ASTRO® Digital XTL™ 5000 Mobile Radio Consolette (Control Heads W7 and W9) Instruction Manual

ASTRO®
Digital XTL™ 5000

Mobile Radio Consolette
(Control Heads W7 and W9)
Instruction Manual
M ASTRO® Digital XTL™ 5000
Consolette
(Control Heads W7 and W9)
Instruction Manual
Motorola, Inc.
8000 West Sunrise Boulevard
Fort Lauderdale, Florida 33322 6881098C21-P
Foreword
The information contained in this manual relates to all ASTRO® Digital XTL™ 5000 Consolettes, unless otherwise
specified. This manual provides sufficient information to enable service shop personnel to troubleshoot and repair an
ASTRO Digital XTL 5000 Consolette to the component level.
Product Safety and RF Exposure Compliance
Before using this product, read the operating instructions

! for safe usage contained in the Product Safety and RF
Caution Exposure booklet enclosed with your radio.
ATTENTION!
This radio is restricted to occupational use only to satisfy FCC RF energy exposure requirements.
Before using this product, read the RF energy awareness information and operating instructions in the
Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number
6881095C99) to ensure compliance with RF energy exposure limits.
For a list of Motorola-approved antennas, batteries, and other accessories, visit the following web site
which lists approved accessories: http://www.motorola.com/cgiss/index.shtml.
Before operating an ASTRO Digital XTL 5000 Consolette, please read the “Consolette Installation Guidelines,” on page ix
in the front of this manual.
Manual Revisions
Changes which occur after this manual is printed are described in FMRs (Florida Manual Revisions). These FMRs provide
complete replacement pages for all added, changed, and deleted items. To obtain FMRs, contact the Customer Care and
Services Division (see “Replacement Parts Ordering”).
Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in
semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce in
any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the
Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or distributed in
any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not
be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or
patent applications of Motorola, except for the normal non-exclusive license to use that arises by operation of law in the
sale of a product.
Document Copyrights
No duplication or distribution of this document or any portion thereof shall take place without the express written permission
of Motorola. No part of this manual may be reproduced, distributed, or transmitted in any form or by any means, electronic
or mechanical, for any purpose without the express written permission of Motorola.
Disclaimer
The information in this document is carefully examined, and is believed to be entirely reliable. However, no responsibility is
assumed for inaccuracies. Furthermore, Motorola reserves the right to make changes to any products herein to improve
readability, function, or design. Motorola does not assume any liability arising out of the applications or use of any product
or circuit described herein; nor does it cover any license under its patent rights nor the rights of others.
Trademarks
MOTOROLA, the Stylized M logo, ASTRO, and FLASHport are registered in the US Patent & Trademark Office. All other
product or service names are the property of their respective owners.
© Motorola, Inc. 2004, 2009
Table of Contents
Foreword.........................................................................................................ii
Product Safety and RF Exposure Compliance............................................................................................ ii
Manual Revisions........................................................................................................................................ ii
Computer Software Copyrights ................................................................................................................... ii
Document Copyrights.................................................................................................................................. ii
Disclaimer ................................................................................................................................................... ii
Trademarks ................................................................................................................................................. ii
List of Figures ..............................................................................................vii

List of Tables...............................................................................................viii
Related Publications...................................................................................viii
Consolette Installation Guidelines ..............................................................ix

RF Operational Characteristics .................................................................................................................. ix
Product Safety and RF Exposure Compliance........................................................................................... ix
Operational Cautions ................................................................................................................................. ix
Lightning and Surge Suppression .............................................................................................................. ix
General............................................................................................................................................. ix
Recommendations ............................................................................................................................ x
Recommended Protectors................................................................................................................. x
Safe Handling of CMOS Integrated-Circuit Devices ................................................................................... x
Introduction........................................................................................................................................ x
Handling Precautions ....................................................................................................................... xi
Parts Replacement and Substitution ................................................................................................ xi
Chapter 1 Introduction ..........................................................................1-1

1.1 Notations Used in This Manual ......................................................................................................1-1
1.2 General...........................................................................................................................................1-1
1.3 Options ...........................................................................................................................................1-3
1.3.1 Consolette Configuration Options .....................................................................................1-3
1.3.1.1 Local Control Configuration, G80 .............................................................................1-3
1.3.1.2 Digital Remote Control Configuration, G81 ..............................................................1-3
1.3.1.3 Audio Interface Board, L791.....................................................................................1-3
1.3.1.4 Tone Remote Control, L146 .....................................................................................1-3
1.3.1.5 12 Vdc Only, L32......................................................................................................1-3
1.3.1.6 Omit Microphone, L73 ..............................................................................................1-3
1.3.1.7 VU Meter/Clock, L114 (No Longer Available) ..........................................................1-3
1.3.2 Software Options ...............................................................................................................1-3
1.3.2.1 Enhanced Digital ID Display, G114 ..........................................................................1-4
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iv Table of Contents
Chapter 2 Installation............................................................................2-1
2.1 Planning the Installation .................................................................................................................2-1
2.2 Ventilation.......................................................................................................................................2-1
2.3 Station Mounting Procedures .........................................................................................................2-1
2.3.1 Desktop Installation ...........................................................................................................2-1
2.3.2 Wall Mounting....................................................................................................................2-1
2.4 Antenna Connections .....................................................................................................................2-2
2.5 Power and Ground Connection ......................................................................................................2-2
2.5.1 General..............................................................................................................................2-2
2.5.2 AC Power Input .................................................................................................................2-3
2.5.3 DC Input Power (Optional) ................................................................................................2-4
2.6 DIP Switch and Jumper Settings....................................................................................................2-4
2.6.1 Audio Interface Board (AIB) Settings ................................................................................2-5
2.6.2 Tone Remote Control (TRC) Board Settings.....................................................................2-6
2.7 Clock/VU Meter Setup (Optional) (No Longer Available) ...............................................................2-9
2.7.1 Operation...........................................................................................................................2-9
2.7.2 Time Setting ......................................................................................................................2-9
2.7.3 Month and Day Setting......................................................................................................2-9
2.7.4 Year Setting.......................................................................................................................2-9
2.8 Accessory Connector 2 ..................................................................................................................2-9
2.9 Accessory Connector 3 ................................................................................................................2-11
2.10 Remote Control Installation ..........................................................................................................2-12
2.10.1 Digital Remote Control Installation ..................................................................................2-12
2.10.2 Tone Remote Control Installation....................................................................................2-13
2.11 Controller Board Adjustment Procedures.....................................................................................2-15
2.11.1 AIB Adjustment Procedure ..............................................................................................2-15
2.11.1.1 Transmit (Auxiliary Audio Input) .............................................................................2-15
2.11.1.2 Receive ..................................................................................................................2-15
2.11.2 TRC Adjustment Procedure ............................................................................................2-15
2.11.2.1 Transmit (Wireline Input) ........................................................................................2-15
2.11.2.2 Transmit (Auxiliary Audio Input) .............................................................................2-15
2.11.2.3 Receive ..................................................................................................................2-16
2.12 Emergency Alarm Receive Indicator ............................................................................................2-16
2.12.1 Feature Limitations..........................................................................................................2-19
2.13 Programming................................................................................................................................2-20
2.13.1 Codeplug Programming ..................................................................................................2-20
2.13.2 Tone Remote Control, L146 ............................................................................................2-20
2.13.3 Enhanced Digital ID Display, G114 .................................................................................2-21
2.13.4 HUB Defeats PL ..............................................................................................................2-22
2.13.5 AUX TX/AUX MIC ...........................................................................................................2-23
2.13.6 AGC Gain Settings within the Radio ...............................................................................2-24
2.13.7 FLASHport Programming ................................................................................................2-25
Chapter 3 Theory of Operation ............................................................3-1

3.1 Introduction.....................................................................................................................................3-1
3.2 General...........................................................................................................................................3-1
3.3 Audio Interface Board (AIB) ...........................................................................................................3-2
3.3.1 Detailed Description ..........................................................................................................3-3
3.3.1.1 Receive Audio Paths ................................................................................................3-3
3.3.1.2 Transmit Audio Paths ...............................................................................................3-4
3.3.1.3 Control and Data Paths ............................................................................................3-4
May 5, 2009 6881098C21-P

Table of Contents v
3.4 Tone Remote Control (TRC) Board................................................................................................3-5

3.4.1 General Description...........................................................................................................3-5
3.4.2 Detailed Description ..........................................................................................................3-7
3.4.2.1 Control Point Monitor................................................................................................3-7
3.4.2.2 Receive Audio Path..................................................................................................3-7
3.4.2.3 Transmit Audio Path.................................................................................................3-8
3.4.2.4 Tone Processing Section .........................................................................................3-9
3.4.2.5 AGC Circuit Operation............................................................................................3-10
3.4.2.6 Power Distribution ..................................................................................................3-10
3.4.2.7 Input/Output Control Definitions .............................................................................3-11
3.4.2.8 Smart Modem Protocol (SMP) Control...................................................................3-11
3.5 Power-Up .....................................................................................................................................3-14
3.6 Receive ........................................................................................................................................3-14
3.7 Transmit .......................................................................................................................................3-14
3.8 Power-Up Self-Check Errors ........................................................................................................3-14
Chapter 4 Maintenance .........................................................................4-1

4.1 Alignment .......................................................................................................................................4-1
4.2 Maintenance and Troubleshooting Procedures..............................................................................4-1
4.3 Recommended Test Equipment and Service Aids.........................................................................4-1
4.3.1 Electrical............................................................................................................................4-1
4.3.2 Mechanical ........................................................................................................................4-1
4.4 Disassembly and Reassembly .......................................................................................................4-2
4.4.1 Top Cover..........................................................................................................................4-2
4.4.1.1 Removing the Top Cover .........................................................................................4-2
4.4.1.2 Replacing the Top Cover..........................................................................................4-3
4.4.2 XTL 5000 Transceiver .......................................................................................................4-3
4.4.2.1 Removing the Transceiver .......................................................................................4-3
4.4.2.2 Replacing the Transceiver........................................................................................4-4
4.4.3 AIB/TRC Interface Board...................................................................................................4-4
4.4.3.1 Removing the AIB/TRC Board .................................................................................4-4
4.4.3.2 Replacing the AIB/TRC Board..................................................................................4-5
4.4.4 Power Supply ....................................................................................................................4-6
4.4.4.1 Removing the Power Supply ....................................................................................4-6
4.4.4.2 Replacing the Power Supply ....................................................................................4-6
4.4.5 Fan ....................................................................................................................................4-7
4.4.5.1 Removing the Fan ....................................................................................................4-7
4.4.5.2 Replacing the Fan ....................................................................................................4-7
4.4.6 Control Head (G80 Option Only) .......................................................................................4-7
4.4.6.1 Removing the Control Head .....................................................................................4-7
4.4.6.2 Replacing the Control Head .....................................................................................4-8
Chapter 5 Cable Diagrams....................................................................5-1

5.1 Standard Cables.............................................................................................................................5-1
5.2 Optional Cables..............................................................................................................................5-6
Chapter 6 Troubleshooting Charts ......................................................6-1

6.1 List of Troubleshooting Charts .......................................................................................................6-1
6881098C21-P May 5, 2009

vi Table of Contents
6.2 Troubleshooting Charts ..................................................................................................................6-2
Chapter 7 Schematics, Board Layouts, and Parts Lists....................7-1

7.1 List of Schematics, Board Layouts, and Parts Lists .......................................................................7-1
7.2 Schematics, Board Layouts, and Parts Lists..................................................................................7-2
Appendix A Cross Patch Configuration ................................................ A-1

A.1 General Description....................................................................................................................... A-1
A.2 Detailed Description ...................................................................................................................... A-1
A.3 Level Settings................................................................................................................................ A-2
A.3.1 Consolette 1 to Consolette 2 Path.................................................................................... A-2
A.3.2 Consolette 2 to Consolette 1 Path.................................................................................... A-2
A.4 Radio-Wide Changes Using CPS.................................................................................................. A-3
A.5 Audio Degradation Issues ............................................................................................................. A-3
Appendix B Replacement Parts Ordering ............................................. B-1

B.1 Basic Ordering Information............................................................................................................ B-1
B.2 Motorola Online ............................................................................................................................. B-1
B.3 Mail Orders.................................................................................................................................... B-1
B.4 Telephone Orders ......................................................................................................................... B-1
B.5 Fax Orders .................................................................................................................................... B-2
B.6 Parts Identification......................................................................................................................... B-2
B.7 Product Customer Service ............................................................................................................ B-2
Index .................................................................................................... Index-1
May 5, 2009 6881098C21-P

List of Figures vii
List of Figures
Figure 2-1. Wall Mounting........................................................................................................................2-2

Figure 2-2. Rear Panel ............................................................................................................................2-2
Figure 2-3. Power Supply VAC – Select Switch.......................................................................................2-3
Figure 2-4. Accessory 2 and 3 Mating Connector..................................................................................2-12
Figure 2-5. Consolette Setup with Multiple MC3000 Desksets..............................................................2-12
Figure 2-6. Consolette Setup with the Gold Elite Console.....................................................................2-14
Figure 2-7. Consolette Setup with the MCC 5500 .................................................................................2-14
Figure 2-8. Radio Wide -> TPS Screen .................................................................................................2-17
Figure 2-9. Radio Configuration –> Controls -> Radio VIP Screen .......................................................2-18
Figure 2-10. ASTRO System - # -> Advanced Screen ............................................................................2-18
Figure 2-11. Trunking System - # -> Advanced Screen...........................................................................2-19
Figure 2-12. Radio Wide—Advanced II Tab Screen ................................................................................2-21
Figure 2-13. Display and Menu—PTT ID Tab Screen..............................................................................2-22
Figure 2-14. Conventional Configuration—HUB Defeats PL Feature......................................................2-23
Figure 2-15. Radio Wide Screen — Advanced Tab Screen.....................................................................2-24
Figure 2-16. Transceiver AGC Gain Settings ..........................................................................................2-25
Figure 3-1. Consolette Block Diagram .....................................................................................................3-1
Figure 3-2. Consolette Front Panel—G80 Option....................................................................................3-2
Figure 3-3. Consolette Front Panel—G81 Option....................................................................................3-2
Figure 3-4. Remote Key-Up .....................................................................................................................3-5
Figure 3-5. TRC to ACIM Cable Diagram ..............................................................................................3-12
Figure 3-6. TRC to ACIM Cable Orientation (not provided by Motorola) ...............................................3-13
Figure 4-1. Removing the Top Cover .......................................................................................................4-2
Figure 4-2. Removing the Transceiver.....................................................................................................4-3
Figure 4-3. Removing the AIB/TRC Board...............................................................................................4-5
Figure 4-4. Removing the Power Supply .................................................................................................4-6
Figure A-1. Cross Patch Cable................................................................................................................ A-1
6881098C21-P May 5, 2009

viii List of Tables
List of Tables
Table 2-1. Audio Interface Board DIP Switch Settings ...........................................................................2-5

Table 2-2. Audio Interface Board Jumper Settings.................................................................................2-5
Table 2-3. Tone Remote Control Board DIP Switch Settings (S100) .....................................................2-6
Table 2-4. Tone Remote Control Board DIP Switch Settings (S101) .....................................................2-7
Table 2-5. Tone Remote Control Board Jumper Settings .......................................................................2-7
Table 2-6. Tone Remote Control Board Plug Settings............................................................................2-8
Table 2-7. Tone Table Selection .............................................................................................................2-8
Table 2-8. Accessory Connector 2—Pin Descriptions..........................................................................2-10
Table 2-9. Accessory Connector 3—Pin Descriptions.......................................................................... 2-11
Table 2-10. Accessory Connector 2 Pins: Digital Remote Control Operation ........................................2-13
Table 2-11. Accessory Connector 2 Pins: Tone Remote Control Operation ..........................................2-14
Table 3-1. TRC Function Tone Descriptions...........................................................................................3-6
Table 3-2. Accessory Connector 1 (J13) ..............................................................................................3-12
Table 3-3. Supported IDs .....................................................................................................................3-13
Table 3-4. XTL 5000 Consolette Power-Up Self-Check Error Codes...................................................3-15
Table 5-1. Power LED Cable Part #3084459T01 (P/O TKN8676) .........................................................5-1
Table 5-2. RF Coaxial Cable Part #0112004E09 (P/O TKN8676)..........................................................5-1
Table 5-3. Speaker Cable Part #3084457T01 (P/O TRN7394) ..............................................................5-1
Table 5-4. Control Head Cable ...............................................................................................................5-2
Table 5-5. Radio Cable...........................................................................................................................5-3
Table 5-6. Accessory Cable ...................................................................................................................5-4
Table 5-7. Clock/VU Cable (No Longer Available) ................................................................................5-6
Table 6-1. List of Troubleshooting Charts...............................................................................................6-1
Table 7-1. List of Schematics, Board Layouts, and Parts Lists ..............................................................7-1
Table 7-2. XTL 5000 Consolette Exploded View Parts List ...................................................................7-4
Table 7-3. TRN7393B Control Head Interface Board Parts List .............................................................7-4
Table 7-4. PLN1688A Audio Interface Board Parts List .......................................................................7-10
Table 7-5. PLN1687A Tone Remote Control Board Electrical Parts List ..............................................7-19
Table 7-6. PLN1687B Tone Remote Control Board Electrical Parts List ..............................................7-31
Related Publications
ASTRO Digital XTL 5000 Mobile Radio with W3 Control Head User’s Guide................................ 6881096C67
ASTRO Digital XTL 5000 Mobile Radio with W4, W5, W7, and W9 Control Heads User’s Guide. 6881096C68
ASTRO Digital XTL 5000 Mobile Radio Installation Manual........................................................... 6881096C72
ASTRO Digital XTL 5000 Mobile Radios Universal Crypto Module Field Installation Instructions . 6881097C53
ASTRO Digital XTL 5000 VHF/UHF Range 1/700-800 MHz Mobile Radio Basic Service Manual 6881096C73
ASTRO Digital XTL 5000 VHF/UHF Range 1/700-800 MHz Mobile Radio Detailed Service
Manual....................................................................................................................................... 6881096C74
ASTRO Digital Spectra and Digital Spectra Plus Mobile Radios W3/W4/W5/W7/W9
Control Head Models Service Manual ...................................................................................... 6881096C77
CPS Programming Installation Guide............................................................................................. 6881095C44
KVL 3000 User’s Manual.................................................................................................................6881131E16
System 9000 Direct Entry Keyboard Instruction Manual ............................................................. 68P80101W22
May 5, 2009 6881098C21-P

Consolette Installation Guidelines ix
Consolette Installation Guidelines
RF Operational Characteristics
Your ASTRO Digital XTL 5000 Consolette contains a digital mobile wireless two-way radio. When the
Consolette is ON, it receives and transmits radio frequency (RF) energy.
Product Safety and RF Exposure Compliance
Before using this product, read the operating instructions for safe
! usage contained in the Product Safety and RF Exposure booklet

enclosed with your radio (Motorola Publication part number
Caution 6881095C99).
Operational Cautions
• Because of danger of introducing additional hazards, do not install substitute parts or perform
any unauthorized modifications of equipment.
• DO NOT operate the transmitter of any Consolette unless all RF connectors are secure and all
connectors are properly terminated.
• All equipment must be properly grounded in accordance with Motorola Standards and
Guideline for Communications Sites “R56” 68P81089E50 and specified installation instructions
for safe operation.
• Slots and openings in the Consolette housing are provided for ventilation. To ensure reliable
operation of the product and to protect if from overheating, these slots and openings must not
be blocked or covered.
• Only an authorized technician familiar with the Consolette should service equipment.
Lightning and Surge Suppression

General
The installation of Transient Voltage Surge Suppression (TVSS) devices is a requirement for all
communication sites and is essential for all facilities where communication-related electronics and
electrical equipment are in use. Surges and transient power anomalies are potentially destructive
electrical disturbances, the most damaging being over-voltage occurrences and short duration over-
voltage events. Sometimes referred to as “spikes,” high-energy transient power anomalies can arise
from inductive load switching of other events within the power system or capacitive and inductive
coupling from environmental events, such as nearby lightning activity. Environmental and inductive
power anomalies are wideband occurrences with a frequency range from close to DC to well into the
RF high frequency spectrum. It is critical that each point-of-entry (AC, telephone, LAN, signal/control,
and RF) into the equipment area be protected against these anomalies. This protection is essential
to reduce the risk of personal injury, physical equipment damage, and loss of operations (equipment
downtime).
6881098C21-P May 5, 2009

x Consolette Installation Guidelines
Recommendations
To protect your equipment from lightning and surge damage, do the following:
• Install these TVSS devices as described in Chapter 9, “Transient Voltage Surge Suppression,”
of the Motorola Standards and Guideline for Communications Sites “R56” 68P81089E50
manual.
• Ground all RF transmission lines from the antenna structure to the shelter or building as
described in Chapter 6, “External Grounding,” of the Motorola Standards and Guideline for
Communications Sites “R56” 68P81089E50 manual. Upon entering the building, all RF
transmission lines shall route through a coaxial RF-type TVSS (or Surge Protection Device).
Recommended Protectors
TVSS devices are available through Motorola's Accessories and Aftermarket Products Division.
Installation instructions are generally included with each device. The following listing includes phone
line suppressors, AC line surge protectors, coaxial cable in-line lightning arrestors, and coaxial cable
ground clamp kits.
• Phone Line Suppressors
- RRX4021 - Single Line Suppressor, 3-electrode gas tube protector
- TRN4589 - Dual Line Suppressor, 3-electrode gas tube protector
- RRX4021 - Single Line Suppressor, 3-electrode gas tube protector
• AC Line Surge Protectors
- RRX4034 - AC Line Surge Protector, 117VAC line, 7/8" x 14 conduit hole mounting
• Coaxial Cable In-Line Lightning Arrestors
- RLN4711 - UHF-Type Connector
- RRX4025 - N-Type Connector
- RRX4032 - Tower Mount Kit
• Coaxial Cable Ground Clamp Kits
- RDN5826 - 1/4" or 3/8" Cable Ground Clamp Kit
- RDN5514 - 1/2" Cable Ground Clamp Kit
- RDN5517 - 5/8" to 7/8" Cable Ground Clamp Kit
Safe Handling of CMOS Integrated-Circuit Devices

Introduction
This section will aid you in troubleshooting a malfunctioning Consolette. It is intended to be detailed
enough to localize the malfunctioning circuit and isolate the defective component.
Before using this product, read the operating instructions for
! safe usage contained in the Product Safety and RF Exposure

booklet enclosed with your radio (Motorola Publication part
Caution number 6881095C99).
May 5, 2009 6881098C21-P

Consolette Installation Guidelines xi
Handling Precautions
Complementary metal-oxide semiconductor (CMOS) devices and other high-technology devices are
used in the Consolette. While the attributes of these devices are many, their characteristics make
them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges.
Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special
precautions must be taken to prevent device damage during disassembly, troubleshooting, and
repair. Handling precautions are mandatory for this radio and are especially important in low humidity
conditions. DO NOT attempt to disassemble the radio without observing the following handling
precautions.
1. Eliminate static generators (plastics, Styrofoam, etc.) in the work area.
2. Remove nylon or double-knit polyester jackets, roll up long sleeves, and remove or tie back
loose hanging neckties.
3. Store and transport all static-sensitive devices in ESD-protective containers.
4. Disconnect all power from the unit before ESD-sensitive components are removed or inserted
unless otherwise noted.
5. Use a static-safeguarded workstation, which can be accomplished through the use of an
antistatic kit (Motorola part number 01-80386A82). This kit includes a wrist strap, two ground
cords, a static-control table mat and a static-control floor mat.
6. Always wear a conductive wrist strap when servicing this equipment. The Motorola part
number for a replacement wrist strap that connects to the table mat is 42-80385A59.
Parts Replacement and Substitution

Special care should be taken to ensure that a suspected component is actually the one at fault. This
special care will eliminate unnecessary unsoldering and removal of parts, which could damage or
weaken other components or the printed circuit board (PCB) itself.
When damaged parts are replaced, identical parts should be used. If the identical replacement
component is not locally available, check the parts list for the proper Motorola part number and order
the component from the nearest Motorola Communications Parts facility.
For information on ordering parts replacement, refer to Appendix B, "Replacement Parts Ordering".
6881098C21-P May 5, 2009

xii Consolette Installation Guidelines
Notes
May 5, 2009 6881098C21-P

xiii
ASTRO Digital XTL 5000 Consolette Model Chart

MODEL NUMBER DESCRIPTION
L20KSS9PW1_N 10–50 W 136–174 MHz
L20QSS9PW1_N 10–40 W 380–470 MHz
L20SSS9PW1_N 10–40 W 450–520 MHz
L20URS9PW1_N 10–35 W 762–870 MHz
L20WRS9PW1_N 10–30 W 896–941 MHz
OPTION NUMBER DESCRIPTION
G80_ ADD: Local Control Configuration
G81_ ADD: Digital Remote Control Configuration
L791_ ADD: Audio Interface Board
L146_ ADD: Tone Rem Control Option (Must have G80 Option)
L114_ ADD: VU Meter/Clock (No longer available)
L113_ ADD: Desk Microphone
L32_ ADD: 12 Volt DC only Operation
L681 ADD: AC Power Supply
ITEM NUMBER DESCRIPTION
X X X X X HHN4045_ Transceiver Hardware
X HUD4022_ VHF Main Board
X HUE4039_ UHF Range 1 Main Board
X HUE4041_ UHF Range 2 Main Board
X HUF4017_ 700/800 Main Board
X PMLF 4035_ 900 Main Board
X X FRN5358_ Fan
X X HLN6883_ Interface Board
X X THN6676_ Housing Assembly
X X TKN8676_ Cable Kit
X X HLN6607_ Front Panel Assembly
X X HLN6185_ Front Plate of Mobile Brick
X X HLN6865_ Remote Interconnect Hardware
X HLN6396_ Control Head Board
X HLN6441_ Control Head Display
X TRN7392_ Control Head Bracket Hardware
X TRN7393_ Control Head Interface Board
X TRN7394_ Speaker Hardware
X HLN6105_ Spare Button Kit
X HLN6688_ Spare Button Kit
X TGN6150_ Blank Control Head Panel
X PLN1688_ Audio Interface Board
X PLN1687_ Tone Remote Control Board
X FRN5360_ VU Meter/Clock Assembly (No longer available)
X TKN8680_ VU Meter/Clock Cable Kit (No longer available)
X HMN1050_ Desk Microphone
X FPN5366_ DC PS Interface
X HPN4005_ Power Supply, 13.8V, 10-Amp
X HLN6282_ Power Cord, 100V
Key: X = Item Included
6881098C21-P May 5, 2009

xiv
ASTRO Digital XTL 5000 Consolette Options – VHF, UHF, 7/800 MHz Bands
OPTION DESCRIPTION
Software Options
G48 ENH: Conventional Operation
G50 ENH: SmartNET Operation
G51 ENH: SmartZone Operation
G101 ENH: Repeater Access
G114 ENH: Digital ID Display
G173 ENH: SmartZone OmniLink Multizone Operation
G241 ADD: SW ASTRO Ready Analog Operation
G387 ADD: Multicast Voting Scan
G361 ENH: ASTRO Project 25 Trunking SW
G806 ENH: ASTRO Digital CAI Operation
W947 ADD: RS232 Packet Data Interface
Consolette Encryption Options
G113 ADD: ADP Encryption
G159 ADD: Encryption UCM Hardware
G193 ADD: ADP Software DSP Based Encryption
G194 ADD: ADP with DES/DES-XL/DES-OFB Encryption
G298 ADD: Encryption P25 and MDC OTAR
G336 ADD: Key Retention 30 Seconds
G625 ENH: DES/DES-XL/DES-OFB Encryption
G843 ADD: AES Encryption
G851 ADD: AES with DES-XL/DES-OFB Encryption
W793 ADD: DVI-XL Encryption
W797 ADD: DVP-XL Encryption
W969 ADD: Multiple Key Encryption Operation
Consolette Configuration Options
L32 12 Volts DC Only
L73 Omit Microphone–Only compatible with G80 Option
G80 Local Control Configuration
G81* Digital Remote Control Configuration
L114 VU Meter/Clock–Only compatible with G80 Option (No longer available)
L146 Tone Remote Control (TRC)—Only compatible with G80 Option
L791 Audio Interface Board
G799 Printed Test Results
* Option G81 configures the ASTRO Digital XTL 5000 Consolette for operation with a Digital
Remote Control Deskset. The Consolette is compatible with DGT9000 models L1751 and
L1752, RCH3000 models L3030 and CDN1337, and MC3000 model L3223.
May 5, 2009 6881098C21-P

xv
ASTRO Digital XTL 5000 Consolette Options – 900 MHz Band
OPTION DESCRIPTION
Software Options
G51 ENH: SmartZone Operation
G114 ENH: Digital ID Display
G173 ENH: SmartZone OmniLink Multizone Operation
G241 ADD: SW ASTRO Ready Analog Operation
G806 ENH: ASTRO Digital CAI Operation (Future Option)
Consolette Configuration Options
L32 12 Volts DC Only
L73 Omit Microphone–Only compatible with G80 Option
G80 Local Control Configuration
G81* Digital Remote Control Configuration
L114 VU Meter/Clock–Only compatible with G80 Option (No longer available)
L146 Tone Remote Control (TRC)—Only compatible with G80 Option
L791 Audio Interface Board
G799 Printed Test Results
* Option G81 configures the ASTRO Digital XTL 5000 Consolette for operation with a Digital
Remote Control Deskset. The Consolette is compatible with DGT9000 models L1751 and L1752,
RCH3000 models L3030 and CDN1337, and MC3000 model L3223.
6881098C21-P May 5, 2009

xvi
ASTRO Digital XTL 5000 Consolette VHF Specifications

GENERAL RECEIVER TRANSMITTER
FCC Designation: AZ492FT3806 Frequency Range: Frequency Range:

Range 1: 136–174 MHz Range 1: 136–174 MHz
Temperature Range: –20°C to +50°C
Channel Spacing: 12.5/25 kHz Rated Output Power:
Power Supply: 115 VAC/230 VAC Mid Power: 25-50 Watt Variable
12 Vdc Input Impedance: 50 Ohms
Channel Spacing: 12.5/25 kHz
AC Current Drain: (Maximum) Frequency Separation: Full Bandsplit
25-50 Watts Variable: Output Impedance: 50 Ohms
Receive: 0.7 A/0.4 A Analog Sensitivity:+
Transmit: 2.30 A/1.16 A (25 kHz Channel Spacing) Frequency Separation: 30 MHz
20 dB Quieting: 0.40 µV
DC Current Drain: (Maximum) 12 dB Quieting: 0.30 µV Frequency Stability: ±0.00020%
25-50 Watts Variable: (–20 to +50°C; 25°C Ref.)
Receive: 3A Digital Sensitivity:*
Transmit: 13.5 A (12.5 kHz Channel Spacing) Modulation Limiting:+
1% BER: 0.40 µV 25 kHz Channel Spacing: ±5.0 kHz
Dimensions (H x W x D): 5% BER: 0.30 µV 12.5 kHz Channel Spacing: ±2.5 kHz
4.25" x 15.75"x 17"
(108 mm x 400 mm x 432 mm) Selectivity:+ Modulation Fidelity (C4FM):*
25 kHz Channel Spacing: –80 dB 12.5 kHz Channel Spacing: ±2.8 kHz
Weight: 16.1 lbs (7.31 kg) 12.5 kHz Channel Spacing: –70 dB
FM Hum and Noise:+
Intermodulation:+* –85 dB 25 kHz Channel Spacing: –50 dB
(25/30 kHz Channel Spacing) 12.5 kHz Channel Spacing: –40 dB
Spurious Rejection:+* –90 dB Emissions:+*

(Conducted and Radiated) –85 dBc
Audio Output @<3% Distortion:
(Local Control Only) 5W Audio Response:+
(6 dB/Octave Pre-Emphasis +1, –3 dB
from 300 to 3000 Hz)
Audio Distortion:+ 2%
Emissions Designators:
8K10F1E/F1D, 11K0F3E, 16K0F3E,
and 20K0F1E
+ = Measured in Analog Mode per TIA/EIA-603

* = Measured in Digital Mode per TIA/EIA TSB102.CAAB
Specifications subject to change without notice.
May 5, 2009 6881098C21-P

xvii
ASTRO Digital XTL 5000 Consolette UHF Specifications

FCC Designation: Frequency Range: Frequency Range:

Range 1: AZ492FT4862 Range 1: 380–470 MHz Range 1: 380–470 MHz
Range 2: AZ492FT4867 Range 2: 450–520 MHz Range 2: 450–520 MHz
Temperature Range: –20°C to +50°C Channel Spacing: 12.5/25 kHz Rated Output Power:
Range 1: 10-40 Watt Variable
Power Supply: 115 VAC/230 VAC Input Impedance: 50 Ohms Range 2: 10-45 Watt Variable
12 Vdc
Frequency Separation: Full Bandsplit Channel Spacing: 12.5/25 kHz
AC Current Drain: (Maximum)
25-40 Watts Variable: Analog Sensitivity:+ Output Impedance: 50 Ohms
Receive: 0.7 A/0.4 A (25 kHz Channel Spacing)
Transmit: 2.30 A/1.16 A 20 dB Quieting: 0.40 µV Frequency Stability:
12 dB Quieting: 0.30 µV (–20 to +50°C; 25°C Ref.): ±0.00020%
DC Current Drain: (Maximum)
25-40 Watts Variable: Digital Sensitivity:* Modulation Limiting:+
Receive: 3A (12.5 kHz Channel Spacing) 25 kHz Channel Spacing: ±5.0 kHz
Transmit: 13.5 A 1% BER: 0.40 µV 12.5 kHz Channel Spacing: ±2.5 kHz
5% BER: 0.30 µV
Dimensions (H x W x D): Modulation Fidelity (C4FM):*
4.25" x 15.75"x 17" Selectivity:+ 12.5 kHz Channel Spacing: ±2.8 kHz
(108 mm x 400 mm x 432 mm) 25 kHz Channel Spacing: –82 dB
12.5 kHz Channel Spacing: –75 dB FM Hum and Noise:+
Weight: 16.1 lbs (7.31 kg) 25 kHz Channel Spacing: –45 dB
Intermodulation:+* –85 dB 12.5 kHz Channel Spacing: –40 dB
Spurious Rejection:+* –90 dB Emissions:+*

(Conducted and Radiated) –85 dBc
Audio Output @<3% Distortion:
(Local Control Only) 5W Audio Response:+
(6 dB/Octave Pre-Emphasis +1, –3 dB
from 300 to 3000 Hz)
8K10F1E/F1D, 11K0F3E, 16K0F3E,
and 20K0F1E

6881098C21-P May 5, 2009

xviii
ASTRO Digital XTL 5000 Consolette 700–800 MHz Specifications


700 MHz Band: 764–776 MHz 700 MHz Band:
Temperature Range: –20°C to +50°C 800 MHz Band: 851–870 MHz Repeater Mode: 794–806 MHz
TalkAround Mode: 764–776 MHz
Power Supply: 115 VAC/230 VAC Channel Spacing: 12.5/20/25 kHz 800 MHz Band:
12 Vdc Repeater Mode: 806–825 MHz
Input Impedance: 50 Ohms TalkAround Mode: 851–870 MHz
AC Current Drain: (Maximum)
35 Watts Variable: Frequency Separation: Full Bandsplit Rated Output Power:
Receive: 0.7 A/0.4 A 700 MHz Band: 2**/30 W
Transmit: 2.30 A/1.16 A Analog Sensitivity:+ 800 MHz Band: 35 W
(25 kHz Channel Spacing)
DC Current Drain: (Maximum) 20 dB Quieting: 0.30 µV Channel Spacing: 12.5/20/25 kHz
35 Watts Variable: 12 dB Quieting: 0.25 µV
Receive: 3A Output Impedance: 50 Ohms
Transmit: 13.5 A Digital Sensitivity:*
(12.5 kHz Channel Spacing) Frequency Stability:
Dimensions (H x W x D): 1% BER: 0.30 µV (–20 to +50°C; 25°C Ref.): ±0.00015%
4.25" x 15.75"x 17" 5% BER: 0.25 µV
(108 mm x 400 mm x 432 mm) Modulation Limiting:+
Selectivity:+ 25 kHz Channel Spacing: ±5.0 kHz
Weight: 16.1 lbs (7.31 kg) 25 kHz Channel Spacing: –80 dB 20 kHz Channel Spacing: ±2.5 kHz
12.5 kHz Channel Spacing: –65 dB (NPSPCA)
Intermodulation:+* –80 dB Modulation Fidelity (C4FM):*

12.5 kHz Channel Spacing: ±2.8 kHz
Spurious Rejection:+* –90 dB
FM Hum and Noise:+
Audio Output @3% Distortion: 25 kHz Channel Spacing: –40 dB
(Local Control Only) 5 W into 8 Ohms
Emissions:+* –70 dBc/–85 dBc (GNSS)
(Conducted and Radiated)
Audio Response:+
(6 dB/Octave Pre-Emphasis
from 300 to 3000 Hz) +1, –3 dB
8K10F1D/F1E, 11K0F3E, 16K0F3E,
and 20K0F1E
** = 2W itinerant frequencies
May 5, 2009 6881098C21-P

xix
ASTRO Digital XTL 5000 Consolette 900 MHz Specifications


900 MHz Band: 935–941 MHz 900 MHz Band:
Temperature Range: –20°C to +50°C Repeater Mode: 896–902 MHz
Channel Spacing: 12.5 kHz TalkAround Mode: 935–941 MHz
Power Supply: 115 VAC/230 VAC
12 Vdc Input Impedance: 50 Ohms Rated Output Power:
900 MHz Band: 10–30 W
AC Current Drain: (Maximum) Frequency Separation: Full Bandsplit
30 Watts Variable: Channel Spacing: 12.5 kHz
Receive: 0.7 A/0.4 A Analog Sensitivity:+
Transmit: 2.30 A/1.16 A 20 dB Quieting: 0.30 µV Output Impedance: 50 Ohms
12 dB Quieting: 0.25 µV
DC Current Drain: (Maximum) Frequency Stability:
30 Watts Variable: (–20 to +50°C; 25°C Ref.): ±1.5ppm
Receive: 3A
Transmit: 13.5 A Modulation Limiting:+
Selectivity:+ 12.5 kHz Channel Spacing: ±2.5 kHz
Dimensions (H x W x D): 12.5 kHz Channel Spacing: –65 dB
4.25" x 15.75"x 17"
(108 mm x 400 mm x 432 mm) Intermodulation:+ –70 dB FM Hum and Noise:+
12.5 kHz Channel Spacing: –38 dB
Weight: 16.1 lbs (7.31 kg) Spurious Rejection:+ –80 dB (Hear Clear Off)
Audio Output @3% Distortion: Emissions:+ –70 dBc

(Local Control Only) 5 W into 8 Ohms (Conducted and Radiated)
Audio Response:+
(6 dB/Octave Pre-Emphasis
from 300 to 3000 Hz) +1, –3 dB
(TIA 603)
8K10F1D/F1E, 11K0F3E,
6881098C21-P May 5, 2009

xx
Notes
May 5, 2009 6881098C21-P

Chapter 1 Introduction
1.1 Notations Used in This Manual

Throughout the text in this publication, you will notice the use of note, caution, warning, and danger
notations. These notations are used to emphasize that safety hazards exist, and due care must be
taken and observed.
NOTE: An operational procedure, practice, or condition that is essential to emphasize.
! CAUTION indicates a potentially hazardous situation which, if

not avoided, might result in equipment damage.
Caution
! WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or injury.
WARNING
DANGER indicates an imminently hazardous

! situation which, if not avoided, will result in death or
DANGER injury.
1.2 General
This manual describes the installation, operation, and maintenance of the ASTRO Digital XTL 5000
Consolette. Refer to page xiii of this manual for the model/option chart and the performance
specifications beginning on page xvi. For additional information about the XTL 5000 radio, refer to
the XTL 5000 radio user’s guide (6881096C68) and service manual (6881096C74).
The XTL 5000 Consolette incorporates functional design in a modern, lightweight, plastic housing.
This housing was designed using design-for-assembly principles to minimize fasteners, part count,
and assembly time, while improving versatility, assembly ease, and quality.
6881098C21-P May 5, 2009

1-2 Introduction: General
The XTL 5000 Consolette consists of a base plate onto which the entire Consolette is assembled.
Subassemblies, which snap-fit into this base, include the following:
• Fan
• Power supply
• Audio interface or optional tone remote control board
• XTL 5000 radio
• RF connector
• Front panel assembly
The XTL 5000 radio, fan, and power supply also have screws that are used to secure them.
The front panel assembly consists of the following:
• XTL 5000 control head assembly
• Speaker
• Power-on LED
• Optional VU meter/clock (No longer available)
• Optional keyloading connector
In addition, all internal cabling for the station is completely connectorized. To complete the assembly,
the top cover snaps into the base plate. See Chapter 7, "Schematics, Board Layouts, and Parts
Lists" for the Consolette exploded view and Chapter 5, "Cable Diagrams" for detailed cable
connector information.
VHF, UHF, 7/800 MHz Bands
The XTL 5000 Consolette allows conventional or trunked operation, analog or digital operation,
SECURENET™ operation, local control, tone remote control, Digital Remote Control, and a variety
of other options. The Microsoft Windows-based Customer Programming Software (CPS) allows for
field programming for such items as channel frequencies, PL/DPL, etc.
900 MHz Bands
The XTL 5000 Consolette allows conventional operation, analog operation, local control, tone
remote control, Digital Remote Control, and a variety of other options. The Microsoft Windows-based
Customer Programming Software (CPS) allows for field programming for such items as channel
frequencies, PL/DPL, etc.
The XTL 5000 Consolette supports all XTL 5000 features except Siren, Vehicular Repeater System,
and those requiring the addition of a direct-entry keyboard (DEK). Refer to the applicable XTL 5000
service manual for additional information about XTL 5000 features.
NOTE: While SCAN can be enabled on the XTL 5000 Consolette, it is advisable that this feature not
be used in conjunction with the Tone Remote Control option. This feature does not indicate to
the remote user which channel the XTL 5000 transceiver may have scanned to, and thus
might cause confusion.
Two DB-25 connectors located on the back panel of the unit provide connections for external
equipment. The bottom connector (Accessory 2) provides an interface for tone remote and digital
remote desksets.
May 5, 2009 6881098C21-P

