Wouxun KG-689 User manual

Service Manual
Model: KG-689
Frequency: 400-470MHz
Version: KG-689-0801-V1
QUANZHOU WOUXUN ELECTRONICS CO., LTD
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 1 of 35
KG-689 transceiver service manual
Contents
Introduction………………………………………………………………………………………….2
Personal safety…………………………………………………………………………………….. .2
Disassembly for repair…..……………………………………………………..................................3
Circuit description………………………………………………………………………………...…5
Part list…………………………………………………………………………………...…………14
LCD part list.......................................................................................................................................22
Exploded view...…………………………………………………………………………………….23
Packing………………………………………………………………………………………....…....23
Adjustment…………………………………………………………………………………………..24
Schematic…………………………………………………………………………………………....27
LCD Schematic...................................................................................................................................28
LCD Board..........................................................................................................................................29
Layout Board…………………………………………………………………………………...…....30
PCB Board……………………………………………………………………………………...…....32
Block diagram……………………………………………………………………………….……….34
Specification………………………………………………………………………………………….35
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 2 of 35
Introduction
Scope of this manual
This manual is intended for use by experienced technicians familiar with similar types of commercial
grade communications equipment. It contains all required service information the equipment and is
current as of the publication date. This manual almost correct and complete, if there is something
oversight, WOUXUN company keeps the right of explanation. And we also keep the right of change
the design and the specification.
Personal Safety:
▣ Do not transmit, if you don’t check all transmitting pins or one of the opening pins hasn’t connect
to the correspond port.
▣ Switch off power when you are on flammability gas condition.
▣Do not take it apart, or have it repaired by a nonprofessional.
▣Turn off the radio before of detonator and blasting area.
▣In order to avoid the problem arising by Electromagnetic interference and/or Electromagnetic
Compatibility, please turn off the radio where there has a mark: Turn off radio, such as hospital or
other health care place and enplane.
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 3 of 35
Disassembly for repair
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 4 of 35
Disassembly for repair
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Circuit Description
1. Frequency association
Frequency association is shown in Chart 1.
Chart 1
AF AMP
MIX.IF.DET
38.850MHz
1ST MX
RF AMPANT SW
PA AMP TX AMP (2) (1) PLLVCO MICAMP MIC
SP
MCF
450KHz
CF
2nd LO
LPF
ANT
T:400-470MHz
R:400-470MHz
2. Receive system
(1). RF amplifier is shown in Chart 2.
The radio wave enter by antenna, through a low-pass and a transmit/receive switch circuit(D215,D216),
then input to RF amplifier, blow up by T220, the disturb signal will be unchained by band-pass filter.
LPF
ANTSW
BPF
Chart 2
PFAMP
SP
BPF XF1
MIXER
MCF
IFAMP
MIX.IF.DET
AF AMP
VCO
PLL
ANT
(2). The first mixer
The receive signal and the first PLL unit output root flap signal will mix on the first mixer T233, then give
birth to the first intermediate frequency(IF) signal, except that all disturb signals will be unchained by crystal
filter..
Version: KG-689-0801-V1 Page 5 of 35
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 6 of 35
APO
BEEP/CTCSS
ARX
AN SQL
RXI
14
9
U261
T463
U460
T451
SB
T453
AFC
SP MUTE
15
20
72
71
T455
SP
Chart 3
U8 11
MCU
Circuit Description
(3). Intermediate amplifier
As Chart 3 shows, the first intermediate frequency blow up by T253, then enter U261 (FM signal frequency
modulation integrate circuit). At time signal will mix with second root flap, switch to second IF signal.
Through 450K filter, except that all disturb signals will be unchained, then be blew up and inspected.
Audio frequency amplifier
The audio frequency signal comes from inspected filter and be aggravated, then input to MCU(U811), then
through adjust potentiometer, blow up by U460, get the audio frequency power, contact with MIC via T463.
