver
oscillator shift to position No. 2. When field programming,
the receive frequencies for Orion UHF mobiles, the oscillator
shift must be programmed to position No. 1 or No. 3. Enter
the CONVENTIONAL and/or TRUNKED FREQUENCY
SET screen of the PC programmer and set the values in the
“OS” column to “1” or “3”.
4

UNPACKING AND CHECKING EQUIPMENT
Carefully unpack the radio and identify each item in the shipping container as
listed below. The available options for the Orion Mobile Radio are covered in
Table 1. If damage has occurred to the equipment during shipment, file a
claim with the carrier immediately.
• Orion Mobile radio unit
• Microphone D2MC3Z
• Speaker D2LS1H
• Power Cable D2CE1V
or D2CF9A
Control Cable D2CE1Y
• Front Mount Bracket Kit or D2MA3N
Remote Mount Kit with D2MA3R
Control Unit Mount Kit D2MA3J
• Operator's Manual LBI-38888
• Installation Manual LBI-38901
Figure 1: Orion Mobile Radio Components
USA EURO
Figure 2: Rear View of Radios
5

Figure 3: Option Cables
6

NOTE
At the time this manual was published, M/A-COM, Inc. was
in the process of offering additional programming cables and
replacing some of the accessory cables for the Orion mobile
radio. This manual provides information on both the existing
cable offerings and the replacement cables. The following
cables are impacted:
CA101288V2 will replace 19B802554P2
CA101288V4 will replace 19B802554P4
CA101288V10 will replace 19B802554P10
CA101287V1, V2 and V3 will be added
CA101288V15 and V30 will be added
Figure 4: Option Cables con’t
7

NOTE
The programming cables shown in Figure 5 do not require the
TQ3370 interface box. The field programming cables shown
in Figure 5 are ONLY compatible with the following
accessory cables:
CA101288V2, CA101288V4, CA101288V10
CA101287V2
Keyloading Interface
Programming Interface Cable,
CA101287V1 and Mobile Data Interface,
CA101287V3
Figure 5: Programming/Interface Cables
8

9
Table 1: Orion Mobile Radio Options And Accessories
OPTION DESCRIPTION
Z OPTIONS
D2ZN1A Accessory Kit–Front Mount with Standard Option Cable
D2ZN1B Accessory Kit–Front Mount with Extended Option Cable
D2ZN1C Accessory Kit–Front Mount Euro with Standard Option Cable
D2ZN1D Accessory Kit–Front Mount Euro with Extended Option Cable
D2ZN1F Accessory Kit–Remote Mount with Standard Option Cable, 50W TX and below
D2ZN1G Accessory Kit–Remote Mount with Standard Option Cable, 60W TX and above
D2ZN1H Accessory Kit–Remote Mount with Extended Option Cable, 50W TX and below
D2ZN1J Accessory Kit–Remote Mount with Extended Option Cable, 60W TX and above
D2ZN1K Accessory Kit–Remote Mount with Standard Option Cable, Low Band
D2ZN1L Accessory Kit–Remote Mount with Extended Option Cable, Low Band
D2ZN1M Accessory Kit–Remote Mount Euro with Standard Option Cable
D2ZN1N Accessory Kit–Remote Mount Euro with Extended Option Cable
D2ZN1P Accessory Kit–Remote Mount Motorcycle with Extended Option Cable
D2ZN1R Accessory Kit–Remote Mount Motorcycle with no Option Cable
D2ZN1S Accessory Kit–Remote Mount Euro Motorcycle with Extended Option Cable
D2ZN1T Accessory Kit–Remote Mount Euro Motorcycle with no Option Cable
D2ZN1U Dual Control, Scan Control Unit
D2ZN1V Dual Control, System Control Unit
D2ZN1W Dual Radio (50 watt TX and below)
D2ZN1X Dual Radio (60 watt TX and above)
D2ZN1Y Motorcycle Conversion, Field Upgrade, Remote Mount Radio
D2ZN1Z Motorcycle Conversion, Field Upgrade, Remote Mount Euro Radio
4 DIGIT OPTIONS
D2AN1E Antenna, Low Band WB, 29.7-38 MHz
D2AN1F Antenna, Low Band WB, 33-43 MHz
D2AN1G Antenna, Low Band WB, 37-49 MHz
D2AN1L Antenna, 800 MHz, ¼ Wave Whip
D2AN1M Antenna, 900 MHz, ¼ Wave Whip
D2AN1R Antenna, VHF/UHF, ¼ Wave Whip
D2CE1V Power Cable, 7.5M (60W TX and above)
D2CE1W Accessory Cable, Front Mount
D2CE1X Accessory Cable, Remote Mount
D2CE1Y Radio Control Cable, Remote Mount, 5.5M
D2CE1Z Accessory Cable, Euro Front Mount
D2CE5R Extended Option Accessory Cable, Front Mount
D2CE5S Radio Control Cable, Extended Option, Remote Mount, 5.5M
D2CE5T Extended Option Accessory Cable, Remote Mount
D2CE5U Extended Option Accessory Cable, Euro Front Mount