Introduction: Options 1-3
1.3 Options
Several software, encryption, and configuration options are available on the XTL 5000 Consolette.
For a complete list of available options, please refer to the options list on page xv of this manual. Any
unique options are described in this section.
1.3.1 Consolette Configuration Options
1.3.1.1 Local Control Configuration, G80

This option configures the consolette for operation from a local control head. It adds a W7 style
control head and speaker to the front panel. This option is compatible with L791, L146, L114, and
L73.
1.3.1.2 Digital Remote Control Configuration, G81

This option configures the consolette for operation from a remote control head such as the MC3000.
This option is not compatible with L146, L114, and L73. This option requires option L791.
NOTE: Mode names, phone lists, call lists, and message names are programmed using Customer
Programming Software (CPS) for Consolettes equipped with either configuration, G80 or
G81.
1.3.1.3 Audio Interface Board, L791

This option provides a digital interface to the local control head (W7 style) or the remote control head
(ex. MC3000). This option is compatible with G80 and G81.
1.3.1.4 Tone Remote Control, L146

This option provides tone remote control capability, as well as a digital interface to the Gold Series
Elite and MCC 5500 Consoles. This option is not compatible with G81. See the note on page 1
concerning SCAN.
1.3.1.5 12 Vdc Only, L32

This optional module replaces the AC power supply in sites where AC power is not available and
allows the Consolette to operate with a 12 Vdc battery or generator.
1.3.1.6 Omit Microphone, L73

This option omits the desk microphone, which is part of the standard product. This option is not
compatible with G81.
1.3.1.7 VU Meter/Clock, L114 (No Longer Available)

This option provides a digital clock display with provisions for time setting and a VU meter, which
provides an indication of the transmit audio level in the form of incremental bars. This option is not
compatible with G81.
1.3.2 Software Options

For a complete description of the operation of the available software features, refer to the ASTRO
Digital XTL 5000 radio user’s guide (6881096C68).
6881098C21-P May 5, 2009

1-4 Introduction: Options
1.3.2.1 Enhanced Digital ID Display, G114

This option provides display capability of Push-To-Talk, Private Call, Call Alert, and Emergency Call
IDs. This information will either be displayed on the local control head (if equipped) or at the remote
control head (if equipped). If the TRC option L146 is ordered in combination with the G114 option,
then the ID will be made available to the console. The PTT-ID option is not automatically enabled in
the Consolette. To enable the G114 option, the ID Display field in the Consolette codeplug will need
to be enabled using CPS. The ID Display field can be found in the Radio Configuration –> Display &
Menu section of the Consolette codeplug.
NOTE: The G114 option provides ID display capability for those IDs that are generated by a PTT of
the transmitting radio. ASTRO IDs generated by a subscriber radio due to an emergency
button press (typically the orange button on a portable radio) can be decoded when the
codeplug field Emergency Alarm Receive Indicator is set to “Display” or “Alert and Display.”
See Section 2.12, "Emergency Alarm Receive Indicator," on page 2-16 for more information.
May 5, 2009 6881098C21-P

Chapter 2 Installation
2.1 Planning the Installation

Since a good installation is important to obtain optimal performance of the Consolette, carefully plan
the installation before the actual work is started. Location of the Consolette in relation to power,
control lines, and antenna, as well as convenience and access for servicing, should be considered.
NOTE: The RF transmission line should be kept as short as possible to minimize line losses;
however, the antenna should not be placed so close as to cause interference with the
Consolette. See "Lightning and Surge Suppression," on page ix of this manual for additional
antenna, RF transmission line, and control line installation considerations.
Read the entire procedure and the suggestions offered to help plan the installation. Make sure all
necessary equipment and facilities are available during installation.
The ASTRO Digital XTL 5000 Consolette is not recommended for dense site applications (that is,
dense metropolitan areas or antenna farms).
2.2 Ventilation
The Consolette is designed for wall mount or horizontal flat plane installation with forced convection
cooling on both mountings. For proper cooling, the Consolette must be kept free of obstructions at its
back and sides for at least 4 inches (100 mm), so as not to restrict airflow.
NOTE: Make certain that the air temperature around the unit does not exceed the recommended
operating temperature range of –20°C to +50°C.
2.3 Station Mounting Procedures

Refer to the specifications section in the front of this manual for unit dimensions.
2.3.1 Desktop Installation

The Consolette may be placed on any solid, flat surface with easy access to the power source and
RF transmission line. Keep in mind the ventilation requirements as previously described in section
2.2, "Ventilation," on page 2-1.
2.3.2 Wall Mounting

Ensure that the selected mounting surface is strong enough to support the Consolette weight of 16
lbs. Mark the location of the four mounting screws (Figure 2-1 on page 2-2). Use screws suitable for
the wall material. The maximum diameter of the screw and screw head should be 0.25 inches (6.5
mm) and 0.43 inches (11 mm), respectively. Allow the bottom surface of the screw head to protrude
0.3 inches (7.5 mm) from the wall surface. Hold the station with the front panel facing up and guide
the holes provided on the bottom of the cabinet over the mounting screws.
6881098C21-P May 5, 2009

2-2 Installation: Antenna Connections
Figure 2-1. Wall Mounting
2.4 Antenna Connections

The antenna and transmission lines are not part of the Consolette; therefore, antenna installation
instructions are not included in this section. Refer to the instructions shipped with the antenna for
applicable information.
In its primary application, the Consolette is used for communication with mobile radios. Therefore, an
omni-directional antenna is recommended. However, if the Consolette is located at the outer
perimeter of a communications area, or if it is to be used for communication with a fixed station, an
antenna with specific directional characteristics may be preferred. Local government agencies may
also dictate the type of antenna to be used.
The coaxial antenna cable connects to an N-type coaxial connector located on the rear panel of the
station. See Figure 2-2.
Figure 2-2. Rear Panel
2.5 Power and Ground Connection

2.5.1 General
All Consolettes should have a separate AC power circuit with proper current and voltage for
Consolette operation. Refer to the specifications section in the front of this manual for AC
requirements of each model. The power lines should be installed in accordance with local electrical
codes. A substantial earth ground must be provided in a straight line close to the ground terminal
provided on the Consolette. DO NOT consider an electrical output box as a substantial earth ground.
See "Lightning and Surge Suppression," on page ix for additional grounding recommendations.
May 5, 2009 6881098C21-P

Installation: Power and Ground Connection 2-3
Even if a three-wire grounding AC power source is
! available, the radio equipment must be grounded

separately to prevent electrical shock hazards and provide
W A R N I N G lightning protection.
The AC power line leading to the selected site for the Consolette may be installed prior to installation
of the Consolette itself.
2.5.2 AC Power Input
The Consolette is shipped standard from the factory for
! operation from a 115 VAC power source. For 230 VAC

operation, remove the Consolette top cover (see 4.4,
W A R N I N G "Disassembly and Reassembly," on page 4-2) and slide the
AC power selector switch, located on the Consolette power
supply, to the 230 VAC position. Install the appropriate AC
power connector on the end of the 115 VAC power cord
provided with the Consolette.
VAC-Select Switch
Figure 2-3. Power Supply VAC – Select Switch

NOTE: Replacement 115 VAC power cords may be ordered from Motorola as kit number HLN6282A.
1. Install the Consolette as described in section 2.3, "Station Mounting Procedures," on page 2-
1.
2. Connect the female plug of the AC line cord to the AC input power connector on the rear
panel of the station. See Figure 2-2. Rear Panel on page 2-2.
3. Connect the ground terminal on the Consolette in as straight a line as possible to a
substantial earth ground located as close as possible to the Consolette ground terminal.
6881098C21-P May 5, 2009

2-4 Installation: DIP Switch and Jumper Settings
4. Make certain the AC power source is of the proper current and voltage rating for the
Consolette. Refer to the specifications section in the front of this manual for the AC
requirement of each model. Then connect the male plug of the AC line cord to the AC power
source.
NOTE: The ON/OFF power button located on the ASTRO control head is disabled before shipment;
therefore, the Consolette is immediately operational when its power cord is plugged into a live
AC outlet. To enable the ON/OFF power button on the ASTRO control head, refer to the
information in section 2.6, "DIP Switch and Jumper Settings," on page 2-4. Please note that
the ON/OFF power button on the control head controls the power to the control head only. For
Consolettes containing the Digital Remote Control feature, Option G81, no control head is
present and the Consolette will always be immediately operational when its power cord is
plugged into a live AC outlet.
2.5.3 DC Input Power (Optional)

Connection of DC input power to the Consolette is offered as an option. The battery should be
connected to the DC connector (DC IN) on the rear panel of the Consolette. See Figure 2-2. Rear
Panel on page 2-2. Note that the top and bottom pins of DC IN are the negative and positive
terminals, respectively.
To prevent damage to the Consolette, be sure to use a battery
! that is connected only to the Consolette. Disconnect both

battery terminals from the Consolette when connecting the
Caution battery to any other equipment, including a battery charger.
Be sure to observe proper polarity when making the DC
power connections.
2.6 DIP Switch and Jumper Settings

The DIP switches and jumpers are used to provide various operating configurations to the
Consolette. The Audio Interface Board (AIB) has a DIP switch package and three jumpers. The
optional Tone Remote Control (TRC) board has two DIP switch packages, two jumpers, and two
plugs. Refer to the tables below for detailed descriptions of switch and jumper settings for each
board.
NOTE: 0Ω chip resistors are used for some jumpers. A low-power soldering iron must be used to
install and remove them.
Review "Safe Handling of CMOS Integrated-Circuit

! Devices," on page x before setting any DIP switches or
jumpers.
Caution
May 5, 2009 6881098C21-P

Installation: DIP Switch and Jumper Settings 2-5
2.6.1 Audio Interface Board (AIB) Settings
Table 2-1. Audio Interface Board DIP Switch Settings
Switch State Description
S101-1 ON ASTRO control head power button disabled
OFF ASTRO control head power button enabled
S101-2 Not used
S101-3 ON EMER active high
OFF EMER active low
S101-4 ON 600Ω Impedance
OFF 900Ω Impedance
S101-5 ON 900Ω Impedance
OFF 600Ω Impedance
S101-6 ON Local desk microphone not present
OFF Local desk microphone present
S101-7 ON Digital Remote Control option present
OFF Digital Remote Control option not present
S101-8 Not used
BOLD indicates factory default setting
Table 2-2. Audio Interface Board Jumper Settings
Jumper State Description
JU101 IN Always placed for ASTRO
J14 A-B Transmitted and received audio is routed to

TAPE_OUT (Accessory Connector 3, pin 11)
B-C Only received audio is routed to TAPE_OUT

(Accessory Connector 3, pin 11)
J15 A-B SPKR_UNMUTE active high (COR)
B-C SPKR_UNMUTE active low (COR)
6881098C21-P May 5, 2009

2.6.2 Tone Remote Control (TRC) Board Settings
IMPORTANT: Be sure to remove power to the Consolette when making changes to the
DIP switch settings for S100. This DIP switch resides under the RFI
shield on the Tone Remote Control board. The XTL 5000 mobile unit and
the shield cover must be removed in order to access the DIP switch. After
changes have been made, replace the shield cover, XTL 5000 mobile
unit, and Consolette lid before restoring power to the Consolette.
Table 2-3. Tone Remote Control Board DIP Switch Settings (S100)
S100-1 OFF Always off for ASTRO
S100-2 ON Local mic audio not routed down wireline
OFF Local mic audio routed down wireline
S100-3 ON Tone Remote Control
OFF SMP Control
S100-4 ON AGC Disabled
OFF AGC Enabled
S100-5 ON Tone Table Select 1*
OFF
OFF
OFF
OFF
* Refer to Table 2-7 for setting information
May 5, 2009 6881098C21-P

Installation: DIP Switch and Jumper Settings 2-7
Table 2-4. Tone Remote Control Board DIP Switch Settings (S101)
S101-1 ON ASTRO control head power button disabled
OFF ASTRO control head power button enabled
S101-2 Not used
S101-3 ON EMER active high
OFF EMER active low
S101-4 ON 600Ω impedance
OFF 900Ω impedance
S101-5 ON 900Ω impedance
OFF 600Ω impedance
S101-6 ON Local desk microphone not present
OFF Local desk microphone present
S101-7 ON Two-wire operation
OFF Four-wire operation
S101-8 ON Four-wire operation
OFF Two-wire operation
Table 2-5. Tone Remote Control Board Jumper Settings
Jumper State Description
JU100 IN Crystal frequency shift circuit enabled
OUT Crystal frequency shift circuit disabled
JU101 IN Always placed for ASTRO
6881098C21-P May 5, 2009

Table 2-6. Tone Remote Control Board Plug Settings
Plug Jumper Description
P101 A-B Transmitted and received audio is routed to TAPE_OUT

(Accessory Connector 3, pin 11)
B-C Only received audio is routed to TAPE_OUT (Accessory

Connector 3, pin 11)
P102 A-B SPKR_UNMUTE active high
B-C SPKR_UNMUTE active low
P103 A-B Enables AUX_TX_AUD as the transmit audio source

associated with PTT*
(PLN1687B
Only) B-C Enables wireline transmit audio as the transmit audio
source associated with PTT*
Table 2-7. Tone Table Selection
SEL #4 SEL #3 SEL #2 SEL #1 Selected Tone Table
OFF OFF OFF OFF Standard
OFF OFF OFF ON CentraCom II
OFF OFF ON OFF No Mode Sel
OFF OFF ON ON Mode 1 only
OFF ON OFF OFF No Mode 1
OFF ON OFF ON Not supported
OFF ON ON OFF Not supported
OFF ON ON ON Not supported
ON OFF OFF OFF Not supported
ON OFF OFF ON Not supported
ON OFF ON OFF Not supported
ON OFF ON ON Not supported
ON ON OFF OFF Not supported
ON ON OFF ON Not supported
ON ON ON OFF Not supported
ON ON ON ON Not supported
May 5, 2009 6881098C21-P

Installation: Clock/VU Meter Setup (Optional) (No Longer Available) 2-9
2.7 Clock/VU Meter Setup (Optional) (No Longer Available)

The clock displays the time, day, month, and year.
2.7.1 Operation
Press the mode button to change the display cyclically between the time, month.day, and year.
2.7.2 Time Setting

After power up, the display blinks and the clock starts from the default time of: 00:00:00, month.day:
1.1, year: 1990. To set the time, do the following:
1. Press the mode button until the time is displayed (HH:MM).
2. Press the set button for 5 seconds.
3. Press the mode button to reset the seconds. The display shows the seconds.
4. Press the set button. The display shows the hours and minutes (blinking).
5. Press the mode button until the correct minutes are displayed.
6. Press the set button. The display shows the hours (blinking) and minutes.
7. Press the mode button until the desired hour is displayed.
8. Press the set button to complete the time setting.
2.7.3 Month and Day Setting

To set the month and day, do the following:
1. Press the mode button until the month.day (MM.DD) is in the display.
2. Press the set button for 5 seconds (the day blinks).
3. Press the mode button until the desired day appears in the display.
4. Press the set button (the month blinks).
5. Press the mode button until the desired month is displayed.
6. Press the set button to complete the month and day setting.
2.7.4 Year Setting

To set the year, do the following
1. Press the mode button until the year is in the display (1990 default).
2. Press the set button for 5 seconds (the right digit blinks).
3. Press the mode button until the correct digit blinks.
4. Press the set button (the next digit blinks).
5. Repeat the previous two steps to set all the digits.
The setting is complete. To display the time, press the mode button.
2.8 Accessory Connector 2

Table 2-8 on page 2-10 contains pin descriptions for Accessory Connector 2. See Figure 2-4.
Accessory 2 and 3 Mating Connector on page 2-12 for pin locations on mating connector.
6881098C21-P May 5, 2009

2-10 Installation: Accessory Connector 2
To avoid possible damage to external equipment and the
! Consolette, make sure equipment is connected to the proper

accessory connector pins before applying power to the
Caution station.
Table 2-8. Accessory Connector 2—Pin Descriptions
Pin Signal Name Description
1 RX+ (LINE1+)† Receive high used with TRC desksets (TX and RX high for two-wire operation;
RX high for four-wire operation)†
2 AUD_SHLD Ground: audio or analog
3 TX+ (LINE2+)† Transmit high used with all desksets (TX high for four-wire operation)†
4 FILT_AUD RX filtered audio (RX detect or discriminator audio)†

(DET_AUD)†
5 A+ +13.8VDC or battery voltage
6 BUSY Busy line of data bus; 5V logic
7 BUS+ High side of bus data: 180° out of phase with BUS–; 5V logic
8 NC Currently not used
9 VIP OUTPUT 1 Vehicle interface output port 1
10 PTT* Push-To-Talk initiates a transmission; 5V logic
11 TX– (LINE2–)† Transmit low use with all desksets (TX low for four-wire operation)†
12 DIG_GND Ground for 5V logic signals
13 VIP INPUT 1 Vehicle interface input port 1
14 REMOTE_RX+ Remote deskset speaker high output (CAUTION: grounding this pin will result
(SPKR_HI)† in damage to the radio) (Speaker high output)†
15 REMOTE_RX– Remote deskset speaker low output (CAUTION: grounding this pin will result
(SPKR_LO)† in damage to the radio) (Speaker low output)†
16 RX– (LINE1–)† Receive low used with TRC desksets (TX and RX low for two-wire operation, RX
low for four-wire operation)†
17 AUX_TX_AUD Linear transmit audio path used with auxiliary PTT
19 BUS– Low side of bus data: 180° out of phase with BUS–; 5V logic
20 RESET Data bus reset line; 5V logic
21 5V 5V for logic circuits
22 VIP INPUT 3 Vehicle interface input port 3
24 MONITOR* Allows activation of monitor (used with MRTI telephone interconnect)
May 5, 2009 6881098C21-P

Installation: Accessory Connector 3 2-11
Table 2-8. Accessory Connector 2—Pin Descriptions (Continued)
25 SPKR_UNMUTE Signal indicating if the Consolette is receiving valid audio
* indicates an active-low condition

† indicates TRC information
NC indicates Not Connected
2.9 Accessory Connector 3

Table 2-9 contains pin descriptions for Accessory Connector 3. See Figure 2-4. Accessory 2 and 3
Mating Connector on page 2-12 for pin locations on mating connector.
To avoid possible damage to external equipment and the
! Consolette, make sure equipment is connected to the proper

accessory connector pins before applying power to the
Caution station.
Table 2-9. Accessory Connector 3—Pin Descriptions
1 RS232_RXD (NC)† RS232 receive data (pin not used on TRC)†
2 ANA_GND Ground: audio or analog
3 AUX_RX_AUD External SECURENET not supported by the Consolette
4 FILT_AUD RX filtered audio (RX detect or discriminator audio)†

(DET_AUD)†
5 A+ +13.8 Vdc or battery voltage
6 BUSY Busy line of data bus; 5V logic
7 BUS+ High side of bus data: 180° out of phase with BUS–; 5V logic
8 BUS_SHLD Ground for data bus; logic ground
9 N/C (RS232_RXD)† Pin not used on AIB (RS232 receive data)†
10 VSENSE1_SHLD Analog ground
11 TAPE_OUT Tape recorder audio output
12 DIG_GND Ground for 5V logic signals
13 EMER Activates emergency MDC1200 transmission
14 RS232_TXD (NC)† RS232 transmit data (pin not used on TRC)†
15 RS232_RTS (NC)† RS232 request to send (pin not used on TRC)†
16 RS232_CTS RS232 clear to send (external SECURENET not supported

(PS_AUD_OUT)† by the Consolette)†
17 AUX_TX_AUD Linear transmit audio path used with auxiliary PTT
6881098C21-P May 5, 2009

2-12 Installation: Remote Control Installation
Table 2-9. Accessory Connector 3—Pin Descriptions (Continued)
18 SWB+ Switched +13.8 Vdc or battery voltage
19 BUS– Low side of bus data: 180° out of phase with BUS–; 5V logic
20 RESET Data bus reset line; 5V logic
21 NC Currently not used
22 NC (RS232_TXD)† Pin not used on AIB (RS232 Transmit data)†
23 N/C (RS232_RTS)† Pin not used on AIB (RS232 request to send)†
24 VSENSE2_SHLD Analog ground
25 NC (RS232_CTS)† Pin not used on AIB (RS232 clear to send)†
† indicates TRC information

NC indicates Not Connected
Figure 2-4. Accessory 2 and 3 Mating Connector
2.10 Remote Control Installation

2.10.1 Digital Remote Control Installation
Figure 2-5 shows a typical setup using multiple MC3000 desksets with the Consolette.
Figure 2-5. Consolette Setup with Multiple MC3000 Desksets
This procedure is to be used for installation of the RCH3000 or MC3000 digital remote deskset.
Make sure switches 1 and 7 of S101 on the audio interface board are in the ON position. Refer to the
Digital Remote Deskset Manual for information regarding deskset operation. Table 2-10 on page 2-
13 lists the Accessory Connector 2 pins used for Digital Remote Control operation.
May 5, 2009 6881098C21-P

Installation: Remote Control Installation 2-13
NOTE: All information, such as mode names, phone lists, call lists, and message names should be
programmed in the Consolette using Customer Programming Software (CPS).
External Alarms (Horn and Lights): The Consolette routes the VIP lines from the local control
head in Option G80 models to the rear accessory connector of the Consolette for the External
Alarm feature. Access to the VIP lines in Option G81 models is at the remote deskset. Consult
the MC3000 manual for detailed information concerning configuration and support.
Table 2-10. Accessory Connector 2 Pins: Digital Remote Control Operation
Pin
Signal Name
Number
2 AUD_SHLD
3 TX+
6 BUSY
7 BUS+
11 TX–
12 DIG_GND
14 REMOTE_RX+
15 REMOTE_RX–
19 BUS–
20 RESET
2.10.2 Tone Remote Control Installation

NOTE: The Tone Remote Control Option (L146) must be ordered for this option to be available.
Tone remote desksets are to be connected to Accessory Connector 2 on the rear panel of the
Consolette. See Figure 2-2. Rear Panel on page 2-2. Two-wire or four-wire operation is available.
Two-wire operation uses Line1+ and Line1- for both receive and transmit audio. Four-wire operation
uses Line 1+ and Line1- for receive audio and Line2+ and Line2- for transmit audio. The default
setting for wireline operation is two-wire. Impedance flexibility of 600Ω or 900Ω between Line1+ and
Line 1- is also provided. The default setting for impedance is 600Ω. For information regarding
changing wireline operation or impedance, refer to Table 2-3 on page 2-6 for S100 and Table 2-4 on
page 2-7 for S101. Refer to the applicable tone remote deskset manual for information regarding
deskset operation. Table 2-11 on page 2-14 identifies the Accessory Connector 2 pins used for tone
remote control operation.
6881098C21-P May 5, 2009

2-14 Installation: Remote Control Installation
Table 2-11. Accessory Connector 2 Pins: Tone Remote Control Operation
Pin Number Signal Name
1 LINE1+
3 LINE2+
16 LINE1–
11 LINE2–
Figure 2-6. Consolette Setup with the Gold Elite Console

Figure 2-6 shows a typical setup using the Gold Elite Console with the Consolette.
Figure 2-7. Consolette Setup with the MCC 5500

Figure 2-7 shows a typical setup using the MCC 5500 with the Consolette.
May 5, 2009 6881098C21-P

Installation: Controller Board Adjustment Procedures 2-15
Follow the instructions at the beginning of this section to set up the wireline paths (used for audio
routing as well as tone remote control tones) between the Console and the Consolette. Refer to
3.4.2.8, "Smart Modem Protocol (SMP) Control," on page 3-11 for details on the data connection
(used for ID reporting as well as remote control) between the Console and the Consolette.
2.11 Controller Board Adjustment Procedures

The next two subsections explain the controller board adjustment procedures.
2.11.1 AIB Adjustment Procedure

This section explains the AIB adjustment procedure.
2.11.1.1 Transmit (Auxiliary Audio Input)

R244 is set fully clockwise, then turned counterclockwise aligning the slot between the two dots with
the first triangle. This adjustment enables the Consolette to transmit and obtain 3 kHz deviation
when a 2 Vrms, 1 kHz audio signal from a 600Ω source is applied to the AUX_TX_AUD input
(Accessory Connector 2 pin 17). This adjustment and input level is based on a Cross Patch setup
between two Consolettes (See Appendix A). R244 can be adjusted to accommodate various 1 kHz
audio input levels (approximately 35 mVrms to 5 Vrms) into AUX_TX_AUD to enable the Consolette
to transmit and obtain 3 kHz deviation.
NOTE: AUX_TX_AUD is used only with the external hardware PTT feature; therefore, if adjustment
of R244 is needed, the Consolette must be keyed up using the external hardware PTT
(grounding pin 10 on Accessory Connector 2).
2.11.1.2 Receive
While receiving a 1 kHz, 3 kHz deviation audio signal, R111 is adjusted for 1.0 Vrms across a 600Ω
load at RX+ and RX- (Accessory Connector 2 pins 1 and 16, respectively).
2.11.2 TRC Adjustment Procedure

This section explains the TRC adjustment procedure.
2.11.2.1 Transmit (Wireline Input)

From the factory, AGC is enabled with S100-4 set to the OFF position. R529 is set fully clockwise,
then turned counterclockwise one-half turn. This sets the AGC gain to somewhat less than
maximum. Using 4-wire operation, the factory inputs a 120 mVrms, 1 kHz audio signal from a 600Ω
source into Line 2+ and Line 2– (Accessory Connector 2 pins 3 and 11, respectively). The
Consolette is placed in transmit and R569 is adjusted to obtain 3 kHz deviation. This allows for
operation with signals between -20 dB to +13 dB without any additional field adjustments.
If AGC is disabled in the field with S100-4 set to the ON position, then R529 should be adjusted to
obtain 0.7 VAC at TP1 when a 1 kHz audio signal is sent from the wireline.
2.11.2.2 Transmit (Auxiliary Audio Input)

For PLN 1687B boards, plug P103 needs to be in the A-B jumper position. R193 is set fully
clockwise, then turned counterclockwise aligning the slot between the two dots with the first triangle.
This adjustment enables the Consolette to transmit and obtain 3 kHz deviation when a 2 Vrms, 1 kHz
audio signal from a 600Ω source is applied to the AUX_TX_AUD input (Accessory Connector 2 pin
17). This adjustment and input level is based on a Cross Patch setup between two Consolettes (See
Appendix A). R193 can be adjusted to accommodate various input levels (approximately 35 mVrms
to 5 Vrms) into AUX_TX_AUD to enable the Consolette to transmit and obtain 3 kHz deviation.
6881098C21-P May 5, 2009

2-16 Installation: Emergency Alarm Receive Indicator
NOTE: AUX_TX_AUD is used only with the external hardware PTT feature; therefore, if adjustment
of R193 is needed, the Consolette must be keyed up using the external hardware PTT
(grounding pin 10 on Accessory Connector 2).
2.11.2.3 Receive
While receiving a 1 kHz, 3 kHz deviation audio signal, R545 is adjusted for 0 dBm (775 mVrms)
across a 600Ω load at Line1+ and Line1– (Accessory Connector 2 pins 1 and 16, respectively).
2.12 Emergency Alarm Receive Indicator

NOTE: There are limitations with the Subscriber-to-Consolette/Console Emergency Alarm Receive
Indication feature that should be taken into consideration when using the Consolette in a
dispatch position. This is in contrast to a Subscriber-to-Quantar/DIU/Console Emergency
Alarm Receive feature which does not have these limitations. See “Feature Limitations”
paragraph in this section for a description of these limitations.
This feature selects the type of notification that the Consolette generates when an Emergency Alarm
is received on either an MDC or an ASTRO channel (ASTRO Conventional, Type II Trunking, and
ASTRO 25 Trunking) from another radio. The user can choose from four indication types:
• No Indication
• Alert Only: The Consolette will sound an audio alert tone. Repeated Emergency Alarms from
the same initiating radio within a 30 second period will result in one indication at the Consolette.
• Display Only: The Consolette will display “EA RCVD” alternating with the ASTRO System ID,
Trunking Personality Talkgroup ID or ID Alias of the subscriber radio that generated the
Emergency Alarm. This continues for ten seconds. Pressing any button on the control head
(except for the Dim or Volume) discontinues this information from appearing in the radio’s
display. This information will either be displayed on the local control head (if equipped) or at the
remote control head (if equipped). If the Consolette is equipped with the TRC option (L146),
then the ID will be made available to the Console. Repeated Emergency Alarms from the same
initiating radio within a 30 second period will result in one indication at the Consolette.
• Alert and Display: The Consolette will perform both the Alert tone generation and ID display
as described for the Alert Only and Display Only types.
The Emergency Alarm Receive Indicator Type field can be found on the Radio Configuration –>
Radio Wide -> TPS screen (Figure 2-8 on page 2-17) of the ASTRO 25 Mobile CPS (RVN4185_).
May 5, 2009 6881098C21-P

Installation: Emergency Alarm Receive Indicator 2-17
Figure 2-8. Radio Wide -> TPS Screen
In addition to the above indication types, the Emergency Alarm RX Indicator feature can be
programmed to a single VIP Out. This VIP Out will be active for 10 seconds. The VIP Out fields can
be found on the Radio Configuration –> Controls -> Radio VIP screen (Figure 2-9 on page 2-18)
of the ASTRO 25 Mobile CPS (RVN4185_).
NOTE: The Consolette routes the VIP lines from the local control head in Option G80 models to the
rear accessory connector. Access to the VIP lines in Option G81 models is at the remote
deskset. Consult the MC3000 manual for detailed information concerning configuration and
support.
6881098C21-P May 5, 2009

2-18 Installation: Emergency Alarm Receive Indicator
Figure 2-9. Radio Configuration –> Controls -> Radio VIP Screen
The decoding of the Emergency Alarm ID can be disabled in a specific ASTRO Conventional or
Trunking system by unchecking the Emergency Alarm RX field. This field can be found in ASTRO 25
Mobile CPS (RVN4185_) on the Conventional -> ASTRO Systems -> ASTRO System -> ASTRO
System - # ->Advanced screen (Figure 2-10) for ASTRO Conventional systems and Trunking ->
Trunking Systems -> Trunking System - # -> Advanced screen (Figure 2-11 on page 2-19) for
Trunking systems.
Figure 2-10. ASTRO System - # -> Advanced Screen
May 5, 2009 6881098C21-P

Installation: Emergency Alarm Receive Indicator 2-19
Figure 2-11. Trunking System - # -> Advanced Screen
2.12.1 Feature Limitations

There are situations where the Emergency Alarm ID may not be decoded by the Consolette. Two of
the more common situations are:
• When on a Trunking channel, the Emergency Alarm will not be seen by the Consolette if it is
currently transmitting or receiving a voice call. This is due to the normal operation of a Trunking
System where the subscriber unit (e.g., Consolette) cannot receive control channel information
while it is handling a voice call on a designated voice channel. The Trunking system will only
broadcast the Emergency Alarm on the control channel and only those subscriber units
listening to the control channel will receive the Emergency Alarm.
• If the Consolette is set to priority scan, it could miss the Emergency Alarm if it is currently busy
on a Priority Channel and the Emergency Alarm is generated on a non-priority channel.
Other situations may exist. Due to the inherent nature of this feature, it is not recommended that this
Consolette feature be used as the only Emergency Alarm Indicator in heavy use systems where
Emergency Alarm is heavily relied upon. Consult your local Motorola Systems Engineer on the
proper use of this feature.
6881098C21-P May 5, 2009

2-20 Installation: Programming
2.13 Programming
This section describes codeplug and FLASHport programming.
2.13.1 Codeplug Programming

When the ASTRO Digital XTL 5000 Consolette arrives from the factory it will contain a default
codeplug configuration based on the options ordered with the unit. For Example: If the Consolette is
ordered with the L146 option, the “TRC Enable” field should be enabled in the codeplug.
Some options come enabled in the codeplug by default, but some options are disabled by default.
For those options that are default-enabled from the factory, the following information should only be
needed if the transceiver is replaced or repaired and the default configuration was not saved. For
those options that are default-disabled, use this information to enable the option if desired.
To configure the codeplug of the ASTRO Digital XTL 5000 Consolette using ASTRO 25 Mobile CPS
(RVN4185_), the XTL 5000 transceiver must be connected directly to the PC. The PC must be
connected directly to the 26-pin accessory connector on the XTL 5000 transceiver using either a
USB (HKN6163_) or RS232 (HKN6160_) mobile data cable, and not to the accessory connectors on
the rear panel of the consolette. The HKN6155 cable can also be used. Connection is via the
connector on the front of the XTL 5000 but not via the Control Head. Therefore, the first step in
programming the codeplug of the Consolette is to remove the top cover. see ”4.4. Disassembly and
Reassembly” on page 4-2 for cover removal and replacement instructions.
2.13.2 Tone Remote Control, L146

When the ASTRO Digital XTL 5000 Consolette is ordered with the L146 option, the “TRC Enable”
field should be enabled in the codeplug for all of the features of the consolette to function properly. If
this field is not already enabled when the Consolette is received from the factory, then it can be
enabled on the Radio Configuration->Radio Wide->Advanced II screen (Figure 2-12 on page 2-
21) in the ASTRO 25 Mobile CPS (RVN4185_).
May 5, 2009 6881098C21-P

Installation: Programming 2-21
Figure 2-12. Radio Wide—Advanced II Tab Screen
2.13.3 Enhanced Digital ID Display, G114

This option provides display capability of Push-To-Talk, Private Call, Call Alert, and Emergency Call
IDs. This information will either be displayed on the local control head (if equipped) or at the remote
control head (if equipped). If the TRC option L146 is ordered in combination with the G114 option,
then the ID will be made available to the console. The PTT-ID option is not automatically enabled in
the Consolette. To enable the G114 option, the ID Display field in the Consolette codeplug will need
to be enabled using ASTRO 25 Mobile CPS (RVN4185_). The ID Display field can be found in the
Radio Configuration – > Display & Menu->PTT ID section of the Consolette codeplug (Figure 2-13
on page 2-22).
6881098C21-P May 5, 2009

NOTE: The ASTRO Digital XTL 5000 Consolette uses an ASTRO Digital XTL 5000 mobile subscriber
radio as its transceiver. Therefore, the Consolette will NOT decode an Emergency Alarm
generated by field subscriber units, and it will NOT display the Emergency Alarm ID locally or
at a console station. This signal is typically generated by the subscriber radio by pushing the
orange alarm button.
Figure 2-13. Display and Menu—PTT ID Tab Screen
2.13.4 HUB Defeats PL

The HUB Defeats PL feature enables the Consolette user to monitor all carrier squelch activity on a
conventional dispatch channel when the monitor button is pressed. This is true even when the
selected radio channel’s Unmute/Mute rule requires PL (Private Line). The HUB Defeats PL field can
be found on the Conventional->Conventional Configuration->General screen (Figure 2-14 on
page 2-23) of the ASTRO 25 Mobile CPS (RVN4185_).
May 5, 2009 6881098C21-P

Figure 2-14. Conventional Configuration—HUB Defeats PL Feature
2.13.5 AUX TX/AUX MIC

In order to use the External Hardware PTT feature (Pin 10 of Accessory Connector 2) of the XTL
5000 Consolette, the "AUX TX" transmit audio path (Pin 17 of Accessory Connector 2) must be
selected in the codeplug. The Consolette ships from the factory with the “Aux PTT Audio Source”
codeplug field set to "AUX TX". If this field is not already selected when the Consolette is received
from the factory, then it can be selected on the Radio Configuration->Radio Wide->Advanced
screen (Figure 2-16 on page 2-25) in the ASTRO 25 Mobile CPS (RVN4185_).
NOTE: The "AUX TX" transmit audio path defaults to a 300mV input level. For more information on
this feature, see ”3.3.1.2. Transmit Audio Paths” on page 3-4 in this manual.
6881098C21-P May 5, 2009

Figure 2-15. Radio Wide Screen — Advanced Tab Screen
2.13.6 AGC Gain Settings within the Radio

For the ASTRO Digital XTL 5000 Consolette to function properly, the AGC settings of the Internal
Mic and External Mic fields should be disabled in the codeplug. If these fields are not already
disabled when the Consolette is received from the factory, then they can be disabled on the Radio
Configuration->Radio Wide->Tx Audio Control Per Mode screen (Figure 2-16 on page 2-25) in
the ASTRO 25 Mobile CPS (RVN4185_).
May 5, 2009 6881098C21-P

Figure 2-16. Transceiver AGC Gain Settings
2.13.7 FLASHport Programming

Always be sure you are ordering/using the latest version of the software package. If you are not sure,
contact Motorola Product Services or United States and Canada Aftermarket Products Division at 1-
800-422-4210.
In order to FLASH the internally housed XTL 5000 mobile, the lid must be removed from the
Consolette. Connect the XTL 5000 mobile programming cable (HKN6160 or HKN6163) to the 26-pin
accessory connector on the rear of the XTL 5000 radio and follow the FLASHport instructions. The
HKN6155 cable can also be used. Connection is via the connector on the front of the XTL 5000 but
not via the Control Head.
6881098C21-P May 5, 2009

Notes
May 5, 2009 6881098C21-P

Chapter 3 Theory of Operation
3.1 Introduction
This section explains the general operation of the ASTRO Digital XTL 5000 Consolette. For more
detailed information about the XTL 5000 transceiver, refer to the applicable XTL 5000 operator’s
manual or service manual.
3.2 General
The XTL 5000 Consolette consists of three major building blocks: the XTL 5000 transceiver, the
Audio Interface board (AIB) or optional Tone Remote Control (TRC) board, and the power supply.
The Audio Interface board is standard for the Consolette. The Tone Remote Control board replaces
the Audio Interface board when the L146 option is added. All other blocks contained within the
Consolette are served by the three major building blocks shown in bold (see Figure 3-1).
XTL 5000 Power Supply Fan

Transceiver
Accessory
Connectors
ASTRO Audio Interface Board/
Control Head Tone Remote Control Board
Power On VU Meter/Clock Speaker

LED (Option)
Figure 3-1. Consolette Block Diagram

Each major building block has its own unique function:
• Modulation, demodulation, and all other RF signal processing are performed by the XTL 5000
transceiver.
• All baseband signals being routed to and from the radio pass through the Audio Interface board
or optional Tone Remote Control board. The board provides an interface for the control head,
speaker, accessory connectors, and other options.
• Provisions have been made for the connection of voice recorders to the XTL 5000 Consolette.
• The power supply converts AC power into DC power for use by the radio’s transceiver and the
Audio Interface board or optional Tone Remote Control board.
The XTL 5000 control head and speaker are present in all Option G80 models. Option G81 Digital
Remote Control models (see Figure 3-3 on page 3-2) do not have a control head or speaker. Refer
to the appropriate XTL 5000 radio user’s guide for information regarding the operation of the control
head.
6881098C21-P May 5, 2009

3-2 Theory of Operation: Audio Interface Board (AIB)
The accessory connectors (see Figure 2-4 on page 2-12) are used to connect external equipment to
the Consolette. Accessory Connector 3 (top) is currently used for tape recorder audio out. Tone
remote desksets or digital remote desksets should use Accessory Connector 2 (bottom). Accessory
Connector 1 (RJ45) is used to connect to the digital interface (ex. ACIM) on a Gold Series Elite or
MCC 5500 Console.
If any external equipment is inadvertently connected to the

! wrong accessory connector, damage to the equipment might
occur.
Caution
The optional VU meter/clock provides a transmit audio level indicator and a digital clock display.
Power is provided to the VU meter/clock as soon as the Consolette is plugged into a live AC outlet.
A fan is provided with every Consolette. It circulates the air inside the Consolette to keep the internal
ambient temperature at an acceptable level. It is important for the fan to be operating at all times to
maintain proper Consolette operation. In addition, it is important to leave the top cover in place to
maintain proper thermal conditions inside the Consolette.
The location of the control head, Power On LED, VU meter/clock, and speaker are indicated on the
front panel of the station shown in Figure 3-2.
Figure 3-2. Consolette Front Panel—G80 Option
Figure 3-3. Consolette Front Panel—G81 Option
3.3 Audio Interface Board (AIB)

The PLN1688A Audio Interface board (AIB) serves as the central interface for all internal and
external components of the XTL 5000 Consolette. All signals are routed through the AIB where
processing may occur. Most audio paths incorporate some processing, while most control and data
signals are passed unaltered.
May 5, 2009 6881098C21-P

Theory of Operation: Audio Interface Board (AIB) 3-3
Multiple transmit and receive audio paths provide for numerous configurations of the XTL 5000
Consolette. All audio signals passing through the audio interface board are baseband signals in the
range of 300-3000 Hz.
Most data and control signals are provided by 0-5V protected CMOS logic circuitry. PTT* and
MONITOR* are provided for external control of transmit and receive functions. The XTL 5000 radio
Vehicle Interface Ports (VIPS) are also available at Accessory Connector 2 (Option G80 models
only).
3.3.1 Detailed Description
3.3.1.1 Receive Audio Paths