Squelch circuit and signal intensity list
Check by U261: Output yawp signal, then put it into CPU (U811) and deal with it by the 25 feet interior.
According to the electricity level signal which MCU get, one side, it can control SP MUTE, APX and AFC, to
complete to control audio frequency output circuit (The level of CPU inside control system is from 1 to 9
grades, it can program by software or by keyboard). On the other side, it can control the signal strong list of
LCD screen.
3. Transmit system
(1). Speaker amplifier
As show in Chart 4, audio frequency signal comes from MIC will be aggravated, then limited blow up by
U411-A, all distortion audio frequency signals will be unchained by adjacent filter which makes up with
U411-B caused by limited blow up.
Modulate circuit
The signal comes from speaker amplifier modulated by adjust potentiometer VR382, then modulating
changeable reactance by varactors tube D348.
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 7 of 35
3
2
5
4
1
PTT/RX232
MIC
5C
T430 T43 3
T41 4
MO DE
5T
5T
5T
T471
W/N
U411A U411B
MIC
T443
T43 8
D442
5V
SAVE
VOX
Chart 4
Circuit Description
(2). VOX circuit
Blow up audio frequency signal comes from the speaker’s by T443, change the AC audio frequency to DC
electricity level signal by D442, then put it into the CPU (U811) the 21 feet to manage.
Blow up drive and end level
The goal signal produce by VCO and cushion blow up by T113, then send it to a two grade FEI amplifier
after invigorative blow up T117, and blow up the power about 4W.
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 8 of 35
BATT
P-TX
T171
T181
5T
T181 T18 1 T18 1
RX
ANT
TXin
APC
D146
D215 D216
Chart 5
Circuit Description
4. Select transmit and receive circuit
As shown in Chart 5. Output transmit signal will pass transmit and/or receive switch circuit and low-pass,
then send to antenna. Transmit and/or receive circuit has made up of D146 D145 D216. Start during
transmitting and stop during receiving, switch transmitting system and receiving system.
Auto power control circuit APC, use for get a reliable transmit power and transmit control output. This circuit
check out power discreteness end terminal current exhaust and control transmit output. Two reference
voltage from U170, one is give birth to the voltage which use for adjust the power output(AD1 give birth to ),
the other one is get the R171-R173 two terminal and end terminal exhaust current be direct ratio check out
voltage. On the output terminal of U181 can get a reference voltage and check out voltage dispersion be
direct ratio voltage signal. This signal by reverse then as APC voltage. This voltage be use control power
discreteness’ power control feet and make transmit output level off.
As show in Chart 5
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 9 of 35
5C
T337
T35 5
T35 0
T37 5T37 0
D3 52
D3 53
D3 46
D3 45
D3 48
MO D
TX/ RX
PLL DAT A
10
11
12
13
3
5
20
5C
66
65
64
63
CP U
U811
5C
CR311
19.2MHz
PLL
U311
图6
Circuit Description
5. PLL Circuit
(1) PLL
19.25MHz reference oscillator output through PLL IC(U311) reference frequency then bring 5KHz and 6.5
KHz reference frequency.
VCO output signal blew up by T337, then bring compare frequency by U311 dispart frequency. Use different
dispart frequency ratio by CR311, and get different inspect posture consult frequency. According referenced
frequency and comparable frequency value, then bring 5, 6.25, 10, 12.5 and 25KHz for step frequency
value of PLL synthesizer. According referenced frequency and comparable frequency discrepancy value,
the output correspond pulse voltage from the fifth feet of U311, change it to direct current signal direct
current signal by filter after through Charge Pump, then bring lock voltage.
(2) VCO
Goal frequency is make up of FETT355 and T350 directly produced by Rapids oscillator. Lock controllable
voltage and then modify oscillator frequency by D353, D352, D346 and D345.
