Ericsson Portable Radio LBI 39175A User Manual

LBI-39175A  
SERVICE SECTION  
ORION™  
136-174 MHz Dual Bandwidth  
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  
ericssonz  
 
LBI-39175A  
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  
3
 
LBI-39175A  
DISASSEMBLY PROCEDURE  
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.  
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.  
Control Unit (Front Mounted)  
1. Expose the Logic/Audio/455 kHz IF circuitry  
3. Pull the radio, and remove the mounting bracket.  
according to Steps 1 and 2 in  
Transceiver (TXRX)  
section.  
Module  
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.  
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.  
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,  
2. Remove the inner shield by pulling the attached  
handle.  
while  
simultaneously  
turning  
the  
screw  
counterclockwise with the TORX driver. See LBI-  
38909 for details.  
Transceiver (TXRX) Module  
1. Remove the waterproof top and bottom covers, using  
4. Disengage the control unit from the Transceiver  
chassis using a pivoting motion about the top edge of  
the Transceiver chassis.  
a #20 TORX driver. Four cover mounting screws  
are located on the bottom of the module. The screws  
on the bottom cover are captive.  
5. Disengage the four captive screws on the rear cover,  
2. To expose the Logic/Audio/455 kHz IF circuitry,  
remove the shield on top of the module by pulling the  
attached handle.  
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.  
3. To expose the Exciter/RX Front End circuitry,  
remove the shield on the bottom of the module by  
pulling the attached handle.  
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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LBI-39175A  
3.  
4.  
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.  
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.)  
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.  
Steps:  
1.  
2
Remove dust and dirt from the black O-Ring gasket.  
Apply proper amount of the silicone grease to cloth.  
To Re-Assemble Unit after Servicing  
3.  
Put the silicone grease on throughout the surface of  
the black O-Ring gasket evenly. (see Figures 1A and  
1B)  
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.  
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.  
5
 
LBI-39175A  
Figure 1A - Front Mount Control Unit "O-Ring" Lubrication  
Figure 1B - Remote Mount Control Unit "O-Ring" Lubrication  
6
 
LBI-39175A  
ALIGNMENT PROCEDURES  
CAUTION  
Before bench testing the radio, be sure of the output  
voltage characteristics of your bench power supply.  
INTRODUCTION  
To protect the transmitter power output transistors  
from possible instant destruction, the following input  
voltages must not be exceeded  
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.  
Transmitter unkeyed:  
Transmitter keyed  
16.5 Volts  
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.  
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.  
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.  
The PC must be equipped with the 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.  
Consult the PC Programming Software manuals for  
further details regarding this software.  
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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LBI-39175A  
Figure 2 - ORION Programming Configurations (USA)  
Figure 3 - ORION Programming Configurations (EURO)  
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LBI-39175A  
Furthermore, if the Tracking Data is lost, specialized  
procedures are required to load new Tracking Data.  
TRACKING DATA  
therefore, it is  
to establish a record  
VERY IMPORTANT  
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.  
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.  
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)  
RF Power Modulation  
Parameter  
Squelch Set  
Deviation  
136.0000  
139.9950  
140.0050  
143.9950  
144.0050  
147.9950  
148.0050  
153.0000  
f1L (MHz)  
f1H (MHz)  
f2L (MHz)  
f2H (MHz)  
f3L (MHz)  
f3H (MHz)  
f4L (MHz)  
f4H (MHz)  
136.0000  
N/A  
140.0050  
N/A  
144.0050  
N/A  
148.0050  
153.0000  
136.0000  
N/A  
140.0050  
N/A  
144.0050  
N/A  
148.0050  
153.0000  
Table 3 - Tracking Data Frequencies (High Split)  
Parameter  
RF Power  
Modulation  
Deviation  
150.0000  
155.4950  
155.5050  
161.4950  
161.5050  
167.4950  
167.5050  
174.0000  
Squelch Set  
f1L (MHz)  
f1H (MHz)  
f2L (MHz)  
f2H (MHz)  
f3L (MHz)  
f3H (MHz)  
f4L (MHz)  
f4H (MHz)  
150.0000  
N/A  
155.5050  
N/A  
161.5050  
N/A  
167.5050  
174.0000  
150.0000  
N/A  
155.5050  
N/A  
161.5050  
N/A  
167.5050  
174.0000  
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LBI-39175A  
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  
Replace PA module  
NEW TRACKING DATA  
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  
Replace Synthesizer PWB  
Replace Logic PWB  
None  
Modulation Deviation and Data Offset  
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:  
Parameter  
Limit  
TX Modulation Deviation  
30 kHz channel spacing  
12.5 kHz channel spacing  
4.4 ±0.1 kHz  
2.25 ±0.1 kHz  
1. Using the PC Programming Software , make sure the  
radio is programmed in the following sequence:  
TX High Power 110 W Model  
50 W Model  
110 +4, -0 W  
50 +2, -0 W  
25 +0, -1 W  
a. Customer Operational Software (if necessary)  
25 W Model  
b. Tracking Data (First Iteration -- Tracking Data  
originally shipped with the radio is a good  
starting point.)  
TX Mid Power  
25 W Model  
15 +.5, -.5 W  
TX Low Power 110 W Model  
50 W Model  
55 +2, -0 W  
25 +1, -0 W  
c. Feature Encryption File (if necessary). Note: In  
order to load an Encryption File into a new  
Logic PWB, After Market Services must first be  
contacted at 1-800-368-3277 for authorization  
code. Otherwise the file will not load.  
25 W Model  
6
+.5 -.5 W  
RX Squelch Threshold  
8 +1, -0 dB  
SINAD  
d. Personality, which contains  
a
Conventional  
System using the frequencies given in Tables 2  
and 3.  
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.  
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:  
4. Repeat Steps 2 and 3 until the measurements at every  
frequency given in Tables 2 and 3 are within the  
limits specified.  
10  
 
