Tait Orca 5000 User manual

Tait Orca 5000 Portable Radios
Service Manual
June 2003
IPN: M5000-00-105

ii June 2003 IPN: M5000-00-105
Pre ace
Contacting Tait Electronics Ltd
The contact details for your nearest Tait Electronics regional office, can be found on the Tait
Website: http://www.taitworld.com/
Enquiries and comments
If you have any enquiries regarding this manual, or any comments, suggestions and notifications
of errors, please contact Customer Support, Tait Electronics Ltd, Christchurch, New Zealand, or
refer to the Tait Website.
Conventions
Throughout this manual, the following conventions are used:
■Names of software screen, field and menu names are referred to in bold sans seri ont. For
example:
Check that the information in the Radio Model fields (Speci ications screen) is correct.
■The x
xx
x-character is used as a wildcard in product codes and part numbers, to indicate unspec-
ified characters.
Disclaimer
There are no warranties extended or granted by this manual. Tait Electronics Ltd accepts no
responsibility for damage arising from use of the information contained in the manual or of the
equipment and software it describes. It is the responsibility of the user to ensure that use of such
information, equipment and software complies with the laws, rules and regulations of the applica-
ble jurisdictions.
Updating equipment and manuals
In the interests of improving performance, reliability or servicing, Tait Electronics Ltd reserve the
right to update their equipment and/or manuals without prior notice.
Copyright
All information contained in this manual is the property of Tait Electronics Ltd. All rights are
reserved. This manual may not, in whole or in part, be copied, photocopied, reproduced, translat-
ed, stored, or reduced to any electronic medium or machine-readable form, without prior written
permission from Tait Electronics Limited. All trade names referenced are the service mark, trade-
mark or registered trademark of the respective manufacturers.

June 2003 IPN: M5000-00-105 iii
Publication history
Publication Date Product Code
May 2001 M5000-00-100
June 2001 M5000-00-101
September 2001 M5000-00-102
May 2002 M5000-00-103
September 2002 M5000-00-104
June 2003 M5000-00-105

iv June 2003 IPN: M5000-00-105

June 2003 IPN: M5000-00-105 v
Contents
Part A: Introduction
Servicing Tait Orca 5000 portable radios
Servicing Tait Orca 5000 portable radiosServicing Tait Orca 5000 portable radios
Servicing Tait Orca 5000 portable radios .................................................................................
..................................................................................................................................................................
................................................................................. A-3
A-3A-3
A-3
WWW technical support ..................................................................................................................... A-3
What does this manual contain? .......................................................................................................... A-3
Calibration service kit .......................................................................................................................... A-3
Programming kit .................................................................................................................................. A-4
The Tait Orca 5000 series of portable radios
The Tait Orca 5000 series of portable radiosThe Tait Orca 5000 series of portable radios
The Tait Orca 5000 series of portable radios ............................................................................
........................................................................................................................................................
............................................................................ A-5
A-5A-5
A-5
The Tait Orca product code ................................................................................................................. A-5
Operating instructions ......................................................................................................................... A-5
Accessories ........................................................................................................................................... A-5
Important information
Important informationImportant information
Important information .............................................................................................................
..........................................................................................................................................................................................................................
............................................................................................................. A-9
A-9A-9
A-9
Basic servicing precautions .................................................................................................................. A-9
Programming ....................................................................................................................................... A-9
Calibrating ......................................................................................................................................... A-10
Test facilities ...................................................................................................................................... A-10
Basic maintenance ............................................................................................................................. A-10
Servicing Intrinsically Safe radios
Servicing Intrinsically Safe radiosServicing Intrinsically Safe radios
Servicing Intrinsically Safe radios ...........................................................................................
......................................................................................................................................................................................
........................................................................................... A-11
A-11A-11
A-11
Intrinsically Safe radios ...................................................................................................................... A-11
IS PCB servicing requirements ........................................................................................................... A-11
FM approval ....................................................................................................................................... A-11
FM approved products ....................................................................................................................... A-11
FM approved accessories ................................................................................................................... A-11
Part B: Radio speci ications and circuit descriptions
Radio specifications
Radio specificationsRadio specifications
Radio specifications ..................................................................................................................
....................................................................................................................................................................................................................................
.................................................................................................................. B-3
B-3B-3
B-3
General specifications........................................................................................................................... B-3
Receiver performance ........................................................................................................................... B-3
Transmitter performance ..................................................................................................................... B-4
TOP-Axxxx 66-88MHz radio specifications.......................................................................................... B-5
TOP-Bxxxx 136-174MHz radio specifications ...................................................................................... B-6
TOP-Cxxxx 174-225MHz radio specifications ...................................................................................... B-7
TOP-Gxxxx 336-400MHz radio specifications...................................................................................... B-8
TOP-Hxxxx 400-470MHz radio specifications...................................................................................... B-9
TOP-Ixxxx 450-530MHz radio specifications ..................................................................................... B-10