Two sources from the XTL 5000 radio are used for receive audio. Detect audio (DET_AUD) is
located on J1 pin 17, and filtered audio (FILT_AUD) is located on J1 pins 11 and 36. Both DET_AUD
and FILT_AUD are at a fixed level (approx. 300 mVrms). FILT_AUD is also present at Accessory
Connector 2 pin 4 and Accessory Connector 3 pin 4.
Detect audio (DET_AUD) passes to the Audio Interface board via J1 pin 17 at a level of 300 mVrms,
relative to a 1.0 kHz tone at 60% FSD. It is then amplified by U102 pins 8, 9, and 10 and the level set
by potentiometer R111. The level should be set to attain 1.0 Vrms between RX+ and RX– (Accessory
Connector 2 pins 1 and 16, respectively). The audio then passes through an audio shaping filter
(U102 pins 12, 13, and 14), which has unity gain for frequencies below 3000 Hz. The output of the
audio shaping filter (U102 pin 14) is split into opposing phases by U102 pins 1, 2, 3, 5, 6, and 7 to
provide a balanced output. Q103 and Q104 provide a final amplification stage. The impedance
between RX+ and RX– can be set to 600Ω or 900Ω using S101-4 and 5. See Table 2-1 on page 2-5.
When the radio is in an idle state, the DET_AUD line of the XTL 5000 transceiver is muted using the
Channel Activity (CHAN_ACT*) signal provided by the transceiver, located on J1-6, in combination
with multiplexor U106. The CHAN_ACT* signal is an active low signal. When the mobile radio routes
received audio to the speaker, CHAN_ACT* switches from its idle state of 5 V to its active state of
0 V. Q109 inverts this CHAN_ACT* signal which activates transistor Q101 connected to control input
A of the two-input multiplexor (U106 pin 11). When Q101 is active, U106 allows DET_AUD to be
passed to the receive audio circuitry. When Q101 is inactive, the receive audio path is muted.
Receive audio is also routed from U106 gate 1 to buffer amplifier U101 op-amp 4 (MOB_RX). The
output of this buffer drives the TAPE_OUT line at approximately 190 mVrms, which is used for
external recording purposes.
Speaker audio is available at Accessory Connector 2, pins 14 and 15 (REMOTE_RX+ and
REMOTE_RX–, respectively) for use with Digital Remote Control models. Speaker audio level is
factory set but can be adjusted using Customer Programming Software. An array of resistors
capable of dissipating 10 watts provides a 16Ω impedance for the desksets. To enable this audio
output, S101-7 must be ON.
REMOTE_RX– (SPKR_LO) and REMOTE_RX+ (SPKR_HI)

! should never be grounded. If they are grounded, this will
damage the radio.
Caution
6881098C21-P May 5, 2009

3-4 Theory of Operation: Audio Interface Board (AIB)
3.3.1.2 Transmit Audio Paths

There are three main paths for transmit audio. The first path is a linear transmit audio path
(AUX_TX_AUD) provided at both accessory connectors, Accessory Connector 2 pin 17 or
Accessory Connector 3 pin 17. This path is dedicated for use solely with the external hardware PTT
feature (keying up the Consolette by grounding pin 10 on Accessory Connector 2), and vice versa.
This transmit path has an impedance of 600Ω and is amplified by U107 pins 5, 6, and 7 and the level
set by potentiometer R244. The output of the amplifier (U107 pin 7) following AC-coupling capacitor
C164 is fed into the XTL 5000 radio auxiliary transmit input at J1 pin 15 and J1 pin 40. The level of
this signal should be 300 mVrms relative to a 1.0 kHz tone at 60% FSD. If data is to be transmitted
via the AUX_TX_AUD path, U107 needs to be bypassed. This is done by removing 0 Ohm jumper
R235 and placing it in the R234 location. This supplies a direct, unimpeded path for data to the XTL
5000 radio AUX_TX_AUD input; furthermore, the user must also use CPS to select the
AUX_TX_AUD “Flat” path within the XTL 5000 mobile which is used for data transmission.
The other two transmit audio paths pass through transmit audio summing amplifier U101 pins 8, 9,
and 10. The output of the summing amplifier (U101 pin 8) following AC-coupling capacitor C101 is
fed into the XTL 5000 radio microphone input at J1 pin 23 and J1 pin 48. The level of this signal
should be approximately 90 mVrms relative to a 1.0 kHz tone at 60% FSD.
Local microphone audio passes through the control head to J2 pin 30. The microphone audio is
biased and passed through the summing amplifier with unity gain. This path has an impedance of
600Ω.
A differential transmit path is available at Accessory Connector 2 pins 3 and 11 (TX+ and TX–,
respectively) with an impedance of 1.0kΩ. This signal is combined at U101 pins 2 and 3 into a linear
signal at U101 pin 1 and then routed through the transmit audio summing amplifier with a gain of +6
dB.
Transmit audio taken from the MIC_HI and AUX_TX_AUD lines is routed to the tape recorder output
based on the jumper position at header J14. TX audio is routed to the tape recorder output at
approximately 90 mVrms when the jumper is in the A-B position. If the jumper is moved to the B-C
position, TX audio is not routed to the tape recorder output. (The TX and RX audio measurements
were made relative to a 1 kHz tone at 60% FSD.)
MIC_HI transmit audio is routed to the VU meter/clock (option L114) with a gain of +14dB.
AUX_TX_AUD transmit audio is routed to the VU meter/clock with a gain of +4 dB.
3.3.1.3 Control and Data Paths

The Audio Interface board is transparent to all control and data lines except the data bus lines,
MONITOR*, EMER (Emergency), and SPKR_UNMUTE. The amount of gain developed by U105 is
determined by the current requirements of the remote desksets. Each op-amp on the BUS+, BUS-,
and BUSY lines compares the voltage drop between the + and – inputs. The resulting amplified
signal is further amplified by the transistor following each op-amp.
MONITOR* is presented to the radio with S101-6 OFF. See Table 2-1 on page 2-5. The monitor
function is available at the control head and can also be enabled by grounding the MONITOR* input
on Accessory Connector 2 pin 24.
EMER (Emergency) is available at Accessory Connector 3 pin 13. When triggered, the radio will
broadcast an emergency signal (refer to the XTL 5000 radio user’s guide). S101-3 determines the
method in which the emergency is triggered.
May 5, 2009 6881098C21-P

Theory of Operation: Tone Remote Control (TRC) Board 3-5
SPKR_UNMUTE is available at Accessory Connector 2 pin 25 as an output to provide an indication

to accessories when the radio is receiving valid audio and the speaker is unmuted. This signal is
configurable for either active-high or active-low operation using jumper J15. See Table 2-2 on
page 2-5. When configured for active-high, the emitter of Q101 is used to determine the state of the
speaker. (If the voltage of the emitter of Q101 is high, the speaker is unmuted; if the voltage here is
low, the speaker is muted.) Similarly, if active-low is selected, the collector of Q102 is used to
determine the state of the speaker. (If the voltage at the collector of Q102 is high, the speaker is
muted; if the voltage here is low, the speaker is unmuted.) Typically, this signal is known as COR
(Carrier-Operated Relay).
3.4 Tone Remote Control (TRC) Board

NOTE: For the XTL 5000 Consolette to work properly with the Tone Remote Control (TRC) option,
several codeplug parameters must be properly set using the XTL 5000 mobile CPS. The TRC
option must be enabled, and “HUB defeats PL” must be selected. For instructions on setting
these parameters, see the Installation: Programming section of this manual.
3.4.1 General Description

Tone Remote Control allows control of a Consolette from a remote location using a pair of wires
(wireline) which need not have DC continuity. Control is accomplished using a tone remote control
console that sends a sequence of control tones that are interpreted by the Consolette. A Consolette
function normally corresponds to a function tone (FT) of a predefined frequency. All function tones
must be preceded by a high-level guard tone (HLGT—usually 2175 Hz), which alerts the Consolette
for a sequence of one or more function tones. On two-wire operation, receiver audio is muted when
HLGT is detected, so there will be no interfering audio signals on the wireline when the function
tones are being received. Upon receipt of the function tone(s), the appropriate functions (are)
executed by the Consolette. An example might be the monitor function, which disables receiver PL;
the monitor function tone frequency is usually designated 2050 Hz. See Table 3-1 on page 3-6 for
function tone descriptions.
Receiver audio is gated through the radio and passed through a guard tone notch filter on the TRC
board. This processed audio is then filtered and applied to the phone line. Transmit audio passes
through a sample-and-hold AGC circuit, a guard tone notch filter, and then to the radio to transmit.
Audio coming from the wireline is also passed through a bandpass filter that is centered at the guard
tone frequency. This audio is then routed to the microprocessor (U123) to be decoded.
Figure 3-4 illustrates the sequence of tones involved in a line push-to-talk (LPTT) function. In such a
case, the function tone must be defined as a transmit function on a certain mode (that is, 1950 Hz is
usually defined as the function tone for keying on mode 1). If an LPTT function tone is sent, the
remote control console follows the function tone with a continuous low-level guard tone (LLGT),
which is at the same frequency as the HLGT, but at an amplitude 30 dB lower. LLGT is a pilot tone
that is present, along with the transmitted audio, for the duration of the transmission. At the end of
the transmission, the Consolette dekeys after the LLGT is no longer detected.
Voice Amplitude
HLGT FT LLGT
Time
120 ms 40 ms
Figure 3-4. Remote Key-Up
6881098C21-P May 5, 2009

3-6 Theory of Operation: Tone Remote Control (TRC) Board
Table 3-1. TRC Function Tone Descriptions
Tone Table Description

Function
0010
Tone 0000 - Standard 0001 0011 0100
No Mode
Table CentraCom II Mode 1 Only No Mode 1
Select
2175 Hz Guard Tone/PTT Guard Tone/PTT Guard Tone/PTT Guard Tone/PTT Guard Tone/PTT
2050 Hz Monitor Monitor Monitor Monitor Monitor
1950 Hz Mode 1 Select Mode 1 Select No effect Mode 1 Select Mode 2 Select
1850 Hz Mode 2 Select Mode 2 Select No effect No effect Mode 2 Select
1150 Hz Secure Coded Mode 5 Select Secure Coded Secure Coded Secure Coded
Select Select Select Select
1050 Hz Secure Clear Mode 6 Select Secure Clear Secure Clear Secure Clear
Select Select Select Select
0 indicates OFF state of S100 (8-5)

0101-1111 indicates same as Standard Table
1 indicates ON state of S100 (8-5)
During an LPTT function, the LLGT is removed from the transmitted audio path by a notch filter on
the TRC board. This notch filter is tuned to the guard tone frequency (2175 Hz).
When not in the LPTT mode, the TRC board accepts receiver audio from the XTL 5000 radio, passes
it through a notch filter (tuned to guard tone), and then through a line driver for transmission down
the wireline to the remote console. The receive notch filter prevents false HLGT detection due to
possible receiver audio components near the guard tone frequency (since on a two-wire board,
receiver audio output and transmit audio/tone inputs are tied together at the wireline).
May 5, 2009 6881098C21-P

3.4.2 Detailed Description
3.4.2.1 Control Point Monitor

The XTL 5000 Consolette with the TRC option (L146) supports Control Point Monitor as defined by
the FCC. The local Consolette speaker will unmute for remote audio that is being passed from the
remote device to the Consolette to be transmitted. When the local microphone is keyed, the local
speaker will be muted to voice audio. In addition, audio from the local microphone that is to be
transmitted by the Consolette is routed, via the wireline interface, to the remote device. (This is not
needed for FCC Control Point Monitor and can be disabled by S100-2.)
When the XTL 5000 Consolette with the TRC option is being used by both a local and a remote user
at the same time, situations arise in which one user has priority over the other.
The following cases describe the effect of dual interaction:
• If the remote user performs a push-to-talk (PTT) while the local user is already keyed, the
remote user’s audio will be transmitted with the encryption state that the local user has
selected. This is only the case if the remote user requested a PTT on the same channel that
was selected by the local user. If the remote user requested a PTT on a different channel than
what was selected by the local user, the Consolette will dekey and a “bad” alert tone will be
heard by both users until both PTTs are released.
• If the remote user attempts to change channels while the local user is keyed, the Consolette will
dekey and a “bad” alert tone will be heard until the local user releases the PTT.
• All attempts by the remote user to change the state of encryption are ignored if the local user is
already keyed.
• If the local user performs a PTT while the remote user is already keyed, the local user’s audio
will be transmitted on the channel that the remote user has selected with the encryption state
that the remote user has selected.
• If the local user attempts to either change channels or the state of encryption while the remote
user is keyed, the Consolette will dekey and a “bad” alert tone will be heard until the remote
user releases the PTT.
3.4.2.2 Receive Audio Path

Audio from the receiver, as well as the various tones produced from the mobile (that is, keyfail tones
and button-press “beeps”), are gated through the XTL 5000 transceiver and sent to the TRC board
via a ribbon cable that plugs into J1 pin 42 (DET_AUD). Audio coming from the transceiver should
measure approximately 300 mVrms.
DET_AUD from the XTL 5000 transceiver is always passed through U116 gate 2 (S100-1 is always
OFF for the Consolette). Audio at U116 pin 14 should measure approximately 90 Vrms. Receive
audio then passes through the muting gate (U116 gate 1), controlled by RX_MUTE. Receive audio
muting is controlled by the microprocessor (U123 pin 36), which toggles the RX_MUTE output line.
When HLGT is detected or an LPTT is in progress, the receiver audio will be muted. This gate is also
muted for a local PTT in order to block ASTRO noise at the DET_AUD line from entering the wireline.
The audio is passed through buffer amplifier U105 op amp 3 and then notched at the guard tone
frequency (2175 Hz) by hybrid HY2 filter 1. This hybrid contains an MF10 dual switched capacitor
filter and a dual op-amp for summing purposes. The notch filter is formed by summing together the
high-pass and low-pass outputs of the filter IC. The MF10s on both HY1 and HY2 require a high-
frequency clock input that is derived from a divider circuit (U127 and U129) and the MPU “E” clock.
The output of the clock divider circuit (FILTER CLK) is a 110.4 kHz square wave that is used by the
MF10s to create the filters. The purpose of the notch filter is to notch out the guard tone frequency
area of the voice spectrum prior to transmission across the wireline.
6881098C21-P May 5, 2009

The receive notch filter has a gain of 0 dB at 1 kHz. At the 2175 Hz notch frequency the response is
-35 dB, relative to 1 kHz. To allow the slight drifting of the guard tone frequency due to wireline
translation, the filter must guarantee 30 dB of attenuation at ±5 Hz from the center frequency. The
filter has a “Q” of 3.8 in order to remove all voice components in the guard tone frequency range
before reaching the wireline. Without this protection, false guard tone detects by the TRC board
would be inevitable, since the audio leaving the TRC board is up to 20 dB higher than that arriving to
make up for wireline attenuation.
The output of the notch filter passes through another muting gate (U114 gate 2). This audio path is
always closed when the Consolette is receiving. Local microphone audio and trunking tones also
share this audio path to the console. During local PTT this gate can be used to mute local audio on
the receive path (see section 3.4.2.3, "Transmit Audio Path," on page 3-8).
Receive audio is also routed from U116 gate 1 to buffer amplifier U106 op amp 4 (MOB_RX). The
output of this buffer drives the TAPE OUT line, which is used for external recording purposes.
The line-adjust circuit (U111 op amp 3 and R545) allows the notched audio level to be adjusted via
R545. By varying R545, you can adjust the audio level to the line. This allows you to compensate for
line losses to obtain the desired audio levels. The adjusted audio is then sent through an audio-
shaping filter (U111 op amp 4). This filter is a unity-gain, low-pass filter with a corner frequency of 3
kHz.
The output of the line audio-shaping filter is split into opposing phases in the line driver circuit (U111
op amps 1 and 2, Q114 and Q115), where the receiver audio is applied to the line transformer and
the phone line. With two-wire selected, the line driver audio is also applied to the input of the transmit
audio/tones detection path through T100-6. A portion of the line driver audio is also fed into the input
amplifier of the transmit audio/tone detection path, via U111 op amp 2 and S101-7,8; this audio is
approximately 180° out of phase with the received audio at T100. This is done in order to, at least
partially, cancel the receive audio so that a tone from a control console may be more easily detected
in the presence of receiver audio. With four-wire selected, this cancellation is not necessary and
S101-7 should be open and S101-8 should be closed.
3.4.2.3 Transmit Audio Path

Wireline audio originating from a console to be transmitted over the air is applied to the wireline
interface network. The wireline interface network consists of T100 (two-wire operation), T1610 (four-
wire operation), U110, and other discrete components. The purpose of this circuitry is to match the
impedance of the TRC board to that of the wireline (T100, T1610, S101), block any DC components
between the TRC board and the wireline (C502, C501), and provide protection from surges on the
line (E1, E2).
The input from the phone line is applied to U112 op amp 1 pin 2, along with the line driver audio-
canceling voltage (described previously) via S101-7 and S101-8. The gain of U112 op amp 1 is
controlled by FET transistor Q113. The lower the DC gate voltage on Q113, the higher the gain,
since a more negative gate voltage tends to turn off the FET, creating maximum feedback resistance
across pins 1 and 2 of U112 op amp 1. The AGC potentiometer (R529) sets the maximum gain point
of the AGC. Normally, the potentiometer setting allows input signals as low as –35 dBm to achieve
full deviation. After the AGC circuit, the audio is amplified by a factor of 20 (U112 op amp 4) and is
sent to the transmit guard-tone notch filter (HY2 filter 2).
The transmit guard-tone notch filter is formed by summing the two outputs of the hybrid in the same
manner as the receive notch filter previously discussed. This filter notches out the guard-tone
frequency area of the voice spectrum before sending the audio to the radio to be transmitted. The
notch filter's high “Q” of 5.8 ensures removal of the guard-tone frequency component without
affecting the adjacent voice energy in the audio signal being transmitted.
May 5, 2009 6881098C21-P

The filtered audio level is adjusted by potentiometer R569 to set the transmitted deviation. The audio
is routed through buffer amplifier U105 op amp 4 and then (via TX_AUDIO) into amplifier U110 op
amp 1, after which it is sent to the XTL 5000 transceiver to be transmitted. The audio is also passed
to buffer amplifier U106 op amp 2. The output of this buffer drives the TAPE OUT line, which is used
for external recording purposes.
The filtered audio is also passed to amplifier U106 op amp 1, whose gain is set by digital
potentiometer U107. The audio is passed to the AUX_RX_AUD input of the radio, where it is then
output to the local speaker.
Audio tones associated with trunking operation are generated locally on the TRC board. They
originate from the microprocessor (U132 pin 38) and are filtered by low-pass filter U106 op amp 3.
The filtered tones are then sent to buffer amplifier U105 op amp 3 to be sent down the wireline to the
remote speaker.
Local microphone audio (MIC_AUDIO) is passed to buffer amplifier U105 op amp 2. It is then sent
down the wireline allowing local transmit audio to be monitored at the remote unit. If it is desired to
prevent local audio (audio not received by the radio) from being routed to the remote speaker via the
wireline, place S100-2 to the ON position. This will cause microprocessor U123 pin 35 (WL MUTE) to
be asserted, opening the wireline path at U114 gate 2 for local microphone audio, local trunking
tones, and locally generated beeps. Local microphone audio is also passed through buffer amplifier
U105 op amp 1 to TX_AUDIO to the transmitter
A linear transmit audio path (AUX_TX_AUD) is provided at both accessory connectors: Accessory
Connector 2 pin 17 or Accessory Connector 3 pin 17. This path is dedicated for use with the external
hardware PTT feature (keying up the Consolette by grounding pin 10 on Accessory Connector 2),
NOTE: For PLN1687A boards, this path is always active. However, for PLN1687B boards, plug P103
needs to be placed in the A-B jumper position for this path from the Accessory connectors’
AUX_TX_AUD pins to be active.
This transmit path has an impedance of 600Ω and is amplified by U101-3 pins 8, 9, and 10 and the
level set by potentiometer R193. The output of the amplifier (U101-3 pin 8) following AC-coupling
capacitor C174 is fed into the XTL 5000 radio auxiliary transmit input at J1 pin 15 and J1 pin 40. The
level of this signal should be 300 mVrms relative to a 1.0 kHz tone at 60% FSD. If data is to be
transmitted via the AUX_TX_AUD path, U101-3 needs to be bypassed. This is done by removing 0Ω
jumper R197 and placing it in the R196 location. This supplies a direct, unimpeded path for data to
the XTL 5000 radio AUX_TX_AUD input; furthermore, the user must also use CPS to select the
AUX_TX_AUD “Flat” path within the XTL 5000 mobile which is used for data transmission.
The PLN1687B TRC board can also be configured to route wireline transmit audio to the
AUX_TX_AUD linear transmit path to be used with the external hardware PTT feature. Placing plug
P103 in the B-C jumper position routes the filtered wireline transmit audio from the output of amplifier
U105 op amp 4 to amplifier U101-3 where its level is adjusted by potentiometer R193. This adjusted
output following AC-coupling capacitor C174 is fed into the XTL 5000 radio auxiliary transmit input at
J1 pin 15 and J1 pin 40. The level of this signal should be 300 mVrms relative to a 1.0 kHz tone at
60% FSD.
3.4.2.4 Tone Processing Section

Inputs to this section originate from TP1 (the output of U112 op amp 4) in the wireline transmit audio
path. When looking for guard tone (standby operation), the audio is selected by U114 gate 1 to be
routed through the guard tone bandpass filter and then sent to the filter/limiter. After high-level guard
tone (HLGT) has been detected, U114 gate 1 is toggled to allow audio to bypass the bandpass filter.
This permits unfiltered audio to be decoded and allows for proper identification of the function tones.
6881098C21-P May 5, 2009

The limiter consists of a gain stage (U112 op amp 3), which also provides some broadband filtering,
followed by a limiter stage that converts the signal to a square wave. The output of U112 op amp 2
drives transistor Q116. This transistor provides an input to the microprocessor's Input Capture (U123
pin 41). The input to this pin is a 0-5V peak-to-peak square wave. The frequency of the square wave
depends on the particular guard/function tone being sent. The microprocessor determines which
tone is being sent and then takes the corresponding actions.
3.4.2.5 AGC Circuit Operation

The output of U112 op amp 4 feeds reference comparators (U117 op amps 2, 3, and 4) of the AGC
circuit. If the peak voltage at the input exceeds the threshold of U117 op amp 4 (+5.8V) in the
positive direction, the output of U117 op amp 4 pulses high, causing current to pass through R510
and charge C506 via D1012. Similarly, if the peak minimum voltage at the input dips below the
threshold of U117 op amp 3 (+3.6V), U117 op amp 3 will allow a pulse of current to pass through
R509 to charge C506 via D1013. As C506 charges, the DC voltage on the gate of Q113 rises. This
rise in gate voltage on Q113 will reduce the drain-source resistance and hence the gain of U112 op
amp 1. This in turn will reduce the output of the AGC circuit. This output is again used to feed the
comparators, and the process continues until the voltage is just equal to the threshold of U117 op
amp 4 minus the threshold of U117 op amp 3, or 2.2V peak-to-peak.
The “sample-and-hold” action of the AGC occurs when a new HLGT is received. Upon detection of
HLGT by the microprocessor (U123 pin 41), the AGC_RESET* line (which has been low when no
LPTT was present) and the TONE detect line will go high (approximately 5V). This action will cause
the gain of Q113 to rapidly increase (C503 is placed parallel with the smaller C506, reducing the gate
voltage on Q113), and also turns Q110 off to allow a higher gain in the U112 op amp 1 stage. This
action will momentarily cause a rise in the AC voltage level on TP1 above the usual compression
point of 0 dBm. During the time that the peak voltage on TP1 is more than 0.7V higher than the 1.1V
peak (0 dBm) threshold, comparator U112 op amp 2 and Q116 are actuated to provide faster than
normal attack (gain reduction) time. In this manner, the gain is always reset to maximum at the
beginning of a new line push-to-talk, and then is reduced as required until the HLGT is at 0 dBm
(which is the AGC compression point) as measured on TP1. This ensures full deviation, regardless
of the amplitude of any audio signal on the line just prior to the line push-to-talk.
During an LPTT function, the Auto Level Control (ALC) action of the AGC causes the gain to freeze
for the duration of LLGT. This will preserve the natural characteristics of the speech without
producing any pumping effects.
In extreme cases where the audio signal received at the Consolette is unusually low (due to very
long lines or other attenuating factors), the AGC action of the TRC board may be inhibited, yielding
slightly more gain. Switch S100-4, when set to the ON position, will disable the AGC circuitry.
Absolute gain and transmit deviation is then adjustable by potentiometers R529 and R569,
respectively. This option is NOT recommended because the Low-Level Guard Tone (LLGT) may
already be too low to be detected and thus the Consolette will not transmit.
3.4.2.6 Power Distribution

A+ is routed to the TRC board from the power supply through J11. This connection provides ignition
sense to the control head and the mobile. When S101-1 is in the ON position, A+ is immediately
sourced from the power supply to the SWB+ connections of the mobile, control head, and TRC
board. When S101-1 is in the OFF position, the user must enable power at the front of the control
head. SWB+ is then sourced from the control head to the mobile and to the TRC board.
On the TRC board, A+ is converted to regulated 9.6V through U100. From this 9.6V source, several
comparator voltages are produced. SWB+ is routed to a 5V regulator (U132) on the TRC board,
which provides regulated 5V to all of the logic ICs.
May 5, 2009 6881098C21-P

On the PLN1687A TRC board, the one exception to the IC power distribution is the Serial I/O IC
(U131). This IC needs to be powered at all times, regardless of the state of S101-1. A+ is routed to
U131, as well as a continuous 5V source from the regulated 9.6V source. This IC is no longer used
on the PLN1687A board. Therefore, 9.6V and 5V are the only voltages needed for this part of the
circuit. A+ is no longer used here.
3.4.2.7 Input/Output Control Definitions

AGC_INHIBIT*—This signal is generated by the microprocessor (U123) through the latch (U124 pin
14). It is used to disable the AGC circuit of the TRC.
TONE_DETECT—This signal is generated by the microprocessor (U123) through the latch (U124
pin 12). It is toggled from low(0V) to high(5V) when a guard/function tone is successfully detected.
This line provides a discharge path between C503 and C506, which varies the gain of the AGC
circuit.
LPTT*—This signal is generated by the microprocessor (U123) through the latch (U124 pin 19). It is
high during an LPTT to provide additional gain for LLGT. This additional gain improves the accuracy
of the tone decoding process.
GT/FT*—This signal is generated by the microprocessor (U123) through the latch (U124 pin 17).
During the detection of guard tone, the bandpass filter is switched into the path of the audio. This
allows isolation of the 2175 Hz signal and provides more accurate decoding. Once the guard tone
has been detected, the signal line goes low. This switches the bandpass filter out of the path to allow
the function tone(s) to pass to the limiter/decoder undisturbed.
RX_MUTE—This signal is generated by the microprocessor (U123 pin 36). It is used to mute
receiver audio (DET_AUD) when an HLGT has been detected or an LPTT is in progress. DET_AUD
is also muted during a local PTT to block ASTRO noise from entering the wireline.
WL_MUTE—This signal is generated by the microprocessor (U123 pin 35). It is used to mute the
wireline during a remote PTT, and when S100-2 is in the ON position (mute local audio and local
trunking tones).
AGC_RESET*—This signal is generated by the microprocessor (U123) through the latch (U124 pin
16). It is used to provide an additional discharge path for C503 and C506 (changing the feedback
path of U112A in the AGC circuit). Upon detection of HLGT by the microprocessor, the AGC_RESET
line will go high. AGC_RESET will go low at the end of LPTT.
SPKR_UNMUTE—This signal is available at Accessory Connector 2 pin 25 as an output to provide
an indication to accessories when the radio is receiving valid audio and the speaker is unmuted. This
signal is configurable for either active high or active low operation using Plug P102. See Table 2-6 on
page 2-8. When configured for active high, the emitter of Q117 is used to determine the state of the
speaker. (If the voltage at Q117's emitter is low, the speaker is muted, and if the voltage here is high,
the speaker is unmuted.) Similarly, if active low configuration is selected, the collector of Q118 is
used to determine the state of the speaker. (If the voltage at Q118's collector is low, the speaker is
unmuted, and if the voltage here is high, the speaker is muted.)
3.4.2.8 Smart Modem Protocol (SMP) Control

The XTL 5000 Tone Remote Control Board also provides an RS232 port through which the
Consolette communicates digitally with a Gold Elite or MCC 5500 Console using the Smart Modem
Protocol (SMP).
Depending on the setting of S100-3, the operation of the Tone Remote Control board can vary as
follows:
6881098C21-P May 5, 2009

3.4.2.8.1 S100 Pin 3 ON—Tone Remote Control

In this setup, the Consolette can only be controlled remotely by a tone remote deskset, via the
wireline, as described in section 3.4.1, "General Description," on page 3-5 under “Tone Remote
Control (TRC) Board.” The Consolette will report both PTT-IDs and Call Alert IDs, when applicable,
to Accessory Connector 1 (J13) (see Table 3-2). For a list of supported IDs, see See Table 3-3 on
page 3-13.
Table 3-2. Accessory Connector 1 (J13)
J13
Pin Signal
Number
1 N/C
2 N/C
3 N/C
4 ACIM_TXD
5 N/C
6 ACIM_RXD
7 N/C
8 GND
1 1
2 2
3 3
ACIM_TXD
To 4 4
Accessory 1 To the ACIM
of the TRC 5 5
ACIM_RXD
6 6
7 7
8 GND 8
MAEPF-27878-O
Figure 3-5. TRC to ACIM Cable Diagram
May 5, 2009 6881098C21-P

MAEPF-27879-O
Figure 3-6. TRC to ACIM Cable Orientation (not provided by Motorola)
1 8 1 8
Accessory 1 on the Consolette ACIM Connector

(looking from the outside) (looking from the outside)
Table 3-3. Supported IDs
Emergency Emergency
Call Alert PTT-ID
Call PTT-ID Alarm PTT-ID
Analog Conventional (MDC) Not Reported Not Reported Not Reported Not Reported
APCO Conventional Reported Reported Reported Reported
Type II Trunking – Analog TG Reported Reported Reported Reported
Type II Trunking – Digital TG Reported Reported Reported Reported
ASTRO 25 Trunking Reported Reported Reported Reported
3.4.2.8.2 S100-3 OFF—SMP Control

In this setup, the Consolette can only be controlled remotely by the Gold Series Console or
MCC 5500 via Accessory Connector 1 (J13). The Consolette reports both PTT-IDs and Call Alert
IDs, when applicable, to Accessory Connector 1. For a list of supported IDs, see Table 3-3.
Do not connect anything to Accessory Connector 1 other than

! the supported SMP device (e.g., ACIM). Damage could occur
to the Consolette and unsupported external devices.
Caution
6881098C21-P May 5, 2009

3-14 Theory of Operation: Power-Up
As with Tone Remote Control, the Gold Series Console or MCC 5500 (using Smart Modem Protocol)
can command the Consolette to do the following:
• Change modes (the number depends on console support)
• Enable/disable encryption
• Enable/disable monitor
• PTT with positive mode
Audio routing to and from the Consolette continues to pass down the wireline. See 3.4.2.2, "Receive
Audio Path," on page 3-7 and 3.4.2.3, "Transmit Audio Path," on page 3-8 for audio routing details.
3.5 Power-Up
The ON/OFF power button located on the ASTRO control head is disabled before shipment.
Therefore, the station is immediately operational when its power cord is plugged into a live AC outlet.
To enable the ON/OFF power button on the control head, refer to the information in 2.6, "DIP Switch
and Jumper Settings," on page 2-4 of this manual. Note that the ON/OFF power button on the
control head controls the power to the control head only. For Option G81 model Consolettes (Digital
Remote Control), no control head is present and the station will become immediately operational
when its power cord is plugged into a live AC outlet.
Once the station is powered, the Power On LED should light up, and the station should be ready to
receive or transmit.
3.6 Receive
Since there can be various configurations of the Consolette depending upon the user's
requirements, no detailed receive operating instructions will be given in this section. However,
detailed operating instructions can be found in the XTL 5000 radio user’s guide. For information
regarding remote control deskset operation, refer to the applicable instruction manual.
3.7 Transmit
Since there can be various configurations of the Consolette depending upon the user's
requirements, no detailed transmit operating instructions will be given in this section. However,
detailed operating instructions can be found in the XTL 5000 radio user’s guide. For information
regarding the operation of the digital remote deskset, refer to the applicable instruction manual.
NOTE: Each Consolette is shipped with the Emergency (Emer) button disabled. Use the current
version of the ASTRO 25 CPS to enable the Emergency button, if desired.
3.8 Power-Up Self-Check Errors

Each time the radio is turned on, the MCU and DSP perform some internal diagnostics. These
diagnostics consist of checking the programmable devices such as the FLASH ROMs, internal and
external EEPROMs, SRAM devices, and ADSIC configuration bus checksum. At the end of the
power-up self-check routines, if an error exists, the appropriate error code is shown on the display.
Self-test errors are classified as either “fatal” or “non-fatal.” Fatal errors will inhibit user operation;
non-fatal errors will not. For non-display radios, the error codes can be read using the Customer
Programming Software (CPS) from the universal connector at the rear of the XTL 5000 transceiver.
See Table 3-4 on page 3-15 lists the XTL 5000 Consolette power-up self-check error codes.
May 5, 2009 6881098C21-P

Theory of Operation: Power-Up Self-Check Errors 3-15
Table 3-4. XTL 5000 Consolette Power-Up Self-Check Error Codes
Troubleshooting
Error Code Description Error Type
Chart
ERROR 01/02 FLASH ROM Codeplug Checksum NON-FATAL See Note 1
ERROR 01/12 Security Partition Checksum NON-FATAL See Note 1
ERROR 01/20 ABACUS Tune Failure NON-FATAL See Note 1
ERROR 01/22 Tuning Codeplug Checksum NON-FATAL See Note 1
FAIL 01/81 FLASH ROM Checksum FATAL See Note 1
FAIL 01/82 FLASH ROM Codeplug Checksum FATAL See Note 1
FAIL 01/88 External SRAM Failure FATAL See Note 1
FAIL 01/90 General Hardware Failure FATAL See Note 1
FAIL 01/92 Security Partition Checksum FATAL See Note 1
FAIL 01/93 FLASHport Authentication Code Failure FATAL See Note 1
FAIL 01/98 Internal RAM Failure FATAL See Note 1
FAIL 01/A0 ABACUS IC Failure/Wrong ABACUS IC Version FATAL See Note 1
FAIL 01/A2 Tuning Codeplug Checksum FATAL See Note 1
FAIL 02/81 DSP ROM Checksum FATAL See Note 1
FAIL 02/88 DSP RAM Fatal Error FATAL See Note 1
FAIL 02/90 General DSP Hardware Failure FATAL See Note 1

(DSP start-up message not received correctly)
FAIL 02/C0 Wrong Microprocessor Version in XTL 5000 FATAL See Note 1
Transceiver
ERROR 05/10 Control Head Hardware Error NON-FATAL See Note 1
FAIL 05/81 Control Head ROM Checksum Error FATAL See Note 1
ERROR 09/10 Secure Hardware Failure NON-FATAL See Note 1
FAIL 09/90 Secure Hardware Fatal Error FATAL See Note 1
ERROR 1C/10 TRC Option Hardware Failure NON-FATAL See Note 2
FAIL 1C/81 TRC ROM Checksum Error FATAL See Note 3
FAIL 1C/82 TRC Configuration Register Corrupted FATAL See Note 3
FAIL 1C/88 TRC RAM Failure FATAL See Note 3
In the case of multiple errors, the codes are logically OR’d and the results displayed. As an example,
in the case of an ADSIC checksum failure and a DSP ROM checksum failure, the resultant code
would be 02/A1.
6881098C21-P May 5, 2009

3-16 Theory of Operation: Power-Up Self-Check Errors
NOTES:
1. For troubleshooting charts and information, refer to the ASTRO Digital XTL 5000 Mobile
Radio Detailed Service Manual, Motorola Publication 6881096C74.
2. Refer to the Figure 6-1., "Consolette Does Not Work Troubleshooting Chart," on page 6-2 in
this manual.
3. For hardware failure with the TRC option, contact an authorized service shop for repair.
May 5, 2009 6881098C21-P

Chapter 4 Maintenance
4.1 Alignment
Advanced design and manufacturing techniques eliminate the need for traditional tuning tasks for
the XTL 5000 transceiver. All circuits in the transceiver have been aligned at the factory with
specialized equipment. Alignment in the field should not be necessary or attempted.
4.2 Maintenance and Troubleshooting Procedures

Depending upon the environment in which the XTL 5000 Consolette operates, a service schedule
should be created to periodically clean out the inside of the Consolette. This will ensure proper air
flow within the station at all times.
Table 6-1., "List of Troubleshooting Charts," on page 6-1 provides a listing of Troubleshooting Charts
and Table 7-1., "List of Schematics, Board Layouts, and Parts Lists," on page 7-1 provides a listing of
Schematics, Boards, and Parts Lists. These diagrams contain detailed cable connectorization
information for each cable in the XTL 5000 Consolette. These diagrams should be used in
conjunction with the applicable XTL 5000 service manual to efficiently service the Consolette.
The troubleshooting charts assist you in tracing a problem to its source. Start with the Figure 6-1.,
"Consolette Does Not Work Troubleshooting Chart," on page 6-2 and you will be directed to the
source of the problem. Use other troubleshooting charts and the applicable XTL 5000 service
manual to further identify the source of the problem.
4.3 Recommended Test Equipment and Service Aids

4.3.1 Electrical
• R2001 Communications System Analyzer or R2600 Service Monitor (or equivalent)
• R1037 or R1024 Digital Multimeter (or equivalent)
• HP8903 Audio Analyzer (or equivalent)
• HP3552 Transmission Test Set (or equivalent)
• 13.8Vdc, 15A Power Supply (for DC-only operation)
• Radio Service Cable (Motorola PN 3084565T01)
• ASTRO Digital XTL 5000 Basic Service Manual (Motorola PN 6881096C73)
• ASTRO Digital XTL 5000 Detailed Service Manual (Motorola PN 6881096C74)
• Current ASTRO 25 Mobile Customer Programming Software
4.3.2 Mechanical
• T10, T15, and T25 Torx™ Drivers
• Straight Blade and Phillips Screwdrivers
• Tuning Tool (Motorola PN 66-84974L01)
• 3/16-inch (4.7625 mm) and 11/32-inch (8.73125 mm) Hex Nut Drivers/Wrenches
• Needle-nose Pliers
• 3/32-inch (2.38125 mm) Allen Wrench
6881098C21-P May 5, 2009

4-2 Maintenance: Disassembly and Reassembly
4.4 Disassembly and Reassembly
Make sure to remove power to, and disconnect, all

! accessories from the Consolette when performing any of the
following Disassembly and Reassembly instructions.
Caution
The following is a list of detailed instructions on how to remove and replace the main components of
the Consolette. All of the retainer snaps surrounding the individual components must be released for
removal.
Never attempt to lift the station by the front panel after the top
! cover is removed as damage may occur to the connected

cables. Also, never attempt to disconnect any cable by pulling
Caution on the wires; disconnect by connectors only.
4.4.1 Top Cover
4.4.1.1 Removing the Top Cover

1. Raise the two latches on the rear of the Consolette upwards (see Figure 4-1).
2. Simultaneously lower both latches all the way down. When both latches are lowered, the top
cover will automatically spring toward the rear of the Consolette.
3. Pull the top cover towards the rear of the Consolette to further separate it from the front
panel.
4. Lift the top cover straight up to remove.
Figure 4-1. Removing the Top Cover

NOTE: The rear view of the Consolette shown in Figure 4-1 might be of an earlier model.
May 5, 2009 6881098C21-P

Maintenance: Disassembly and Reassembly 4-3
4.4.1.2 Replacing the Top Cover

1. Lower the top cover straight down onto the base, making certain that the four side tabs on the
cover (two on each side) align with, and set into, the corresponding grooves in the base.
2. From the rear of the unit, push the top cover forward to close. It may be necessary to use a
soft mallet to tap the top cover forward so that it locks into place securely.
NOTE: It is assumed from this point on that all disassembly and reassembly procedures begin with
the top cover removed and end with the top cover being replaced.
4.4.2 XTL 5000 Transceiver
4.4.2.1 Removing the Transceiver

1. Begin removing the XTL 5000 transceiver by placing the Consolette on a solid surface with
the front of the unit facing you. Refer to Figure 4-2.
2. Disconnect the DC power cable from the rear of the transceiver.
3. Disconnect the coaxial cable from the antenna port at the rear of the transceiver.
4. Remove the screw holding the transceiver in place. This screw is located on the left side of
the transceiver in-between the two retainer snaps.
5. Pull out on the two retainer snaps on the left side of the transceiver to release it.
6. Tilt the transceiver to the right (lift from the left side) to release it from the retaining bosses on
the right side of the transceiver.
7. Disconnect the interface cable from connectors J5 and J6 on the front of the transceiver.
These connectors are held in place by four screws (two per connector).
8. Disconnect the Keyload Cable from the front panel of the transceiver, if present.
Figure 4-2. Removing the Transceiver
6881098C21-P May 5, 2009