(3) Lose lock detection circuit
When PLL is on lose lock, one pulse will be plastic by R312 D312 C312 and R313, then add to LD side of
PLL (tenth LD side), and the voltage of LD side will be rose, CPU will control transmitting and receiving by
detecting the voltage of LD side.
(4) Digital control circuit
Conformation of Keyboard circuit: Directly input the signal come From the keyboard to CPU (U811).
Chart 6
5C
T337
T355
T350
T375T37 0
D352
D353
D346
D345
D348 MO D
TX/ RX
PLL DAT A
10
11
12
13
3
5
20
5C
66
65
64
63
CP U
U811
5C
CR311
19.2MHz
PLL
U311
图6
Chart 6
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 10 of 35
Circuit Description
6. Reset and reserve circuit
When connect with power, one reset circuit made up of T823 R823 R825 C825 output a positive impulse,
this impulse signal add to the 37th feet reset side of U81. When turn off the power, the 37th feet side of
U811 turn low, and CPU send all data to U835 to store, then go into reserve.
Detect battery voltage circuit
Input SB to the 23rd side A/D switch port of CUP(U811) after be disparted, and after disposal by CUP, drive
LCD battery level indicator.
Floodlight and LCD circuit
Floodlight and LCD directly be controlled on of off by CPU port circuit
DATA
CS
R/W
U711
HT1621
LCD
D442 D442
5V
CLK
DATA
U853
EEPROM
5V
PTT
MO NI
46
61
47
48
49
50
55 56 57 58 59
T823
5V
37
5M
54 60
SB
51 52 53
23
38
图 7
Chart 7
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 11 of 35
Circuit Description
7. Battery save circuit
One receive state the squelch turn off, if not press any key within 5 second, the power circuit will enter save
state mode, This control circuit through CPU directly control.
1 2 34
A
B
C
D
4
321
D
C
B
A
1
1
44
22
33
T1 A
S8212
88
55
7
76
6
T1 B
S8212
Sens
1
Do
2
VM
4Vss 5
ICT 6 Co
3Vc 7
Vcc 8
U1
S8 232 B
C9
224P
C6
224P
C8
224P
C1
224P
C5
254P
R4
4.7M
R3
1K
R2
1K
R8
1K
R5
1K
C4
102P
D1
DIO-1
B+
BC
B-
CH+
TEMP
CH-
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 12 of 35
Circuit Description
8. Select power circuit
Power offset circuit as following:
TX POWER Power voltage of power amplifier
5V
Output 5V by U906 regulator circuit, used for reset
circuit power VDD of U511 U853 D711 and U8111.
5M
Output 5M by U911 regulator circuit, used for CPU
power VDD.
5C
T301 be controlled by the 40th side of CPU (811),
output 5C by 5V, used for PLL circuit, VCO circuit and
CR311 power circuit VDD.
5R
T202 be controlled by the 27th side of CPU (811),
output 5R by 5V, used for U261, T233, T253, T220
power VDD.
5T
T103 be controlled by the 26th of CPU (811), output 5T
by 5V, used for T113 T117 T430 T433 T171 U411 U170
and D146 D216 switch (transmit and/or receive
transform switch voltage).
POWER
P-7368
T451 and T453 be controlled by the 72th side of CPU,
output P-7368 power by BATT, used for U460 power.
VR 4 11 A
BATT
SB 5M
U911
U906
5V
T45 1
T453
P-7368
U811第72脚
U811第38脚
T301
T202
T103
5C
5R
5T
U711
T813
T812
U811第40脚
U811第27脚
U811第54脚
U811第60脚
T12 8 T130
图 8
Chart 8
U811 72th side
U811 38th side
U811 40th side
U811 27th side
U811 54th side
U811 60th side
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 13 of 35
Circuit Description
9. CTCSS / DCS circuit
DCS signal output CTCSS audio frequency signal from the 15th feet of CPU (U811), and output DCS signal
from the 29th. When transmit CTCSS, the DCS output from CPU be modulated by low-pass; When receive,
directly disposed by CUP after through detection frequency.