LBI-39175A  
TRANSMITTER ALIGNMENT  
NOTICE  
The components listed above have been set at the factory  
and are NOT adjustable.  
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:  
ANY RE-ADJUSTMENT OF THESE COMPONENTS WILL  
VOID THE WARRANTY OF THIS PRODUCT.  
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.  
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.  
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.  
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.  
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:  
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.  
Synthesizer:  
CV240, CV280, RV201  
Power Amp - 25 W:  
Power Amp - 50 and 110 W:  
RV1  
RV2  
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  
These components have been set at the factory, and  
mounting surface.  
mounting hole. Align the leads as shown on the  
Outline Diagram. Then replace the transistor  
Place the transistor in the  
are NOT ADJUSTABLE. ANY RE-ADJUSTMENT OF  
THESE  
COMPONENTS  
WILL  
VOID  
THE  
WARRANTY OF THIS PRODUCT.  
mounting screws using moderate torque (9.4 kg.cm).  
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  
11  
 
LBI-39175A  
wire board runs to separate from the board. Check  
for shorts and solder bridges before applying power.  
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.  
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.  
ADJUSTMENT PROCEDURES  
Receiver Frequency Adjustment  
No receiver frequency adjustment is required.  
2nd Receiver Oscillator  
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.  
Using a frequency counter to monitor Terminal TP5,  
set L521 for a frequency of 44.645 MHz ±200 Hz.  
TEST EQUIPMENT REQUIRED  
IF/FM Detector Alignment  
Distortion Analyzer  
Apply a 1000 microvolt, on-frequency test signal  
modulated by 1000 Hz with standard deviation to antenna  
jack J1.  
AC Voltmeter  
RF Signal Generator  
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).  
Frequency Counter (136-174 MHz)  
4-Ohm, 25 Watt Resistor  
Adjust the VOLUME control for 15 watts output  
(7.75 VRMS) using the Distortion Analyzer as a  
voltmeter.  
Audio Isolation Transformer (1:1)  
19A116736P1 or equivalent **  
Set the output signal level of the RF signal generator  
so as to obtain 12 dB SINAD at the audio output.  
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.  
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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LBI-39175A  
ISOLATION  
TRANSFORMER  
Not required if instrument  
input is balanced with respect  
to ground.  
DISTORTION  
ANALYZER  
OR  
4-OHM  
LOAD  
AC VOLTMETER  
1 : 1  
Figure 4 - Audio Isolation Transformer  
SQUELCH ADJUSTMENT  
MICROPHONICS  
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.  
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.  
TROUBLESHOOTING GUIDE  
INTRODUCTION  
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.  
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  
Service Center. A list of serviceable parts is given in the  
next section.  
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LBI-39175A  
Radio Unit - Power Amplifier 110 Watts  
CAH-515H  
SERVICEABLE PARTS  
Control Unit - Switch Circuit CDF-368B/M  
C25  
C25  
C26  
C26  
C27  
C28  
C33  
C33  
HC1  
HC1  
TR2  
TR3  
Capacitor, 270 pF (136-153 MHz)  
Capacitor, 220 pF (150-174 MHz)  
Capacitor, 270 pF (136-153 MHz)  