4.4.2.2 Replacing the Transceiver

1. Connect the interface cable to the connectors J5 and J6 on the front of the transceiver. Be
sure to tighten the four screws (two per connector) so that the connectors do not inadvertently
come loose.
2. Connect the Keyload cable to the microphone connector on the front panel of the transceiver,
if the cable is present.
3. Insert the right side of the transceiver at a 45-degree angle so the bracket on the radio hooks
under the retaining bosses in the center of the Consolette housing.
4. Lower the left side of the transceiver into the snap retainers on the left side of the Consolette
housing, making sure that both retainers snap into place, locking the transceiver down.
5. Insert the screw between the two retainer snaps.
6. Connect the coaxial cable to the antenna port at the rear of the transceiver. (Make sure the
connector is tightened down to where no threads are exposed. If threads are exposed, then
the connector is not seated properly.)
7. Connect the DC power cable to the DC plug on the rear of the transceiver.
4.4.3 AIB/TRC Interface Board

NOTE: Follow the instructions for removing the XTL 5000 transceiver prior to attempting to remove
or replace the AIB/TRC interface board.
4.4.3.1 Removing the AIB/TRC Board

The AIB/TRC board is located underneath the transceiver. Therefore, you must remove the
transceiver before removing the interface board.
1. Disconnect the accessory cable from connector J3 of the AIB/TRC board. Refer to Figure 4-3
on page 4-5.
2. Disconnect the transceiver cable from connector J1 of the AIB/TRC board.
3. Disconnect the power cable from connector J11 of the AIB/TRC board.
4. Disconnect the power LED cable from connector J5 of the AIB/TRC board.
5. Disconnect the fan cable from connector J8 (AIB) or J13 (TRC).
6. Disconnect the control head cable TRN7393 from connector J2 of the AIB/TRC board. (This
cable is present only on the Local Control (Option G80) Consolettes.)
7. Disconnect the speaker cable from connector J4 of the AIB/TRC board. (This cable is present
only on the Local Control (Option G80) Consolettes.)
8. Disconnect the cable for the Clock/VU Meter from J6 of the AIB/TRC board, if this option is
present.
9. With everything disconnected from the AIB/TRC board, the board can be removed by
releasing the three retainer snaps on either side of the board (six total). It is easier if you start
from the front of the unit and work to the back when releasing the retainers.
10. The AIB/TRC board should now be free from the Consolette housing.
May 5, 2009 6881098C21-P

Fan Accessory Power

Cable Cable Cable
Retainer
Snaps
Retainer
Snaps
Transceiver
Cable
Control Head Cable Power LED Speaker

(Underneath the Cable Cable
Transceiver Cable)
Figure 4-3. Removing the AIB/TRC Board
4.4.3.2 Replacing the AIB/TRC Board

1. Insert the AIB/TRC board into the Consolette housing and snap it into place. When inserting
the TRC into the Consolette housing, make sure that the board is secured by the two
retainers to the right and left of the opening for Accessory Connector 1.
2. Connect the accessory cable to connector J3 on the AIB/TRC board.
3. Connect the transceiver cable to connector J1 on the AIB/TRC board.
4. Connect the power cable to connector J11 on the AIB/TRC board.
5. Connect the power LED cable to connector J5 on the AIB/TRC board.
6. Connect the fan cable to connector J8 (AIB) or J13 (TRC).
7. Connect the control head cable TRN7393 to connector J2 on the AIB/TRC board. (This cable
is only present on the Local Control (Option G80) Consolettes.)
8. Connect the speaker cable to connector J4 on the AIB/TRC board. (This cable is only present
on the Local Control (Option G80) Consolettes.)
9. Connect the cable for the Clock/VU meter to J6 on the AIB/TRC board, if the option is
present.
10. Perform the steps for replacing the transceiver (see 4.4.2.2, "Replacing the Transceiver," on
page 4-4).
6881098C21-P May 5, 2009

4.4.4 Power Supply
4.4.4.1 Removing the Power Supply

1. Make sure that the AC power cord is disconnected from the Consolette and that the ground
connection has been removed.
2. Remove the screw located to the left of the power supply retainer snap. Refer to Figure 4-4.
3. Disconnect the DC power cable from the rear of the transceiver.
4. Disconnect the power cable from connector J11 on the AIB/TRC board. (It may be necessary
to remove the transceiver in order to access connector J11.)
5. Push down on the power supply retainer snap to release the power supply.
6. Slide the power supply toward the front of the Consolette to free the power supply from the
Consolette housing.
7. Lift the power supply out of the Consolette housing.
Power
DC Power Supply
Cable
Screw
Transceiver
AIB/TRC
Retainer
Power Cable
Snap
(Under
Transceiver)
Figure 4-4. Removing the Power Supply
4.4.4.2 Replacing the Power Supply

1. Set the new power supply into the Consolette housing in the right rear corner.
2. Align the slits in the base of the power supply with the retainers on the Consolette housing so
that the retainers come through the base of the power supply.
3. Slide the power supply to the rear of the Consolette. The retainer snap should engage and
lock the power supply into place.
4. Connect the power cable to connector J11 on the AIB/TRC board.
5. Connect the DC power cable to the DC connector on the rear of the transceiver.
6. Insert the screw in the hole to the left of the retainer snap.
7. Make sure to reconnect the ground wire to the power supply before plugging the power
supply back in to an AC outlet.
May 5, 2009 6881098C21-P

4.4.5 Fan
4.4.5.1 Removing the Fan

1. Make sure that the AC power cord is disconnected from the Consolette.
2. Disconnect the fan power leads from either connector J8 (AIB) or J13 (TRC). (If this is an
older model Consolette, the fan may be plugged directly into the power supply.)
3. Remove the dust filter cover from its mounting bracket by releasing the four snap retainers
holding it in place. This will expose the four Phillips screws holding the fan in place.
4. Remove the four Phillips screws and lock nuts that secure the fan to the rear of the
Consolette housing. (There are openings in the bottom of the Consolette housing that will
allow access to the two lock nuts on the bottom of the fan.) This will release the dust filter
mounting bracket from the rear of the Consolette.
5. Release the two retainer snaps, one on each side, and tilt the top of the fan towards the front
of the Consolette housing. This should release the fan from the retaining boss in the bottom
of the Consolette housing.
6. Lift the fan out of the Consolette housing.
4.4.5.2 Replacing the Fan

1. Insert the fan at the rear of the Consolette housing at an angle.
2. Tilt the fan to the rear of the Consolette housing, making sure that the lower lip of the fan
locks underneath the retaining boss in the bottom of the Consolette housing and the retainer
snaps lock into place.
3. Insert the four phillips screws through the dust filter mounting bracket, the Consolette
housing, and the fan assembly and secure them in place with the four lock nuts. (The bottom
two screws can be accessed through two holes in the bottom of the Consolette housing to
tighten down the lock nuts.)
4. Replace the dust filter cover onto the mounting bracket.
4.4.6 Control Head (G80 Option Only)
4.4.6.1 Removing the Control Head

1. Make sure the AC power cord is disconnected from the Consolette.
2. Remove the two control head mounting screws located on either side of the control head.
3. Push the control head from the rear to free it from the front panel.
4. Disconnect the TRN7393 control head interface kit from the rear of the control head.
6881098C21-P May 5, 2009

4.4.6.2 Replacing the Control Head
When servicing control heads, it is recommended that all

! water seals (O-ring, keypads, etc.) that are disturbed in the
procedure be replaced to ensure radio sealing integrity.
Caution
1. Connect the TRN7393 control head interface kit to the connector on the rear of the control
head.
2. Push the control head into the front panel.
3. Insert the two control head mounting screws, one on either side of the control head.
NOTE: Care must be taken to shield the control head (front and back) from direct exposure to
pressurized water. The pressurized water from a hose is, in most cases, more severe than
the stated tests, conditions, and typical environments.
May 5, 2009 6881098C21-P

Chapter 5 Cable Diagrams
5.1 Standard Cables
Table 5-1. Power LED Cable Part #3084459T01 (P/O TKN8676)
Pin Number
Signal
Power LED J5
1 1 POWER_LED_A
2 2 POWER_LED_K
3 N/C
Table 5-2. RF Coaxial Cable Part #0112004E09 (P/O TKN8676)
Pin Number
Signal
1 RX Radio
1 1 RF
2 2 ANA_GND
Table 5-3. Speaker Cable Part #3084457T01 (P/O TRN7394)
Pin Number
Signal
Speaker J4
1 1 SPKR_HI
2 2 SPKR_LO
6881098C21-P May 5, 2009

5-2 Cable Diagrams: Standard Cables
Table 5-4. Control Head Cable
Pin Number
Signal
Control Head J2
1 1 N/C
2 2 N/C
3 3 N/C
4 4 N/C
5 5 ANA_GND(DIG_GND)†
6 6 N/C
7 7 N/C
8 8 ANA_GND(DIG_GND)†
9 9 BUS+
10 10 BUS-
11 11 A+
12 12 SWB+
13 13 BUSY
14 14 SWB+
15 15 IGN
16 16 RESET
17 17 VO3
18 18 VI3
19 19 N/C
20 20 VI1
21 21 VO1
22 22 VO2
23 23 N/C
24 24 N/C
25 25 N/C
26 26 MIC_LO
27 27 N/C
28 28 HUB
29 29 N/C
30 30 CTRL_HD_MIC
31 N/C
May 5, 2009 6881098C21-P

Cable Diagrams: Standard Cables 5-3
Table 5-4. Control Head Cable (Continued)
Pin Number
Signal
Control Head J2
32 N/C
33 N/C
34 N/C
* Denotes active low signal

† Denotes TRC signal name
Table 5-5. Radio Cable

Pin Number
Signal
Radio J6 Radio J5 J1
1 1 PTT*
14 2 N/C
2 3 RS232-RXD
15 4 MONITOR*
3 5 RS232-TXD
16 6 CHAN_ACT* (N/C)†
4 7 RS232_RTS
17 8 N/C
5 9 RS232_CTS
18 10 DIG_GND
6 11 FILT_AUD (N/C)†
19 12 N/C
7 13 AUX_RX_AUD
20 14 N/C
8 15 AUX_TX_AUD
21 16 N/C
9 17 DET_AUD
22 18 SWB+
10 19 ANA_GND
23 20 N/C
11 21 MIC_LO (N/C)†
24 22 SPKR_LO
12 23 RAD_MIC (MIC_HI/
MOD_CTRL)†
25 24 SPKR_HI
13 25 N/C
1 26 PTT*
14 27 BUS-
2 28 FLT_AUD_SHD
15 29 MONITOR* (N/C)†
3 30 IGN
6881098C21-P May 5, 2009

5-4 Cable Diagrams: Standard Cables
Table 5-5. Radio Cable (Continued)

Pin Number
Signal
Radio J6 Radio J5 J1
16 31 N/C
4 32 N/C
17 33 N/C
5 34 BUS+
18 35 DIG_GND
6 36 FILT_AUD
19 37 RESET
7 38 AUX_RX_AUD
20 39 N/C
8 40 AUX_TX_AUD
21 41 BUS_SHLD
9 42 N/C (DET_AUD)†
22 43 SWB+
10 44 ANA_GND†
23 45 BUSY
11 46 MIC_LO
24 47 SPKR_LO (N/C)†
12 48 RAD_MIC (N/C)†
25 49 SPKR_HI (N/C)†
13 50 EMER
Table 5-6. Accessory Cable

Pin Number
Accessory Accessory Signal
J3
2 3
1 1 RX+ (LINE1+)†
14 2 REMOTE_RX+ (SPKR_HI)†
2 3 AUD_SHLD
15 4 REMOTE_RX- (SPKR_LO)†
3 5 TX+ (LINE2+)†
16 6 RX- (LINE1-)†
4 7 FILT_AUD (DET_AUD)†
17 8 AUX_TX_AUD
5 9 A+
18 10 VO3
6 11 BUSY
19 12 BUS-
7 13 BUS+
20 14 RESET
8 15 N/C
May 5, 2009 6881098C21-P

Cable Diagrams: Standard Cables 5-5
Table 5-6. Accessory Cable (Continued)

Pin Number
Accessory Accessory Signal
J3
2 3
21 16 5V
9 17 VO1
22 18 VI3
10 19 PTT*
23 20 VO2
11 21 TX- (LINE2-)†
24 22 MONITOR*
12 23 DIG_GND
25 24 SPKR_UNMUTE
13 25 VI1
1 26 RS232_RXD (N/C)†
14 27 RS232_TXD (N/C)†
2 28 ANA_GND
15 29 RS232_RTS (N/C)†
3 30 AUX_RX_AUD
16 31 RS232_CTS (PS_AUD_OUT)†
4 32 FILT_AUD (DET_AUD)†
17 33 AUX_TX_AUD
5 34 A+
18 35 SWB+
6 36 BUSY
19 37 BUS-
7 38 BUS+
20 39 RESET
8 40 BUS_SHLD
21 41 N/C
9 42 N/C (RS232_RXD)†
22 43 N/C (RS232_TXD)†
10 44 VSENSE1_SHLD
23 45 N/C (RS232_RTS)†
11 46 TAPE_OUT
24 47 VSENSE2_SHLD
12 48 DIG_GND
25 49 N/C (RS232_CTS)†
13 50 EMER
6881098C21-P May 5, 2009

5-6 Cable Diagrams: Optional Cables
5.2 Optional Cables
Table 5-7. Clock/VU Cable (No Longer Available)
Pin Number
Signal
Clock/VU J6
1 1 VU_AUD
2 2 N/C
3 3 ANA_GND
4 4 A+
May 5, 2009 6881098C21-P

Chapter 6 Troubleshooting Charts
This chapter contains detailed troubleshooting flowcharts. These should be used as a guide in determining the problem
areas. They are not a substitute for knowledge of circuit operation and astute troubleshooting techniques. It is advisable to
refer to the related detailed circuit descriptions in the theory of operation chapter prior to troubleshooting a radio.
6.1 List of Troubleshooting Charts
Table 6-1. List of Troubleshooting Charts
Chart Title Page
Consolette Does Not Work Troubleshooting Chart 6-2

Power Problem Troubleshooting Chart 6-3
TRC Local TX Troubleshooting Chart 6-4
TRC RX Audio Troubleshooting Chart 6-5
Trunking Tones Not Heard at Remote Console Troubleshooting Chart 6-6
TRC Board DC Voltage Troubleshooting Chart 6-7
TRC TX Audio Troubleshooting Chart 6-7
AIB TX Audio Troubleshooting Chart 6-8
AIB RX Audio Troubleshooting Chart 6-9
AIB DC Power Troubleshooting Chart 6-10
6881098C21-P May 5, 2009

6-2 Troubleshooting Charts Troubleshooting Charts
6.2 Troubleshooting Charts
CONSOLETTE DOES NOT WORK
Consolette
does not work
Is there
No an ASTRO Spectra
control head
present?
Yes
Are
the radios in
Does No Program
the system programmed
the message Is the Disable to correct frequencies correctly
Yes No
ERROR IC/10 TRC board TRC option and PL/DPL
appear on the present? in codeplug codes?
display?
Yes
No Yes Apply
push to talk
to consolette
Reprogram
the TRC board Check connections and/or refer
or replace Connect to Troubleshooting Procedures in
properly ASTRO Digital XTL 5000
Detailed Service Manual
Refer to Troubleshooting No No
Other Yes Procedures in the
error With
ASTRO Digital XTL 5000 Apply standard test Is volume turned Does Apply modulation
messages? Yes Is it Yes Yes
Detailed Service Manual speaker up can 1kHz tone RF signal
signal to receiver properly and push to talk
present? be heard at appear at RX/TX
(see note) connected? to radio
No speaker? port?
No Yes No
Is the Refer to power

No
power on problem trouble-
LED lit? shooting chart
Yes Is 1kHz Check connections and/or refer Is Does

signal routed to No RF cable modulating Check and/or
to Troubleshooting Procedures in Connect No No
pin 17 of connector J1 connected to signal appear at pin repair or
on board from ASTRO Digital XTL 5000 cable 23 of J1 on
Is the Is the radio? replace board
unit being radio? Detailed Service Manual board?
Yes equipment No Connect
operated with any connected to the proper
external accessory properly Yes Yes Yes
equipment? connector?
No Yes Check connections and/or refer Check connections and/or refer

Is the Check
No connections to Troubleshooting Procedures in to Troubleshooting Procedures in
board getting
DC power? and/or power ASTRO Digital XTL 5000 ASTRO Digital XTL 5000
Is the Is the supply Detailed Service Manual Detailed Service Manual
Program No radio programmed Yes equipment No Repair
correctly to correct frequencies functioning equipment Yes
and PL/DPL NOTE:
properly? Standard test signal is an on-channel
codes?
signal at 1mV, modulated by a 1kHz tone
at 3kHz deviation and a correct PL tone
Yes modulated at 0.75kHz deviation.
Check and/or
repair or
replace board MAEPF-28029-O
Figure 6-1. Consolette Does Not Work Troubleshooting Chart
May 5, 2009 6881098C21-P

Troubleshooting Charts Troubleshooting Charts 6-3
POWER PROBLEM
TROUBLESHOOTING
START
Is
AC power No Connect the Disconnect
cable connected and power cable
AC power power cable.
available? from radio.
Yes
Is Put switch to Is Is
115/230 volt No 12.0V ±10% Reconnect radio, 12.0V ±10% Yes Repair or
correct position and Yes
switch in the correct present on pin 1 of disconnect ribbon present on pin 1
change fuse to of J11 on replace board.
position? J11 on board? cable to J1 on board.
proper rating. board?
Yes No No
Is a Reconnect radio;
No disconnect any Repair or
control head
external equipment replace radio.
present?
if present.
Yes
Is the Is
cable to the No Connect 12.0V ±10% Yes
Repair or
control head the cable. present on pin 1 of replace external
connected? J11 on board? equipment.
Yes No
Is the
power cable No Connect the Reconnect external
to the radio power cable. equipment; disconnect
connected? cable to J11 on board.
Yes
Is the Is
cable from power 12.0V ±10%
No Connect Yes Repair or
supply to J11on board present on yellow and
the cable. black cable from the replace board.
connected?
power supply?
Yes No
Is
12.0V ±10% Yes DC power Repair or
present on pin 1 of replace power
J11 on board? is okay.
supply.
MAEPF-26158-A
No
Figure 6-2. Power Problem Troubleshooting Chart
6881098C21-P May 5, 2009

TRC LOCAL TX
Set up
radio for test.
Inject a 90mVrms
1kHz signal into Check VB, 9.6V and Refer to TRC
Is 1kHz No Is No
the mic input of FILTER_CLOCK signal, Board Voltage
signal present 9.6V and VB
the control head. at U114-13? also, be certain HY2 present? Troubleshooting
is inserted properly. Chart.
1 Yes Yes
4
Check control head and mic Is

Is 1kHz Check for Is 1kHz FILTER_CLOCK Check for
operation as specified in No No No
signal present proper operation signal present signal a 0-5V square correct operation
ASTRO Digital XTL 5000 wave at
at C605? of U124. at U114-14? of U127 and U123.
Detailed Service Manual. 110.4kHz?
2 Yes Yes Yes

1 5 3
Mic Hi Check 9.6V and VB,

Is 1kHz Is Is 1kHz Check HY2 for
Check/replace No Check/replace Yes No also, evaluate
signal present WL_MUTE signal present correct operation and
U110 and U105. at J1-23? U113 and U114. operation of U111 and
signal high? at TP3? replace if necessary.
position of R545 wiper.
3 Yes No Yes
2 4 6 5 3
VU Meter
Determine why Is Check 9.6V and VB;
Is 1kHz Is 1kHz No No
Check/replace No U123 is holding signal at also, check for
signal present at line1
U101. signal low and output? U111-1? correct operation
at J6-1?
repair. of U111.
Yes Yes Yes

3 4 4 6
(Tape Out)
Is 1kHz Is Check/replace
Check/replace No signal at No
signal present STOP secondary of Q114 and/or
U106.
at J3-46? T100? Q115.
Yes Yes
4 6
Is 1kHz
Check/replace No signal present Check/replace
U105. between R556 transformer.
and R559?
Yes
4 6 MAEPF-28030-O
Figure 6-3. TRC Local TX Troubleshooting Chart
May 5, 2009 6881098C21-P

active Does
START Is jumper Is jumper
Is RX_Mute Yes Yes high voltage at R190 Yes Check / Replace
low when P102 placed placed for active go from 0V to 5V jumper
receiving appropriately high or active when receiving P102.
? ? low? ?
Setup radio for test.
Be sure all jumpers, switches, No active
No No
and connectors are in correct low
TRC RX AUDIO positions. Transmit on channel a
1kHz tone at 60%FSD (3kHz dev). Determine why
U123 is holding Yes Place the jumper for Does Does
Is S100_1
signal high, and either active high or voltage between voltage between
off? No Check / Replace
repair. active low operation. the collector of Q118 the collector of Q102 Yes
Q117 and/or
and R186 go from and R189 go from
Q118.
Troubleshooting Yes No 5V to 0V when 0V to 8V when
SPKR_Unmute receiving receivng
Operation ? ?
? Set
S100 Yes No
No Correctly.
Check / Replace Check / Replace

Refer to ASTRO Digital jumper
Is 1kHz No Q102.
XTL 5000 Detailed P102.
signal present
Service Manual for correct
at J1-42?
operation and troubleshooting.
1 Yes
Are
Yes RX_MUTE and Is 1kHz
Check/replace No
RADIO_SEL signals signal present
U116 and U118.
low? at U116-15?
Is 1kHz No Check for
No Yes signal present proper operation
1 3 2 at U114-14? of U124.
(Tape Out)
Determine why U123 Is 1kHz 5 Yes
Yes Is S100-1 No Check/replace
is holding signal signal present
off? U106.
high and repair. at J3-46?
Check 9.6V and VB,
No Is 1kHz
also, evaluate
No Yes signal present
1 3 2 operation of U111 and
at TP3?
position of R545 wiper.
Check VB, 9.6V and Yes

Is 1kHz No 5 6
Set S100 FILTER_CLOCK signal;
signal present
correctly. also, be certain HY2
at U114-13?
is inserted properly. Is 1kHz
Check 9.6V and VB; Is Is
also, check for No No signal present WL_MUTE Yes Check/replace
Yes signal present
4 correct operation at line 1 signal high? U113 and U114.
1 at U111-1?
of U111. output?
Yes Yes No
Is Refer to 6 4
No
9.6V and VB TRC board voltage
present? troubleshooting chart. Is STOP
Check/replace Yes signal at Determine why
Yes transformer. secondary of U123 is holding
T100? signal low and repair.
Is
No
FILTER_CLOCK Check for 6 4
No
signal a 0-5V square wave correct operation
at 110.4kHz? of U127 and U123.
Check/replace
Yes Q114 and/or Q115.
3
Check HY2 for

6
correct operation
and replace if
necessary.
3
MAEPF-28031-O
Figure 6-4. TRC RX Audio Troubleshooting Chart
6881098C21-P May 5, 2009

TRUNKING/MDC TONES NOT HEARD

AT REMOTE CONSOLE
START
Apply a Push-to-Talk
to the consolette Yes Is S100-2 No Set S100
on a trunking set to OFF? correctly
channel.
1
START
Monitor U123-38 Are
during the time when associating Is the
Yes No No Connect the
trunking tones should trunking tones heard at local speaker
the local consolette connected? speaker.
be present
(on each push-to-talk). speaker?
Yes
1
Is a Check the
0-5VDC signal No Check/replace programming of the
present at microprocessor. trunking channel in the
U123-38? consoletteÕs codeplug.
2 Yes Check VB, 9.6V and Refer to TRC

1 Does the Is
START No FILTER_CLOCK signal, No Board Voltage
signal appear 9.6V and VB
at U114-13? also, be certain HY2 present? Troubleshooting
Do the is inserted properly. Chart.
Check/replace No trunking tones
U106. appear at Yes Yes
R171? 4
3 Yes Is
2 Check for Does the Check for
No filter_clk signal No
proper operation signal appear a 0-5V square wave correct operation
Do the of U124. at U114-14? at 110.4kHz? of U127 and U123.
trunking tones No
appear at line 1 Yes
5 Yes 3
output?
Yes Check 9.6V and VB,

Is Does the Check HY2 for
Check/replace Yes No also, evaluate
WL_MUTE signal signal appear correct operation and
U113 and U114. operation of U111 and
high? at TP3? replace if necessary.
STOP position of R545 wiper.
No Yes
4 6 5 3
Determine why Is Check 9.6V and VB;

Does the No No also, check for
U123 is holding signal appear at signal at
signal low and line 1 output? U111-1? correct operation
repair. of U111.
Yes Yes
4 6
Is Check/replace
signal at No
STOP secondary of Q114 and/or
T100? Q115.
Yes
6
Check/replace
transformer.
MAEPF-26159-O
6
Figure 6-5. Trunking Tones Not Heard at Remote Console Troubleshooting Chart
May 5, 2009 6881098C21-P

TRC BOARD DC VOLTAGE TRC TX AUDIO

START
START
AUX_TX_AUD Testing Wireline

See
TX audio or
Set up for radio test, AIB TX Audio. AUX_TX_AUD
be sure all connectors, ?
switches and jumpers Wireline
are in connect positions TX audio
NOTE;
Set up
To set up radio for test, be sure all connectors,
radio for test.
jumpers, switches, are configured appropriately.
Refer to manual for proper set up procedure.
Check AC source
Is No
12.0V present is present and
START Inject a 440mVrms
at J11-1? that power supply Check that U127, Set S100
is functioning U123, and U129 are 1kHz signal into correctly and
operating correctly. the TX wireline. reset consolette.
Yes
1
2 No No
Is
Is Replace 9.6V Check for
FILTER_CLOCK Is signal Is
No proper operation Yes No
9.6V present regulator (U100) a 0-5V square wave and at TP1 0dBm S100-4
START of HY2 and replace –1dBm
on audio ICs? and check for at 110.4kHz? off?
if necessary. ?
short in circuit
Wireline Yes
2 2 TX audio
Yes
Is
Check that No Is 1kHz Check U117
voltage on C506 No
Is Check for HY2 is inserted signal present
approximately
comparators for
No correct operation properly. at TP4? correct operation.
4.8V present 0VDC?
of U102 and replace START
at audio ICs?
if necessary Yes Yes
3 1
Yes
Check that JU101 Is 1kHz
is installed and No Remove drain
signal present and source leads
U110 and U105 are at J1-23?
operating correctly. of Q113.
Is Replace VR101
5V present No
and check START 4
Yes
at U131-3? 3
for short in circuit
Check for proper
operation of U106 No Is 1kHz Is Trace signal
Yes No
and U107 and signal present signal present from input
replace if necessary. at J1-13? at TP1 now? to find failure.
Note: Yes
Is 4 5 Yes
For PLN1687A No Replace 5V regulator 1
only. Skip if using 5V present (U132) and check START
PLN1687B. at U132-2? for short in circuit
No Is 1kHz
Check signal present Replace
P101 and U106. at J3-46? Q113.
Yes
Yes
5 1
STOP
MAEPF-28032-P STOP MAEPF-28033-O
Figure 6-6. TRC Board DC Voltage Troubleshooting Chart Figure 6-7. TRC TX Audio Troubleshooting Chart
6881098C21-P May 5, 2009

AIB TX AUDIO
START
Set up standard
transmit test
configuration
(see notes)
Remove all
external
accessories
NOTES: Verify accessory

1. Standard transmit receive signal is 1kHz cabling continuity
Keyup using Testing 1 and consult appropriate
MIC_HI AUX_TX_AUD
either Remote at 60% FSD on appropriate carrier. component manual
PTT or Local PTT or MIC_HI
Path? 2. Be sure all jumpers and switches are
appropriately set for application (see schematic).
AUX_TX_AUD
Repair or
Short J3-19 to 2 replace board
digital ground as necessary
J1-1 No Consult
0V? 2 appropriate radio
service manual
Is
Yes Inject 1kHz tone 1kHz Yes 1kHz signal Yes
onto appropriate 90mVrms at present at 1
Yes U101-8? J3-46?
MIC_HI source path
Carrier No No Replace No No
Radio cable
at RX/TX continuity ok? radio
connector? cable
2
MIC_HI
2 2
Yes
No
9.6V –5% Testing AUX_TX_AUD Inject 1kHz tone Is

Yes 9.6V –5% Yes 4.8V Yes 1kHz Yes 1kHz signal Yes
present between present at AUX_TX_AUD 300mVrms 1
R104 and present at or MIC_HI into J3-8 or present at
U101-4? U101-3, 5, 10? J3-33 at J1-15? J3-46?
C105? path?
No No No No
2 2 2 Tune
potentiometer
R244
1kHz Yes
300mVrms
at J1-15?
No
MAEPF-28034-O
2
Figure 6-8. AIB TX Audio Troubleshooting Chart
May 5, 2009 6881098C21-P

START
AIB RX AUDIO
Set up standard
receive test
configuration
(see notes)
Is Consult
No
busy light appropriate radio
on? service manual
Yes
Yes
1kHz Radio cable Verify accessory

No No Replace cabling continuity
present at continuity 1
J1-17, 36, 49? ok? cable and consult appropriate
component manual
Yes
Repair or
2 replace board
Determine as necessary
NOTES:
receiver audio
routine source 1. Standard receive receive signal is 1kHz
1 at 60% FSD on appropriate carrier.
2. Be sure all jumpers and switches are
Yes appropriately set for application (see schematic).
Continuity
Filtered Yes between J1-11, No
Audio? 36 and J3-32,
2
7 ok? 2 2
No No No
WARNING: Continuity Continuity

Yes Digital No Yes Yes
Speaker SPKR_LO must not be between J1-24, between J1-22,
deskset 1
audio? grounded or damage present? 49 and J4-1 47 and J4-2
to the radio may result ok? ok?
No Yes
Active Is
Does Is jumper
Check/Replace Yes TP17 go from high placed for active Yes Jumper J15 Yes Speaker
jumper J15 0V to 5V when high or active placed UnMute?
receiving? low? appropriately?
No Active No No
low Ensure Continuity Continuity
between J1-24, Yes between J1-22, Yes
S101-SW7 1
49 and J3-2 47 and J3-4
is on ok? ok?
Does Does TP16 Place the jumper for
Check/Replace No TP25 go from No voltage go from Detect
either active high or No No
Q109 0V to 8V when 5V to 0V when Audio
receiving? receiving? active low operation
2 2
Yes Yes
No
Check/Replace Check/Replace 9.6V –5% Yes 9.6V –5% Yes 2.2V Yes Remove cables 1kHz Yes Yes
present between present at 1kHz
Q101 and/or Q102 jumper J15 present at from accessory at J3-1 and at J3-46? 1
R104 and C105? U102-4? U102-5, 10? J3-6?
connectors
No No No No
2
2 2 2
MAEPF-28035-O
Figure 6-9. AIB RX Audio Troubleshooting Chart
6881098C21-P May 5, 2009

AIB DC POWER
START Done
Yes
Is
12.0V ±10% Is Is Is
Yes No switch No Move S101-SW1
present between control head SW B+
pins 1 & 2 present? S101-SW1 to "ON" position 12.0V ±10%?
of J11? on?
No Yes Yes No
Check
S101-SW1
Disconnect Press power

power cable button on
from J11 control head
Is Is Leaving power Is Verify component

12.0V ±10% Yes Remove all Connect 12.0V ±10% Yes 12.0V ±10% No
present between cable connected, present between cabling and consult
on power cables from power cable
pins 1 & 2 connect other cables pins 1 & 2 appropriate
cable? board connectors to J11
of J11? one at a time of J11? component manual
No No Yes
No
Power-ground short All

Troubleshoot
on interconnect cables
power supply
board, replace or tested?
and/or radio
repair as necessary
Yes
DC
power
ok MAEPF-26316-A
Figure 6-10. AIB DC Power Troubleshooting Chart
May 5, 2009 6881098C21-P

Chapter 7 Schematics, Board Layouts, and Parts Lists Table 7-1. List of Schematics, Board Layouts, and Parts Lists
Name Page
PLN1687B Tone Remote Control Board Schematic Diagram (Sheet 3 of 6) 7-27
This chapter contains schematics, board layouts, and parts lists. These should be used as a guide in determining the problem PLN1687B Tone Remote Control Board Schematic Diagram (Sheet 4 of 6) 7-28
areas. They are not a substitute for knowledge of circuit operation and astute troubleshooting techniques. It is advisable to PLN1687B Tone Remote Control Board Schematic Diagram (Sheet 5 of 6) 7-29
refer to the related detailed circuit descriptions in the theory of operation chapter prior to troubleshooting a radio.
7.1 List of Schematics, Board Layouts, and Parts Lists PLN1687B Tone Remote Control Board Electrical Parts List 7-31
Table 7-1. List of Schematics, Board Layouts, and Parts Lists
Name Page
XTL 5000 Consolette Exploded View 7-2
TRN7393B Control Head Interface Board Schematic 7-3
TRN7393B Component Location Diagram–Side 1 7-3
TRN7393B Component Location Diagram–Side 2 7-3
XTL 5000 Consolette Exploded View Parts List 7-4
TRN7393B Control Head Interface Board Parts List 7-4
Tone Remote Control Board Block Diagram 7-5
Audio Interface Board Block Diagram 7-6
PLN1688A Audio Interface Board Schematic Diagram (Sheet 1 of 2) 7-7
PLN1688A Audio Interface Board Schematic Diagram (Sheet 2 of 2) 7-8
PLN1688A Audio Interface Board 7-9
PLN1688A Audio Interface Board Parts List 7-10
PLN1687A Tone Remote Control Board Component Location Diagram (Viewed from Side 1) 7-12
PLN1687A Tone Remote Control Board Schematic Diagram (Sheet 1 of 6) 7-13
PLN1687A Tone Remote Control Board Electrical Parts List 7-19
PLN1687B Tone Remote Control Board Component Location Diagram (Viewed from Side 1) 7-24
6881098C21-P May 5, 2009

7-2 Schematics, Board Layouts, and Parts Lists Schematics, Board Layouts, and Parts Lists
7.2 Schematics, Board Layouts, and Parts Lists
MAEPF-27904-A
Figure 7-1. XTL 5000 Consolette Exploded View
May 5, 2009 6881098C21-P

Schematics, Board Layouts, and Parts Lists Schematics, Board Layouts, and Parts Lists 7-3
VIEWED FROM SIDE 1
30 26 22 P502 15 12 8 4
TO C O N T R O L H E A D TO A U D I O I NT E RFA CE
C
J103 P502 29 25 21 18 14 11 7 3
R2
VSENSE1 1 1 VSENSE1
20K R4
2 NC
28 24 20 17 13 10 6 2
3 NC
10K
27 23 19 16 9 5 1
R1
VSENSE2 2 4 VSENSE2
20K R3
10K
ANA_GND 13 5 ANA_GND
ANA_GND 6 R5 R6 8 ANA_GND
1991
0 0 1 14
J103
S PA R E 2 7 6 SPARE2
28 15
S PA R E 1 8 7 SPARE1
BUS+ 22 9 BUS+
BUS- 10 10 BUS-
A+ 5 11 A+
BUSY 25 13 BUSY
MAEPF-26343-O
SWB+ 12 12 SW B+
SWB+ 4 14 SW B+ Figure 7-3. TRN7393B Component Location Diagram–Side 1
IGN 11 15 IGN
RESET 23 16 RESET
VO3 14 17 VO3
15 18
HUB
VI3
16 19
VI 3
HUB
VIEWED FROM SIDE 2
VI1 17 20 VI 1
VO1 18 21 VO1
VO2 19 22 VO2
SNET_KID 20 23 SNET_KI D
SNET_WE 21 24 SNET_W E R1
PTT 24 25 PTT
MIC_LO 3 26 MIC_LO
SNET_KEY 9 27 SNET_KEY
HUB 28 28 HUB
KEYED_SLOT 26 R7 0 29 NC
27 30
CTRL_HD_MIC CTRL_HD_M I C R7
R3
R2 R4 R5
NOTES: T E P S -4 8 2 8 6 -O LEGEND
1 . U N L E S S S P E C I F I E D O TH E RW I S E , A L L
R E S I S TO R VA L U E S A R E I N O H M S .
R6
2 . A N A S T E R I S K ( ) F O L L O W I N G A S I G N A L N A ME ANALOG GROUND
I N D I C AT E S A N A C TI V E L O W S I G N A L .
MAEPF-26344-O
Figure 7-2. TRN 7393B Control Head Interface Board Schematic Figure 7-4. TRN7393B Component Location Diagram –Side 2
6881098C21-P May 5, 2009

Table 7-2. XTL 5000 Consolette Exploded View Parts List Table 7-3. TRN7393B Control Head Interface Board Parts
List
Ref. Des. Part Number Description
Res. Des. Part Number Description
1 0385144C01 SCREW, Control Panel (2
req’d) CONNECTOR:
2 HLN1072A CONTROL HEAD, ASTRO J103 0980113M03 Receptacle, 28-Contact

Spectra
4 3083139N40 CABLE, Control Head

CONNECTOR:
5 6408270S01 PANEL, Front
P502 3083139N40 Cable, Flat (with
6 3308509S05 NAMEPLATE connectors)
7 0784466T01 BRACKET, Control Head
8 3084459T01 CABLE, LED RESISTOR: W±5%; 1/8W

unless stated
9 L114 OPTION, Clock/VU Meter
R1, 2 0611077B06 20k
10 5005913X02 SPEAKER
R3, 4 0611077A98 10k
11 0310945A11 SCREW, Speaker (4 req’d)
R5 thru R7 0611077A01 0Ω
12 3084457T01 CABLE, Speaker
13 0784465T02 BRACKET, Radio (2 req’d)

MISCELLANEOUS:
14 0380114M02 SCREW, Radio Bracket (4
req’d) 5483865R01 Label, Bar Code; 1/4”
Wide
15 3084460T01 CABLE, Radio
8484501T03 Board, Circuit
16 RADIO, ASTRO Digital
XTL 5000 Notes:
For optimum performance, order replacement diodes,
17 PLN1688 Audio Interface Board transistors, and circuit modules by Motorola part number only.
and PLN1687 Tone Remote Control Board Part value notations:
(Optional) p=10-12 n=10-9 µ=10-6
-3 3
m=10 k=10 M=106
18 3084493T01 CABLE Power
19 0112004E09 CABLE, Antenna
20 3808649S01 SUPPORT, N-Type
21 FRN5358A FAN
22 2708271S01 CHASSIS, Main

or 2708271S02 CHASSIS, Main
23 5508626S01 LATCH (2 req’d)
24 3808649S02 COVER, N-Type (2 req’d)
25 3084462T01 CABLE, Accessory
26 1508346S01 COVER, Top
27 HPN4005 SUPPLY, Power
May 5, 2009 6881098C21-P

RS232
DATA LINES
DRIVER/ ACIM
RECEIVER CONNECTION
RX_MUTE
RADIO_SEL LINE 2 + BUFFER
WIRELINE TX_AUDIO
TRUNK_TONES WIRELINE LINE 2 - INTERFACE
TONE_DETECT
AGC_RESET
3
LOGIC AGC_INHIBIT
TO SERIAL BUS
& GT/FT TONE_DETECT
RADIO GT/FT LPTT
CONTROL AGC_ RESET
RESET LPTT
WL_MUTE AGC_INHIBIT
CLOSE
FOR 4-WIRE
5.8V
DECODE OPERATION
FILTER 6.5V
TONES GUARD TONE
& AGC 3.8V
BANDPASS FILTER
LIMITER
AUX_RX_AUD VOLUME
ADJUST FILTER-CLK
TO
FILTER_CLK
RADIO
OPEN
TX AUDIO LEVEL GUARD TONE FOR 4-WIRE
ADJUST NOTCH FILTER OPERATION
BUFFER BUFFER
9.6V
JUMPER LINE 1 + RX_AUDIO
A+ 6.5V TX_AUDIO
P101 BUFFER WIRELINE
5.8V WIRELINE LINE 1 - INTERFACE
POWER 5.0V VB WL_MUTE BUFFER
ROUTING 4.8V
CH_MIC FROM
CONTROL SWB + 3.6V
HEAD 2.2V
TAPE_OUT
TO GUARD TONE LEVEL ADJUST LINE

ACCESSORY NOTCH FILTER & FILTER DRIVER
CONNECTOR BUFFER
SPKR_UNMUTE
BUFFER
RADIO_SEL RX_MUTE MAEPF-26235-A
DET_AUDIO 100K
FROM
RADIO FILT_AUDIO
TRUNK TONES LOW PASS

FILTER
Figure 7-5. Tone Remote Control Board Block Diagram
6881098C21-P May 5, 2009

T100 ELC
DETECT ELEC RX AUDIO ELC RECEIVE +
AUDIO ELC RX AUDIO ELC RX AUDIO LINE DRIVER RX AUDIO TO
DETECTED MUTING CIRCUIT LEVEL ADJUST SHAPING FILTER IMPEDANCE ACCESSORY 2
AUDIO R111 Q103, Q104, MATCHING CONNECTOR J3
U106-12, 13, 14 U102-8, 9, 10 U102-12, 13, 14 U102-1, 2, 3
U102-5, 6, 7 (600 or 900) ELC
RECEIVE -
TO
SPEAKER - SPEAKER SPEAKER
J4
DESKSET DESKSET
SPEAKER RECEIVE AUDIO
UNMUTE RECEIVE - TO
IMPEDANCE ACCESSORY 2
CIRCUIT S101-7 CONNECTOR J3
16 OHM DESKSET
U107-1, 2, 3 RESISTOR ARRAY RECEIVE +
Q101, Q102 TO
SPEAKER
SPEAKER + SPEAKER + J4
TO
SPEAKER ACCESSORY 2
TAPE OUT UNMUTE
AUDIO CONNECTOR J3
SUMMER TAPE OUTPUT TO
ACCESSORY 3
U101-12, 13, 14 CONNECTOR J3
DESKSET DESKSET
TRANSMIT TRANSMIT -
AUDIO
DESKSET FROM
U101-1, 2, 3 TRANSMIT + ACCESSORY 2
CONNECTOR J3
JU101 TRANSMIT
AUDIO TRANSMIT
TO/FROM MIC HI SUMMER
RADIO AUDIO
J1 U100-8, 9, 10
LOCAL CONTROL CONTROL FROM
DESK HEAD LOCAL MIC
MICROPHONE MIC HI J2
AUDIO BIAS
VU AUDIO
BUFFER VU/CLOCK TO VU/CLOCK
AUDIO INPUT J6
U101-5, 6, 7
AUXILIARY AUX RX AUDIO