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 14 of 35
PARTS LIST
Designators Name and specifications Footprint
C211 Capacitance 0.3P B 0402
C246 C226 Capacitance 0.5P B 0402
C348 Capacitance 0.75P B 0402
C351 C358 368 C228 C230 Capacitance 1P B 0402
C251 C213 C253 Capacitance 2P B 0402
C117 C337 C338 C216 Capacitance 3P B 0402
C231 C267 Capacitance 4P B 0402
C219 Capacitance 4.3P B 0402
C334 C356 C217 C229 Capacitance 5P B 0402
C357 C371 C372 C377 C227 Capacitance 6P C 0402
C232 C116 Capacitance 7P C 0402
C252 C350 Capacitance 8P C 0402
C236 C321 C332 C811 Capacitance 10P C 0402
C349 Capacitance 12P J 0402
C827 C826 Capacitance 20P J 0402
C289 Capacitance 33P J 0402
C312 Capacitance 51P J 0402
C1147 Capacitance 56P J 0402
C1086 C288 Capacitance 82P J 0402
C102 C224 C271 C287 C303 C329 C335
C336 C461 C841 Capacitance 100P J 0402
C1138 C238 C138 C212 C902 C1051
C1084 C1083 C127 C125 C115 C121
C319 C328 C333 C342 C376 C410
C439 C322 C296 C220 C1155 C222
C1143 C283 C183 C176 C173 C872
C871 C837 C421 C419 C256 C1101
Capacitance 102P J 0402
C1102 C1144 C1128 C233 C331 C901
C361 C364 C374 C451 C454 C1156
C440 C1154 C181 C174 C907
C903-C905 C852 C820 C802 C512
C402 C274 C255 C1103
Capacitance 103P J 0402
C1103 C133 C1054 C1130 C137 C221 C1127
C1023 C1056 C101 C455 C318 C330 C339
C366 C291 C182 C846 C843 C825 C514 C513
C417 C412 C403 C401 C272 C270 C263 C301
C1094 C1039 C373 C438 C442-C445 C1552
C103 C281 C294 C297 C298 C279
Capacitance 104P J 0402
C1045 C821 Capacitance 105P J 0402
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Version: KG-689-0801-V1 Page 15 of 35
PARTS LIST
Designators Name and specifications Footprint
C1081 C284 Capacitance 180P J 0402
C278 Capacitance 200P J 0402
C870 C424 C265 C264 C465 Capacitance 220P J 0402
C295 Capacitance 222P J 0402
C324 C460 C422 C420 Capacitance 223P J 0402
C1124 C273 Capacitance 224P J 0402
C521 C213 Capacitance 273P J 0402
C290 Capacitance 330P J 0402
C286 C285 C432 C430 Capacitance 332P J 0402
C1047 C282 Capacitance 333P J 0402
C325-C327 Capacitance 390P J 0402
C1100 C1131 C126 C1129 C135 C136
C234 C235 C145 C128 C111 C112 C118
C120 C362 C1142 C292 C180 C175
C906 C860-C863 C413 C411 C268
C363 C365 C367 C370 C375 C452
C453 C223 C225
Capacitance 470P K 0402
C1046 C293 C431 C840 C426 C418
C446 Capacitance 473P K 0402
C462 Capacitance 474P K 0402
C433 C429 Capacitance 680P K 0402
C1099 C1145 C1551 C1009 C1021
C352 C1018 C1040 C1146 C1014 C237
C572 C569 C1012 C1015 C1013 C847
C845 C269 C261 C260 C1020 C113
C353 C355
Capacitance NC 0402
C152 C142 Capacitance 0.5P B 0603
C154 C156 C158 Capacitance 1.5P B 0603
C1038 C1037 Capacitance 2P B 0603
C153 Capacitance 3P B 0603
C157 Capacitance 4P B 0603
C1150 C155 Capacitance 6P C 0603
C150 Capacitance 7P C 0603
C1029 C143 Capacitance 8P C 0603
C215 Capacitance 9P C 0603