10
OPTION DESCRIPTION
D2CE5V Radio Control Cable, Euro Remote Mount, 5.5M
D2CE5W Radio Control Cable, Extended Option Euro Remote Mount, 5.5M
D2CE5Z Dual Control Cable, Remote Mount, 9.0M
D2CE7A Dual Radio Cable, Remote Mount, 2.0M
D2CF7B Extended Option Accessory Cable, Motorcycle
D2CF7C Radio Control Cable, Extended Option Remote Mount Motorcycle, 2.3M
D2CF7D Radio Control Cable, Extended Option Euro Remote Mount Motorcycle, 2.3M
D2CF7E Power Cable, Motorcycle, 1.0M
D2CF9A Power Cable, 7.5M (50W TX and below)
D2CP5L Scan Control Unit (4 BTN), Front Mount (including Label)
D2CP5M System Control Unit (16 BTN), Front Mount (including Label)
D2CP5R Scan Control Unit (4 BTN), Remote Mount (including Label)
D2CP5S System Control Unit (16 BTN), Remote Mount (including Label)
D2LS1H Speaker (4 OHM)
D2LS1U Speaker (8 OHM, Parallel Audio Appl)
D2MA3J Mounting Bracket Kit, Remote Mount Control Unit
D2MA3N Mounting Bracket Kit, Front Mount Radio/Euro Remote Mount Radio
D2MA3R Mounting Bracket Kit, Remote Mount Radio
D2MA5G Mounting Bracket Kit, Motorcycle CU (Microphone Hanger included)
D2MA5H Mounting Bracket Kit, Motorcycle Radio Case
D2MA5J Mounting Bracket Adapter Kit, Motorcycle Radio Case
D2MC3Z Microphone
D2MC5A Desk Microphone
D2MC5L Noise Canceling Microphone
D2MC5N DTMF Microphone
D2MK3B Radio Front (Remote Mount) (including Label)
D2MK3E Keycap Kit, Scan Control Unit
D2MK3F Keycap Kit, System Control Unit
D2MN1A Microphone Hanger
D2PD1T Filter, Power, Motorcycle Appl
1016 Siren and Light Control Module
1020 100W Speaker TS100
1021 100W Speaker BP100
RADIO PROGRAMMING OPTIONS
TQ3409 Programming Cable, Shop (CA101288V5). Does not require TQ3370
TQ3410 Programming Cable, Field (CA101287V1). Does not require TQ3370
TQ3370 Programming Interface Module Kit 110 VAC, only needed for 19B802554P15
TQ3370-
220 Programming Interface Module Kit 220 VAC, only needed for 19B802554P15
TQ3377 Programming Cable for Orion (19B802554P15). Requires TQ3370
TQ3385 ProVoice™/EDACS®Windows®Radio ProGrammer Only
TQ3389 Conventional Windows Radio ProGrammer Only

INSTALLATION (SINGLE CONTROL UNIT)
STEP 1 – PLAN THE INSTALLATION
Figure 6 provides an example of a typical mobile radio (remote mount)
installation. Before starting, plan the radio installation carefully so that it will
be:
• safe for the operator and passengers
• away from airbag deployment area
• convenient for the operator to use
• protected from water damage
• neat and easy to service
• safe and out of the way for passengers and auto mechanics
M/A-COM, Inc. recommends the radio be installed by one of the many M/A-
COM, Inc. Authorized Service Centers located throughout the United States.
Experienced service centers can provide a proper radio installation and make
any required final adjustments.
Figure 6: Typical Installation (Remote Mount Shown)
WARNING
• Vehicular Electronics- fuel injection systems, anti-skid
braking systems, cruise control systems, etc., are typical of
the types of electronic devices which may be prone to
malfunction due to the lack of protection from radio
frequency energy present when a radio is transmitting. If the
vehicle contains such equipment, consult dealer to determine
if such electronic equipment will perform normally when the
radio is transmitting.
• For passenger safety, mount the radio securely so the unit
will not break loose in the event of a collision.
11