vi June 2003 IPN: M5000-00-105
TOP-Jxxxx 806-870MHz radio specifications...................................................................................... B-11
TOP-Kxxxx 896-941MHz radio specifications .................................................................................... B-12
Circuit descriptions
Circuit descriptionsCircuit descriptions
Circuit descriptions .................................................................................................................
..................................................................................................................................................................................................................................
................................................................................................................. B-13
B-13B-13
B-13
Transmitter ........................................................................................................................................ B-13
Transmit (Tx) audio ........................................................................................................................... B-13
Receiver .............................................................................................................................................. B-13
Receive (Rx) audio .............................................................................................................................. B-13
DSP .................................................................................................................................................... B-14
Synthesiser and VCO .......................................................................................................................... B-14
Power supplies ................................................................................................................................... B-14
Accessory connector interface ............................................................................................................ B-15
Universal band versus wideband IF filtering ...................................................................................... B-15
Part C: Diagnostics and ault inding
Test facilities
Test facilitiesTest facilities
Test facilities .............................................................................................................................
..........................................................................................................................................................................................................................................................
.............................................................................................................................C-3
C-3C-3
C-3
Error codes ........................................................................................................................................... C-3
Test commands..................................................................................................................................... C-5
Calculating the parameters required for test command 101................................................................. C-7
Fault finding charts
Fault finding chartsFault finding charts
Fault finding charts ...................................................................................................................
......................................................................................................................................................................................................................................
................................................................................................................... C-8
C-8C-8
C-8
Radio cannot be switched on ................................................................................................................ C-9
Cannot change channel ...................................................................................................................... C-10
No serial communication ................................................................................................................... C-11
Receive faults ...................................................................................................................................... C-12
Cannot transmit ................................................................................................................................. C-13
No transmit audio .............................................................................................................................. C-14
Part D: Servicing the radio
Servicing the radio
Servicing the radioServicing the radio
Servicing the radio ...................................................................................................................
......................................................................................................................................................................................................................................
................................................................................................................... D-3
D-3D-3
D-3
Screw head types ..................................................................................................................................D-3
Disassembling the radio
Disassembling the radioDisassembling the radio
Disassembling the radio ..........................................................................................................
....................................................................................................................................................................................................................
.......................................................................................................... D-4
D-4D-4
D-4
Removing the front panel from the chassis ..........................................................................................D-4
Removing the shield sub-assembly from the chassis ............................................................................D-5
Removing the PCB from the chassis .....................................................................................................D-6
Removing the rear panel ......................................................................................................................D-7
Replacing key mechanical and ancillary devices
Replacing key mechanical and ancillary devicesReplacing key mechanical and ancillary devices
Replacing key mechanical and ancillary devices ......................................................................
............................................................................................................................................
...................................................................... D-8
D-8D-8
D-8
Replacing the lens (Orca 5015/2x/35/40) ...........................................................................................D-8
Replacing the PTT keypad ....................................................................................................................D-8
Replacing the speaker ...........................................................................................................................D-9