Capacitor, 200 pF (150-174 MHz)  
Capacitor, 200 pF (150-174 MHz)  
Capacitor, 220 pF (150-174 MHz)  
Capacitor, Mica, 47 pF  
B19/5CAAA05042  
B19/5CAAA03175  
B19/5CAAA05042  
B19/5CAAA05122  
B19/5CAAA05122  
B19/5CAAA03175  
B19/5CMAB01252  
B19/5CMAB01252  
B19/5DHAA00049  
B19/5DHAA00050  
B19/5TCAF00510  
B19/5TCAF00510  
No serviceable parts.  
Capacitor, Mica, 47 pF  
Power Module (136-153 MHz)  
Power Module (150-174 MHz)  
Transistor, NPN  
Control Unit - Panel Control CMC-638  
Transistor, NPN  
No serviceable parts.  
Radio Unit - Power Amplifier 55 Watts CAH-515L  
Remote Control Unit - RIA NQZ-4882  
C8  
C8  
C9  
Capacitor, 270 pF (136-153 MHz)  
Capacitor, 220 pF (150-174 MHz)  
Capacitor, 270 pF (136-153 MHz)  
Capacitor, 220 pF (150-174 MHz)  
Capacitor, Mica, 47 pF  
Power Module, (136-153 MHz)  
Power Module, (150-174 MHz)  
Transistor, NPN  
B19/5CAAA05042  
B19/5CAAA03175  
B19/5CAAA05042  
B19/5CAAA03175  
B19/5CMAB01252  
B19/5DHAA00051  
B19/5DHAA00052  
B19/5TCAF00510  
J2  
Connector, 18 Pin  
B19/5JBAX00020  
C9  
C159  
HC1  
HC1  
TR1  
Radio Unit - System Control CMC-682  
F601  
IC604  
J701  
Fuse, 5 Amp  
AF Power Amplifier  
Connector, 18 Pin  
B19/5ZFAP00008  
B19/5DAAA00350  
B19/5JDAG00315  
Radio Unit - Power Amplifier 25 Watts CAH-515E  
Radio Unit - IF CMF-135  
HC1  
HC1  
Power Module, (136-153 MHz)  
Power Module, (150-174 MHz)  
B19/5DHAA00049  
B19/5DHAA00050  
No serviceable parts.  
Radio Unit - Synthesizer/Receiver/Exciter  
CMN-352  
No serviceable parts.  
14  
 
LBI-39175A  
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.  
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  
Figure 5 - Typical ORION Test Configuration  
15  
 
LBI-39175A  
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  
DIAGNOSTIC PROCEDURE  
SYMPTOM  
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.  
Low or no modulation.  
Adjust XU201 on the Synthesizer PWB. If the frequency is still out of  
specification, replace the Synthesizer PWB.  
a. Program a Conventional System with frequencies 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-39175A  
RECEIVER  
DIAGNOSTIC PROCEDURE  
SYMPTOM  
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 µV. 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 µV RF signal [with 1 kHz audio modulation at 3  
kHz deviation (1.5 kHz for 12.5 kHz channel spacing)] 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  
 
LBI-39175A  
CONTROL UNIT  
DIAGNOSTIC PROCEDURE  
SYMPTOM  
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:  
- 1993  
EGE  
or  
- 1994  
EGE  
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:  
- 1993  
EGE  
or  
- 1994  
EGE  
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-39175A  
GENERAL  
DIAGNOSTIC PROCEDURE  
SYMPTOM  
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.  
All System Groups ORION  
ERROR CODES  
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.  
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.  
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.  
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.  
19  
 
LBI-39175A  
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  
SOFTWARE  
TRACKING  
NO LOCK  
FREQDATA  
PERSDATA  
ROM errors  
UNKNOWN  
FEAT ERR  
DSP ERR  
General software failure  
Tracking data fatal error  
Synthesizer not locking  
Frequency data fatal error  
Personality errors  
Feature encryption error  
DSP error  
20  
 