12
STEP 2 - LOCATE TOOLS REQUIRED
The equipment required for installing the Orion Mobile Radio is listed below:
• Crimping tool for fuse holder
• Electric drill for drilling mounting holes
• Drills and circle cutters as follows:
No. 31 (1/8”) drill
No. 27 (9/64”) drill
5/8” drill or circle cutter
3/4” circle cutter, hole saw or socket punch
• Phillips and flat-blade screwdrivers
• POZIDRIV®driver
• No. 20 TORX®driver
CAUTION
Be careful to avoid damaging vital part (fuel tank,
transmission housing, etc.) of the vehicle when drilling
mounting holes. Always check to see how far the mounting
screws will extend below the mounting surface before
installing.
If pilot holes must be drilled, remove all metal shavings from
drilling holes before installing screws.
Vehicles Powered By Liquefied (Lp) Gas
Radio installation in vehicles powered by liquefied petroleum gas, where
the LP gas container is located in the trunk or other sealed-off space
within the interior of the vehicle, must conform to the National Fire
Protection Association Standard NFPA 58. This requires that:
•The space containing radio equipment be isolated by a seal from the
space containing the LP gas container and its fittings.
•Outside filling connections be used for the LP gas container.
•The LP gas container space be vented to the outside of the vehicle.

13
STEP 3 – INSTALL CABLES
To ensure the feasibility of the planned cable routings, it is recommended that
the cables be run before mounting the radio. The radio can be installed as a
Front Mount, Remote Mount or Cassette Mount. The type of mount, the
application, and the options to be installed should be considered when
planning the cable runs. The following figures should be referenced
throughout the installation:
• Front Mount Installation Diagram - Figure 8 thru Figure 12
• Front Mount Cable Diagrams - Figure 13 thru Figure 17
• Remote Mount Installation Diagrams – Figure 18 thru Figure 24
• Remote Mount Cable Diagrams – Figure 25 thru Figure 29
Be sure to leave some slack in each cable going to the radio, so the radio can
be pulled out for servicing with the power applied and antenna attached. Coil
any surplus cables and secure them out of the way. Try to route the cables
away from locations where they will be exposed to heat (exhaust pipes,
mufflers, tailpipes, etc.), battery acid, sharp edges or mechanical damage or
where they will be a nuisance to automobile mechanics, the driver, or
passengers. In order to prevent interference, keep wiring away from
electronic computer modules, other electronic modules, and ignition circuits.
In addition, try to utilize existing holes in the firewall, trunk wall, and the
channels above or beneath doors. Channels through door and window
columns, convenient for running cables, can also be used unless rigid or
flexible conduit is to be installed for cable runs.
Power Cable
The USA power cable (19B802622P1 or P3) consists of a red lead (A+) and a
black lead (A-) connected to a molded 2-pin power connector and supplied
with ring terminals. The EURO power cable also consists of a red lead (A+) a
black lead (A-) terminated with ring terminals, but it is connected to P1 of the
accessory cable or P1 of the control cable (in remote applications).
To install the power cable:
1. Drill a 5/8”hole in the firewall for the cable run and insert the rubber
grommet. Run the cable through this grommet to the battery location.
Secure the cable at several locations within the engine compartment to
prevent possible damage to cable.
2. Strip back the insulation approximately 3/8″from the end of the black
lead. Slide one of the large heat shrink sleeves onto the wire and crimp a
battery ring terminal onto this lead. Heat shrink the sleeve over the crimp
connection. Connect the black lead directly to the battery negative (-) or
ground frame member.