C122 Capacitance 10P C 0603
C1168 Capacitance 22P J 0603
C141 Capacitance 24P J 0603
C139 Capacitance 27P J 0603
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Version: KG-689-0801-V1 Page 16 of 35
PARTS LIST
Designators Name and specifications Footprint
C144 Capacitance 33P J 0603
C132 C129 Capacitance 102P J 0603
C276 C275 Capacitance 104P J 0603
C835 Capacitance 105P J 0603
C124 C151 Capacitance 470P J 0603
C1010 C131 C140 C1148 Capacitance NC 0603
C1163 Capacitance 5P B 0805
C1050 C147 Capacitance 104P J 0805
E341 Laminated
capacitance 0.1UF 0805
E340 Laminated
capacitance 2.2UF/16V/±10% 0805
E146 E454 Laminated
capacitance 1UF/16V/±10% 0805
E332 E423 Laminated
capacitance 4.7UF/16V/±10% 0805
E280 E180 E801 E274 E330 Laminated
capacitance 10UF/16V/±10% 0805
E1140 E912 E910 E1035 Laminated
capacitance 22UF/6.3V±20% 0805
E1134 E1141 Laminated
capacitance NC 0805
E908 Laminated
capacitance 22UF 1206
R1550 R341 R1025 R1082 R454 R460
R437 R467 R1106 R822 R436 R415
R262
Resistance 0R J 0402
R118 Resistance 5.6R J 0402
R462 R366 R367 R373 R469 Resistance 10R J 0402
R121 Resistance 22R J 0402
R124 R116 R332 Resistance 47R J 0402
R234 R1085 R357 R364 R371 R376
R221 R224 R283 R282 R274 R256
R417
Resistance 100R J 0402
R350 R461 R511 Resistance 150R J 0402
R317 Resistance 180R J 0402
R233 R444 Resistance 330R J 0402
R1553 Resistance 470R J 0402
R237 R1070 R338 R253 R814 R813 Resistance 560R J 0402
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 17 of 35
PARTS LIST
Designators Name and specifications Footprint
R114 R117 R119 R375 Resistance 680R J 0402
R1053 R1122 R203 R848 R323 R303
R336 R453 R280 R875 R272 R870
R843 R416 R473
Resistance 1K J 0402
R270 R340 R422 Resistance 1.2K J 0402
R349 R446 R845 R422 Resistance 1.5K J 0402
R255 R187 Resistance 2K J 0402
R836 R452 R120 Resistance 2.2K J 0402
R325 R326 R377 R381 R293 R268
R434 Resistance 3.3K J 0402
R380 R87 R852 R844 R1159 R815 R818
R817 R236 R1152 R212 R111 R112
R361 102
Resistance 4.7K J 0402
R281 R426 R414 R440 Resistance 5.6K J 0402
R846 R322 Resistance 6.8K J 0402
R425 Resistance 8.2K J 0402
R1137 R571 R1121 R342 R439 R442
R284 R266 R842 R520 R515 R433
R430 R1160 R184 R177
Resistance 10K J 0402
R1049 R823 Resistance 15K J 0402
R418 Resistance 18K J 0402
R324 R291 R512 R421 Resistance 22K J 0402
R441 R133 R518 R853 Resistance 27K J 0402
R423 Resistance 30K J 0402
R1022 R465 R432 R429 R427 R424
R431 R472 Resistance 33K J 0402
R321 Resistance 39K J 0402
R857 R450 R126 R115 R374 R101 R320
R220 R222 R522 R510 R186 R872
R829 R828 R435 R411 R864-R868
R182 R876-R878
Resistance 47K J 0402
R1052 R1055 Resistance 51K J 0402
R464 R294 Resistance 56K J 0402
R125 R185 Resistance 68K J 0402
R824 Resistance 82K J 0402
R1024 R337 R345 R370 R825 R513
R413 Resistance 100K J 0402
R323 Resistance 120K J 0402