RECEIVE AUDIO
AUXILIARY AUX TX AUDIO TO/FROM
TRANSMIT AUDIO ACCESSORY 3
FILTERED FILTERED CONNECTOR J3
RECEIVE AUDIO RECEIVE AUDIO
EMERGENCY EMERGENCY
S101-3
FILTERED
RECEIVE AUDIO
PTT PTT TO/FROM
CONTROL ACCESSORY 2
CHANNEL LOGIC CONNECTOR J3
ACTIVITY UNAVAILABLE
TO U103
CONTROL MONITOR MONITOR
HEAD
J9 SWB+
820
ANODE
TO
POWER LED
J5
CATHODE
VSENSE BUS VSENSE TO ACCESSORY 3

VEHICLE VEHICLE CONNECTOR
INTERFACE INTERFACE J3
I/O BUS I/O BUS
TO/FROM RESET RESET
CONTROL TO/FROM
HEAD ACCESSORY 2
J2 CONNECTOR
BUSY TRANSIENT BUS + J3
BUS DRIVER PROTECTION
BUS + BUS -
Q106, Q107, Q108 VR101, VR102,
BUS - U105 VR103, VR104 BUSY
SIGNAL LEGEND
AUDIO DATA CONTROL
MAEPF-27884-O
Figure 7-6. Audio Interface Board Block Diagram
May 5, 2009 6881098C21-P

2.2V
9.6V
A+ SWB+ C139
MOB_RX TP3 2.2V TP94 C111
TP103
330pF
A+ J2 11 ELC RECEIVE AUDIO 0.1uF
10 11 11.6 VDC
A+ J11 1 LEVEL ADJUST R113 R118 1
8 12 11 TP91
IGN J1 30 U102
5V 9 14 2.0 VDC 3 11
IGN J2 15 MC3303 84.5K 84.5K U102
4 13 1 Q104 R139 R141
SWB+ J1 43 C124 MC3303 U102
C103 R111 TP92 4 2 1.2K 1.8K
SWB+ J1 18 1uF 9.6V C110 MC3303
39pF 200K 1000pF 9.6V 4
SWB+ J2 12
TP21 9.6V R135
SWB+ J2 14 TP90 TP106
C146 C147 C100 4.7K
TP19 R102
470pF 0.1uF
DET_AUD J1 17 TP105
300mVrms 18K 0.33uF ADJUST TO 1.0 Vrms R121
AT ELC RECEIVE OUTPUT
R119 TP93
TP95 R188 4.7K
16
100K A+ S101 SWB +
VCC
6 9.6V C121 R138 SWITCH
TP51 EN 10
12 39pF 75 1 16
X0
14 9.6V 5V 2 15
X TP16 TP1
13 11 R143 3 14
X1 A
2 4.7K TP25 TP23 5V 4 13
Y0
15 5 12
Y R144 R187 R129
1 10 R140 TP26 Q101 R137 6 11
C157 Y1 B 100K TP17 TP89 TP87
1uF 5 TP153 TP14 75 7 10
Z0 10K 47K 47K
4 8 9
Z R142 R186 R132
3 9 Q109 Q102
Z1 C C144 J15 A TP169 TP104
GND
9.6V
VEE
10K 470pF 10K 47K
2.2V
J15 B TP27 6 4
C140
7
U106 R145
470pF C149 7 2.6 VDC TP151 TP150
MC14053B 47K C120 Q103
470pF J15 C 5 U102
11
39pF TP86 2
R134 11.6 VDC
5V TP88 MC3303 4.7K
CHAN_ACT* J1 6
R236
5V 10K
SPKR_LO J1 22
SPKR_H
I J1 24 R116 R131
10K
3
MONITOR* J1 29 TP145 10K
SPKR_LO J1 47 4
TP18 5
SPKR_HI J1 49 6
PTT* J1 1 7
PTT* J1 26 TP143 TP29
TP170
HUB1 J2 28
MONITOR* J1 4 8
TP146 R237 1.8K

EMER J1 50 9
AUX_RX_AUD J1 13 10
AUX_TX_AUD J1 15 11
FILT_AUD J1 11 12
V03 J2 17 13
VI3 J2 18 14
VI1 J2 20 15
VO1 J2 21 16
V02 J2 22 17
RESET J2 16 18
BUSY1 J2 13 19
BUS+1 J2 9 20
BUS- J2 10
BUS- J1 27 4.8V
R120
BUS+ J1 34 TP110
BUSY TP35 C118 5V
J1 45 MC3303 200K R125
TP32 TP43 TP59 TP61
RESET J1 37 R220
11 3
4.8VDC 200K .015uF
4.8V 1 4.8V
U101 10K
2 TP79 TP108 R127 TP167 SWB+
FILT_AUD J1 36 MC3303 TP77 C113
AUX_TX_AUD J1 40 9.6V 4 1K C164 CR104
C138 22pF 1uF
11 10 TP162 11 5
AUX_RX_AUD J1 38 1uF TP38
8 C117 7 2 4 MC33074A
U101 R110 C107 R124 U107 R219
9 R117 6 C162 1 Q106
TP160 TP34 U105
TP121 9.6V 4 1 9.6V 4 220pF 3
47K 200K 200K 10K
TP119 TP60 TP122 .015uF .015uF R244 11
TP82 R216 R217 TP44
TP78 TP164 200K MC3303 R149
R122 C163 2 1.2K 120
R243 TP37
330K 90mVrms 3 TP181 TP168
MIC_LO J1 21 R106 R130 R218 10
MIC_LO J1 46 R101 C101 62K C116
0.1uF R112
MIC_LO J2 26 100K TP166 1K 100K VR101 R221
TP118 TP165 6.8V 1K
10K TP83 R211 10K TP36
4.7uF 0.22uF
C104 C108
TP96 TP4 R210
TP113 10
RAD_MIC J1 48 JU101 C135 R109 100K C127 R215 C128
220pF .015uF R214
RAD_MIC J1 23
DIG_GND J1 35 90mVrms 0 100K 18K 0.1uF 100K 0.1uF 21
1uF
BUS_SHLD J1 41 J14 A TP161 22
C112 TP163 9.6V
DIG_GND J1 10 R108 TP80 TP81 23
ANA_GND J2 5 J14 B 24
AND_GND TP158 4.8V 6 4
J2 8 TP11 100K 1uF 400mVrms 25
C137 TP101 7
FLT_AUD_SHD J1 28 R114 J14 C U101 26
9.6V R241 VR107 C154 5 9.6V
ANA_GND J1 44 27
C145 15K 5.6V 470pF 11 MC3303
ANA_GND J1 19 100K R212 VU AUDIO BUFFER C158
1uF 470pF 13 4
TP9 9.6V TP102 560
TP159 TP10
C136 14 R123
R115 U101 R213 C126
4.8V 12 0.1uF 680
MOB_RX 11 MC3303 MAEPF-28194-O
160K 1K TP13
1uF 10uF
CONTROL HEAD
MICROPHONE BIAS
Figure 7-7. PLN1688A Audio Interface Board Schematic Diagram (Sheet 1 of 2)
6881098C21-P May 5, 2009

TP97 TP99 5V SWB+ A+

T100
XFMR JUMPER STATE DESCRIPTION SWITCH ON (CLOSED) OFF (OPEN)
6 1
1 J3 1 RX+ S101-1 *ASTRO CONTROL HEAD POWER BUTTON DISABLED ASTRO CONTROL HEAD POWER BUTTON ENABLED
A+ JU101 *IN ALWAYS PLACED FOR ASTRO
J6 4 A+
5 S101-3 *EMER ACTIVE HIGH EMER ACTIVE LOW
ELC RECEIVE AUDIO 1 Vrms BETWEEN RX+ AND
- RX J3 9 A+ TRANSMITTED AND RECEIVED AUDIO IS ROUTED TO
J14 A-B
J3 34 A+ TAPE_OUT (ACCESSORY CONNECTOR 3, PIN 11)
4 3 S101-4 *600 OHM IMPEDANCE 900 OHM IMPEDANCE
J3 6 RX-
C125 J3 35 SWB+ ONLY RECEIVED AUDIO IS ROUTED TO
TP128 TP126 *B-C S101-5 900 OHM IMPEDANCE *600 OHM IMPEDANCE
100uF J3 16 5V TAPE_OUT (ACCESSORY CONNECTOR 3, PIN 11)
TP100 TP127 S101-6 LOCAL DESK MICROPHONE NOT PRESENT *LOCAL DESK MICROPHONE PRESENT
J15 A-B SPKR_UNMUTE ACTIVE HIGH (COR) S101-7 DIGITAL REMOTE CONTROL OPTION PRESENT *DIGITAL REMOTE CONTROL OPTION NOT PRESENT
J1 3 J3 26 RS232_RXD *B-C *SPKR_UNMUTE ACTIVE LOW (COR)
SWITCH NOTES:
TP98
J1 5 J3 27 RS232_TXD JUMPER NOTES: 1. AN ASTERISK (*) INDICATES DEFAULT FACTORY SETTING
1. AN ASTERISK (*) INDICATES DEFAULT FACTORY SETTING 2. SWITCHES S101-2 AND S101-8 ARE UNUSED
J1 7 J3 29 RS232_RTS
SCHEMATIC NOTES
:
J1 9 J3 31 RS232_CTS
VR116 VR115 VR114 VR113 1. UNLESS OTHERWISE SPECIFIED, ALL RESISTOR VALUES
15V TP149 ARE IN OHMS AND ALL CAPACITOR VALUES ARE IN MICROFARADS.
15V 15V 15V
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
2. AN ASTERISK (*) FOLLOWING A SIGNAL NAME INDICATES AN
ACTIVE LOW SIGNAL. UNUSED CONNECTOR PINS
C153 C152 C151 C150
470pF 470pF 470pF 470pF 3. ALL VOLTAGE MEASUREMENTS TAKEN USING 1 KHZ AT 60% FSD. J1 2 TP132
R176
R177
R178
R191
R192
R193
R198
R184
R185
R189
R190
R199
R194
R166
R200
5V REGULATOR J1 8 TP148
SWB+ 5V
J1 12 TP137
U104 J1 14 TP138
MC78M05 AUDIO REFERENCES J1 16 TP139
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
J3 24 SPKR_UNMUTE TP7 J1 20 TP154
1 3 4.8V 2.2V
IN OUT J1 25 TP140
GND
9.6V
TP8 9.6V REGULATOR TP112
VR105 C148 A+ TP173 TP174 J1 31
U100
R203
R204
R205
R172
R173
R196
R201
R202
R156
R157
R158
R168
R171
R174
R169
R197
5.6V 470pF 2 J1 32 TP141
LT1129CQ
2 TP144 C115 C119 R104 R105 J1 33
C114 5 1 TP115
220pF 4.7uF IN OUT
10uF 4 2 J1 39 TP142
SHDN SENSE 33K 18K J1 42
VR109 VR110 TP136
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
GND1
GND2
5.6V 5.6V TP54 C102 C105 C129 C106 J2 2 TP64
R100 C109 R107
TP55 68K 4.7uF .01uF 1uF 1uF 1uF 15K J2 3 TP65
J3 4 REMOTE_RX-
J2 6 TP66
3
6
3 J4 2 SPKR_LO
R175
R160
R161
R162
R163
R164
R159
R170
R180
R181
R182
R183
R195
R167
R179
R165
TP12 TP152 J2 7 TP67
J2 19 TP155
4
SWB+ TP52 J2 23 TP68
5 J3 2 REMOTE_RX+ TO DISSAPATE MAXIMUM 10W J2 24
TP2 R103 TP69
6 J4 1 SPKR_HI 47 RESISTORS IN PARALLEL R147 J2 25
R146 10 43K TP70
7 J3 19 PTT* J5 1 PWR_LED_A
PROVIDES 16 OHM OUTPUT J2 27 TP71
820
TP24 A+ J2 29 TP72
J5 3 PWR_LED_A J2 31
TP111 TP73
R153 J2 32 TP74
8 J3 22 MONITOR* J5 2 PWR_LED_K TP175
TP107 J2 33 TP75
10 R240 J2 34 TP76
J13 1 TP176 J3 15
TP124 TP156
9 J3 50 EMER J13 3 51
J3 43 TP157
10 J3 30 AUX_RX_AUD J13 2
R234 0 C142 C141 J3 41 TP129
11 J3 33 AUX_TX_AUD J3 49 TP131
DNP 100uF 100uF
12 J3 32 FILT_AUD
J6 2 TP125
13 J3 10 V03
14 J3 18 VI3
15 J3 25 VI1 TP177 TP178
16 J3 17 V01
17 J3 20 V02
R152 10
18 J3 39 RESET
9.6V SWB+
19 J3 36 BUSY
20 J3 38 BUS+
R239 J3 13 BUS+
6.8K TP62 TP123
TP120 J3 11 BUSY
J3 14 RESET
5V C159 C160
J3 7 FILT_AUD
5V 0.1uF 0.1uF
TP22 R233
R222 10K 5V
SWB+ CR103 TP46
1 2 4 MC3303 13 4
1K R136 R225 TP41 CR105 C123
1 14
1
TP48 3
TP171 U107 U105
Q107 9 4 MC33074A 2 3 12
R223 1K 100K 8 R232 0.1uF MC33074A
VR102 Q108 11 11
1.2K TP50 U105
R224 6.8V 10 R133
TP33 4.7K TP47
120 5 R229 11 10K TP179
11 R226 R227 R228 TP42
1.2K 120 CR102 TP45
U105 R151
6 7 2
10K 10K R230 R231 C122
4 MC33074A
1
R150 3
10
SWB+ 10 1K 100K VR103 TP49 1
0.1uF
9.6V
6.8V R154 TP53
1K 9 4 MC3303
8
U107
10
J6 3 ANA_GND 11
J3 37 BUS- J3 3 AUD_SHLD
TP180
21 J3 12 BUS- J3 28 ANA_GND
22 J3 21 TX-
23 J3 5 TX+
R235 0
24 J3 8 AUX_TX_AUD J3 23 DIG_GND
J2 30 CTRL_HD_MIC J3 40 BUS_SHLD 9.6V
25
26 J6 1 VU_AUD J3 44 VSENSE1_SHLD
13 4 MC3303
27 J3 46 TAPE_OUT J3 47 VSENSE2_SHLD
C156 14
C155 J3 48 DIG_GND U107
12
TP117 11
J11 2 CHASSIS_GND
470pF TP116 TP63 470pF
VR100 VR112 MAEPF-28195-O
15V TP109 TP114 15V
Figure 7-8. PLN1688A Audio Interface Board Schematic Diagram (Sheet 2 of 2)
May 5, 2009 6881098C21-P

VR109
C156
VR115
VR116
VR114
VR100
VR110
FRICTION LOCK
VR112
FRICTION LOCK
FRICTION LOCK
J4
R153
J5
2
C153 C152 C151 C155
J6
R146 R152
J11
3
49 2
4
J3
50 2 2
FRICTION LOCK
C150
R234
VR1131
VR105
C148
16 9
S101 R235
1
8
R236 R239
R166 R170 R175 R201 R194 R198 R176
R123
R200 R180 R160 R202 R203 R184 R177
C164
R237
R112
C116
R174 R181 R161 R156 R204 R185 R178 C125
R142 R147
R111 R244 2
R140
3 2 3
2 R169 R182 R162 R157 R205 R189 R191 C140 C122
R131
R243 C162 2
Q109
CR102
R165 R183 R163 R158 R172 R190 R192 5
R103
R154
C142 UIDO
C159
R133
7 R143 2
U107 6
CR103
R167 R195 R164 R168 R173 R199 R193 8 14
R100
R115
R144 R151
CR105
R145 C144 R107
C141 R179 R197 R159 R171 R196 C102
C149
C123
VR103 Q108
VR102
R150
Q107
3 Q101 C109
R186
Q102 R222
C146
Q103 R137 R138 4 Q140
C105
C106
J2
R105
R188
3 1 8
1 R228 R232 R227 R224
U106
C147
R104
4 R214 C127 9 16
R187 J1
C129
R240 R135 R223
1 J15 R226
C126 R215
FRICTION LOCK
R212 C B A R229 R233

C121
C124
R136
R225
J13
R231
R230
C157
8
7
R141 R211 R127 C117
R132 R119
U105
3
C118 R124 C119

C111 R129 JU101 C160
R125
R218
R130
14
R139 R118 C110
C108 C107 R220
R117
CR104
Q106
R113 R121 C115 33 34 R216
R210 R219
C126 C113
C103 C139 3 R217
R110
R120 2 U104 R221

R134
VR101
1 R149
R213 C104
C120
R106 C163 C114

1 3 49 50
C101
C100
7
T100
7
8
8
R101
C158
U101
U102
A R122
C145
14
14
6 5 4
R102 C138
R109
C135
C112
B
R108
C
C137
J14
VR107
R241
C154
R115
R114
C136
MAEPF-28201-O
Figure 7-9. PLN1688A Audio Interface Board
6881098C21-P May 5, 2009

Table 7-4. PLN1688A Audio Interface Board Parts List

Ref. Des. Part Number Description Ref. Des. Part Number Description Ref. Des. Part Number Description
C135 2311049A08 CAP,1uF J1 2882505T15 CONN_P R113 0611077G81 RES,84.5K
– 0984728L01 Socket, Yellow Conn. C136 2311049A08 CAP,1uF J2 2882505T04 CONN_P R114 0611077B23 RES,100K
– 0984728L01 Socket, Yellow Conn. C137 2311049A08 CAP,1uF J3 2882505T15 CONN_P R115 0611077B28 RES,160K
C100 2380090M15 CAP,0.33uF C138 2311049A08 CAP,1uF J4 2884324M07 CONN_P R116 0611077A98 RES,10K
C101 2311049A15 CAP,4.7uF C139 2113741B69 CAP,0.1uF J5 2884324M08 CONN_P R117 0611077B30 RES,200K
C102 2311049A14 CAP,4.7uF C140 2113740B65 CAP,470pF J6 2884324M09 CONN_P R118 0611077G81 RES,84.5K
C103 2113740B39 CAP,39pF C141 2380090M25 CAP,100uF J11 2880004T02 CONN_P R119 0611079B23 RES,100K
C104 2113740B57 CAP,220pF C142 2380090M25 CAP,100uF J13 2884324M08 CONN_P R120 0611077B30 RES,200K
C105 2113741B45 CAP,.01uF C144 2113740B65 CAP,470pF J14 2880001R03 CONN_P R121 0611077A90 RES,4.7K
C106 2311049A08 CAP,1uF C145 2113740B65 CAP,470pF J15 2880001R03 CONN_P R122 0611077B35 RES,330K
C107 2113741B49 CAP,.015uF C146 2113740B65 CAP,470pF JU101 0611077A01 RES, 0 R123 0611077A70 RES,680
C108 2113741B49 CAP,.015uF C147 2113741B69 CAP,0.1uF Q101 4813824A10 MMBT3904 R124 0611077B30 RES,200K
C109 2311049A08 CAP,1uF C148 2113740B65 CAP,470pF Q102 4813824A10 MMBT3904 R125 0611077B30 RES,200K
C110 2113740B73 CAP,1000pF C149 2113740B65 CAP,470pF Q103 4813822A07 MJD340 R127 0611077A74 RES,1K
C111 2113740B61 CAP,330pF C150 2113740B65 CAP,470pF Q104 4813822A07 MJD340 R129 0611077B15 RES,47K
C112 2311049A08 CAP,1uF C151 2113740B65 CAP,470pF Q106 4813824A18 MMBT4403 R130 0611077A74 RES,1K
C113 2113740B33 CAP,22pF C152 2113740B65 CAP,470pF Q107 4813824A11 MMBT2222A R131 0611077A98 RES,10K
C114 2311049A45 CAP,10uF C153 2113740B65 CAP,470pF Q108 4813824A18 MMBT4403 R132 0611077B15 RES,47K
C115 2113740B57 CAP,220pF C154 2113740B65 CAP,470pF Q109 4813824A10 MMBT3904 R133 0611077A98 RES,10K
C116 2311049A03 CAP,.22uF C155 2113740B65 CAP,470pF R100 0611077B19 RES,68K R134 0611077A90 RES,4.7K
C117 2113741B49 CAP,.015uF C156 2113740B65 CAP,470pF R101 0611077A98 RES,10K R135 0611077A90 RES,4.7K
C118 2113741B49 CAP,.015uF C157 2311049A08 CAP,1uF R102 0611077B05 RES,18K R136 0611077A74 RES,1K
C119 2311049A15 CAP,4.7uF C158 2113741B69 CAP,0.1uF R103 0611077B14 RES,43K R137 0611072A22 RES,75
C120 2113740B39 CAP,39pF C159 2113741B69 CAP,0.1uF R104 0611077B11 RES,33K R138 0611072A22 RES,75
C121 2113740B39 CAP,39pF C160 2113741B69 CAP,0.1uF R105 0611077B05 RES,18K R139 0611077A76 RES,1.2K
C122 2113741B69 CAP,0.1uF C162 2113740B57 CAP,220pF R106 0611077B23 RES,100K R140 0611077B23 RES,100K
C123 2113741B69 CAP,0.1uF C163 2113741B69 CAP,0.1uF R107 0611077B03 RES,15K R141 0611077A80 RES,1.8K
C124 2311049A08 CAP,1uF C164 2311049A08 CAP,1uF R108 0611077B23 RES,100K R142 0611077A98 RES,10K
C125 2380090M25 CAP,100uF CR102 4813833C04 BAV70 R109 0611077B23 RES,100K R143 0611077A90 RES,4.7K
C126 2311049A45 CAP,10uF CR103 4813833C03 BAW56 R110 0611077B15 RES,47K R144 0611077A98 RES,10K
C127 2113741B69 CAP,0.1uF CR104 4813833C10 MMBD6050 R111 1813905A14 RES,200K R145 0611077B15 RES,47K
C128 2113741B69 CAP,0.1uF CR105 4813833C10 MMBD6050 R112 0611077A98 RES,10K R146 0611077A26 RES,10
C129 2311049A08 CAP,1uF
May 5, 2009 6881098C21-P

Ref. Des. Part Number Description Ref. Des. Part Number Description Ref. Des. Part Number Description Ref. Des. Part Number Description
R147 0611072A47 RES,820 R181 0611072A46 RES,750 R217 0611077A52 RES,120 U105 5113819A05 MC33074A
R149 0611077A26 RES,10 R182 0611072A46 RES,750 R218 0611077B23 RES,100K U106 5113806A20 MC14053B
R150 0611077A26 RES,10 R183 0611072A46 RES,750 R219 0611077A98 RES,10K U107 5113819A04 MC3303
R151 0611077A26 RES,10 R184 0611072A46 RES,750 R220 0611077A98 RES,10K VR100 4813830A28 MMBZ5245B
R153 0611077A26 RES,10 R186 0611077A98 RES,10K R222 0611077A74 RES,1K VR102 4813830A18 MMBZ5235B
R154 0611077A74 RES,1K R187 0611077B15 RES,47K R223 0611077A76 RES,1.2K VR103 4813830A18 MMBZ5235B
R156 0611072A46 RES,750 R188 0611077A26 RES,10 R224 0611077A52 RES,120 VR105 4813830A15 MMBZ5232B
R157 0611072A46 RES,750 R189 0611072A46 RES,750 R225 0611077B23 RES,100K VR107 4813830A15 MMBZ5232B
R160 0611072A46 RES,750 R192 0611072A46 RES,750 R228 0611077A76 RES,1.2K VR112 4813830A28 MMBZ5245B
R161 0611072A46 RES,750 R193 0611072A46 RES,750 R229 0611077A52 RES,120 VR113 4813832C28 MMBZ15
R162 0611072A46 RES,750 R194 0611072A46 RES,750 R230 0611077A74 RES,1K VR114 4813832C28 MMBZ15
R163 0611072A46 RES,750 R195 0611072A46 RES,750 R231 0611077B23 RES,100K VR115 4813832C28 MMBZ15
R164 0611072A46 RES,750 R196 0611072A46 RES,750 R232 0611077A90 RES,4.7K VR116 4813832C28 MMBZ15
R165 0611072A46 RES,750 R197 0611072A46 RES,750 R233 0611077A98 RES,10K
R166 0611072A46 RES,750 R198 0611072A46 RES,750 R234 0611077A01 RES,0
R167 0611072A46 RES,750 R199 0611072A46 RES,750 R235 0611077A01 RES,0
R168 0611072A46 RES,750 R200 0611072A46 RES,750 R236 0611077A98 RES,10K
R169 0611072A46 RES,750 R201 0611072A46 RES,750 R237 0611077A80 RES,1.8K
R170 0611072A46 RES,750 R202 0611072A46 RES,750 R239 0611077A94 RES,6.8K
R171 0611072A46 RES,750 R203 0611072A46 RES,750 R240 0680194M18 RES,51
R172 0611072A46 RES,750 R204 0611072A46 RES,750 R241 0611077B03 RES,15K
R173 0611072A46 RES,750 R205 0611072A46 RES,750 R243 0611077B18 RES,62K
R174 0611072A46 RES,750 R210 0611077B23 RES,100K R244 1813905A14 RES,200K
R175 0611072A46 RES,750 R211 0611077A26 RES,10 S101 4083706T01 SWITCH
R176 0611072A46 RES,750 R212 0611077A68 RES,560 T100 2584422T01 XFMR
R177 0611072A46 RES,750 R213 0611077A74 RES,1K U100 5105109Z13 LT1129CQ
R178 0611072A46 RES,750 R214 0611077B05 RES,18K U101 5113819A04 MC3303
R179 0611072A46 RES,750 R215 0611077B23 RES,100K U102 5113819A04 MC3303
R180 0611072A46 RES,750 R216 0611077A76 RES,1.2K U104 5113816A07 MC78M05
6881098C21-P May 5, 2009

8464286H01 REV A
VR123
VR105
VR103
R141
VR104 VR100
R196
VR106
R145
J4
2
FRICTION LOCK
49 39 29 19 9 C608
J3 J11 C145
50 40 30 20 10 2
C502 2
R610
C607 14
VR127 3
R139
R138
R528 R524 U101
R176
R609
R182
C615
C165
R140
3 FRICTION LOCK
C175
VR122 VR121 VR126 E1
16 9 C503 3 2
7 8
R516 R193
3
R195
S101 E2
C511 C506 1 C507 R174 C604
8
J8 FRICTION L0CK C519 JU101
T1610 C176
R533 C103 J5
J6
R615
R503
R105
R502
3 7 C174
R540
C516 3 VR110
U115 3
C518
14 8 14
R530
Q113 4
TP3 FRICTION L0CK
C521
R538
D
C512
U111 R501 R505 6 5 4 3 G
C162 S FRICTION L0CK
D1007 C501 4 Q115 R525
Q110 T100 R187
C524
R536 R526
D1008
C550
7 8
C536
R512 R539 R560 1
C526 C504
C517
R194 C603 C505

C558
C171
C523
C520
R604 3 R529 C543 R522 R523
R543
R534 4
C522
6 5
R579
2 VR101
R504
C163 R562 2
R541 R197 R544 D1005 D1013 D1012 VR131
3 R545 C601 VR501
R179
C527
R542 R561
C548
R507
C170
R601
2 14 R518
C513
C602
D1017 14 C508
R547
C514
8 C542 R135
R531
R517 R519
U110 U112 R557 VR502
R514
VR130
4
R520 R511 R509
C105
R535 7 1 C104
R537
C168
R508
R106
R551
3
C530
TP2 C169
C510
C557 Q114 4 Q111
R554
C529 R563 R558 R532
R566
7 8 R510
Q116 14 9 10
C537 R555
D1018 VR129 2
C118
3
R116
C539
1 1 C531
R521
R515 R527 C515
C551
C509
R107
R125
U117
C538
R513 R564 R565 U100
R567
C146
6 VR128
SH2
3 C155 R606 7 8
R506
C107
C154 C109 5
C148
C156
TP4 8 39 29
R128
R127
C112
C606
C534 R553
R162 40 28 R607 C159

C546
R161 19 20
S100 R163
R171
R160
C532 C544 C540

R164 C141 C605 R103 C164 4
U131 U102 R181
TP1 9 16
HY1
C549 R159 5 8
R568 R165 1 C562 C114
C132
C533
8 J1
C142
C160 J2
R546 C528
R158 8 1
R137
R129
R148
U116
VR120 VR119
R550
HY2
C556
C135
16 9 9 16 R134
10 C319 6 18 29 30
R552
C126 C127 U114 60 44 7 17 R188 C161

61 43 16 9
R102
1 8 R572
C545
R155
R549
C320 U118 C113

12 3 R157 R571 1 8
R569 Q307 R189
C552
13 17 16
2 R548 C316 R112 Q102 R183
10 R321
1 1 C547 C555 VR125
C563 C166
R184
U126
R146
R111
C313
2 L300
R322 Q306
R114
U133 U123
C315 C561 Q117 39 40
R556 32 1 C564 R185
J13 R110 R115
11 20 R559 R120 C325
R575 R121
C167
L301
C525 33 34
R323
7 R109 7 C136
R118
1
R190
TP5 2
C541
8 C326 16 9 C301 U105 R101 R186
C309
U127 Y301 Q118
8
C151
18 18 14
1 8 4
C128 3
R172
C311 9 27 C312
10 26 R117 R104 R573 C B A P102
2 R108 C172
R191
SH1 C314 39 29 R576 R574
C152
C134 C137 49 50
VR108 VR107 40 28 P101
C125
R123 JU100 R124 VR112
14 8 C B A
C143
C535
C308
C324
R570
U129
C173
R122 R175
C327
R192
7
R154
C149 C122 1 20
C305
U125 SH3 4 3
C157
Q101
C566
C124 L101 R577 C131
C310
C119 R173 5
C651 C130 C129
C133
C565
U124 3 7 9
C158
R119
R169
2 1 6
R578
7 VR113
14 8 8 10
R113
Y101 2 4
6 18 U106 J14
C120
U132 U130 7 17
C123 C328 7 3 4 8 14
C110
C138
C302
C554
C323 10 11 1 2 VR114
VR115
C139
C111
C153
R168
R156
R170
C560
C303
C140
C121 C322 C101 10
C102 R180
C150
R301 16 9
14 8 14 8 C100 U107
U121 U122 U113
R166
C307 C108
7 7 1 8
11 20
R167
C553
C304
C559
D103 C106
Figure 7-10. PLN1687A Tone Remote Control Board Component Location Diagram (Viewed from Side 1)
May 5, 2009 6881098C21-P

A+ SWB+
+5V SWB+ A+
A+ J11-1
A+ +9.6V +6.5V +5.8V VB +3.6V +2.2V
A+ J2-11 J3-9 A+
S101-1
IGN J1-30 J3-34 A+
1 16 VR100 U100
IGN J2-15 J6-4 A+ R116 R125 R127
20V 5 1 5 4
IN OUT R129 R134
4 2 7
SWB+ J1-43 J3-35 SWB+ SHDN SENSE 10K 2.2K 3.3K U102-2
6
SWB+ J1-18 8.2K 10K
3 GND1
6 GND2
C112 LM2904
R106 C104 C105 C107 C109 R128 8
SWB+ J2-12 J3-16 +5V .01uF
68K 4.7uF .01uF .01uF .01uF 15K +9.6V C114 R137
SWB+ J2-14 .01uF
LT1129CQ 15K
E1 45L04
1 3
MT3
MT1 MT2
2
R107 C146 C118
A+ 43K R135 470pF 0.1uF
180 +5V_CONT
LINE1- J3-6 LINE1- R182
LINE1+ J3-1 LINE1+ J8-1
51
E2 45L04 +5V
J8-3
1 3
MT3
MT1 MT2
C162 C163 VR101
J8-2 5.1V C161
2
100uF 100uF
R187
4.7uF
10K
LINE2- J3-21 LINE2-

LINE2+ J3-5 LINE2+
DET_AUD J3-7 1
FILT AUD J1-36 FILT_AUD
SPKR LO J1-22 2
SPKR HI J1-24 3
PTT* J1-1
PTT* J1-26 4
+5V
R179
10K
MONITOR* J1-4
S101-6
6 11
HUB J2-28
AUX RX AUD J1-13 6

AUX TX AUD J1-15 7
DET AUD J1-17 8
V03 J2-17 9
VI3 J2-18 10
VI1 J2-20 11
V01 J2-21 12
V02 J2-22 13
RESET J2-16 14
BUSY J2-13 15
BUS+ J2-9 16
BUS- J2-10 17
VB +9.6V
BUS- J1-27
VB
BUS+ J1-34 RESET BUSY BUS+ BUS- R607 R606
3 C174
BUSY J1-45 11
1 1uF
RESET J1-37 U110-1 560 1K
2 CONTROL HEAD
MICROPHONE BIAS
+9.6V 4 C602 MC3303 C606
C175
100pF R604 10uF
DET AUD J1-42 DET_AUD 220pF
11 680
AUX TX AUD J1-40 R601
10 C603
AUX RX AUD J1-38 AUX_RX_AUD U101-3 R194
R195 8
R615 100K 18
62K 1 4 9
EMER J1-50 J3-50 EMER 10K
R193 0.22uF C605
1.8K C604 C601
2 200K +9.6V
TX_AUDIO MIC_AUDIO 19
C133 3
MIC HI/MOD CTRL J1-23 C172 R191 100pF 20
4.7uF TAPE_OUT C176 .015uF
JU101 J3-46 21
.1uF
330K C103
R101 1uF 1uF
0 C607
10K R609 R610
C136 R172 470pF
A VR110 100K +9.6V
MIC LO J1-46 P101-1 R173 18K .1uF
R105 5.6V
MIC LO J2-26 100K
10K 1uF VB 2 4 C608
100K R174
B +9.6V 15K 1
P101-2 U101-1
3
DIG GND J1-35 11 .1uF
3 6 4
BUS SHLD J1-41 C173 R192
C 7
DIG GND J1-10 S101-3 P101-3 U106-2 MC3303 VU AUDIO BUFFER
5
DIG GND J2-5 1uF 100K
14 VB 11
DIG GND J2-8
FLT AUD SHD J1-28 C131 R175
ANA GND J1-44 MOB_RX
ANA GND J1-19 1uF 47K
MAEPF-28188-O
Figure 7-11. PLN1687A Tone Remote Control Board Schematic Diagram (Sheet 1 of 6)
6881098C21-P May 5, 2009

R190
10
+5V
+5V R186
47K
R183
Q117 A +9.6V
P102-1 9
U116-3
10K
Q118
+9.6V +9.6V
C166 R185
B
470pF P102-2 J3-24 SPKR_UNMUTE
5 13 4 13 4
10K
R189 14 C615 C145 14
U101-4 U106-4
4.7K R184 C167 C 12 0.1uF 470pF 12
470pF P102-3 11
47K C165 3 4 11
VR127 470pF
5.6V MC3303
MC14053B
R188
RX_MUTE_1 Q102 SWB+
10K R146 SCHEMATIC NOTES:
J5-1 PWR LED A 1. UNLESS OTHERWISE SPECIFIED, ALL
820 RESISTOR VALUES ARE IN OHMS AND ALL
C113 +9.6V CAPACITOR VALUES ARE IN MICROFARADS.
470pF J5-3 PWR LED A
+9.6V 2. AN ASTERISK (*) FOLLOWING A SIGNAL NAME
J5-2 PWR LED K INDICATES AN ACTIVE LOW SIGNAL.
4 3 6 4
2 7
1 U117-1 U101-2
5 5
J3-4 SPKR LO
12 11
2 J4-2 SPKR LO
3 J3-2 SPKR HI LM2901 MC3303
R145 J4-1 SPKR HI
4 J3-19 PTT*
10 R176
5 J3-22 MONITOR*
10 U118-2
4
5 4
SET
6 2
MC14504 Q* D
VR123
5.6V VR126 7 U118-3 6 U129-1
VR121 5.6V
VR122 5 Q 3
RESET
5.6V MC14504 CLK
5.6V
9 U118-4 10
1
MC14504 MC74HC74A
11 U118-5 12 UNUSED CONNECTOR PINS
6 J3-30 AUX RX AUD
R196 0
7 J3-33 AUX TX AUD MC14504 J1-2 J2-1 J3-15
DNP
8 J3-32 DET AUD J1-6 J2-2 J3-26
J1-8 J2-3 J3-27
5 6 J1-11 J2-4 J3-29
9 J3-10 V03 J1-12 J2-6 J3-41
10 J3-18 VI3 U122-3 J1-14 J2-7
MC74HC14A J1-16 J2-19 J6-2
+5V
11 J3-25 VI1 J1-20 J2-23
13 12
12 J3-17 V01 J1-21 J2-24 J13-1
13 J3-20 V02 U122-6 J1-25 J2-25 J13-2
R141 22 R113
14 J3-39 RESET MC74HC14A J1-29 J2-29 J13-3
R140 22 10K
15 J3-36 BUSY J1-31 J2-31 J13-5
R139 22
16 J3-38 BUS+ J1-32 J2-32 J13-7
R138 22 12
17 J3-37 BUS- J1-33 J2-33
13
J3-12 BUS- U130-4 U121-1 J1-39 J2-34 J14-6
11 MC74HC00A
J3-13 BUS+ J1-47 J14-7
1
J3-11 BUSY J1-48 J14-9
9 3
VR103 VR104 VR105 VR106 J3-14 RESET J1-49
10 2
5.6V 5.6V 5.6V 5.6V J3- 8 AUX_TX_AUD U130-3
8
J2-30 CH MIC/MOD CTRL
4
J6-1 VU AUD
6
UNUSED PARTS
5
R197 J6-3 ANA GND LEGEND
18 J3-3 AUD SHLD U121-2
VR125
0 15V J3-28 ANA GND MC74HC00A JUMPER IN
19
JUMPER OUT
20
21 J3-31 PS_AUD_OUT
J3-23 DIG GND

RS232_RXD J1-3 J3-42 RS232_RXD J3-40 BUS SHLD
RS232_TXD J1-5 J3-43 RS232_TXD J3-44 VSENSE1 SHLD DIGITAL GROUND
RS232_RTS J1-7 J3-45 RS232_RTS J3-47 VSENSE2 SHLD
RS232_CTS J1-9 J3-49 RS232_CTS J3-48 DIG GND
ANALOG GROUND
VR128 VR129 VR130 VR131
C168 C169 C170 C171 CHASSIS GROUND

J11-2 CHASSIS GND
470pF 470pF 470pF 470pF
15V 15V 15V 15V

MAEPF-28189-O
May 5, 2009 6881098C21-P

1
2
+5V_CONT
3
C142 A+
4
C141 5
470pF C111 R181 TRUNKING_TONES
APOS 39
6
POS5_REG 3
470pF
POS5V
C132 R168 R169 10K R171
10 .039uF +9.6V 100K +5V +5V
C148 11 R180
8
0.1uF 10K 4.32K U106-3
43 2 9 2 8 C159
WDT_T_CAP WDT_TICKLE 0.1uF 1MEG
25 42 C150 C110 4 +9.6V 1
VIP OSC_OUT U102-1 R154 R155
22 41 470pF .01uF VB 3 10K 10K
VIP* EXT_OSC_IN 4
35 24 4.7uF
VIP1 VIP_IN_1
R170 15K
9 11 LM2904
RESET RESET BUSY_IN
10 4
BUSY BUSY RESET1
16 29 +5V
BUS- BUS_NEG IGN*
17 21 C307
BUS+ BUS_POSR VIP_IN_2 6
7 36
RESET_FILT VIP_IN_3
44 30 R301
WDT_IN_T_CAP HUB_INV 7
28 38 470pF 6.8K
IGN PTT
32 20 D103
HUB_POL RX_DATA
ADDRESS(15:0)
14 13 51 7
NC BUSY_OUT PF7
8 19 52 6
NC1 TX_DATA PF6
40 U131 37 +5V_CONT 53 5
NC2 SC74487F PTT1 PF5
27 31 C304 54 4
NC3 RES_HUB PF4
26 12 .01uF 55 3
NC4 NC7 PF3
33 18 35 56 2
NC5 NC8 WL_MUTE PA7 PF2 8
GND1
GND2
15 23 36 57 1
GND
NC6 NC9 RX_MUTE PA6 PF1
37 58 0
DATA(7:0)
PA5 PF0
9 0
34
1
5
38 U123-1
PA4 PC0
39 10 1
PA3 PC1
C135 40 11 2
PA2 PC2
470pF 41 12 3
DECODE_TONES PA1 PC3
42 13 4
PA0 PC4
17 14 5
RESET* PC5
18 15 6
XIRQ* PC6
19 16 7
IRQ* PC7
28 50 8
PD0 PB0
29 49 9
PD1 PB1
30 48 10
MOSI-MISO PD2 PB2 9
31 47 11
PD3 PB3
C138 +5V 32 46 12
VR113 SCK PD4 PB4
5.6V 470pF C151 C152 S100-1 33 45 13
RADIO_SEL PD5 PB5
470pF 470pF 1 16 59 44 14
PE0 PB6
2 15 61 43 15
PE1 PB7
3 14 63
PE2
4 13 65 4
PE3 E
VR112 5 12 60 5
PE4 RW
5.6V VR114 6 11 62 6 +5V
PE5 EXTAL JU100 R123
5.6V 7 10 64 7 C143 470pF
PE6 XTAL
8 9 66 2 +5V
PE7 MODB 0 10K
23 3
47K
47K
47K
47K
PG4/CSIO2* MODA Y101
20 67 Q101 74W03
PG7/CSPROG* VRL R124
22 68 1 2 47K R117
PG5/CSIO1* VRH IN1 OUT1
C137 4 3 10K
IN2 OUT2
470pF
R158
R160
R162
R164
C139
470pF L101 7.9488MHz
R120 10
+5V 4.7K 22uH
47K
47K
47K
47K
R122
1MEG
R159
R161
R163
R165
C129 C130
15pF 15pF
SRIB BUSY
J14-3
SRIB RX
J14-2 11
12
SRIB TX
J14-10
13
SRIB MOD CTRL
J14-8
R156
Q307 +5V
J14-5
C140 +5V
VR115 47K 14
15V 470pF
J14-1 C326 C311 15
10
16
R157 C319 +5V
220pF 470pF 0.1uF
VCC
SET
82K 2 8
CLK Q* D 12
SWB+ 7
EN_P
10 15 U129-2
EN_T RCO
1 9 11
RESET
J14-4 RESET Q CLK
9
LOAD
14
Q0 FILTER_CLOCK
U132 3 13 MC74HC74A
13
SWB+ +5V P0 U127 Q1 +5V
4 12
RESET* 5 P1 Q2 R322
1 5 11
VIN VOUT 2 P2 Q3 Q306
SH2
GND
3 6 SH3
GND DELAY 4 P3 15K SHIELD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
C119 HS 1 6 7 HS 2 C122 C123 R323
8
MC74HC163A R321
1uF 47uF 47uF
1
2
3
4
C120 C121 2.7K 4.7K
470pF 4700pF
MAEPF-28190-O
6881098C21-P May 5, 2009