LBI-39175A  
ROM Fatal Systems Errors  
ROM fatal errors may be corrected by cycling the radio power (turn it off then on). When the power cycle does not  
correct the problem the radio must be serviced.  
ERROR NAME  
MESSAGE  
CODE  
DESCRIPTION  
FATAL_SYS_TRAP  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
HARDWARE  
0
1
2
3
4
Fatal system error trap number.  
NMI occurred outside of sleep.  
8K RAM test error.  
32K ROM checksum test error.  
Flash checksum test error.  
ASIC driver failed initialization.  
ICP driver failed initialization.  
ASP driver failed initialization.  
FATAL_NMI_ERROR  
FATAL_RAM_ERROR  
FATAL_ROM_CHKSUM  
FATAL_FLSH_CHKSUM  
FATAL_ASIC_LOAD  
FATAL_ICP_LOAD  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
30  
31  
40  
41  
50  
60  
70  
80  
90  
91  
92  
FATAL_ASP_LOAD  
FATAL_EE_LOAD  
EEPROM driver failed initialization.  
ICP digital I/O initialization failed.  
Standard input/output driver failed initialization.  
Standard input driver failed initialization.  
RADIO driver failed initialization.  
MODEM driver failed initialization.  
External I/O driver failed initialization.  
Serial communication interface driver failed initialization.  
ICP prom checksum.  
ADI did not respond to command.  
ADI Rx circular queue underflowed.  
LCD did not acknowledge message.  
LCD hardware is invalid.  
Serial communication interface out of heap (RAM memory) space.  
ICP did not acknowledge message.  
ICP failed in a fork.  
Radio driver could not write to ASP.  
Software memory error - ROM task.  
Software memory error - Boot loader.  
Boot loader could not attach to SCI.  
FATAL_ICP_PORTNIT  
FATAL_INTOUT_LOAD  
FATAL_INTIN_LOAD  
FATAL_RADIO_LOAD  
FATAL_MODEM_LOAD  
FATAL_EXTIO_LOAD  
FATAL_SCI_LOAD  
FATAL _ICP_CHKSUM  
FATAL_ADI_NOACK  
FATAL_ADI_QUNDERFLOW  
FATAL_LCD_NOACK  
FATAL_LCD_HARD_FAIL  
FATAL_SCI_NOHEAP  
FATAL_ICP_NOACK  
FATAL_EXTIO_ICPFAIL  
FATAL_RADIO_ASPWRT  
FATAL_ROM_NOHEAP  
FATAL_BL_NOHEAP  
FATAL_BL_SCI_ATACH  
Operational Software Non-Fatal System Errors  
ERROR NAME  
MESSAGE  
CODE  
DESCRIPTION  
PIFEAT_SNR_ERROR  
PIFEAT_READ_ERROR  
PIFEAT_CRC_ERROR  
RI_DSPDOWN_NOATTEMPT  
AEGIS_ADIDOWN_  
FEAT ERR  
FEAT ERR  
FEAT ERR  
DSP ERR  
550  
551  
552  
850  
851  
Feature encryption - Can not read radio ROM serial number.  
Personality feature encryption read failure or data not available.  
Decryption failure. Personality feature encryption CRC failure.  
DSP not found  
DSP ERR  
DSP file not found.  
NOTFOUND  
AEGIS_ADIDOWN_CRCFAIL  
AEGIS_ADIDOWN_ENCERR  
AEGIS_ADIDOWN_PMFAIL  
DSP ERR  
DSP ERR  
DSP ERR  
852  
853  
854  
DSP file not found.  
Radio feature encryption does not match DSP file.  
DSP file is corrupted or hardware failure. RE-program radio or power cycle the  
radio.  
AEGIS_ADIDOWN_DMFAIL  
AEGIS_ADIDOWN_BIOSERR  
AEGIS_KEYLOAD_  
NOBANKS  
DSP ERE  
DSP ERR  
DSP ERR  
855  
856  
860  
DSP file is corrupted or hardware failure. Re-program radio or power cycle radio.  
Hardware failure.  
Personality did not assign banks for the keys.  
AEGIS_PVT_NONE  
FEAT ERR  
870  
Private is not feature encrypted.  
21  
 