R313 R292 R874 Resistance 150K J 0402
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 18 of 35
PARTS LIST
Designators Name and specifications Footprint
R265 R264 R181 Resistance 180K J 0402
R524 R254 R841 R519 R514 Resistance 220K J 0402
R443 Resistance 270K J 0402
R1126 R182 Resistance 330K J 0402
R1158 Resistance 470K J 0402
R420 Resistance 680K J 0402
R517 Resistance 750K J 0402
R404 R428 Resistance 1.8M J 0402
R1017 R572 R572 R1016 R1019 R1098
R113 R372 R468 R273 R521 R516
R180 R176 R275
Resistance NC 0402
R1153 Resistance 10R J 0603
R131 Resistance 47R J 0603
R145 R146 Resistance 270R J 0603
R132 Resistance 47K J 0603
R834 Resistance 56K J 0603
R170-R175 Resistance 150K J 0603
R1011 R123 Resistance NC 0603
R1157 R810 R141 Resistance 0R J 0805
R1151 Resistance 10K J 0805
R1044 Resistance 100K J 0805
R1091-R1093 Resistance 0.33R J 1206
R901 Resistance 0R 1206
R1125 Resistance 10R 1206
PR311 PR858 Resistance 1K×4 RP-1206
PR856 Resistance
4.7K×4 RP-1206
VR318 VR413 Adjustable Resistance 50K RV1208
E1090 E435 E417 Ta Capacitance 2.2UF/A/16V/±10% EIA3216
E907 E844 E905 Ta Capacitance 10UF/A/16V/±10% EIA3126
E461 E362 Ta Capacitance 10UF/A/10V EIA3126
E463 Ta Capacitance
100UF/C/10/±10% EIA7343
L130 High frequency fold
Inductance 2.2NH 0603
L232 L117 L1139 L337 L374 L820 High frequency fold
Inductance 18NH 0603
L113 L370 High frequency fold
Inductance 22NH 0603
L282 L283 High frequency fold
Inductance 68NH 0603
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QUANZHOU WOUXUN ELECTRONICS CO., LTD Model: KG-689
Version: KG-689-0801-V1 Page 19 of 35
PARTS LIST
Designators Name and specifications Footprint
L354 L357 L366 L412 High frequency fold
Inductance 100NH 0603
L331 L345 L352 High frequency fold
Inductance 120NH 0603
L1167 L364 High frequency fold
Inductance 220NH 0603
L121 L871 L870 L451 Low frequency fold
Inductance 100NH 0603
L380 Low frequency fold
Inductance 270NH 0603
L314 Low frequency fold
Inductance 560NH 0603
L311 Low frequency fold
Inductance 1uH 0603
L350 Low frequency fold
Inductance 2.2uH 0603
L310 L363 Low frequency fold
Inductance 3.3uH 0603
L341 Low frequency fold
Inductance 6.8uH 0603
L371 NC 0603
L127 L135 Low frequency fold
Inductance 100NH 0805
L1149 Line Inductance
19NH±2% 0603
L230 L217 L223 L229 Line Inductance 15NH±2% 0805
L1161 Line Inductance
22NH±2% 0805
L145 Line Inductance
220NH±5% 0805
L237 Line Inductance
560NH±5% 0805
L128 L236 Line Inductance 1uH 0805
L158 Module Inductance
1uH±2% 1206
L281 L216 0.31*1.4*7T LC042125
L152 0.35*1.2*4T LC032319
L154 L156 L215 0.35*1.4*4T LC032121
L132 0.35*1.5*8T LC032334
L131
High temperature without
high loop
NC LC032319
D1 D813 Green light GREEN 0603
D2 D814 Red light RED 0603
D345 D346 Diode A D-ESC
D352 D353 Diode B9 D-ESC
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