June 2003 IPN: M5000-00-105 vii
Replacing the LCD display (Orca 5015/2x/35/40) .............................................................................. D-9
Replacing the shield, user interface PCB and polyester dome (Orca 5015/2x/35/40) ....................... D-12
Replacing the antenna connector, channel selector switch and volume control switch ..................... D-12
Replacing the microphone .................................................................................................................D-12
Replacing the battery and speaker contacts .......................................................................................D-12
Replacing the tact switch ....................................................................................................................D-12
Replacing the chassis .......................................................................................................................... D-13
Reassembling the radio
Reassembling the radioReassembling the radio
Reassembling the radio ..........................................................................................................
....................................................................................................................................................................................................................
..........................................................................................................D-14
D-14D-14
D-14
Rear panel reassembly and replacing the auxiliary flexible PCB ........................................................D-14
Fitting the PCB to the chassis and replacing the RF out assembly ......................................................D-15
Fitting the shield to the chassis .......................................................................................................... D-15
Fitting the front panel to the chassis .................................................................................................. D-16
Spares kits
Spares kitsSpares kits
Spares kits ..............................................................................................................................
............................................................................................................................................................................................................................................................
..............................................................................................................................D-17
D-17D-17
D-17
Information contained in the tables ................................................................................................... D-17
PCB Product Codes ............................................................................................................................ D-17
Orca 5010/11/30 spares kit (TOPA-SP-401G) .................................................................................. D-18
Orca 5035 spares kit (TOPA-SP-402G) .............................................................................................. D-19
Orca 5015/2x/40 spares kit (TOPA-SP-403G)................................................................................... D-20
Orca 5010/11/30 re-skinning kit (TOPA-SP-404) ............................................................................. D-21
Orca 5035 Re-skinning kit (TOPA-SP-405)........................................................................................ D-21
Orca 5020/40 Re-skinning kit (TOPA-SP-406).................................................................................. D-21
Orca 5015/2x/35/40 User Interface PCB and Shield (TOPA-SP-407) ............................................... D-22
Orca 5015/21 Re-skinning kit (TOPA-SP-408).................................................................................. D-22
Part E: Battery packs and chargers
Battery packs
Battery packsBattery packs
Battery packs .............................................................................................................................
..........................................................................................................................................................................................................................................................
.............................................................................................................................E-3
E-3E-3
E-3
Battery shift life .....................................................................................................................................E-3
Disposing of used nickel-cadmium batteries .........................................................................................E-4
Battery chargers
Battery chargersBattery chargers
Battery chargers ........................................................................................................................
................................................................................................................................................................................................................................................
........................................................................................................................E-5
E-5E-5
E-5
Desktop fast charger
Desktop fast chargerDesktop fast charger
Desktop fast charger ..................................................................................................................
....................................................................................................................................................................................................................................
..................................................................................................................E-6
E-6E-6
E-6
Fast charger operation ..........................................................................................................................E-6
Using the fast charger ............................................................................................................................E-9
Repairing the fast charger ...................................................................................................................E-10
Desktop trickle charger
Desktop trickle chargerDesktop trickle charger
Desktop trickle charger ...........................................................................................................
......................................................................................................................................................................................................................
...........................................................................................................E-12
E-12E-12
E-12
Trickle charger operation ....................................................................................................................E-12
Using the trickle charger .....................................................................................................................E-13
Repairing the trickle charger ...............................................................................................................E-13