1 +5V
2
3
+5V
4
C301 C312 C125
5
5.1pF 5.1pF
Y301 +5V C124 C134 C149

74W04 10uF 10uF 0.1uF 470pF
C308 J13 8 GND
1 2
IN1 OUT1
4 3
IN2 OUT2 0.1uF
VDD 17
19
3.6864MHz C310 +5V C128 C127 J13 4 ACIM TXD
VCC
J13 6 ACIM RXD
+5V 20 1
470pF 10uF C1_POS C2_POS 10uF
18 3
C1_NEG C2_NEG
VR107
R118 C325 C309 16 5 15V VR119
DO1 RX1
10K 470pF 0.1uF 15 6 15V
6 DI1 TX1
U133-1 7
8
14
DO2 RX2
VCC
13 8
7 DI2 TX2
12 9
DO3 RX3
30 11 10 VR108
EN_CE DI3 TX3
37
22
34
NC2 12
23
44
35
33
15V
GND
32
4 VSS
1
8
5
EN_OE VR120
GND
VCC
RXDA
NC1
NC3
TXDA
36 15V
IP0
NC
X2
IN
7
X1CLK EN_WE E
2
U126
3 0 20 21 C126
IP3 A0 IO0
40 43 1 19 22 0
IP2 IP4 A1 IO1
31 42 2 18 23 1
8 OP2 IP5 A2 IO2 10uF
24 41 3 17 25 2
IRQ* IP6 A3 IO3
0 28 14 4 16 26 3
D0 OP1 A4 IO4
1 18 U125 15 5 15 27 4
D1 SN_PTT A5 IO5
2 27 30 6 14 28 5 +5V
D2 OP4 A6 IO6
3 19 16 7 13 29 6 +9.6V +9.6V A+ +5V +5V +5V
D3 OP5 A7 IO7
4 26 29 8 3 7
D4 OP6 A8
5 20 9 2
D5 A9
6 25 10 31 C153 C154 C155 C156 C157 C158
RESET
D6 A10
CSI01
RXDB
TXDB
C324 C305
20
7 21 11 1 470pF 470pF 470pF 470pF 470pF 470pF
WE*
OP7
OP0
RS1
RS2
RS3
RS4
OE*
D7 A11 470pF 0.1uF
VCC
12 12
A12
39
10
38
17
13
32
11
2
4
6
7
9
13 4 11
11 A13 EN_LE
14 5 1
0 1 2 3 A14 6 EN_OE
15 11
9 A15 NC1
U122-5 10 9 2 19
GND
A16 NC2 D0 Q0 LPTT
0 3 U124 18
D1 Q1
10
24
AT29C010A 1 4 17
D2 Q2 GT_FT*
2 5 16
D3 Q3 AGC_RESET*
3 6 15
D4 Q4
4 7 14
D5 Q5 AGC_INHIBIT*
5 8 13
D6 Q6
6 9 12
GND
D7 Q7 TONE_DETECT
7
MOSI-MISO
10
MC74HCT573A
+5V
+5V
R166
10K
R167
1
10K U107 C102
20 X9241M 10uF
10 VSUP VCC
U130-1 3
11 SCK VH0_RH0
U122-2 2
MC74HC00A VL0_RL0
3 4 9 2MC74HC02A 3 2 1
VW0_RW0
8 5 U122-1 C108 C106
U121-3 U121-4
10 4 1 2 1000pF 100pF 8
U130-2 VH1_RH1
6 14 7
SCL VL1_RL1
13 12 +5V 9 6
SDA VW1_RW1
8
11
4 4 11
12 A0 VH2_RH2
U122- C100 C101 16 12
A1 VL2_RL2 EEPOT_IN
R119 100pF 1000pF 5 13
13 A2 VW2_RW2
10K 9 15
A3
17
VH3_RH3
18
VL3_RL3
19
14 VW3_RW3 EEPOT_OUT
15
10
VSS
MAEPF-28191-O
+5V +5V
+5V +5V +5V
L300
6.8uH 14 14
34 14 14 VCC C327 VCC C328 C651
C314
SH1 C313 C315 POWER C320 C316 VCC C322 C302 VCC C323 C303 U129-3 470pF 0.1uF U130-5 470pF 0.1uF
SHIELD 1000pF 47pF U123-2 470pF 0.1uF U121-5 470pF 0.1uF U122-7 470pF 0.1uF GND GND
1 GND GND 7 7
L301
7 7
1
2
3
4
6.8uH
May 5, 2009 6881098C21-P

Q110
R505 D
1.0MEG S R512
U113-1
3 2 12K
AGC_INHIBIT*
MC14504
5
4 3
6 U115- 2 1
C538
9 8 +9.6V
U115-3
+9.6V
0.1uF
+9.6V
HEF4066 +5.8V C551 R510
3.9K
10 3 C512
470pF R522 D1017
13
12 U117-4
11
82K .056uF
12 D1012 C520 R539
11 10 +9.6V
U115-4 LM2901 2
0.22uF 12K
R526
+9.6V R509 100K
3.9K D1018
+3.6V 8 3 R529
U113-2
5 4 R503 14 200K
TONE_DETECT U117-3
10K 9 Q113
MC14504
12 D1013
R518 5459
LM2901
13 100
+9.6V
D1005 R525
+6.5V VB +9.6V Q111 100K
R501
2 1
U115-1 R506
6 3
1.2K R511
D1008 1 +9.6V C548 C529
330K U117-2 R523
C503 7 470pF 0.1uF
HEF4066 820 R514
47uF 12
1K
VB
LM2901 5.6K
U113-4 3 11
R502 R535 R537
9 10 1
AGC_RESET* S101-8 R516 C511 U112-1
9 8 2 270
MC14504 1.0MEG 10K
D1007 4
47K 0.1uF
C506 +9.6V
4.7uF 7 C514
39pF
S101-7
10
R508 C515
R515 R527 R534 R536
C558
R507 20K 12K 3.3K 47K 47K
0.22uF
200K C509 R532 +9.6V 470pF 3

VB 6.8pF 75
1% C526
11 5
7 0.1uF
+9.6V U110-2 C513
R513 R517 R521 4
C501 C505 6 Q114 6
T1610 R504 13 4 +2.2V
3 4 4 7
LINE2+ 20K 100K 200K 0.1uF U111-2
14 +9.6V 1% 1% 5
4.7uF 0.1uF 200K U110-4
5 C504 12 VB MJD340 11 TP3
R579 1% 11
.022uF 680 VB R531 C517
1 6 +9.6V 4.7K 39pF 1
LINE2- MC3303
C557 C525 R519
470pF 0.1uF 100K
4 9 1%
8 C510
U110-3 R520
10
11 C516
200K R530
0.1uF 75 39pF
1% 5 4
S101-5 S101-4 VR502
56V +2.2V
T100
1 6 A+ 12 13
LINE1-
C507 C508 +9.6V
5 .022uF R538
C502 Q115 4 2 470K
100uF
3 4 R524 R528 VR501 1 C518
LINE1+ U111-1
1.8K 1.2K 56V 3
4.7uF 11
MJD340
0.1uF
R533
4.7K
MAEPF-28192-O
6881098C21-P May 5, 2009

+9.6V
+5V
+5V
U113-5 A+ +9.6V
11 12
GT_FT*
MC14504
1 6
C553 C559 16 1 6
POWER
U113-3 470pF 0.1uF C554 C560 POWER C552 C545 C555 C561 POWER
U113-7 470pF 0.1uF 470pF 0.1uF C556 C562
7 6 U116-4 470pF 0.1uF
LPTT U118-7 470pF 0.1uF
8 3 6 7 8
MC14504
8 3
U114-3 9 U114-1 10
VB +9.6V
R548
5 2
1
C523 180K C543
11
13
R550 R552 TRC DECODER FILTER & LIMITER
VCC
3 1 15
VBIAS
4 10 2 +5V
100pF INV_A BP_B 270pF
47K 27K
R542 MC14053B HY1 MC14053B R562 +9.6V
C533 C539 C540 R567
1000pF 3 12 100pF .018uF 10K
270K BP_A GNDX 33K TP2
INV_B
GND
CLK
TP1 +9.6V 1 14
DECODE_TONES
18
17
+9.6V
1
+9.6V VDD
R560
1 9 4
R554 C550 C536
13 4 8 6 4 U115-5
2 12K U112-3 R565 470pF 0.1uF
14 10 7 PWR_GND
U112-4 470K U112-2 Q116
12 11 5 10K
11 11 VSS
R557 R561 MC3303
VB R566 7
MC3303 +9.6V MC3303
C534 4.7K
5.6K 180K
VB +9.6V C542
R563 R564
R544 R558
270pF
13
15
C522 10K 3.9K
3.3K 180K RX_MUTE_1
1uF VBIAS VCC1 22uF
+9.6V TP4
R553 R570 EEPOT_IN
6 C566 U118-1
R546 R549 N_A
12 1 C546 3 2
INV_A HY2-2 27K 0 RX_MUTE
5
12K 12K B_N_A 0.1uF MC14504
0.1uF C547 C565
C528 CLK GND2 +9.6V U118-6 R102
1000pF 10
17
16
14 15 U116-1 100K
R573 0.1uF 470pF RADIO_SEL
R569
EEPOT_OUT MC14504
50K
100K 11
+9.6V U116-2 2
FILTER_CLOCK R576 R577

4 13 2 4
R574 R578 R571 12 R103
14 1 1 15
U105-4 33K 43K U106-1 DET_AUD
12 3
100K 0 13K 100K
11 11 C160
VB VB C535 R572 13 14 C164 4.7uF
R575
0 4.7uF 6.2K 1uF
VB
AUX_RX_AUD
U113-6 R148
14 15 R104
WL_MUTE FILT_AUD MOB_RX
C521 VB 100K
MC14504 100K
330pF
11 10 VB +9.6V VB
R541 R543 TRUNKING_TONES
C519 11 12 8
U111-3 11 U114-2 C537 R108
14 9 VB
3 U111-4 84.5K 84.5K
13 4 C527
39pF 100K
0.1uF 4 C524 1000pF TP5
1
1000pF 12 VCC VB2 VB1
R545 +9.6V R551 R568 +9.6V
R555
+9.6V 200K 1MEG 470K 2 1
N_B R556
C531 C544 18 4 9
R547 C530 27K HY2-1 INV_B R559
14 13 3 8
B_N_B 12K U105-3
10
RX LEVEL CONTROL 20K 0.33uF 0.1uF 1uF 12K
GND1 GND 11
14
8
+9.6V C541 VB
1000pF
R540
4.7K
AUDIO SHAPING FILTER R115
R110
100K MIC_AUDIO
C563 C564
100K
10uF 470pF
+9.6V
R114 R112 R111

4 2 6 4
R121 R109
1 7 +9.6V
TX_AUDIO U105-1 100K 0 100K U105-2
3 5
100K 12K
11 11
VB VB 16
POWER C549 C532
U114-4 470pF 0.1uF
6 7 8
MAEPF-28193-O
May 5, 2009 6881098C21-P

Table 7-5. PLN1687A Tone Remote Control Board Electrical

Parts List Ref. Des. Part Number Description Ref. Des. Part Number Description Ref. Des. Part Number Description
Ref. Des. Part Number Description C128 2311049A19 CAP TANT CHIP 10 10 25 A/P C161 2311049A14 CAP TANT CHIP 4.7 1020 A/P C313 2113740A79 CAP CHIP REEL CL1 +/-30
1000
C129 2113740A33 CAP CHIP REEL CL1 +/-30 15 C162 2380090M25 CAP ALU 100UF 25V
– 2605255S01 HT SINK
C314 2113741B69 CAP CHIP CL2 X7R REEL
C130 2113740A33 CAP CHIP REEL CL1 +/-30 15 C163 2380090M25 CAP ALU 100UF 25V 100000
– 2605455Z04 SHLD 3 X 3.5 COVER
C131 2311049A08 CAP TANT CHIP 1 10 35 A/P C164 2311049A07 CAP TANT CHIP 1 10 16 A/P C315 2113740A46 CAP CHIP REEL CL1 +/-30 47
C100 2113740F51 CAP CHIP REEL CL1 +/-30 100
C132 2113741B69 CAP CHIP CL2 X7R REEL C165 2113741A13 CAP CHIP CL2 X7R REEL 470 C316 2113741B69 CAP CHIP CL2 X7R REEL
C101 2113741A21 CAP CHIP CL2 X7R REEL 1000
100000 100000
C102 2311049A19 CAP TANT CHIP 10 10 25 A/P
C133 2311049A08 CAP TANT CHIP 1 10 35 A/P C319 2113740A63 CAP CHIP REEL CL1 +/-30 220
C134 2113741B69 CAP CHIP CL2 X7R REEL C320 2113741A13 CAP CHIP CL2 X7R REEL 470
100000 C168 2113741A13 CAP CHIP CL2 X7R REEL 470
C104 2311049A14 CAP TANT CHIP 4.7 1020 A/P
C135 2113741A13 CAP CHIP CL2 X7R REEL 470 C169 2113741A13 CAP CHIP CL2 X7R REEL 470
C105 2113741A45 CAP CHIP CL2 X7R REEL
C136 2311049A08 CAP TANT CHIP 1 10 35 A/P C170 2113741A13 CAP CHIP CL2 X7R REEL 470
C106 2113740F51 CAP CHIP REEL CL1 +/-30 100 C324 2113741A13 CAP CHIP CL2 X7R REEL 470
C137 2113741A13 CAP CHIP CL2 X7R REEL 470 C171 2113741A13 CAP CHIP CL2 X7R REEL 470
C107 2113741A45 CAP CHIP CL2 X7R REEL C325 2113741A13 CAP CHIP CL2 X7R REEL 470
C138 2113741A13 CAP CHIP CL2 X7R REEL 470 C172 2311049A08 CAP TANT CHIP 1 10 35 A/P
10000
10000 C141 2113741A13 CAP CHIP CL2 X7R REEL 470 C175 2113740A63 CAP CHIP REEL CL1 +/-30 220
C501 2382174V01 CAP LYTIC 4.7UF 200V 20% N/
C110 2113741F49 CAP CHIP CL2 X7R REEL C142 2113741A13 CAP CHIP CL2 X7R REEL 470 C176 2113741B69 CAP CHIP CL2 X7R REEL
PLR
10000 100000
C143 2113741A13 CAP CHIP CL2 X7R REEL 470 C502 2382174V01 CAP LYTIC 4.7UF 200V 20% N/
C111 2113743K05 CER CHIP CAP 0.039UF C301 2113740A20 CAP CHIP REEL CL1 +/-30 5.1
PLR
C112 2113741A45 CAP CHIP CL2 X7R REEL C302 2113741B69 CAP CHIP CL2 X7R REEL
C503 2380090M07 CAP ALU 47 20 16.0V SURF
10000 C146 2113741A13 CAP CHIP CL2 X7R REEL 470 100000
MT
C113 2113741A13 CAP CHIP CL2 X7R REEL 470 C148 2113741B69 CAP CHIP CL2 X7R REEL C303 2113741B69 CAP CHIP CL2 X7R REEL
100000 100000
10000 C149 2113741A13 CAP CHIP CL2 X7R REEL 470 C304 2113741A45 CAP CHIP CL2 X7R REEL
10000
C118 2113741B69 CAP CHIP CL2 X7R REEL C150 2113741A13 CAP CHIP CL2 X7R REEL 470 100000
100000 C305 2113741B69 CAP CHIP CL2 X7R REEL
C151 2113741A13 CAP CHIP CL2 X7R REEL 470 C506 2380090M22 CAP ALU 4.7 20 50V SURF MT
100000
C152 2113741A13 CAP CHIP CL2 X7R REEL 470 C507 2380090M25 CAP ALU 100UF 25V
C153 2113741A13 CAP CHIP CL2 X7R REEL 470 C508 2113741A53 CAP CHIP CL2 X7R REEL
C121 2113741A37 CAP CHIP CL2 X7R REEL 4700 22000
100000
C122 2311049A23 CAP TANT CHIP 47 10 10 C509 2113740A24 CAP CHIP REEL CL1 +/-30 6.8
C123 2311049A23 CAP TANT CHIP 47 10 10
C157 2113741A13 CAP CHIP CL2 X7R REEL 470 C511 2113741B69 CAP CHIP CL2 X7R REEL
C125 2311049A19 CAP TANT CHIP 10 10 25 A/P 100000
C126 2311049A19 CAP TANT CHIP 10 10 25 A/P C512 2113741B63 CAP CHIP CL2 X7R REEL
C159 2311049A14 CAP TANT CHIP 4.7 1020 A/P C312 2113740A20 CAP CHIP REEL CL1 +/-30 5.1
56000
C160 2311049A14 CAP TANT CHIP 4.7 1020 A/P
6881098C21-P May 5, 2009

C513 2113741B69 CAP CHIP CL2 X7R REEL C538 2113741B69 CAP CHIP CL2 X7R REEL C565 2113741A13 CAP CHIP CL2 X7R REEL 470 J1 2882505T15 CONN HEADER 50 PIN
100000 100000
C566 2113741B69 CAP CHIP CL2 X7R REEL J11 2880004T02 HDR 0.156 FLK SNPB SR ST 2
C514 2113740A43 CAP CHIP REEL CL1 +/-30 39 C539 2113740A55 CAP CHIP REEL CL1 +/-30 100 100000 POS
C515 2311049A03 CAP TANT CHIP A/P 0.22 10 35 C540 2113741A51 CAP CHIP CL2 X7R REEL C601 2113740A55 CAP CHIP REEL CL1 +/-30 100 J13 0960113B01 JACK MOD. 8 PIN MT
18000
C516 2113740A43 CAP CHIP REEL CL1 +/-30 39 C602 2113740A55 CAP CHIP REEL CL1 +/-30 100 J14 2880068M01 HEADER MIC
C541 2113740A79 CAP CHIP REEL CL1 +/-30
C517 2113740A43 CAP CHIP REEL CL1 +/-30 39 1000 C603 2311049A03 CAP TANT CHIP A/P 0.22 10 35 J2 2882505T04 PLUG HEADER 34 CKT
C518 2113741B69 CAP CHIP CL2 X7R REEL C542 2311049A21 CAP TANT CHIP 22 10 20 A/P C604 2311049A14 CAP TANT CHIP 4.7 1020 A/P J3 2882505T15 CONN HEADER 50 PIN
100000
C543 2113740A65 CAP CHIP REEL CL1 +/-30 270 C605 2113741A49 CAP CHIP CL2 X7R REEL J4 2884324M07 PLUG HDR 2.54MM GLD ST
C519 2113741B69 CAP CHIP CL2 X7R REEL 15000 SR 2POS
100000 C544 2311049A07 CAP TANT CHIP 1 10 16 A/P
C606 2311049A19 CAP TANT CHIP 10 10 25 A/P J5 2884324M08 PLUG HDR 2.54MM GLD ST
C520 2311049A03 CAP TANT CHIP A/P 0.22 10 35 C545 2113741B69 CAP CHIP CL2 X7R REEL SR 3POS
C521 2113740A67 CAP CHIP REEL CL1 +/-30 330 100000 J6 2884324M09 PLUG HDR 2.54MM GLD ST
C546 2113741B69 CAP CHIP CL2 X7R REEL SR 4POS
C522 2113743G21 CER CHIP CAP 1.0 UF 100000 C608 2113741B69 CAP CHIP CL2 X7R REEL
100000 J8 2884324M08 PLUG HDR 2.54MM GLD ST
C523 2113740A55 CAP CHIP REEL CL1 +/-30 100 C547 2113741B69 CAP CHIP CL2 X7R REEL SR 3POS
C524 2113740A79 CAP CHIP REEL CL1 +/-30 100000 JU100 0662057B47 CHIP RES 0 OHMS +-.050
1000 C548 2113741A13 CAP CHIP CL2 X7R REEL 470 OHMS
C525 2113741B69 CAP CHIP CL2 X7R REEL C549 2113741A13 CAP CHIP CL2 X7R REEL 470 100000 JU101 0662057B47 CHIP RES 0 OHMS +-.050
100000 OHMS
C550 2113741A13 CAP CHIP CL2 X7R REEL 470 D1005 4813833C10 DIODE GEN PUR 70V
C526 2113741B69 CAP CHIP CL2 X7R REEL MMBD6050 L101 2480289M16 COIL IF 22UH 1611 CS 223
D1007 4813833C10 DIODE GEN PUR 70V L300 2411087B36 COIL CHIP 6.8 UH 5 A/I
C527 2113740A43 CAP CHIP REEL CL1 +/-30 39 C552 2113741A13 CAP CHIP CL2 X7R REEL 470 MMBD6050
L301 2411087B36 COIL CHIP 6.8 UH 5 A/I
C528 2113740A79 CAP CHIP REEL CL1 +/-30 C553 2113741A13 CAP CHIP CL2 X7R REEL 470 D1008 4813833C10 DIODE GEN PUR 70V
1000 MMBD6050 P101 2880001R03 CON PCB HDR 0.1 GLD SR ST
C554 2113741A13 CAP CHIP CL2 X7R REEL 470 3 POS
C529 2113741B69 CAP CHIP CL2 X7R REEL D1012 4813833C10 DIODE GEN PUR 70V
100000 C555 2113741A13 CAP CHIP CL2 X7R REEL 470 P102 2880001R03 CON PCB HDR 0.1 GLD SR ST
MMBD6050
3 POS
C530 2311049A04 CAP TANT CHIP A/P 0.33 10 35 C556 2113741A13 CAP CHIP CL2 X7R REEL 470
D1013 4813833C10 DIODE GEN PUR 70V
MMBD6050 Q101 4813824A10 TSTR NPN 40V 0.2A GEN
C531 2113741B69 CAP CHIP CL2 X7R REEL C557 2113741A13 CAP CHIP CL2 X7R REEL 470
PURP
100000 D1017 4813833C10 DIODE GEN PUR 70V
MMBD6050 Q102 4813824A10 TSTR NPN 40V 0.2A GEN
C532 2113741B69 CAP CHIP CL2 X7R REEL PURP
100000 D1018 4813833C10 DIODE GEN PUR 70V
100000
MMBD6050 Q110 4813823A08 XSTR P-CH FET SW
C533 2113740A79 CAP CHIP REEL CL1 +/-30 MMBFJ175LT1
1000 D103 4813825A05 DIODE 30V HOT CARRIER
100000
MMBD301L Q111 4813824A18 XSTR PNP 40V 0.6A SW B=100
C534 2113740A65 CAP CHIP REEL CL1 +/-30 270
E1 8083545L04 SPKGAP 3P-4L1 Q113 4885316E11 FET GENPUR N-CH _5459_ 6L
C535 2311049A14 CAP TANT CHIP 4.7 1020 A/P 100000
SOT
C562 2113741B69 CAP CHIP CL2 X7R REEL E2 8083545L04 SPKGAP 3P-4L1
C536 2113741B69 CAP CHIP CL2 X7R REEL Q114 4813822A07 TSTR NPN 300V 0.5A
100000 100000
HY1 TFN6061A HYBRID FLTR BANDPASS MJD340T4
C563 2311049A19 CAP TANT CHIP 10 10 25 A/P 2175
C537 2113740A79 CAP CHIP REEL CL1 +/-30 Q115 4813822A07 TSTR NPN 300V 0.5A
1000 HY2 TFN6056A HYBRID FLTR NOTCH 2175 MJD340T4
May 5, 2009 6881098C21-P

Q116 4813824A10 TSTR NPN 40V 0.2A GEN R124 0662057A89 CHIP RES 47K OHMS 5% R171 0662057A97 CHIP RES 100K OHMS 5% R502 0660079V49 RES CHIP 1.M OHM 5 1/8W
PURP 200PPM
R125 0660076A57 RES CHIP 2200 5 1/8 R172 0662057A97 CHIP RES 100K OHMS 5%
Q117 4813824A10 TSTR NPN 40V 0.2A GEN R503 0662057A73 CHIP RES 10K OHMS 5%
PURP R127 0660076A61 RES CHIP 3300 5 1/8 R173 0662057A97 CHIP RES 100K OHMS 5%
R504 0660079L33 RES CHIP 200. KOHM 11/8
Q118 4813824A10 TSTR NPN 40V 0.2A GEN R128 0660076A77 RES CHIP 15K 5 1/8 R174 0660076A77 RES CHIP 15K 5 1/8 200PPM
PURP
R129 0660076A71 RES CHIP 8200 5 1/8 R175 0662057A89 CHIP RES 47K OHMS 5% R505 0660079V49 RES CHIP 1.M OHM 5 1/8W
Q306 4813824A10 TSTR NPN 40V 0.2A GEN 200PPM
R134 0662057A73 CHIP RES 10K OHMS 5% R176 0660076A01 RES CHIP 10 5 1/8
PURP
R506 0660076B13 RES CHIP 330K 5 1/8
Q307 4813824A10 TSTR NPN 40V 0.2A GEN
PURP R507 0660079L33 RES CHIP 200. KOHM 11/8
R137 0660076A77 RES CHIP 15K 5 1/8 R180 0662057B22 CHIP RES 1.0 MEG OHMS 5%
200PPM
R101 0662057A73 CHIP RES 10K OHMS 5% R138 0660076A09 RES CHIP 22 5 1/8 R181 0662057A73 CHIP RES 10K OHMS 5%
R508 0660076A80 RES CHIP 20K 5 1/8
R102 0662057A97 CHIP RES 100K OHMS 5% R139 0660076A09 RES CHIP 22 5 1/8 R182 0680194M18 RES 51 OHMS 5% 1W
R509 0660076A63 RES CHIP 3900 5 1/8
R510 0660076A63 RES CHIP 3900 5 1/8
R511 0660076A47 RES CHIP 820 5 1/8
R512 0662057A75 CHIP RES 12K OHMS 5%
R106 0660076A93 RES CHIP 68K 5 1/8 R146 0611072A47 RES CHIP 820 5 1/4 R186 0662057A89 CHIP RES 47K OHMS 5%
R513 0660076A80 RES CHIP 20K 5 1/8
R107 0660076A88 RES CHIP 43K 5 1/8 R148 0662057A97 CHIP RES 100K OHMS 5% R187 0662057A73 CHIP RES 10K OHMS 5%
R514 0660076A67 RES CHIP 5600 5 1/8
R108 0662057A97 CHIP RES 100K OHMS 5% R154 0662057A73 CHIP RES 10K OHMS 5% R188 0662057A73 CHIP RES 10K OHMS 5%
R515 0662057A75 CHIP RES 12K OHMS 5%
R109 0662057A75 CHIP RES 12K OHMS 5% R155 0662057A73 CHIP RES 10K OHMS 5% R189 0662057A65 CHIP RES 4700 OHMS 5%
R516 0662057A89 CHIP RES 47K OHMS 5%
R110 0662057A97 CHIP RES 100K OHMS 5% R156 0662057A89 CHIP RES 47K OHMS 5% R190 0662057A01 CHIP RES 10 OHMS 5%
R517 0660078L01 RES CHIP 100 KOHM 1 1/8
R111 0662057A97 CHIP RES 100K OHMS 5% R157 0660076A95 RES CHIP 82K 5 1/8 R191 0662057B10 CHIP RES 330K OHMS 5% 100PPM
R112 0662057B47 CHIP RES 0 OHMS +-.050 R158 0662057A89 CHIP RES 47K OHMS 5% R192 0662057A97 CHIP RES 100K OHMS 5% R518 0660076A25 RES CHIP 100 5 1/8
OHMS
R159 0662057A89 CHIP RES 47K OHMS 5% R193 1813905A14 POT 200K 20% SURF MT TOP R519 0660078L01 RES CHIP 100 KOHM 1 1/8
R113 0662057A73 CHIP RES 10K OHMS 5% ADJ 100PPM
R160 0662057A89 CHIP RES 47K OHMS 5%
R114 0662057A97 CHIP RES 100K OHMS 5% R194 0662057A73 CHIP RES 10K OHMS 5% R520 0660079L33 RES CHIP 200. KOHM 11/8
R161 0662057A89 CHIP RES 47K OHMS 5% 200PPM
R115 0662057A97 CHIP RES 100K OHMS 5% R195 0662057A92 CHIP RES 62K OHMS 5%
R162 0662057A89 CHIP RES 47K OHMS 5% R521 0660079L33 RES CHIP 200. KOHM 11/8
R116 0662057A73 CHIP RES 10K OHMS 5% R196 0662057B47 CHIP RES 0 OHMS +-.050 200PPM
R163 0662057A89 CHIP RES 47K OHMS 5% OHMS
R117 0662057A73 CHIP RES 10K OHMS 5% R522 0660076A95 RES CHIP 82K 5 1/8
R164 0662057A89 CHIP RES 47K OHMS 5% R197 0662057B47 CHIP RES 0 OHMS +-.050
OHMS
R165 0662057A89 CHIP RES 47K OHMS 5%
R301 0662057E50 RES CHIP 6800 OHMS 5%
R166 0662057A73 CHIP RES 10K OHMS 5%
R321 0662057A65 CHIP RES 4700 OHMS 5%
R167 0662057A73 CHIP RES 10K OHMS 5%
R121 0662057A97 CHIP RES 100K OHMS 5% R526 0662057A97 CHIP RES 100K OHMS 5%
R322 0660076A77 RES CHIP 15K 5 1/8
R168 0660076E73 RES CHIP FILM 10K 1 1/8
R122 0660079V49 RES CHIP 1.M OHM 5 1/8W R527 0660076A61 RES CHIP 3300 5 1/8
R323 0660076A59 RES CHIP 2700 5 1/8
200PPM R169 0662057R46 RES CHIP 4320.1W 1%
R501 0660076A51 RES CHIP 1200 5 1/8 R528 0660076A51 RES CHIP 1200 5 1/8
R123 0662057A73 CHIP RES 10K OHMS 5% R170 0660076E77 RES CHIP FILM 15K 1 1/8
6881098C21-P May 5, 2009

R529 1813905A14 POT 200K 20% SURF MT TOP R560 0662057A75 CHIP RES 12K OHMS 5% SH1 2605425Z01 SHIELD U123 5113802A27 IC 68HC11 W.SCI SPI A/D
ADJ
R561 0660076B07 RES CHIP 180K 5 1/8 SH2 2605455Z03 SHLD 3 X 3.5 U124 5113805A91 IC LATCH-TRANSP.OCT 3-ST
R530 0611072A22 RES CHIP 75 5 1/4 N-INV
R562 0662057A85 CHIP RES 33K OHMS 5% SH3 2605887Z01 SHLD BD
R531 0660076A65 RES CHIP 4700 5 1/8 U125 5105625U57 DUART IC
R563 0660076A61 RES CHIP 3300 5 1/8 SKT1 0984728L01 SKT CONN
R532 0611072A22 RES CHIP 75 5 1/4 U126 5105625U79 IC 128KX8 FLASH ROM
R564 0660076B07 RES CHIP 180K 5 1/8 SKT2 0984728L01 SKT CONN
R533 0660076A65 RES CHIP 4700 5 1/8 U127 5113805A41 IC CTR BINP SYNC RST
R565 0662057A73 CHIP RES 10K OHMS 5% T100 2584422T01 XFMR LINE ISOLATION 74HC163D
R534 0662057A89 CHIP RES 47K OHMS 5% TELEPHONE
R566 0660076A65 RES CHIP 4700 5 1/8 U129 5113805A18 IC DUAL D FF W/SET RST
R535 0660076A35 RES CHIP 270 5 1/8 T1610 2584422T01 XFMR LINE ISOLATION 74HC74
R567 0662057A73 CHIP RES 10K OHMS 5% TELEPHONE
R536 0662057A89 CHIP RES 47K OHMS 5% U130 5113805A02 IC QUAD 2INP NOR
R568 0660076B17 RES CHIP 470K 5 1/8 U100 5105109Z13 IC MICRO PWR LOW DROPUT 74HC02AD
R537 0662057A73 CHIP RES 10K OHMS 5% REGLTR
R569 1885848F01 POT 50KOHM 20% SURF MT
U131 5180057S04 “IC CUST SER I/O 13”” REEL”
R538 0660076B17 RES CHIP 470K 5 1/8 TOP ADJ U101 5113819A04 IC QD OP AMP GEN PURP
MC3303D U132 5185130C06 IC 5V REG W/RESET CS-8126-
R539 0662057A75 CHIP RES 12K OHMS 5% R570 0662057B47 CHIP RES 0 OHMS +-.050
1T5
OHMS U102 5113818A01 IC LOW COST SING SPLY
R540 0660076A65 RES CHIP 4700 5 1/8
LM2904DR U133 5113811A11 IC RS-232-C DVR/RCVR SNGL
R571 0662057A76 CHIP RES 13K OHMS 5%
R541 0611077G81 RES CHIP 84.5K 1 1/8W SUP
U105 5113819A04 IC QD OP AMP GEN PURP
R572 0662057A68 CHIP RES 6200 OHMS 5%
R542 0660076B11 RES CHIP 270K 5 1/8 MC3303D VR100 4880140L25 DIODE SOT ZENER 20V
R573 0662057A97 CHIP RES 100K OHMS 5% TAPE&REEL
R543 0611077G81 RES CHIP 84.5K 1 1/8W U106 5113819A04 IC QD OP AMP GEN PURP
R574 0662057A97 CHIP RES 100K OHMS 5% MC3303D VR101 4880140L06 DIODE SOT ZENER 5.1V
R544 0662057A73 CHIP RES 10K OHMS 5% TAPE&REEL
R575 0662057B47 CHIP RES 0 OHMS +-.050 U107 5105109Z14 IC QUAD PROG POT
R545 1813905A14 POT 200K 20% SURF MT TOP OHMS VR103 4880140L07 DIODE SOT ZENER 5.6V
ADJ U110 5113819A04 IC QD OP AMP GEN PURP TAPE&REEL
R576 0662057A85 CHIP RES 33K OHMS 5% MC3303D
R546 0662057A75 CHIP RES 12K OHMS 5% VR104 4880140L07 DIODE SOT ZENER 5.6V
R577 0662057A88 CHIP RES 43K OHMS 5% U111 5113819A04 IC QD OP AMP GEN PURP TAPE&REEL
R547 0660076A80 RES CHIP 20K 5 1/8 MC3303D
R578 0662057B47 CHIP RES 0 OHMS +-.050 VR105 4880140L07 DIODE SOT ZENER 5.6V
R548 0660076B07 RES CHIP 180K 5 1/8 OHMS U112 5113819A04 IC QD OP AMP GEN PURP TAPE&REEL
MC3303D
R549 0662057A75 CHIP RES 12K OHMS 5% R579 0662057A45 CHIP RES 680 OHMS 5% VR106 4880140L07 DIODE SOT ZENER 5.6V
U113 5184704M90 IC CMOS 04M90 LEVEL TAPE&REEL
R550 0662057A89 CHIP RES 47K OHMS 5% R601 0662057A97 CHIP RES 100K OHMS 5% SHIFTER
R551 0660079V49 RES CHIP 1.M OHM 5 1/8W VR107 4880140L20 DIODE SOT ZENER 15V
R604 0660076A45 RES CHIP 680 5 1/8 U114 5184704M60 IC CMOS 04M60 ANALOG TAPE&REEL
200PPM
R606 0660076A49 RES CHIP 1000 5 1/8 U115 5185956E80 IC CMOS 04M52 QUAD SW VR108 4880140L20 DIODE SOT ZENER 15V
R552 0660076A83 RES CHIP 27K 5 1/8
R607 0660076A43 RES CHIP 560 5 1/8 TAPE&REEL
U116 5184704M60 IC CMOS 04M60 ANALOG
R553 0660076A83 RES CHIP 27K 5 1/8
R609 0660076A79 RES CHIP 18K 5 1/8 VR110 4880140L07 DIODE SOT ZENER 5.6V
U117 5113820A03 IC QUAD SING/DUAL SPLY
R554 0660076B17 RES CHIP 470K 5 1/8 TAPE&REEL
LM2901
R610 0662057A97 CHIP RES 100K OHMS 5%
R555 0660076A83 RES CHIP 27K 5 1/8 VR112 4880140L07 DIODE SOT ZENER 5.6V
U118 5184704M90 IC CMOS 04M90 LEVEL
R615 0660076A55 RES CHIP 1800 5 1/8 TAPE&REEL
R556 0662057A75 CHIP RES 12K OHMS 5% SHIFTER
S100 4083706T01 SWITCH DIP SURFACE VR113 4880140L07 DIODE SOT ZENER 5.6V
R557 0660076A67 RES CHIP 5600 5 1/8 U121 5113805A01 IC QUAD 2INP NAND
MOUNT TAPE&REEL
74HC00AD
R558 0660076A63 RES CHIP 3900 5 1/8 S101 4083706T01 SWITCH DIP SURFACE VR114 4880140L07 DIODE SOT ZENER 5.6V
U122 5113805A09 IC INV HEX SCHMITT TRIG
MOUNT TAPE&REEL
R559 0662057A75 CHIP RES 12K OHMS 5% HC14
May 5, 2009 6881098C21-P

VR115 4880140L20 DIODE SOT ZENER 15V

TAPE&REEL

TAPE&REEL

TAPE&REEL
VR121 4880140L07 DIODE SOT ZENER 5.6V

TAPE&REEL

TAPE&REEL

TAPE&REEL

TAPE&REEL

TAPE&REEL

TAPE&REEL
VR128 4813832C28 ZENER BPLR 15V FOR ESD

SOT23

SOT23

SOT23

SOT23
VR501 4813832A46 DIODE 56V TRANS SUP

P6SMB
VR502 4813832A46 DIODE 56V TRANS SUP

P6SMB
Y101 4805574W03 XTAL PRL RESONANCE

7.9488MHZ
Y301 4805574W04 XTAL SURFACE MOUNT
6881098C21-P May 5, 2009

8464286H02 REV B
VR123
FRICTION LOCK
R141
R196
VR106
VR103
VR105
R145
J4
2
VR104 VR100
49 39 29 19 9
C608
J11 C145
J3
C502
50 2 2
40 30 20 10
R610
C607
14
VR127
R140
R139
3
R138
C165
U101
R528 R524 R176
R182
R609
C615
FRICTION LOCK
C175
VR122 VR121 VR126
C503
E1
3
16 9 3 2
R193
8
7
S101 R516
R195
E2
C506
FRICTION L0CK
C511 C507 C604
FRICTION L0CK
FRICTION L0CK
R174
8
C174
T1610
C519 VR110 JU101
J8
C103 C176
J5
R533
J6
R615
R105
R503
3
R540 C521
R502
7
Q113
C516 U115
3
14
C518
3
8
R530
14
4
D
TP3
C512
R538
U111
R501 R505 3 G
C501
C162 S
Q115
D1007
T100
6
4
4
C550
C524
C536
D1008 C505 C504 R526 R525 R187
Q110
8
7
R536 R512 R539 R560 1
R522 R523
C520
C517
C558
C526
R534
VR501
R504
C171
R543
C543
R541
C603
C522
R604 3
R579
R529
R194 2 C523
4
C163 R562
R197 D1005 D1013
2
C601 R544 R542
R179
3 R561
R545
C170
R507
R518
R601
14
2 D1012 VR101
C513
C542
C508
D1017 R537
C602
C514
C527
R547
C548
14 8 VR131
R531
R519 R517
U112 R557
Q111
4
VR502 VR130
U110
R509
C105
R514
R520 7 1 R511 C104
TP2
C510
Q114
C168
R106 R107
R135
R551
C530
3
R508
C557 4 C169
R521
R535 R563 R558
R566
8
7
R510
14
R532
10
9
D1018 VR129
R555 C537
3
2
R116
R515
C531 C529
C551
C509
C538
U117
R513
U100
R564 R565 Q116 R125
C118
C539
R554
R567
C146
R527 C515
6
SH2 VR128
C107
R606
8
7
C209
R506
C154
R221
5
C109
C155
C156
C159
8
TP4
C606
R220
R553 C534 C528 R546 R549
R162 R607
R218
C546
R161
20
19
S100
R163 R216 C304
R127
R128
C112
Q205
R171
C532 R103 C164
HY1
C544 C208 C605 4