LBI-39175A  
Operational Software Fatal System Errors  
ERROR NAME  
RADC_PITD_ERROR  
RADC_PIHW_ERROR  
RADC_FREQ_ERROR  
RADC_PITD_MALLOC_ERROR  
RADC_PITD_CKSUM_ERROR  
DACS_NO_LOCK  
MESSAGE  
CODE  
DESCRIPTION  
TRACKING  
PERSDATA  
FREQDATA  
SOFTWARE  
SOFTWARE  
NO LOCK  
200  
201  
202  
203  
204  
300  
Personality tracking data error. Re-program the tracking data.  
Personality hardware data error. Re-program the personality.  
Personality frequency data error. Re-program the personality.  
Personality tracking data malloc error. Re-program the tracking data.  
Personality tracking data checksum error. Re-program the tracking data.  
Synthesizer did not lock or became unlocked. Check the frequencies in the PC  
programmer and re-program the radio personality.  
Unable to correctly configure the modem for EDACS operation. Re-program  
the personality.  
DACS_MODEM_FATAL_ERROR  
SOFTWARE  
301  
DACS_RADC_FAILURE  
DACS_MODEM_RXOVR  
DACS_MODEM_RXAVR  
CONV_RADC_ERROR  
CONV_NOLOCK_ERROR  
SOFTWARE  
SOFTWARE  
SOFTWARE  
SOFTWARE  
NO LOCK  
302  
304  
305  
400  
401  
Power cycle the radio.  
Hardware Modem overflow. Power cycle the radio.  
Power cycle the radio.  
Error calling RADC function. Power cycle the radio.  
Synthesizer became unlocked. check the frequencies in the PC programmer  
and re-program the radio personality.  
CONV_PUT_UIMSG_ERROR  
CONV_MODEM_RXOVR  
CONV_MODEM_RXAVR  
CONV_MODEM_FATAL_ERROR  
CONV_PERS_ERROR  
PI_NOPERS_ERROR  
PI_CRC_ERROR  
PI_DESC_CRC_ERROR  
PI_MALLOC_ERROR  
SOFTWARE  
SOFTWARE  
SOFTWARE  
SOFTWARE  
PERSDATA  
PERSDATA  
PERSDATA  
PERSDATA  
SOFTWARE  
PERSDATA  
SOFTWARE  
402  
403  
404  
405  
407  
500  
501  
502  
503  
600  
601  
UI message buffer not enabled. Power cycle the radio.  
Conventional DIGV modem overflow.  
Conventional DIGV modem underflow.  
Unable to correctly configure the modem for conventional DIGV operation.  
Conventional personality error.  
Personality data is not present. Program the personality.  
Flash personality CRC did not match EEPROM. Re-program the personality.  
Crucial personality data has incorrect CRC. Re-program the personality.  
Could not allocate memory to store crucial personality data.  
Input/Output device error.  
UI_FATAL_DEVICE_ERROR  
UI_FATAL_SWTO_  
Software memory error.  
MALLOC_ERROR  
UI_FATAL_SWTO_MAX_ERROR  
UI_FATAL_WINDOW_MAX_  
ERROR  
SOFTWARE  
SOFTWARE  
602  
603  
Software error, power cycle the radio.  
Too many open windows.  
UI_FATAL_WINDOW_MALLOC_  
ERROR  
UI_FATAL_MESSAGE_INVPARM  
SOFTWARE  
SOFTWARE  
SOFTWARE  
604  
605  
606  
Software memory error.  
Invalid parameter to UI_PUT_MESSAGE(). software error, report how error  
was encountered.  
UI Task message buffer full error. Software error, report how error was  
encountered.  
UI_FATAL_RI_MSGBUF_FULL  
UI_FATAL_RISYS_MSGBUF_FULL  
UI_FATAL_CI_MSGBUF_FULL  
UI_FATAL_DEVICE_  
SOFTWARE  
SOFTWARE  
PERSDATA  
607  
608  
609  
Radio Interface System (EDACS/CONV) task message buffer full.  
CI Task message buffer full.  
I/O device type (from personality) not supported.  
NOTSUPPORTED  
UI_FATAL_AUXIO_MALLOC_  
ERROR  
SOFTWARE  
610  
Software memory error.  
UI_FATAL_NET_DEVICE_ERROR  
UI_FATAL_INVALID_CUID  
SOFTWARE  
SOFTWARE  
611  
612  
Network I/O device error  
CU ID is invalid or CU not connected. Insure that CU ID is CUA and DUAL  
is disabled in personality.  
UI_FATAL_NO_TONE_DATA  
UI_FATAL_UII0_MSGBUF_FULL  
AEGIS_ADI_OVERFLOW  
AEGIS_RXBUF_MALLOC_ERROR  
AEGIS_KEYLOAD_MALLOC_  
ERROR  
SOFTWARE  
SOFTWARE  
SOFTWARE  
SOFTWARE  
SOFTWARE  
613  
614  
801  
802  
803  
No tone data is available in personality.  
UI I/0 BBOS message buffer full.  
ADI Transmit event not serviced in time and buffer has overflown.  
No memory available.  
No Keyloader table memory available.  
AEGIS_KEYLOAD_ERROR  
AEGIS_DATAMEM_MALLOC_  
ERROR  
SOFTWARE  
SOFTWARE  
804  
805  
General Keyload error has occurred.  
No memory is allocated for data.  
AEGIS_KEYLOAD_NOTABL  
SOFTWARE  
806  
No key table was found in EEPROM.  
22  
 