viii June 2003 IPN: M5000-00-105
Troubleshooting ..................................................................................................................................E-14
Multi-charger
Multi-chargerMulti-charger
Multi-charger ..........................................................................................................................
....................................................................................................................................................................................................................................................
.......................................................................................................................... E-15
E-15E-15
E-15
Multi-charger operation ......................................................................................................................E-15
Repairing the multi-charger ................................................................................................................E-15
Fuse replacement ................................................................................................................................E-16
Part F: Accessories
Tait Orca 5000 accessory connector
Tait Orca 5000 accessory connectorTait Orca 5000 accessory connector
Tait Orca 5000 accessory connector .........................................................................................
..................................................................................................................................................................................
......................................................................................... F-3
F-3F-3
F-3
Screw head types ...................................................................................................................................F-3
Connecting an accessory .......................................................................................................................F-3
Connecting a headset ............................................................................................................................F-5
Accessory connector signal descriptions ...............................................................................................F-6
7.5 mm Accessory adaptor
7.5 mm Accessory adaptor7.5 mm Accessory adaptor
7.5 mm Accessory adaptor ........................................................................................................
................................................................................................................................................................................................................
........................................................................................................ F-8
F-8F-8
F-8
Tait Orca vehicle kit
Tait Orca vehicle kitTait Orca vehicle kit
Tait Orca vehicle kit ................................................................................................................
................................................................................................................................................................................................................................
................................................................................................................ F-10
F-10F-10
F-10
Product codes ......................................................................................................................................F-10
Update to the vehicle kit ......................................................................................................................F-10
Installing a vehicle kit ..........................................................................................................................F-10
Vehicle kit operation ...........................................................................................................................F-10
Vehicle kit specifications .....................................................................................................................F-12
Servicing the vehicle kit .......................................................................................................................F-13
Spares kits ...........................................................................................................................................F-14
Vehicle kit spares kit (TOPA-SP-301).................................................................................................. F-15
Vehicle kit reskinning kit (TOPA-SP-302)........................................................................................... F-16
Custom modifications .........................................................................................................................F-17
Vehicle kit circuit descriptions ............................................................................................................F-19
Part G: Additional in ormation
Glossary
GlossaryGlossary
Glossary ................................................................................................................................
................................................................................................................................................................................................................................................................
...................................................................................................................................
......
... G-3
G-3G-3
G-3
Accessory connector compatibility
Accessory connector compatibilityAccessory connector compatibility
Accessory connector compatibility ..........................................................................................
....................................................................................................................................................................................
.......................................................................................... G-8
G-8G-8
G-8

A
PART
Introduction
This part provides an introduction to servicing Tait Orca 5000
portable radios. It includes an outline of the Tait Orca 5000 range
of products and precautions that should be taken before servicing
Tait Orca 5000 portable radios.
Detailed servicing instructions and information about spare parts
are found in Part D: Servicing the radio.
Contents
Servicing Tait Orca 5000 portable radios
Servicing Tait Orca 5000 portable radiosServicing Tait Orca 5000 portable radios
Servicing Tait Orca 5000 portable radios ......................................................
............................................................................................................
...................................................... A-3
A-3A-3
A-3
WWW technical support ...................................................................................... A-3
What does this manual contain? ........................................................................... A-3
Calibration service kit ........................................................................................... A-3
Programming kit ................................................................................................... A-4
Conventions .......................................................................................................... A-4
The Tait Orca 5000 series of portable radios
The Tait Orca 5000 series of portable radiosThe Tait Orca 5000 series of portable radios
The Tait Orca 5000 series of portable radios .................................................
..................................................................................................
................................................. A-5
A-5A-5
A-5
The Tait Orca product code ................................................................................... A-5
Operating instructions .......................................................................................... A-5
Accessories ............................................................................................................ A-5
Important information
Important informationImportant information
Important information .................................................................................
..................................................................................................................................................................
................................................................................. A-9
A-9A-9
A-9
Basic servicing precautions ................................................................................... A-9
Programming ........................................................................................................ A-9
Calibrating .......................................................................................................... A-10
Test facilities ....................................................................................................... A-10
Basic maintenance ............................................................................................... A-10
Servicing Intrinsically Safe radios
Servicing Intrinsically Safe radiosServicing Intrinsically Safe radios
Servicing Intrinsically Safe radios ...............................................................
..............................................................................................................................
............................................................... A-11
A-11A-11
A-11
Intrinsically Safe radios ....................................................................................... A-11

A - 2 June 2003 IPN: M5000-00-105
IS PCB servicing requirements ............................................................................ A-11
FM approval ........................................................................................................ A-11
FM approved products ........................................................................................ A-11
FM approved accessories ..................................................................................... A-11