R160 R164 R181
U102 1
R159 9 16
R217 R214
C540 5 8
TP1
R165 Q204 C562 C114

C533
C160
R301
R158
R137
8
C549 R568 R129
Q203
U116
R148
C307
C207
HY2
VR120
R550
C556
16
C206
9
R134
16
R215
9
C127
D103
C319
U114
R213
30
R552
29
60
44
VR119 C126 R188
16
C161
43
R212
R102
8
C545
9
61
U118
R572
C320 C113
3
R157 R571
R569
R548
R189
C552
16
17
C316 R112 R183
2
1
R321 Q102 R146

2
10
U126
1 C547 Q307 C563 C555 C166 VR125
C313
L300 R111
U133
R184
U123
R322
R114
R556
32
C315 C561 Q117
40
R185
39
J13
C564
1
R110 R115
11 20 R559 Q306 R120
L301
C167
R121 R575
C325 C525
34
33
R109
R323
R118
2 1 7
TP5
C541
C136
R190
Y301
C326 16 9 C301 U105 R101 Q118 R186
C309
7
1 U127 8 14
C151
8
J2
8 3 4
27
C128
9
26
10
R104 R573
C
B
A
R117
C312 P102
C311
2
R172
R191
R108 R574 C172
SH1
39
29
C134 C314
C152
C137
28
49
50
VR108 R576
40
C125
VR112
P101
R198
8 R123 JU100 R124
C
B
A
14
C308
Q101
C324
C535
C143
J1
R570
C173
U129 R122 R175
C122
VR107 C327 7
R154
R192
1
C149 20
C157
SH3 4
L101
U125
C565
C566
C124 R577 C131
C310
5
R578 R199
C130 C129
C119
C133
R173
C305
C651
9
3
C158
U124
2 1
6
7 VR113
10
14 8
R113
8
2
4
Y101
18
U106
U132
R119
6
U130
R169 C111
C123
C120
R209
17
R210
C328 7 3 4 8 14
7
C110
C138
J14
C302
10
2
11
C B A
Q200 R205
R206
C139
C153
C554
C204 R168 R170

C560
C140
C303
R156
C200
P103
C323 C101 10 VR114
C102
C322 Q201
C150
Q202 VR115
16
C201
9
8
U113
14 14 8
R202
C121 C100 U107 R180
R203 R201
R211
U121 U122
R208
R204
R166
7 7
8
11 20
C553
C205
R167 C108 C203
R207
C559
C106 R200
Figure 7-17. PLN1687B Tone Remote Control Board Component Location Diagram (Viewed from Side 1)
May 5, 2009 6881098C21-P

A+ SWB+
+5V SWB+ A+
A+ J11-1
A+ +9.6V +6.5V +5.8V VB +3.6V +2.2V
A+ J2-11 J3-9 A+
IGN J1-30 S101-1 J3-34 A+ R116 R125 R127
1 16 VR100 U100
IGN J2-15 J6-4 A+ 10K 2.2K 3.3K R129 R134
20V 5 1 5 4
IN OUT 8.2K 10K
4 2 7
SWB+ J1-43 J3-35 SWB+ SHDN SENSE U102-2
6
SWB+ J1-18
GND1
GND2
R106 C104 C105 C107 C109 R128 C112 8
SWB+ J2-12 J3-16 +5V LM2904
68K 4.7uF .01uF .01uF .01uF 15K .01uF +9.6V C114 R137
SWB+ J2-14
.01uF 15K
3
6
LT1129CQ
E1
1 3
MT3
MT1 MT2
45L04
2
R107 C146 C118
A+ 43K 470pF 0.1uF
R182 R135
180 +5V_CONT
LINE1- J3-6 LINE1- 62
LINE1+ J3-1 LINE1+ J8-1
E2 +5V
J8-3
1 3
MT3
MT1 MT2 VR101
C162 C163 J8-2 5.1V C161
45L04 100uF 100uF
2
R187 4.7uF
10K
LINE2- J3-21 LINE2-

LINE2+ J3-5 LINE2+
DET_AUD J3-7 1
FILT AUD J1-36 FILT_AUD
SPKR LO J1-22 2
SPKR HI J1-24 3
PTT* J1-1
PTT* J1-26 4
+5V
R179
10K
MONITOR* J1-4
S101-6
6 11
HUB J2-28
AUX RX AUD J1-13 6

AUX TX AUD J1-15 7
DET AUD J1-17 8
V03 J2-17 9
VI3 J2-18 10
VI1 J2-20 11
V01 J2-21 12
V02 J2-22 13
RESET J2-16 14
BUSY J2-13 15
BUS+ J2-9 16
BUS- J2-10 17
VB
BUS- J1-27 A
VB
BUS+ J1-34 RESET BUSY BUS+ BUS- P103-1
11 3 C174
BUSY J1-45 R604
1 1uF 680
RESET J1-37 U110-1 B
2
P103-2
+9.6V 4 C602 MC3303
100pF C175 R199
DET AUD J1-42 DET_AUD R601 220pF C 10K
AUX TX AUD J1-40 100K 11 P103-3 AUX_TX_TRC
10
AUX RX AUD J1-38 AUX_RX_AUD U101-3
R195 8
18
C604 62K 1 4 9
EMER J1-50 J3-50 EMER R194
4.7uF R193 C603
R615 10K
1.8K 2 200K +9.6V 0.22uF
TX_AUDIO
3 MIC_AUDIO
J1-23 C601 19
TAPE_OUT C176
J3-46 100pF 20
R191 C103 .1uF
C172 470pF C133 R610
R101 JU101 330K
1uF 1uF 100K
10K 0
A
VR110 +9.6V
MIC LO J1-46 P101-1 R609
5.6V C607
MIC LO J2-26 R105 R172 18K C608
10K C136 .1uF VB
100K R173 R174 2 4 .1uF
1uF
B 100K +9.6V 15K 1
P101-2 U101-1
C173 3
DIG GND J1-35 R192
3 1uF 6 4 11
BUS SHLD J1-41 100K MC3303
C 7
DIG GND J1-10 S101-3 P101-3 U106-2 VU AUDIO BUFFER
5
DIG GND J2-5
14 VB 11
DIG GND J2-8 C131 R175
1uF
FLT AUD SHD J1-28 47K
ANA GND J1-44 MOB_RX
ANA GND J1-19
Figure 7-18. PLN1687B Tone Remote Control Board Schematic Diagram (Sheet 1 of 6)
6881098C21-P May 5, 2009

R190
10 +5V
+5V
R186
47K
R183
10K A
Q117 +9.6V
P102-1 9
U116-3
R185
+9.6V Q118
10K
C166 B
470pF P102-2 J3-24 SPKR_UNMUTE 5
13 4
C615 C145
14
R189 U101-4 0.1uF 470pF
4.7K R184 C167 VR127 12
P102-3 C165 3
47K 470pF 5.6V 4 11
C 470pF
MC3303
MC14053B
R188
10K
Q102 SWB+
RX_MUTE_1
SCHEMATIC NOTES:
J5-1 PWR LED A 1. UNLESS OTHERWISE SPECIFIED, ALL
R146 RESISTOR VALUES ARE IN OHMS AND ALL
C113 820 +9.6V CAPACITOR VALUES ARE IN MICROFARADS.
470pF J5-3 PWR LED A
+9.6V 2. AN ASTERISK (*) FOLLOWING A SIGNAL NAME
J5-2 PWR LED K INDICATES AN ACTIVE LOW SIGNAL.
4 3 6 4
2 7
1 U117-1 U101-2
5 5
J3-4 SPKR LO
12 11
2 J4-2 SPKR LO
3 J3-2 SPKR HI LM2901 MC3303
R145
10 J4-1 SPKR HI
4 J3-19 PTT*
R176
10
5 J3-22 MONITOR*
U118-2
4
5 4
VR126 6 2
SET
5.6V MC14504 Q* D
VR121 VR123
5.6V 5.6V 7 U118-3 6
U129-1
VR122 5 3
RESET
MC14504 Q CLK
5.6V
9 U118-4 10
1
MC14504 MC74HC74A
11 U118-5 12 UNUSED CONNECTOR PINS
6 J3-30 AUX RX AUD
R196 0
7 J3-33 AUX TX AUD MC14504 J1-2 J2-1 J3-15
DNP
8 J3-32 DET AUD J1-6 J2-2 J3-26
J1-8 J2-3 J3-27
J1-11 J2-4 J3-29
9 J3-10 V03 J1-12 J2-6 J3-41
10 J3-18 VI3 J1-14 J2-7
J1-16 J2-19 J6-2
+5V
11 J3-25 VI1 J1-20 J2-23
12 J3-17 V01 J1-21 J2-24 J13-1
13 J3-20 V02 J1-25 J2-25 J13-2
R141 22 R113
14 J3-39 RESET J1-29 J2-29 J13-3
R140 22 10K
15 J3-36 BUSY J1-31 J2-31 J13-5
R139 22
16 J3-38 BUS+ J1-32 J2-32 J13-7
R138 22 12
17 J3-37 BUS- J1-33 J2-33
+9.6V 13
R607 R606 J3-12 BUS- U130-4 U121-1 J1-39 J2-34 J14-6
560 1K 11 MC74HC00A
J3-13 BUS+ J1-47 J14-7
1
J3-11 BUSY J1-48 J14-9
9 3
CONTROL HEAD VR103 VR104 VR105 VR106 J3-14 RESET J1-49
5.6V 5.6V 5.6V 5.6V 10 2
MICROPHONE BIAS J3-8 AUX_TX_AUD U130-3
C606 8
J2-30 CH MIC/MOD CTRL
10uF 4
J6-1 VU AUD
6
UNUSED PARTS
5
J6-3 ANA GND LEGEND
18 J3-3 AUD SHLD U121-2
C605 R197 VR125 J3-28 ANA GND MC74HC00A
15V JUMPER IN
.015uF 0
MIC_AUDIO
JUMPER OUT
19
20 J3-31 PS_AUD_OUT
J3-23 DIG GND
RS232_RXD J1-3 J3-42 RS232_RXD J3-40 BUS SHLD
RS232_TXD J1-5 J3-43 RS232_TXD J3-44 VSENSE1 SHLD DIGITAL GROUND
RS232_RTS J1-7 J3-45 RS232_RTS J3-47 VSENSE2 SHLD
RS232_CTS J1-9 J3-49 RS232_CTS J3-48 DIG GND
ANALOG GROUND
C168 C170 C171 CHASSIS GROUND

C169
470pF 470pF J11-2 CHASSIS GND
470pF 470pF
VR128 VR129 VR130 VR131

15V 15V 15V 15V
May 5, 2009 6881098C21-P

1
+5V +5V
R200 R212
C200
100 4.7K BUSY_IN
39pF
R202 U122-3 2
11 4.7K MC74HC14A R205
12 R213
U106-4 5 6 68K
R201 4.7K
14 Q203
100 R204
13 4 +5V
R203 10K
+5V +9.6V 4.7K Q200 C206 R214 C207
R206 470pF 2.2K 470pF
4.7K
C201 R215
470pF 100 C208 R216
470pF 100K
BUSY_OUT
U122-6 Q204 3
MC74HC14A
R217
Q201 12 13 6.2K
+5V
R207
6.2K RX_DATA
4
C203 TX_DATA
5
470pF
C204 R209
470pF 100K
R208 6
100 +5V
C205 51 7
Q202 470pF PF7
52 6
R210 PF6
53 5
4.7K R198
ADDRESS(15:0)
PF5 7
C111 10K 54 4
PF4
R211 .039uF 55 3
R181 PF3
4.7K 35 56 2
TRUNKING_TONES 10K WL_MUTE PA7 PF2
36 U123-1 57 1
R169 R168 RX_MUTE PA6 PF1
37 58 0
R180 4.32K 10K PA5 PF0
R171 +9.6V 11 10 38 9 0
1MEG PA4 PC0 8
100K 8 39 10 1
U106-3 PA3 PC1
8 2 9 40 11 2
PA2 PC2
1 +9.6V 4 C110 C150 41 12 3
U102-1 .01uF DECODE_TONES PA1 PC3
470pF 4
DATA(7:0)
3 VB 42 13
C159 4 PA0 PC4
R170 17 14 5
4.7uF 15K RESET* PC5
18 15 6
LM2904 XIRQ* PC6
19 16 7
IRQ* PC7
28 50 8
+5V PD0 PB0
C307 +5V 29 49 9
BUSY PD1 PB1
470pF 30 48 10
BUS+ MOSI-MISO PD2 PB2
31 47 11
BUS- PD3 PB3
R218 R301 +5V 32 46 12
RESET SCK PD4 PB4
10K 6.8K S100-1 33 45 13
RADIO_SEL PD5 PB5 9
D103 1 16 59 44 14
PE0 PB6
2 15 61 43 15
PE1 PB7
3 14 63
R220 PE2
20K 4 13 65 4
PE3 E
Q205 C304 5 12 60 MC68HC11F1 5
.01uF PE4 RW JU100 R123
6 11 62 6 +5V
PE5 EXTAL 0 10K
VR112 7 10 64 7
5.6V PE6 XTAL
R221 C209 8 9 66 2
10K 470pF PE7 MODB
C137 23 3 C143 Q101 Y101 +5V
47K
47K
47K
47K
PG4/CSIO2* MODA 470pF 74W03
470pF 20 67 R124
PG7/CSPROG* VRL
22 68 1 2 47K
PG5/CSIO1* VRH IN1 OUT1
4 3 R117
IN2 OUT2
10K
R158
R160
R162
R164
R120 7.9488MHz
+5V 4.7K L101
47K
47K
47K
47K
10
22uH
VR113 C138 C151 C152

470pF 470pF 470pF R122
5.6V
1MEG
C129 C130
R161
R159
R165
R163
15pF 15pF
SRIB BUSY
J14-3
VR114
5.6V 11
SRIB RX C139
J14-2 470pF 12
SRIB TX
J14-10 13
SRIB MOD CTRL +5V

J14-8 R156
+5V
47K
Q307
16
J14-5 C326 C311
10
C140 +5V
VR115 470pF 470pF 0.1uF 14
VCC
8 12
SET
15V 2
J14-1 CLK Q* D 15
R157 C319 7
220pF EN_P
82K 10 15 U129-2
EN_T RCO
SWB+ 1 9 11
RESET
RESET Q CLK
9
LOAD
14
J14-4 Q0 FILTER_CLOCK
SWB+ U132 +5V 3 U127 13 +5V MC74HC74A
13
P0 Q1
5 4 12
RESET* P1 Q2
1 2 5 11 SH2
VIN VOUT P2 Q3 Q306
3 4 SH3
GND
6
GND DELAY P3 R322 SHIELD
15K
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
8
C119 HS1 6 7 HS2 C122 C123 R323 R321

MC74HC163A
47uF 47uF 2.7K 4.7K
1
1uF C121
2
3
4
C120
470pF 4700pF
6881098C21-P May 5, 2009

+5V
1 +5V
C125
10uF
2
C124 C134 C149 J13 8 GND

10uF 0.1uF 470pF
C308 +5V
C301 C312 0.1uF C128 C127
17
19
5.1pF 5.1pF 10uF 10uF
J13 4 ACIM TXD
VDD
VCC
Y301 J13 6 ACIM RXD
74W04 20 1
1 2 +5V 18 C1_POS C2_POS 3
IN1 OUT1 C1_NEG C2_NEG
4 OUT2 3
3 IN2 VR107
+5V 16 5 15V
C310 DO1 RX1 VR119
3.6864MHz 15 6 15V
470pF DI1 TX1
14 7
C325 DO2 RX2
C309 13 8
4 R118
470pF 0.1uF DI2 U133-1 TX2
10K 12 9
5 DO3 RX3 VR108
11 10
8
DI3 TX3 15V
GND
VSS
VR120
VCC
15V
6
+5V
4
2
30 C126
EN_CE
32 10uF
EN_OE
7
EN_WE
7 R154
37
22
34
12
23
44
35
33
0 20 21
8
5
10K A0 IO0
36 U126
X2
GND
NC1
NC2
NC3
VCC
RXDA
TXDA
1 0
NC
IN
19 22
IP0
A1 IO1
X1CLK 2 18 23 1
A2 IO2
3 3 17 25 2 +5V
IP3 A3 IO3
40 43 4 16 26 3 +9.6V +9.6V A+ +5V +5V +5V
IP2 IP4 A4 IO4
31 42 5 15 27 4
8 OP2 U125 IP5 A5 IO5
24 41 6 14 28 5
IRQ* IP6 A6 IO6 C153 C154 C155 C156 C157 C158
0 28 14 7 13 29 6
D0 OP1 A7 IO7 470pF 470pF 470pF 470pF 470pF 470pF
20
1 18 15 8 3 7 C324 C305
D1 SN_PTT A8 470pF 0.1uF
VCC
2 27 30 9 2
D2 OP4 A9
3 19 DUART 16 10 31 11
D3 OP5 11 A10 EN_LE
4 26 SCN2681AA1A44 29 11 1 1
D4 OP6 A11 EN_OE
5 20 12 12
D5 A12
RESET
6 25 13 4 2 19
CSI01
RXDB
TXDB
D6 U122-5 A13 D0 U124 Q0 18 LPTT
0
WE*
OP7
OP0
14
RS1
RS2
RS3
RS4
7 21 5 3
OE*
D7 A14 D1 Q1
10 15 11 6 1 4 17
A15 NC1 D2 Q2 GT_FT*
GND
2
39
10
38
17
13
32
11
2
4
6
7
9
10 9 5 16
A16 NC2 D3 Q3 AGC_RESET*
3 6 15
D4 Q4
4 7 14
24
9 0 1 2 3 AT29C010A D5 Q5 AGC_INHIBIT*
5 8 13
D6 Q6
GND
6 9 12
D7 Q7 TONE_DETECT
7
10
MC74HCT573A
1
U130-1
MOSI-MISO
3 2 +5V
10 11
+5V
U122-2 MC74HC00A U130-2
3 4 9 MC74HC02A 8
U121-4 R166
8 5 U122-1 R167
U121-3 U122-4 10K
10 4 1 2 10K U107 C102
6 13 12 20 X9241M 10uF
9 VSUP VCC
+5V VH0_RH0 3
11 SCK
12 VL0_RL0 2
VW0_RW0 1
R119 C108 C106
13 100pF
10K 1000pF VH1_RH1 8
14 7
SCL VL1_RL1
9 6
SDA VW1_RW1
4 11
14
C101 A0 VH2_RH2
C100 16 VL2_RL2 12
15 100pF 1000pF A1 EEPOT_IN
5 13
A2 VW2_RW2
15
A3
VH3_RH3 17
VL3_RL3 18
+5V +5V +5V +5V +5V VW3_RW3 19
L300 EEPOT_OUT
VSS
6.8uH
10
SH1 34 14 14 14 14
SHIELD C313 C315 POWER C320 C316 VCC C322 C302 VCC C323 C303 VCC C327 C314 VCC C328 C651
1000pF 47pF U123-2 470pF 0.1uF U121-5 470pF 0.1uF U122-7 470pF 0.1uF U129-3 470pF 0.1uF U130-5 470pF 0.1uF
GND
1
1 GND GND GND

2
3
4
7 7 7 7
L301
6.8uH
May 5, 2009 6881098C21-P

Q110
D
R505 S
U113-1 1.0MEG
3 2
AGC_INHIBIT* R512
MC14504 12K
5
4 3
6 U115-2 1
9 8 +9.6V
U115-3
+9.6V C538 0.1uF
+9.6V
HEF4066 +5.8V R510
3.9K C512
10 3 C551 470pF .056uF
13 D1017
12 U117-4
11
12 R522 R539
D1012 12K
82K
11 10 +9.6V
U115-4 LM2901 2
R526 C520
+9.6V 100K 0.22uF
R509
3.9K
+3.6V 8 3 R529
U113-2 D1018
5 4 R503 14 200K
TONE_DETECT U117-3
10K 9 Q113
MC14504 R518
12 5459
D1013 100
LM2901
13
D1005 R525 +9.6V
R501
+6.5V VB +9.6V Q111 100K
1.2K R506
2 1
U115-1 330K R511
6 3
1 820 +9.6V
D1008 C548 C529
U117-2 R514 470pF 0.1uF
C503 7
HEF4066 5.6K
47uF 12
R523
VB
LM2901 1K
U113-4 11
9 10 S101-8 3 1
AGC_RESET* U112-1
9 8
MC14504 R502 R535 R537
D1007 2 4
1.0MEG R516 C511 270 10K
C506 +9.6V
47K 0.1uF
4.7uF 7 C514
39pF
S101-7
10 C515
R508 R515 R527 R534 R536
20K 12K 3.3K 0.22uF 47K 47K
R507
200K
C558
1%
470pF
C509 R532
6.8pF 3
VB 75 +9.6V C526
0.1uF
R521
11 C513
R504 200K
C501 C505 +9.6V 7 U110-2 5 0.1uF Q114
200K 1%
4.7uF 0.1uF MJD340 4 6
1%
3 4 13 4 4 6 7 +2.2V
LINE2+ R513 R517 U111-2
14 +9.6V 20K 100K 5 TP3
C504 U110-4
5 12 1% VB 11 TEST_POINT
R579
.022uF 680 VB 11
R531 C517
1 6 +9.6V 4.7K 39pF 1
LINE2- MC3303 R519
T1610 C557 C525
470pF 0.1uF 100K
4 9 1% R520
8 200K
U110-3 1%
10
11 C516
R530
C510 75 39pF
5 4
0.1uF VR502
S101-5 S101-4 56V
+2.2V
T100 A+ 12 13
C507
LINE1-
1 6 100uF C508 +9.6V
.022uF
R538
5 4 2 470K
R524 R528 1
LINE1+ 56V U111-1
3 4 1.8K 1.2K 3
VR501
C502 11
Q115
4.7uF C518
MJD340 R533
0.1uF
4.7K
6881098C21-P May 5, 2009

+9.6V
+5V
+5V
A+ +9.6V
U113-5
11 12
GT_FT*
MC14504
1 16
C553 C559 POWER 16 1 16
470pF 0.1uF C554 C560 POWER C552 C545 C555 C561 POWER
U113-3 U113-7 470pF 0.1uF 470pF 0.1uF C556 C562
7 6 U116-4 470pF 0.1uF U118-7
LPTT 470pF 0.1uF
8 13 6 7 8
MC14504 8 13
U114-3 9 U114-1 10
R548
VB +9.6V
180K 5 2 C543
1
270pF
R550 R552
11
13
47K 27K TRC DECODER FILTER & LIMITER
3 4 10 2 1 15 +5V
VBIAS
VCC
C523 INV_A BP_B
100pF
MC14053B HY1 MC14053B
C533 C539 C540 TP2 +9.6V
1000pF TEST_POINT R567
3 12 100pF .018uF 10K
INV_B
R542 BP_A GNDX R562
TP1
GND
CLK
270K 33K
TEST_POINT +9.6V 14
1 DECODE_TONES
1
+9.6V +9.6V
18
17
R554 VDD
1 9 4
470K R565
13 4 8 6 4 U115-5 C550 C536
2 R560 U112-3 10K
14 10 7 PWR_GND 470pF 0.1uF
U112-4 12K U112-2 Q116
12 11 5
11 R557 11 VSS
5.6K MC3303
VB C534 R566 7
MC3303 +9.6V MC3303
270pF C542 4.7K
22uF R561 R563 R564
VB +9.6V
180K 3.3K 180K
R544 R558
13
15
C522 10K TP4 3.9K
R553 TEST_POINT R570 RX_MUTE_1
1uF +9.6V VBIAS VCC1
R549 27K 0 EEPOT_IN
6 C546 C566
12K HY2-2 N_A U118-1
12 1 0.1uF 0.1uF 3 2
INV_A RX_MUTE
R546 5
B_N_A MC14504
12K
C528 CLK GND2 +9.6V R102
U118-6 10
1000pF R573 14 15 U116-1 100K
17
16
100K C565 RADIO_SEL
R569 C547
470pF EEPOT_OUT MC14504
50K 0.1uF
+9.6V U116-2 11 2
R577
FILTER_CLOCK 43K R571 R103
4 13 2 4 R578
0 13K 12 100K 1
14 1 15
U105-4 R576 U106-1 DET_AUD
12 33K 3
R574 11 11
100K C160
VB VB C535 R572 13 14 4.7uF
R575 C164
0 4.7uF 6.2K 1uF
AUX_TX_TRC
VB
R148 AUX_RX_AUD
U113-6 100K
14 15 R104
WL_MUTE FILT_AUD MOB_RX
C521 VB 100K
330pF MC14504
R543
11 10 VB C537 +9.6V VB
84.5K TRUNKING_TONES
11 12 8 1000pF
U111-3 11
14 U111-4 9 VB U114-2
3 R541
13 84.5K 4 C527
TP5 R108
C519 4 C524 39pF TEST_POINT
1
100K
0.1uF 1000pF +9.6V 12 VCC VB2 VB1 +9.6V
R545 R551 R568
+9.6V 200K 1MEG 470K C544 2 1
N_B R559
1uF R555 HY2-1 18 4 9
13 INV_B 12K
14 27K 3 8
B_N_B R556 U105-3
12K 10
RX LEVEL CONTROL R547 C531 11
C530 GND1 GND
20K 0.1uF
0.33uF +9.6V C541 VB
14
8
1000pF
R540
4.7K
R115
AUDIO SHAPING FILTER 100K R110
100K
MIC_AUDIO
C563 C564
10uF 470pF
+9.6V
R109
4 2 6 4
12K
1 7
TX_AUDIO U105-1 R114 R112 R111 U105-2
3 0 100K 5 +9.6V
R121 100K
11 11
100K
VB VB
16
POWER C549 C532
U114-4 470pF 0.1uF
6 7 8
May 5, 2009 6881098C21-P

Table 7-6. PLN1687B Tone Remote Control Board Electrical

Parts List Ref. Des. Part Number Description Ref. Des. Part Number Description Ref. Des. Part Number Description
Ref. Des. Part Number Description C133 2311049A08 CAP FXD 1 UF +/-10% C171 2113741A13 CAP CHIP 470 PF +/-5% C322 2113741A13 CAP CHIP 470 PF +/-5%
C134 2113741B69 CAP CHIP 0.1 UF +/-5% C172 2311049A08 CAP FXD 1 UF +/-10% C323 2113741A13 CAP CHIP 470 PF +/-5%
– 2605255S01 HT SINK
C136 2311049A08 CAP FXD 1 UF +/-10% C173 2311049A08 CAP FXD 1 UF +/-10% C324 2113741A13 CAP CHIP 470 PF +/-5%
– 2605455Z04 SHLD CVR
C137 2113741A13 CAP CHIP 470 PF +/-5% C174 2311049A08 CAP FXD 1 UF +/-10% C325 2113741A13 CAP CHIP 470 PF +/-5%
C100 2113740F51 CAP CHIP 100 PF +/-5%
C138 2113741A13 CAP CHIP 470 PF +/-5% C175 2113740A63 CAP CHIP 220 PF +/-5% C326 2113741A13 CAP CHIP 470 PF +/-5%
C101 2113741A21 CAP CHIP 1000 PF +/-5%
C139 2113741A13 CAP CHIP 470 PF +/-5% C176 2113741B69 CAP CHIP 0. 1UF +/-5% C327 2113741A13 CAP CHIP 470 PF +/-5%
C102 2311049A19 CAP FXD 10 UF +/-10%
C140 2113741A13 CAP CHIP 470 PF +/-5% C200 2113740A43 CAP CHIP 39 PF +/-5% C328 2113741A13 CAP CHIP 470 PF +/-5%
C103 2113741A13 CAP CHIP 470 PF +/-5%
C143 2113741A13 CAP CHIP 470 PF +/-5% C201 2113741A13 CAP CHIP 470 PF +/-5% C501 2382174V01 CAP AL EL 4.7 UF +/-20%
C104 2311049A14 CAP FXD 4.7 UF +/-10%
C145 2113741A13 CAP CHIP 470 PF +/-5% C203 2113741A13 CAP CHIP 470 PF +/-5% C502 2382174V01 CAP AL EL 4.7 UF +/-20%
C105 2113741A45 CAP CHIP 0.01 UF +/-5%
C146 2113741A13 CAP CHIP 470 PF +/-5% C204 2113741A13 CAP CHIP 470 PF +/-5% C503 2380090M07 CAP AL EL 47 UF +/-20%
C106 2113740F51 CAP CHIP 100 PF +/-5%
C149 2113741A13 CAP CHIP 470 PF +/-5% C205 2113741A13 CAP CHIP 470 PF +/-5% C504 2113741A53 CAP CHIP 0.022UF +/-5%
C107 2113741A45 CAP CHIP 0.01 UF +/-5%
C150 2113741A13 CAP CHIP 470 PF +/-5% C206 2113741A13 CAP CHIP 470 PF +/-5% C505 2113741B69 CAP CHIP 0.1 UF +/-5%
C108 2113741A21 CAP CHIP 1000 PF +/-5%
C151 2113741A13 CAP CHIP 470 PF +/-5% C207 2113741A13 CAP CHIP 470 PF +/-5% C506 2380090M22 CAP AL EL 4.7 UF +/-20%
C109 2113741A45 CAP CHIP 0.01 UF +/-5%
C152 2113741A13 CAP CHIP 470 PF +/-5% C208 2113741A13 CAP CHIP 470 PF +/-5% C507 2380090M25 CAP AL EL 100 UF+/-20%
C110 2113741F49 CAP CHIP 0.01 UF +/-5%
C153 2113741A13 CAP CHIP 470 PF +/-5% C209 2113741A13 CAP CHIP 470 PF +/-5% C508 2113741A53 CAP CHIP 0.022UF +/-5%
C111 2113743K05 CAP CHIP 0.039 UF +80% -
20% C154 2113741A13 CAP CHIP 470 PF +/-5% C301 2113740A20 CAP CHIP 5.1 PF 0.25 PF+/- C509 2113740A24 CAP CHIP 6.8PF 0.25 PF+/-
C112 2113741A45 CAP CHIP 0.01 UF +/-5% C155 2113741A13 CAP CHIP 470 PF +/-5% C302 2113741B69 CAP CHIP 0.1 UF +/-5% C510 2113741B69 CAP CHIP 0.1 UF +/-5%
C113 2113741A13 CAP CHIP 470 PF +/-5% C156 2113741A13 CAP CHIP 470 PF +/-5% C303 2113741B69 CAP CHIP 0.1 UF +/-5% C511 2113741B69 CAP CHIP 0.1 UF +/-5%
C114 2113741A45 CAP CHIP 0.01 UF +/-5% C157 2113741A13 CAP CHIP 470 PF +/-5% C304 2113741A45 CAP CHIP 0.01 UF +/-5% C512 2113741B63 CAP CHIP 0.056UF +/-5%
C118 2113741B69 CAP CHIP 0.1 UF +/-5% C158 2113741A13 CAP CHIP 470 PF +/-5% C305 2113741B69 CAP CHIP 0.1 UF +/-5% C513 2113741B69 CAP CHIP 0.1 UF +/-5%
C119 2311049A08 CAP FXD 1 UF +/-10% C159 2311049A14 CAP FXD 4.7 UF +/-10% C307 2113741A13 CAP CHIP 470 PF +/-5% C514 2113740A43 CAP CHIP 39 PF +/-5%
C120 2113741A13 CAP CHIP 470 PF +/-5% C160 2311049A14 CAP FXD 4.7 UF +/-10% C308 2113741B69 CAP CHIP 0.1 UF +/-5% C515 2311049A03 CAP FXD 0.22 UF +/ -10%
C121 2113741A37 CAP CHIP 4700 PF +/-5% C161 2311049A14 CAP FXD 4.7 UF +/-10% C309 2113741B69 CAP CHIP 0.1 UF +/-5% C516 2113740A43 CAP CHIP 39 PF +/-5%
C122 2311049A23 CAP FXD 47 UF +/-10% C162 2380090M25 CAP AL EL 100 UF+/-20% C310 2113741A13 CAP CHIP 470 PF +/-5% C517 2113740A43 CAP CHIP 39 PF +/-5%
C123 2311049A23 CAP FXD 47 UF +/-10% C163 2380090M25 CAP AL EL 100 UF+/-20% C311 2113741B69 CAP CHIP 0.1 UF +/-5% C518 2113741B69 CAP CHIP 0.1 UF +/-5%
C124 2311049A19 CAP FXD 10 UF +/-10% C164 2311049A07 CAP FXD 1 UF +/-10% C312 2113740A20 CAP CHIP 5.1 PF 0.25 PF+/- C519 2113741B69 CAP CHIP 0.1 UF +/-5%
C125 2311049A19 CAP FXD 10 UF +/-10% C165 2113741A13 CAP CHIP 470 PF +/-5% C313 2113740A79 CAP CHIP 1000 PF +/-5% C520 2311049A03 CAP FXD 0.22 UF +/ -10%
C126 2311049A19 CAP FXD 10 UF +/-10% C166 2113741A13 CAP CHIP 470 PF +/-5% C314 2113741B69 CAP CHIP 0.1 UF +/-5% C521 2113740A67 CAP CHIP 330 PF +/-5%
C127 2311049A19 CAP FXD 10 UF +/-10% C167 2113741A13 CAP CHIP 470 PF +/-5% C315 2113740A46 CAP CHIP 47 PF +/-5% C522 2113743G21 CAP CHIP 1 UF +80% -20%
C128 2311049A19 CAP FXD 10 UF +/-10% C168 2113741A13 CAP CHIP 470 PF +/-5% C316 2113741B69 CAP CHIP 0.1 UF +/-5% C523 2113740A55 CAP CHIP 100 PF +/-5%
C129 2113740A33 CAP CHIP 15 PF +/-5% C169 2113741A13 CAP CHIP 470 PF +/-5% C319 2113740A63 CAP CHIP 220 PF +/-5% C524 2113740A79 CAP CHIP 1000 PF +/-5%
C130 2113740A33 CAP CHIP 15 PF +/-5% C170 2113741A13 CAP CHIP 470 PF +/-5% C320 2113741A13 CAP CHIP 470 PF +/-5% C525 2113741B69 CAP CHIP 0.1 UF +/-5%
C131 2311049A08 CAP FXD 1 UF +/-10%
6881098C21-P May 5, 2009

C526 2113741B69 CAP CHIP 0.1 UF +/-5% C558 2113741A13 CAP CHIP 470 PF +/-5% J11 2880004T02 CONN RECT HDR 1 ROW M 2 Q116 4813824A10 XSTR GEN PURPOSE SMALL
CONT SIG NPN MMBT3904L
C527 2113740A43 CAP CHIP 39 PF +/-5% C559 2113741B69 CAP CHIP 0.1 UF +/-5%
J13 0960113B01 JACK MOD 8 PIN MOUNT Q117 4813824A10 XSTR GEN PURPOSE SMALL
C528 2113740A79 CAP CHIP 1000 PF +/-5% C560 2113741B69 CAP CHIP 0.1 UF +/-5% SIG NPN MMBT3904L
J14 2880068M01 HDR MIC
C529 2113741B69 CAP CHIP 0. 1UF +/-5% C561 2113741B69 CAP CHIP 0.1 UF +/-5% Q118 4813824A10 XSTR GEN PURPOSE SMALL
J2 2882505T04 PLUG HEADER 34 CKT SIG NPN MMBT3904L
C530 2311049A04 CAP FXD 0.33 UF +/-10% C562 2113741B69 CAP CHIP 0.1 UF +/-5%
J3 2882505T15 CONN HEADER 50 PIN Q200 4813824A10 XSTR GEN PURPOSE SMALL
C531 2113741B69 CAP CHIP 0.1 UF +/-5% C563 2311049A19 CAP FXD 10 UF +/-10%
SIG NPN MMBT3904L
J4 2884324M07 CONN RECT HDR 1 ROW M 2
C532 2113741B69 CAP CHIP 0.1 UF +/-5% C564 2113741A13 CAP CHIP 470 PF +/-5% CONT Q201 4813824A10 XSTR GEN PURPOSE SMALL
C533 2113740A79 CAP CHIP 1000 PF +/-5% C565 2113741A13 CAP CHIP 470 PF +/-5% SIG NPN MMBT3904L
CONT Q202 4813824A18 XSTR GEN PURPOSE SMALL
C534 2113740A65 CAP CHIP 270 PF +/-5% C566 2113741B69 CAP CHIP 0.1 UF +/-5%
SIG PNP MMBT4403L
C535 2311049A14 CAP FXD 4.7 UF +/-10% C601 2113740A55 CAP CHIP 100 PF +/-5%
CONT Q203 4813824A10 XSTR GEN PURPOSE SMALL
C536 2113741B69 CAP CHIP 0.1 UF +/-5% C602 2113740A55 CAP CHIP 100 PF +/-5% SIG NPN MMBT3904L
C537 2113740A79 CAP CHIP 1000 PF +/-5% C603 2311049A03 CAP FXD 0.22 UF +/10% CONT Q204 4813824A18 XSTR GEN PURPOSE SMALL
SIG PNP MMBT4403L
C538 2113741B69 CAP CHIP 0.1 UF +/-5% C604 2311049A14 CAP FXD 4.7 UF +/-10% JU100 0662057B47 RES 0 OHM 5% 0.1 W
Q205 4813824A10 XSTR GEN PURPOSE SMALL
C539 2113740A55 CAP CHIP 100 PF +/-5% C605 2113741A49 CAP CHIP 0.015 UF +/-5% JU101 0662057B47 RES 0 OHM 5% 0.1 W
SIG NPN MMBT3904L
C540 2113741A51 CAP CHIP 0.018 UF +/-5% C606 2311049A19 CAP FXD 10 UF +/-10% L101 2480289M16 COIL 22 UH
C541 2113740A79 CAP CHIP 1000 PF +/-5% C607 2113741B69 CAP CHIP 0.1 UF +/-5% L300 2411087B36 COIL CHIP 6.8 UH SIG NPN MMBT3904L
C542 2311049A21 CAP FXD 22 UF +/-10% C608 2113741B69 CAP CHIP 0.1 UF +/-5% L301 2411087B36 COIL CHIP 6.8 UH Q307 4813824A10 XSTR GEN PURPOSE SMALL
SIG NPN MMBT3904L
C543 2113740A65 CAP CHIP 270 PF +/-5% C615 2113741B69 CAP CHIP 0.1 UF +/-5% P101 2880001R03 CONN RECT HDR 1 ROW M 3
CONT R101 0662057A73 RES 10K OHM 5% 0.063 W
C544 2311049A07 CAP FXD 1 UF +/-10% C651 2113741B69 CAP CHIP 0.1 UF +/-5%
P102 2880001R03 CONN RECT HDR 1 ROW M 3 R102 0662057A97 RES 100K OHM 5% O.063 W
C545 2113741B69 CAP CHIP 0.1 UF +/-5% D1005 4813833C10 DIODE RECT MMBD6050L CONT
R103 0662057A97 RES 100K OHM 5% O.063 W
C546 2113741B69 CAP CHIP 0.1 UF +/-5% D1007 4813833C10 DIODE RECT MMBD6050L P103 2880001R03 CONN RECT HDR 1 ROW M 3
R104 0662057A97 RES 100K OHM 5% O.063 W
CONT
C547 2113741B69 CAP CHIP 0.1 UF +/-5% D1008 4813833C10 DIODE RECT MMBD6050L
R105 0662057A73 RES 10K OHM 5% 0.063 W
C548 2113741A13 CAP CHIP 470 PF +/-5% D1012 4813833C10 DIODE RECT MMBD6050L SIG NPN MMBT3904L R106 0660076A93 RES 68K OHM 5% 0.125 W
C549 2113741A13 CAP CHIP 470 PF +/-5% D1013 4813833C10 DIODE RECT MMBD6050L Q102 4813824A10 XSTR GEN PURPOSE SMALL R107 0660076A88 RES 43K OHM 5% 0.125 W
C550 2113741A13 CAP CHIP 470 PF +/-5% D1017 4813833C10 DIODE RECT MMBD6050L SIG NPN MMBT3904L
R108 0662057A97 RES 100K OHM 5% O.063 W
C551 2113741A13 CAP CHIP 470 PF +/-5% D1018 4813833C10 DIODE RECT MMBD6050L Q110 4813823A08 XSTR FET GP SS P DEPL TO –
236AB R109 0662057A75 RES 12K OHM5% 0.0625 W
C552 2113741A13 CAP CHIP 470 PF +/-5% D103 4813825A05 DIODE MXR MMBD301L
Q111 4813824A18 XSTR GEN PURPOSE SMALL R110 0662057A97 RES 100K OHM 5% O.063 W
C553 2113741A13 CAP CHIP 470 PF +/-5% E1 8083545L04 SPKGAP 3P-4L1 SIG PNP MMBT4403L
R111 0662057A97 RES 100K OHM 5% O.063 W
C554 2113741A13 CAP CHIP 470 PF +/-5% E2 8083545L04 SPKGAP 3P-4L1 Q113 4885316E11 XSTR FET GEN PURPOSE
SMALL SIG N R112 0662057B47 RES 0 OHM 5% 0.1 W
C555 2113741A13 CAP CHIP 470 PF +/-5% HY1 TFN6061A HYBRID FLTR BANDPASS
2175 Q114 4813822A07 XSTR BIP GP POWER BIPLR R113 0662057A73 RES 10K OHM 5% 0.063 W
C556 2113741A13 CAP CHIP 470 PF +/-5% NPN MJD3450T4
HY2 TFN6056A HYBRID FLTR NOTCH 2175 R114 0662057A97 RES 100K OHM 5% O.063 W
C557 2113741A13 CAP CHIP 470 PF +/-5% Q115 4813822A07 XSTR BIP GP POWER BIPLR
J1 2882505T15 CONN HEADER 50 PIN R115 0662057A97 RES 100K OHM 5% O.063 W
NPN MJD3450T4
May 5, 2009 6881098C21-P