LBI-39175A  
Radio Programming Errors  
Programming errors are divided into three categories:  
1. Protocol Errors - These are errors produced by the low level communication routines.  
2. Radio Errors - These are errors that are returned from the radio ROM or operating software.  
3. PC Errors - These are errors that are produced by the PC Programming software.  
MESSAGE  
CODE  
DESCRIPTION  
Successful  
0
5
6
7
8
Command was performed successfully.  
Protocol - Canceled by receiver  
Protocol - Canceled by sender  
Protocol - Terminate transmission  
Protocol - Transmit error  
x328 protocol received a cancel. The radio detected a cancel command.  
x 328 protocol transmitted cancel. The radio is canceling the read command.  
x328 protocol received an end of transmission.  
x328 protocol could not transmit. Reliable communication cannot be established. It could be  
the radio or PC hardware problems (programming cable, interface box, or radio hardware).  
x328 protocol not initialized or failed to initialize.  
Radio responded with a success. Radio acknowledged successful programming.  
Radio could not configure its comport (hardware failure).  
Radio failed to erase the flash memory. The radio flash memory part is unusable or it cannot  
detect the 12 volts power. Check the programming box and cables.  
Radio failed in writing to the flash memory. Retry the programming process (hardware  
failure).  
Protocol - Protocol initialization error  
Radio - Programmed successfully  
Radio - Comport configuration failed  
Radio - Flash erase failed  
9
10  
11  
12  
Radio - Flash write failed  
13  
14  
Radio - Flash code CRC did not match  
Flash code not programmed correctly. CRC did not match. The operating software will not  
execute. Re-program the radio.  
Radio - Canceled by receiver  
Radio - Canceled by sender  
Radio - End of transmission received  
Radio - Transmit error  
15  
16  
17  
18  
The radio operating software received a cancel command.  
The radio software received or sent an end of transmission.  
Radio could not transmit the required data. Check all hardware connections and try  
programming again.  
Radio - Invalid command  
Radio - No application code  
19  
20  
Radio did not understand the received command.  
No application code is loaded, the radio cannot accept personality commands. Re-program the  
operating software (flash code) and re-program the personality.  
The radio application code failed to perform the command.  
Could not program the radio EEPROM part.  
The radio acknowledged a successful baud communication baud rate change.  
The PC programming software could not allocate adequate memory space to perform the  
function.  
Radio - Application code error  
Radio - EEPROM programming error  
Radio - Baud rate has changed  
PC - Cannot allocate memory  
21  
22  
23  
50  
PC - Cannot open data file  
51  
The specified file (code or personality) could not be opened (file does not exist or has access  
protection).  
PC - Cannot read data file  
PC - Cannot write to file  
PC - File not found  
52  
53  
54  
55  
The specified file (code or personality) could not be read.  
The specified file (code or personality) could not be written.  
The specified file (code or personality) is not found in the current directory.  
The radio flash part size is unknown or the operating software file size is larger than the radio's  
flash memory size.  
PC - File is larger than radio memory  
PC - Incorrect Tracking Data RF band  
split  
57  
Incorrect Tracking Data RF band split.  
PC - Incorrect Tracking Data version  
PC - Tracking Data checksum error  
PC- Time-out, radio not responding  
PC - Comport configuration error  
PC - Abort, message canceled  
PC - Requested personality data does  
not exist  
58  
59  
60  
61  
62  
63  
Incorrect Tracking Data version.  
Tracking Data checksum error.  
Radio is not connected or not turned on or the selected PC comport number is invalid.  
Comport configuration error, cannot set comport.  
Aborted by operator, message canceled.  
The personality table does not exist (Tracking or Encryption table).  
23  
 
Ericsson Inc.  
Private Radio Systems  
Mountain View Road  
Lynchburg, Virginia 24502  
1-800-592-7711 (Outside USA, 804-592-7711)  
Printed in U.S.A.  
 

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