3. Cut off 12-18″from the red lead. Strip back the insulation approximately
3/8″on each end of the wires. Insert the wire ends into the small
openings at the end of each fuse holder section and crimp a fuse
connector to each wire. Prepare the other end of the short wire in the
same manner as in (2) and connect to the positive (+) terminal of the
battery.
NOTE
• Do not install fuse into fuse holder until installation is
completed and all connections have been checked.
• USA Power Cable 19B802622P3 is used only with radio
with 50 watts or less RF power output.
Figure 7: Power Cable 19B802622P1 or P3 (USA Only)
Ignition Sense (All Applications)
The fuse holder must be attached to the yellow sense lead along with the ring
terminal as follows:
1. Cut the yellow sense lead approximately 6-12" from the end to be
connected to the power source.
2. Strip the insulation from each end of the short lead and from the end of
the long lead by at least 3/8".
3. Insert the stripped end of the long lead and one end of the short lead into
the narrow end of each fuse holder half.
4. Crimp the leads in the fuse holder halves with a crimping tool.
5. Insert the 3 amp fuse into one end of the fuse holder and join the two fuse
holder halves firmly together.
6. Attach the ring terminal to the end of the short lead and connect this lead
to the ignition "ON" sense point. (Preferably to an "Accessory" point in
the vehicle fuse panel that is switched on when the vehicle ignition
switch is in the ACCESSORY and RUN positions.)
14

NOTE
• The radio, as shipped from the factory, has the
"ignition sense" feature disabled. As such, the radio
is powered ON or OFF as determined by the front
panel ON/OFF/ VOLUME control only (assuming
A+ and A- are connected). To enable "ignition
sense" feature, open top cover of radio and remove
shield from logic PWB. Slide switch SW601 from
position 3-2 to 1-2. Replace shield and top cover.
Be sure to apply correct torque to screws holding top
cover in place. See Maintenance Manual.
• The "Accessory" point should drop to ZERO volts
when the engine is cranked and return to +12 volts
after the engine is started. If a point is chosen that
drops to a voltage between zero and +12 volts, the
radio may execute a power-up cycle several times
during start up. It is recommended that the terminal
be measured with a voltmeter to ensure it shuts off
(goes to zero volts) during engine cranking.
CAUTION
Certain problems may be encountered when accessory
equipment is connected to the ignition or accessory lines of
the vehicle, where these lines may have large filter capacitors
and a leakage path present. If the radio does not turn off
within a reasonable amount of time after the ignition is turned
off, first try a different accessory or ignition sense pick up
point in the vehicle. Many vehicles have more than one
circuit that is switched by the ignition switch, and one may be
available that does not have large filter capacitors or a leakage
path present.
If a different pickup point cannot be found, add a 470-ohm, 1-
watt resistor from the ignition sense pick point to ground.
This will discharge the capacitor(s) or reduce the leakage
voltage to a low value. Current drain through this resistor
will be minimal (less than 0.03A) when the ignition is
switched on.
15

Accessory Cable (Front Mount)
The basic accessory cable consists, at one end, the basic accessories connector
(P3), the speaker connector (P2), and the ignition sense lead. At the other
end, plug P1 connects to the Option/Remote Control connector (ORCC),
which is mounted on the back of the radio. The EURO accessory cable
contains the red and black leads of the power cable.
The Extended Option accessory cable is the same as the basic accessory cable,
but has an Extended Option plug (P4). The CA101288V2 Extended Option
Accessory Cable has a pigtail (P5) at P1 that provides easy access to the front
of the radio for programming, keyloading, and mobile data.
NOTE
The EURO ORCC is the opposite gender from the USA
ORCC. Interconnect diagrams for each of these cables are
provided on pages 19-23.
The following cables are available for Front Mount applications:
• 19B802554P1 - Basic Accessory Cable (USA Models)
• 19B802554P11 - Basic Accessory Cable (EURO Models)
• 19B802554P2 - Extended Option Accessory Cable (USA Models)
• CA101288V2 - Extended Option Accessory Cable (USA Models)
• 19B802554P12 - Extended Option Accessory Cable (EURO Models)
Figure 8: Front Mount Basic Accessory Interconnections
(USA Models Only)
16

Figure 9: Front Mount Basic Accessory Interconnections
(EURO Models Only)
Figure 10: Front Mount Extended Option Accessory Interconnections
using 19B802554P2 (USA Models Only)
17

*(P5) Provides access for Programming/ Keyloading/ Mobile Data
Figure 11: Front Mount Extended Option Accessory Interconnections
using CA101288V2 (USA Models Only)
Figure 12: Front Mount Extended Option Accessory Interconnections
(EURO Models Only)
18

(
19B802554
,
Sh.1
,
Rev. 23
)
Figure 13: USA Front Mount Standard Accessory Cable 19B802554P1
19

(19B802554, Sh.9, Rev. 23)
Figure 14: EURO Front Mount Standard Accessory Cable
19B802554P11
20