R116 0662057A73 RES 10K OHM 5% 0.063 W R164 0662057A89 RES 47K OHM 5% 0.063 W R199 0662057A73 RES 10K OHM 5% 0.063 W R507 0660079L33 RES 200K OHM 1% 0.125 W
R117 0662057A73 RES 10K OHM 5% 0.063 W R165 0662057A89 RES 47K OHM 5% 0.063 W R200 0660076A25 RES 100 OHM 5% 0.125 W R508 0660076A80 RES 20K OHM 5% 0.125 W
R118 0662057A73 RES 10K OHM 5% 0.063 W R166 0662057A73 RES 10K OHM 5% 0.063 W R201 0660076A25 RES 100 OHM 5% 0.125 W R509 0660076A63 RES 3.9K OHM 5% 0.125 W
R119 0662057A73 RES 10K OHM 5% 0.063 W R167 0662057A73 RES 10K OHM 5% 0.063 W R202 0662057A65 RES 4.7K OHM 5% 0.063 W R510 0660076A63 RES 3.9K OHM 5% 0.125 W
R120 0660076A65 RES 4.7K OHM 5% 0.125 W R168 0660076E73 RES 10K OHM 1% 0.125 W R203 0662057A65 RES 4.7K OHM 5% 0.063 W R511 0660076A47 RES 820 OHM 5% 0.125 W
R121 0662057A97 RES 100K OHM 5% O.063 W R169 0662057R46 RES 4.32K OHM 1% 0.1 W R204 0662057A73 RES 10K OHM 5% 0.063 W R512 0662057A75 RES 12K OHM5% 0.0625 W
R122 0660079V49 RES 1M OHM 5% 0.125 W R170 0660076E77 RES 15K OHM 1% 0.125 W R205 0660076A93 RES 68K OHM 5% 0.125 W R513 0660076A80 RES 20K OHM 5% 0.125 W
R123 0662057A73 RES 10K OHM 5% 0.063 W R171 0662057A97 RES 100K OHM 5% O.063 W R206 0662057A65 RES 4.7K OHM 5% 0.063 W R514 0660076A67 RES 5.6K OHM 5% 0.125 W
R124 0662057A89 RES 47K OHM 5% 0.063 W R172 0662057A97 RES 100K OHM 5% O.063 W R207 0662057A68 RES 6.2K OHM 5% 0.0625 W R515 0662057A75 RES 12K OHM5% 0.0625 W
R125 0660076A57 RES 2.2K OHM 5% 0.125 W R173 0662057A97 RES 100K OHM 5% O.063 W R208 0660076A25 RES 100 OHM 5% 0.125 W R516 0662057A89 RES 47K OHM 5% 0.063 W
R127 0660076A61 RES 3.3K OHM 5% 0.125 W R174 0660076A77 RES 15K OHM 5% 0.125 W R209 0662057A97 RES 100K OHM 5% O.063 W R517 0660078L01 RES 100K OHM 1% 0.125 W
R128 0660076A77 RES 15K OHM 5% 0.125 W R175 0662057A89 RES 47K OHM 5% 0.063 W R210 0662057A65 RES 4.7K OHM 5% 0.063 W R518 0660076A25 RES 100 OHM 5% 0.125 W
R129 0660076A71 RES 8.2K OHM 5% 0.125 W R176 0660076A01 RES 10 OHM 5% 0.125 W R211 0662057A65 RES 4.7K OHM 5% 0.063 W R519 0660078L01 RES 100K OHM 1% 0.125 W
R134 0662057A73 RES 10K OHM 5% 0.063 W R179 0662057A73 RES 10K OHM 5% 0.063 W R212 0662057A65 RES 4.7K OHM 5% 0.063 W R520 0660079L33 RES 200K OHM 1% 0.125 W
R135 0611072A31 RES 180 OHM 5% 0.25 W R180 0662057B22 RES 1M OHM 5% 0.0625 W R213 0662057A65 RES 4.7K OHM 5% 0.063 W R521 0660079L33 RES 200K OHM 1% 0.125 W
R137 0660076A77 RES 15K OHM 5% 0.125 W R181 0662057A73 RES 10K OHM 5% 0.063 W R214 0660076A57 RES 2.2K OHM 5% 0.125 W R522 0660076A95 RES 82K OHM 5% 0.125 W
R138 0660076A09 RES 22 OHM 5% 0.125 W R182 0680194M20 RES 62 OHM 5% 0.1 W R215 0660076A25 RES 100 OHM 5% 0.125 W R523 0660076A49 RES 1K OHM 5% 0.125 W
R139 0660076A09 RES 22 OHM 5% 0.125 W R183 0662057A73 RES 10K OHM 5% 0.063 W R216 0662057A97 RES 100K OHM 5% O.063 W R524 0660076A55 RES 1.8K OHM 5% 0.125 W
R140 0660076A09 RES 22 OHM 5% 0.125 W R184 0662057A89 RES 47K OHM 5% 0.063 W R217 0662057A68 RES 6.2K OHM 5% 0.0625 W R525 0662057A97 RES 100K OHM 5% O.063 W
R141 0660076A09 RES 22 OHM 5% 0.125 W R185 0662057A73 RES 10K OHM 5% 0.063 W R218 0662057A73 RES 10K OHM 5% 0.063 W R526 0662057A97 RES 100K OHM 5% O.063 W
R145 0660076A01 RES 10 OHM 5% 0.125 W R186 0662057A89 RES 47K OHM 5% 0.063 W R220 0660076A80 RES 20K OHM 5% 0.125 W R527 0660076A61 RES 3.3K OHM 5% 0.125 W
R146 0611072A47 RES 820 OHM 5% 0.25 W R187 0662057A73 RES 10K OHM 5% 0.063 W R221 0662057A73 RES 10K OHM 5% 0.063 W R528 0660076A51 RES 1.2K OHM 5% 0.125 W
R148 0662057A97 RES 100K OHM 5% O.063 W R188 0662057A73 RES 10K OHM 5% 0.063 W R301 0662057E50 RES 6.8K OHM 5% 0.1 W R529 1813905A14 POT 200K 20%
R154 0662057A73 RES 10K OHM 5% 0.063 W R189 0662057A65 RES 4.7K OHM 5% 0.063 W R321 0662057A65 RES 4.7K OHM 5% 0.063 W R530 0611072A22 RES 75 OHM 5% 0.25 W
R156 0662057A89 RES 47K OHM 5% 0.063 W R190 0662057A01 RES CF 10 OHM 5% 1W SM R322 0660076A77 RES 15K OHM 5% 0.125 W R531 0660076A65 RES 4.7K OHM 5% 0.125 W
0.0603 W
R157 0660076A95 RES 82K OHM 5% 0.125 W R323 0660076A59 RES 2.7K OHM 5% 0.125 W R532 0611072A22 RES 75 OHM 5% 0.25 W
R191 0662057B10 RES 330K OHM 5% 0.0625 W
R158 0662057A89 RES 47K OHM 5% 0.063 W R501 0660076A51 RES 1.2K OHM 5% 0.125 W R533 0660076A65 RES 4.7K OHM 5% 0.125 W
R192 0662057A97 RES 100K OHM 5% O.063 W
R159 0662057A89 RES 47K OHM 5% 0.063 W R502 0660079V49 RES 1M OHM 5% 0.125 W R534 0662057A89 RES 47K OHM 5% 0.063 W
R193 1813905A14 POT 200K 20%
R160 0662057A89 RES 47K OHM 5% 0.063 W R503 0662057A73 RES 10K OHM 5% 0.063 W R535 0660076A35 RES 270 OHM 5% 0.125 W
R194 0662057A73 RES 10K OHM 5% 0.063 W
R161 0662057A89 RES 47K OHM 5% 0.063 W R504 0660079L33 RES 200K OHM 1% 0.125 W R536 0662057A89 RES 47K OHM 5% 0.063 W
R195 0662057A92 RES 62K OHM5% 0.0625 W
R162 0662057A89 RES 47K OHM 5% 0.063 W R505 0660079V49 RES 1M OHM 5% 0.125 W R537 0662057A73 RES 10K OHM 5% 0.063 W
R197 0662057B47 RES 0 OHM 5% 0.1 W
R163 0662057A89 RES 47K OHM 5% 0.063 W R506 0660076B13 RES 330K OHM 5% 0.125 W R538 0660076B17 RES 470K OHM 5% 0.125 W
R198 0662057A73 RES 10K OHM 5% 0.063 W
6881098C21-P May 5, 2009

R539 0662057A75 RES 12K OHM5% 0.0625 W R571 0662057A76 RES 13K OHM 5% 0.1 W U106 5113819A04 IC OP AMP 4 PER PKG SO-14 VR110 4880140L07 DIODE SOT ZEN 5.6 V
R540 0660076A65 RES 4.7K OHM 5% 0.125 W R572 0662057A68 RES 6.2K OHM 5% 0.0625 W U107 5105109Z14 IC PROG POT 2K OHM 10K VR112 4880140L07 DIODE SOT ZEN 5.6 V
OHM 50
R541 0611077G81 RES 84 5K OHM 1% 0.125 W R573 0662057A97 RES 100K OHM 5% O.063 W VR113 4880140L07 DIODE SOT ZEN 5.6 V
U110 5113819A04 IC OP AMP 4 PER PKG SO-14
R542 0660076B11 RES 270K OHM 5% 0.125 W R574 0662057A97 RES 100K OHM 5% O.063 W VR114 4880140L07 DIODE SOT ZEN 5.6 V
R543 0611077G81 RES 84 5K OHM 1% 0.125 W R575 0662057B47 RES 0 OHM 5% 0.1 W VR115 4880140L20 DIODE ZEN SOT 15 V
R544 0662057A73 RES 10K OHM 5% 0.063 W R576 0662057A85 RES 33K OHM 5% 0.1 W VR119 4880140L20 DIODE ZEN SOT 15 V
U113 5184704M90 IC CMOS 04M90 LEV SHIFTER
R545 1813905A14 POT 200K 20% R577 0662057A88 RES 43K OHM 5% 0.1 W VR120 4880140L20 DIODE ZEN SOT 15 V
U114 5184704M60 IC MUX/DEMUX
R546 0662057A75 RES 12K OHM5% 0.0625 W R578 0662057B47 RES 0 OHM 5% 0.1 W VR121 4880140L07 DIODE SOT ZEN 5.6 V
U115 5185956E80 IC SW SM 04M52 QUAD SW
R547 0660076A80 RES 20K OHM 5% 0.125 W R579 0662057A45 RES 680 OHM 5% 0.063 W VR122 4880140L07 DIODE SOT ZEN 5.6 V
U116 5184704M60 IC MUX/DEMUX
R548 0660076B07 RES 180K OHM 5% 0.125 W R601 0662057A97 RES 100K OHM 5% O.063 W VR123 4880140L07 DIODE SOT ZEN 5.6 V
U117 5113820A03 IC COMPTR SO14 4 PER PKG
R549 0662057A75 RES 12K OHM5% 0.0625 W R604 0660076A45 RES 680 OHM 5% 0.125 W VR125 4880140L20 DIODE ZEN SOT 15 V
U118 5184704M90 IC CMOS 04M90 LEV SHIFTER
R550 0662057A89 RES 47K OHM 5% 0.063 W R606 0660076A49 RES 1K OHM 5% 0.125 W VR126 4880140L07 DIODE SOT ZEN 5.6 V
U121 5113805A01 IC NAND 4 PER PKG SOIC14
R551 0660079V49 RES 1M OHM 5% 0.125 W R607 0660076A43 RES 560 OHM 5% 0.125 W VR127 4880140L07 DIODE SOT ZEN 5.6 V
U122 5113805A09 IC INVTR 6 PER PKG SOIC14
R552 0660076A83 RES 27K OHM 5% 0.125 W R609 0660076A79 RES 18K OHM 5% 0.125 W VR128 4813832C28 DIODE TRANSIENT
U123 5171439H01 IC 68HC11 SUPPRESSER MMBZ15VDL
R553 0660076A83 RES 27K OHM 5% 0.125 W R610 0662057A97 RES 100K OHM 5% O.063 W
U124 5113805A91 IC BFR 8 PER PKG 3ST VR129 4813832C28 DIODE TRANSIENT
R554 0660076B17 RES 470K OHM 5% 0.125 W R615 0660076A55 RES 1.8K OHM 5% 0.125 W SOIC20 SUPPRESSER MMBZ15VDL
R555 0660076A83 RES 27K OHM 5% 0.125 W S100 4083706T01 SW MECH DIP AND SLIDE U125 5105625U57 IC CNTLR SCN2681 DUART VR130 4813832C28 DIODE TRANSIENT
SWITCH SPST SUPPRESSER MMBZ15VDL
R556 0662057A75 RES 12K OHM5% 0.0625 W U126 5105625U79 IC 128 KX8 FLSH ROM
S101 4083706T01 SW MECH DIP AND SLIDE VR131 4813832C28 DIODE TRANSIENT
R557 0660076A67 RES 5.6K OHM 5% 0.125 W SWITCH SPST U127 5164852H75 IC CNTR BIN SYNC SUPPRESSER MMBZ15VDL
R558 0660076A63 RES 3.9K OHM 5% 0.125 W SH1 2605425Z01 SHLD U129 5113805A18 IC F-F/D 2 PER PKG SOIC14 VR501 4813832A46 DIODE TRANSIENT
R559 0662057A75 RES 12K OHM5% 0.0625 W SUPPRESSER P6SMB56AT3
SH2 2605455Z03 SHLD U130 5113805A02 IC NOR 4 PER PKG SOIC14
56 V
R560 0662057A75 RES 12K OHM5% 0.0625 W SH3 2605887Z01 SHLD U132 5185130C06 IC 5 V REG W/RESET CS-
VR502 4813832A46 DIODE TRANSIENT
8126-1T5
R561 0660076B07 RES 180K OHM 5% 0.125 W SKT1 0984728L01 CONN HSG SKT CONN SUPPRESSER P6SMB56AT3
U133 5113811A11 IC RS-232-C DVR/RCVR SNGL 56 V
R562 0662057A85 RES 33K OHM 5% 0.1 W SKT2 0984728L01 CONN HSG SKT CONN SUP
Y101 4805574W03 OSC XTAL 7.95 MHz CLK OSC
R563 0660076A61 RES 3.3K OHM 5% 0.125 W SKT3 0984728L01 CONN HSG SKT CONN REF
VR100 4880140L25 DIODE ZEN MMBZ 5250 20 V
R564 0660076B07 RES 180K OHM 5% 0.125 W T100 2584422T01 XFMR LINE ISOLATION Y301 4805574W04 OSC XTAL 3.69 MHz CLK OSC
VR101 4880140L06 DIODE ZEN MMBZ5231 SM
TELEPHONE SOT-23 5.1 V 20 A 5.1 V REF
R565 0662057A73 RES 10K OHM 5% 0.063 W
T1610 2584422T01 XFMR LINE ISOLATION VR103 4880140L07 DIODE SOT ZEN 5.6 V
R566 0660076A65 RES 4.7K OHM 5% 0.125 W
TELEPHONE
R567 0662057A73 RES 10K OHM 5% 0.063 W VR104 4880140L07 DIODE SOT ZEN 5.6 V
U100 5105109Z13 IC LNR MICROPOWER LOW
R568 0660076B17 RES 470K OHM 5% 0.125 W DROPUT REGLTR W SH VR105 4880140L07 DIODE SOT ZEN 5.6 V
R569 1885848F01 RES POT 40K OHM 20% U101 5113819A04 IC OP AMP 4 PER PKG SO-14 VR106 4880140L07 DIODE SOT ZEN 5.6 V
R570 0662057B47 RES 0 OHM 5% 0.1 W U102 5113818A01 IC OP AMP 2 PER PKG SO-8 VR107 4880140L20 DIODE ZEN SOT 15 V
U105 5113819A04 IC OP AMP 4 PER PKG SO-14 VR108 4880140L20 DIODE ZEN SOT 15 V
May 5, 2009 6881098C21-P

Appendix A Cross Patch Configuration
A.1 General Description

The Cross Patch provides interoperability between two systems on different bands, analog or digital
or trunking. An interface cable can be built to allow the interconnection of two Consolette stations to
form a repeater system. The information received by Consolette 1 will be retransmitted or repeated
by Consolette 2. Similarly, information received by Consolette 2 will be retransmitted on Consolette
1. The system is a first come, first served system in that one station does not have priority over the
other. Moreover, the Consolettes must be located in different frequency bands to prevent RF
interference from occurring from one Consolette to another.
A.2 Detailed Description

To enable Cross Patch operation between two Consolettes, build the cable shown in the Cross Patch
Cable diagram below and connect each dB-25 connector to Accessory Connector 2 of the two
Consolettes. If you wish to have the option of enabling/disabling Cross Patch operation, you must
include an in-line switch (or switches) to open and close the connection between SPKR_UNMUTE
and PTT, along with the connection between RX+(LINE1+)† and AUX_TX_AUD. To disable the
Cross Patch, the connection between SPKR_UNMUTE and PTT must be open. This will prevent the
Consolette that is receiving information from keying the Consolette it is connected to. In addition, the
connection between RX+(LINE1+)† and AUX_TX_AUD must also be switched open to prevent
received audio from one Consolette unintentionally mixing into the connected Consolette's Record,
VU meter, and/or Microphone audio paths.
The PTT for Consolette 2 is derived from the SPKR_UNMUTE signal of Consolette 1 which is active
when Consolette 1 is receiving information. RX audio from Consolette 1 is routed to the TX Audio of
Consolette 2. Adjusting the potentiometer (R244 on AIB, R193 on TRC) on the TX Audio path of
Consolette 2 will enable the user to match the receiver audio output sensitivity of Consolette 1. The
behavior of the audio path from Consolette 2 to Consolette 1 is identical to the Consolette 1 to
Consolette 2 path just described.
NOTE:In this configuration, the SPKR_UNMUTE jumper (J15 on AIB, P102 on TRC) should be
placed for active low operation. (See Table 2-2 on page 2-5 for AIB and Table 2-5 on page 2-
7 for TRC jumper location.)
Consolette 1 Consolette 2
PTT* 10 10 PTT*
SPKR_UNMUTE 25 25 SPKR_UNMUTE
AUX_TX_AUD 17 17 AUX_TX_AUD
RX+(LINE+) 1 1 RX+(LINE+)
RX-(LINE-) 16 16 RX-(LINE-)
DIG_GND 12 12 DIG_GND
MAEPF-27883-P
Figure A-1. Cross Patch Cable

NOTE: * Denotes active low signal
6881098C21-P May 5, 2009

A-2 Cross Patch Configuration: Level Settings
A.3 Level Settings

A.3.1 Consolette 1 to Consolette 2 Path
1. Adjust the receive audio path individually on both Consolette 1 and Consolette 2 prior to
connecting together in a Cross Patch configuration. See sections “AIB Adjustment Procedure
- Receive” and “TRC Adjustment Procedure - Receive” of this manual.
2. Connect Consolette 1 to Consolette 2 via the cable described above.
3. Connect a signal generator or communications analyzer to Consolette 1.
4. Connect Consolette 2 to a modulation analyzer or communications analyzer. Set the analyzer
up to measure deviation level.
5. Apply a –47 dBm on channel RF signal modulated with a 1 kHz tone at 60% FSD into
Consolette 1. Consolette 1 will now be receiving and Consolette 2 will be transmitting.
6. Adjust the TX Audio path potentiometer (R244 on AIB, R193 on TRC) on Consolette 2 until
60% FSD is obtained on the Consolette 2 modulation analyzer or communications analyzer.
7. Turn off the –47 dBm RF signal.
A.3.2 Consolette 2 to Consolette 1 Path

1. Adjust the receive audio path individually on both Consolette 1 and Consolette 2 prior to
connecting together in a Cross Patch configuration. See sections “AIB Adjustment Procedure
- Receive” and “TRC Adjustment Procedure - Receive” of this manual.
2. Connect Consolette 2 to Consolette 1 via the cable described above.
3. Connect a signal generator or communications analyzer to Consolette 2.
4. Connect Consolette 1 to a modulation analyzer or communications analyzer. Set the analyzer
up to measure deviation level.
5. Apply a –47 dBm on channel RF signal modulated with a 1 kHz tone at 60% FSD into
Consolette 2. Consolette 2 will now be receiving and Consolette 1 will be transmitting.
6. Adjust the TX Audio path potentiometer (R244 on AIB, R193 on TRC) on Consolette 1 until
60% FSD is obtained on the Consolette 1 modulation analyzer or communications analyzer.
7. Turn off the –47 dBm RF signal.
May 5, 2009 6881098C21-P

Cross Patch Configuration: Radio-Wide Changes Using CPS A-3
A.4 Radio-Wide Changes Using CPS

The Cross Patch uses the SPKR_UNMUTE signal from Consolette 1 as a PTT signal to PTT
Consolette 2. Furthermore, the SPKR_UNMUTE signal is derived from voltage changes on the
speaker leads. The speaker voltage changes if voice audio is present or if alert tones are present.
Therefore, all the Alert Tones should be turned OFF using CPS. This will prevent unintended
mobile PTTs. For example, if TX Clear Alert Tones are enabled, when Consolette 1 receives a signal,
it PTTs Consolette 2. This sends an alert tone to Consolette 2's speaker, which then causes
Consolette 1 to transmit, etc., causing cyclical keying and unkeying of both Consolettes.
To disable the Alert Tones, disable the following fields in CPS:
1. Radio Configuration Radio Wide → Alert Tones
Alert Tones Disabled
Power Up Self Test Alert Tone Disabled
2. Radio Configuration → Secure → Secure Configuration → Advanced
NOTE:These fields will be active only if the “Secure Hardware Equipped” field is enabled in the Radio
Configuration → Secure → Secure Configuration → General section.
Tx Clear Alert Tones Disabled
Periodic Keyfail Alert Tone Disabled
When using the Cross Patch, you may exceed the duty cycle
! rating of the Consolette. If this condition is expected, the

customer may want to reduce the RF power output of the
Caution Consolette.
A.5 Audio Degradation Issues

The Consolette Cross Patch Interface is a base band audio interface that can be used to
interconnect the following:
• Analog to Analog systems
• Digital to Analog systems
• Analog to Digital systems
• Digital to Digital systems
Analog to analog patch systems should experience no audio degradation since there are no
vocoders in the system. The audio will not be degraded in the digital to analog or analog to digital
patches since the voice audio is only vocoded once. The digital to digital patches will experience
degraded audio. The repeated voice will not be as intelligible as the original digital audio. The voice
audio that passes through the patch is vocoded twice, and therefore isn't quite as sharp as the
original. The small artifacts of the first vocoding are amplified and added to by the second vocoding.
The net result is voice that isn't as intelligible as the high quality first vocoding. The voice has some
audio aberrations, but mainly it's harder to understand what is being said. The degree of intelligibility
loss varies with the type of vocoder. Field experience has shown that VSELP is affected more than
IMBE, but both are degraded from the original message.
6881098C21-P May 5, 2009

A-4 Cross Patch Configuration: Audio Degradation Issues
Notes
May 5, 2009 6881098C21-P

Appendix B Replacement Parts Ordering
B.1 Basic Ordering Information

When ordering replacement parts or equipment information, the complete identification number
should be included. This applies to all components, kits, and chassis. If the component part number
is not known, the order should include the number of the chassis or kit of which it is a part, and
sufficient description of the desired component to identify it.
Crystal orders should specify the crystal type number, crystal and carrier frequency, and the model
number in which the part is used.
B.2 Motorola Online

Motorola Online users can access our online catalog at
https://www.motorola.com/businessonline
To register for online access, please call 800-814-0601 (for U.S. and Canada Service Centers only).
International customers can obtain assistance at https://businessonline.motorola.com.
B.3 Mail Orders

Send written orders to the following addresses:
Replacement Parts/ Federal Government Orders: International Orders:

Test Equipment/Manuals/
Crystal Service Items
Motorola Inc. Motorola Inc. Motorola Inc.

Radio Products and Services U.S. Federal Government Markets Radio Products and Services
Division* Division Division*
Attention: Order Processing Attention: Order Processing Attention: Order Processing
2200 Galvin Drive 7230 Parkway Drive 2200 Galvin Drive
Elgin, IL 60123 Landover, MD 21076 Elgin, IL 60123
U.S.A. U.S.A. U.S.A.
* The Radio Products and Services Division (RPSD) was formerly known as the Customer Care and
Services Division (CCSD) and/or the Accessories and Aftermarket Division (AAD).
B.4 Telephone Orders

Radio Products and Services Division*
(United States and Canada)
7:00 AM to 7:00 PM (Central Standard Time)
Monday through Friday (Chicago, U.S.A.)
1-800-422-4210
1-847-538-8023 (International Orders)
U.S. Federal Government Markets Division (USFGMD)
1-800-826-1913 Federal Government Parts - Credit Cards Only
8:30 AM to 5:00 PM (Eastern Standard Time)
6881098C21-P May 5, 2009

B-2 Replacement Parts Ordering: Fax Orders
B.5 Fax Orders

1-800-622-6210
1-847-576-3023 (International)
USFGMD
(Federal Government Orders)
1-800-526-8641 (For Parts and Equipment Purchase Orders)
B.6 Parts Identification

1-800-422-4210, menu 3
B.7 Product Customer Service

Customer Response Center
(Non-technical Issues)
1-800-247-2346
FAX:1-800-247-2347
* The Radio Products and Services Division (RPSD) was formerly known as the Customer Care and
Services Division (CCSD) and/or the Accessories and Aftermarket Division (AAD).
May 5, 2009 6881098C21-P

Index Index AIB
control and data paths ....................................... 3-4
operational theory .............................................. 3-2
receive audio paths ............................................ 3-3
Numerics transmit audio paths ........................................... 3-4
block diagram ........................................................ 3-1
700-800 MHz specifications ...............................xviii, xix front panel view
G80 option ......................................................... 3-2
G81 option ......................................................... 3-2
A installation .............................................................. 2-1
introduction .....................................................1-1, 1-2
AC power installation .................................................2-3 model chart ............................................................. xiii
accessory cable diagrams .........................................5-4 options
accessory connector pinouts chart .............................................................. xiv, xv
1 ...........................................................................3-12 configuration ...................................................... 1-3
2 .............................................................................2-9 encryption ...........................................................xiv
3 ........................................................................... 2-11 software ............................................................. 1-3
adjustment power-up ............................................................. 3-14
audio interface board (AIB) ..................................2-15 power-up self-check errors .................................. 3-14
tone remote control (TRC) board .........................2-15 receive theory ...................................................... 3-14
AGC_INHIBIT signal ............................................... 3-11 safety
AGC_RESET signal ................................................ 3-11 CMOS IC handling ................................................ x
AIB lightning and surge suppression ...........................ix
DC power troubleshooting chart ..........................6-10 operational cautions ..............................................ix
RX audio troubleshooting chart .............................6-9 product ..................................................................ix
TX audio troubleshooting chart ..............................6-8 RF exposure .........................................................ix
AIB/TRC interface board disassembly/reassembly ...4-4 specifications
antenna installation ...................................................2-2 700-800 MHz ..............................................xviii, xix
audio degradation issues, cross patch configuration A-3 UHF ................................................................... xvii
audio interface board (AIB) VHF .....................................................................xvi
adjustment ...........................................................2-15 subassemblies ....................................................... 1-2
control and data paths ...........................................3-4 theory of operation ................................................ 3-1
receive audio paths ................................................3-3 transmit theory ..................................................... 3-14
settings ..................................................................2-5 TRC
theory of operation .................................................3-2 AGC circuit operation ....................................... 3-10
transmit audio paths ..............................................3-4 control point monitor .......................................... 3-7
See also AIB function .............................................................. 3-5
AUX TX/AUX MIC programming ....................2-23, 2-24 input/output control definitions ......................... 3-11
power distribution ............................................. 3-10
receive audio path .............................................. 3-7
B smart modem protocol (SMP) control .............. 3-11
supported IDs .................................................. 3-13
board layouts, list of ..................................................7-1 tone processing section ..................................... 3-9
transmit audio path ............................................ 3-8
C control head
cable diagrams ...................................................... 5-2
cable diagrams disassembly/reassembly ....................................... 4-7
accessory ...............................................................5-4 copyrights
clock/VU .................................................................5-6 computer software .....................................................ii
control head ...........................................................5-2 document ............................................................... 1-ii
cross patch ........................................................... A-1 cross patch configuration
power LED .............................................................5-1 audio degradation issues ......................................A-3
radio .......................................................................5-3 cable ......................................................................A-1
RF coaxial ..............................................................5-1 CPS radio-wide changes .......................................A-3
speaker ..................................................................5-1 detailed description ................................................A-1
TRC to ACIM .......................................................3-12 introduction ............................................................A-1
cable orientation, TRC to ACIM ...............................3-13 level settings
caution notation .........................................................1-1 consolette 1 to 2 path .........................................A-2
clock/VU consolette 2 to 1 path .........................................A-2
cable diagrams ......................................................5-6
meter setup ............................................................2-9 D
codeplug programming ............................................2-20
configuration, cross patch ........................................ A-1 danger notation ......................................................... 1-1
consolette DC input power installation ....................................... 2-4
6881098C21-P May 5, 2009

Index-2
desktop installation ................................................... 2-1 ventilation .............................................................. 2-1

DIP switch settings ................................................... 2-4 wall mounting ........................................................ 2-1
disassembly/reassembly
AIB/TRC interface board ....................................... 4-4
control head .......................................................... 4-7 J
fan ......................................................................... 4-7
power supply ......................................................... 4-6 jumper settings ......................................................... 2-4
top cover ............................................................... 4-2
transceiver ............................................................. 4-3 L
disclaimer, documentation ............................................ii
level settings, cross patch configuration ................... A-2
E lightning and surge suppression .................................. ix
lists
enhanced digital ID display programming ............... 2-21 board layouts ........................................................ 7-1
errors, power-up self-check .................................... 3-14 parts ...................................................................... 7-1
schematics ............................................................ 7-1
troubleshooting charts ........................................... 6-1
F LPTT signal ..............................................................3-11
fan disassembly/reassembly ..................................... 4-7

FLASHport programming ........................................ 2-25 M
maintenance
G alignment .............................................................. 4-1
disassembly/reassembly
GT/FT signal ........................................................... 3-11 AIB/TRC interface board ................................... 4-4
control head ....................................................... 4-7
fan ..................................................................... 4-7
H power supply ..................................................... 4-6
top cover ............................................................ 4-2
HUB Defeats PL programming ............................... 2-22 transceiver ......................................................... 4-3
procedures ............................................................ 4-1
I service aids, recommended .................................. 4-1
test equipment, recommended ............................. 4-1
input/output control definitions manual
AGC_INHIBIT ...................................................... 3-11 notations ............................................................... 1-1
AGC_RESET ...................................................... 3-11 revisions .................................................................... ii
GT/FT .................................................................. 3-11 model chart ................................................................ xiii
LPTT .................................................................... 3-11
RX_MUTE ........................................................... 3-11 N
SPKR_UNMUTE ................................................. 3-11
TONE_DETECT .................................................. 3-11 notations
WL_MUTE ........................................................... 3-11 manual .................................................................. 1-1
installation warning, caution, and danger ................................ 1-1
AC power .............................................................. 2-3
accessory connector pinouts
1 ....................................................................... 3-12 O
2 ......................................................................... 2-9
3 ....................................................................... 2-11 options
antenna connections ............................................. 2-2 configuration ......................................................... 1-3
audio interface board (AIB) consolette
adjustment ....................................................... 2-15 chart .............................................................. xiv, xv
settings .............................................................. 2-5 G80 .................................................................... 3-2
clock/VU meter setup ............................................ 2-9 G81 .................................................................... 3-2
DC input power ..................................................... 2-4 encryption .............................................................. xiv
desktop .................................................................. 2-1 software ................................................................ 1-3
digital remote control ........................................... 2-12 ordering parts ............................................................ B-1
DIP switch and jumper settings ............................. 2-4
planning ................................................................. 2-1
power and ground ................................................. 2-2 P
tone remote control (TRC) board
adjustment ....................................................... 2-15 parts
settings .............................................................. 2-6 lists ........................................................................ 7-1
tone remote control option .................................. 2-13 ordering ................................................................. B-1
May 5, 2009 6881098C21-P

Index-3
replacement ..................................................... xi, B-1 T

substitution ...............................................................xi
pinouts, accessory connector test equipment, recommended ................................. 4-1
1 .......................................................................... 3-12 theory of operation
2 ............................................................................ 2-9 audio interface board (AIB)
3 .......................................................................... 2-11 control and data paths ....................................... 3-4
power and ground installation ................................... 2-2 function .............................................................. 3-2
power LED cable diagrams ....................................... 5-1 receive audio paths ........................................... 3-3
power supply disassembly/reassembly ..................... 4-6 transmit audio paths .......................................... 3-4
power-up block diagram ........................................................ 3-1
self-check errors .................................................. 3-14 major components ................................................ 3-1
theory of operation .............................................. 3-14 power-up
programming operational theory ............................................ 3-14
AUX TX/AUX MIC ...................................... 2-23, 2-24 self-check errors .............................................. 3-14
codeplug .............................................................. 2-20 receive ................................................................ 3-14
enhanced digital ID display ................................. 2-21 tone remote control (TRC) board
FLASHport .......................................................... 2-25 AGC circuit operation ...................................... 3-10
HUB Defeats PL .................................................. 2-22 control point monitor .......................................... 3-7
tone remote control ............................................. 2-20 input/output control definitions ..........................3-11
operational theory .............................................. 3-5
power distribution ............................................ 3-10
R receive audio path ............................................. 3-7
smart modem protocol (SMP) control ...............3-11
radio cable diagrams ................................................ 5-3 supported IDs .................................................. 3-13
receive theory of operation ..................................... 3-14 tone processing section ..................................... 3-9
remote control installation, digital ............................ 2-12 transmit audio path ............................................ 3-8
replacing parts ..................................................... xi, B-1 transmit ............................................................... 3-14
RF coaxial cable diagrams ........................................ 5-1 tone remote control
RF exposure compliance information ...........................ii option installation ................................................ 2-13
RX_MUTE signal .................................................... 3-11 programming ....................................................... 2-20
tone remote control (TRC) board
S adjustment .......................................................... 2-15
AGC circuit operation .......................................... 3-10
safety control point monitor ............................................. 3-7
CMOS IC handling ....................................................x input/output control definitions .............................3-11
lightning and surge suppression ..............................ix power distribution ................................................ 3-10
operational cautions .................................................ix receive audio path ................................................. 3-7
product .....................................................................ix settings .................................................................. 2-6
RF exposure .............................................................ix smart modem protocol (SMP) control ..................3-11
safety information, product ...........................................ii supported IDs ...................................................... 3-13
schematics, list of ..................................................... 7-1 theory of operation ................................................ 3-5
service aids, recommended ...................................... 4-1 tone processing section ........................................ 3-9
settings transmit audio path ............................................... 3-8
audio interface board (AIB) ................................... 2-5 See also TRC
DIP switch ............................................................. 2-4 TONE_DETECT signal ............................................3-11
jumper ................................................................... 2-4 top cover disassembly/reassembly ........................... 4-2
tone remote control (TRC) board .......................... 2-6 trademarks .................................................................... ii
signal transceiver disassembly/reassembly ........................ 4-3
AGC_INHIBIT ...................................................... 3-11 transmit theory of operation .................................... 3-14
AGC_RESET ...................................................... 3-11 TRC
GT/FT .................................................................. 3-11 DC voltage troubleshooting chart .......................... 6-7
LPTT .................................................................... 3-11 local TX troubleshooting chart .............................. 6-4
RX_MUTE ........................................................... 3-11 RX audio troubleshooting chart ............................. 6-5
SPKR_UNMUTE ................................................. 3-11 TX audio troubleshooting chart ............................. 6-7
TONE_DETECT .................................................. 3-11 TRC to ACIM cable
WL_MUTE ........................................................... 3-11 diagram ............................................................... 3-12
speaker cable diagrams ............................................ 5-1 orientation ........................................................... 3-13
specifications troubleshooting
700-800 MHz .................................................. xviii, xix list of charts ........................................................... 6-1
UHF ....................................................................... xvii procedures ............................................................ 4-1
VHF ........................................................................ xvi troubleshooting charts
SPKR_UNMUTE signal .......................................... 3-11 AIB
substituting parts ..........................................................xi DC power ........................................................ 6-10
RX audio ............................................................ 6-9
TX audio ............................................................ 6-8
6881098C21-P May 5, 2009

Index-4
consolette does not work ...................................... 6-2

power problem ...................................................... 6-3
TRC
DC voltage ......................................................... 6-7
local TX .............................................................. 6-4
RX audio ............................................................ 6-5
TX audio ............................................................ 6-7
trunking tones not heard ....................................... 6-6
U
UHF specifications .................................................... xvii
V
ventilation installation ................................................ 2-1
VHF specifications ..................................................... xvi
W
wall mounting installation .......................................... 2-1
warning notation ........................................................ 1-1
WL_MUTE signal .................................................... 3-11
May 5, 2009 6881098C21-P

Motorola, Inc.
8000 West Sunrise Boulevard
Ft. Lauderdale, FL 33322
MOTOROLA, the Stylized M Logo, ASTRO and Flashport are

registered in the U.S. Patent and Trademark Office. All other
product or service names are the property of their respective owners.
© Motorola, Inc. 2004, 2009.
All rights reserved. Printed in U.S.A.
*6881098C21*
6881098C21-P

ASTRO® Digital XTL™ 5000 Mobile Radio Consolette (Control Heads W7 and W9) Instruction Manual

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ASTRO® Digital XTL™ 5000 Mobile Radio Consolette (Control Heads W7 and W9) Instruction Manual

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ASTRO®

Digital XTL™ 5000

Product Safety and RF Exposure Compliance

Before using this product, read the operating instructions

Computer Software Copyrights

List of Figures ..............................................................................................vii

Consolette Installation Guidelines ..............................................................ix

Chapter 1 Introduction ..........................................................................1-1

6881098C21-P May 5, 2009

Chapter 3 Theory of Operation ............................................................3-1

May 5, 2009 6881098C21-P

3.4 Tone Remote Control (TRC) Board................................................................................................3-5

Chapter 4 Maintenance .........................................................................4-1

Chapter 5 Cable Diagrams....................................................................5-1

Chapter 6 Troubleshooting Charts ......................................................6-1

6881098C21-P May 5, 2009

6.2 Troubleshooting Charts ..................................................................................................................6-2

Chapter 7 Schematics, Board Layouts, and Parts Lists....................7-1

Appendix A Cross Patch Configuration ................................................ A-1

Appendix B Replacement Parts Ordering ............................................. B-1

Index .................................................................................................... Index-1

May 5, 2009 6881098C21-P

Figure 2-1. Wall Mounting........................................................................................................................2-2

6881098C21-P May 5, 2009

Table 2-1. Audio Interface Board DIP Switch Settings ...........................................................................2-5

May 5, 2009 6881098C21-P

Consolette Installation Guidelines

Product Safety and RF Exposure Compliance

! usage contained in the Product Safety and RF Exposure booklet

Lightning and Surge Suppression

6881098C21-P May 5, 2009

Safe Handling of CMOS Integrated-Circuit Devices

Before using this product, read the operating instructions for

! safe usage contained in the Product Safety and RF Exposure

May 5, 2009 6881098C21-P

Parts Replacement and Substitution

6881098C21-P May 5, 2009

May 5, 2009 6881098C21-P

ASTRO Digital XTL 5000 Consolette Model Chart

6881098C21-P May 5, 2009

May 5, 2009 6881098C21-P

ASTRO Digital XTL 5000 Consolette Options – 900 MHz Band

6881098C21-P May 5, 2009

ASTRO Digital XTL 5000 Consolette VHF Specifications

FCC Designation: AZ492FT3806 Frequency Range: Frequency Range:

Spurious Rejection:+* –90 dB Emissions:+*

+ = Measured in Analog Mode per TIA/EIA-603

May 5, 2009 6881098C21-P

ASTRO Digital XTL 5000 Consolette UHF Specifications

FCC Designation: Frequency Range: Frequency Range:

Spurious Rejection:+* –90 dB Emissions:+*

+ = Measured in Analog Mode per TIA/EIA-603

6881098C21-P May 5, 2009

ASTRO Digital XTL 5000 Consolette 700–800 MHz Specifications

FCC Designation: AZ492FT5823 Frequency Range: Frequency Range:

Intermodulation:+* –80 dB Modulation Fidelity (C4FM):*

May 5, 2009 6881098C21-P

ASTRO Digital XTL 5000 Consolette 900 MHz Specifications

FCC Designation: AZ492FT5847 Frequency Range: Frequency Range:

Audio Output @3% Distortion: Emissions:+ –70 dBc

6881098C21-P May 5, 2009

May 5, 2009 6881098C21-P

1.1 Notations Used in This Manual

! CAUTION indicates a potentially hazardous situation which, if