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EFJ 1100-series VHF Repeater Service Manual

1. 5 6 TRANSMITTER ALIGNMENT 5 5 6 CARD RACK WIRING 7 1 CARD RACK BLOCK DIAGRAM voie 7 2 25 POWER SUPPLY SCHEMATIC 7 3 25 POWER SUPPLY COMPONENT LAYOUT 7 3 25 POWER SUPPLY COMPONENT LAYOUT 7 3 TEST SWITCH SCHEMA ee du 7 3 RECEIVER BOARD COMPONENT 7 4 FRONT END STRIP COMPONENT 7 4 RECEIVER SCHEMATIC DIAGRAM 7 5 TRANSMITTER BOARD COMPONENT LAYOUT 7 6 POWER CONTROL BOARD COMPONENT LAYOUT 7 6 TRANSMITTER SCHEMATIC DIAGRAM 7 7 POWER AMPLIFIER COMPONENT 7 8 POWER AMPLIFIER AND FILTER COVER ASSEMBLY 7 9 TYPE A CALL GUARD COMPONENT LAYOUT 7 10 GUARD SCHEMA TIG
2. 4 4 2nd MIXER And OSC 10 7 MAZ AMP eque xe os 4 5 INJECTION STRIP AND FIRST MIXER iuret C RR WR coe RR HER ERU E RAS 4 5 TRANSMITTER AUDIO SIGNAL TRACING oie GAs RET e bee 4 6 POWER CONTROL VOLTAGES redeo Ao eeu dfe Adv s ali See 4 6 EXCITER VOLTAGE READINGS ARIA Ie ard POCO dre EE Rabat abus 4 7 TEST PANEL SWITCH POSITIONS Me ai RNa neu wate EEN d 5 1 2 1 VALUES e eter CENE ASIE UG Pd sdb Ru rituum 5 1 C375 VALUES CIS amd eq eate sae 5 2 CALL GUARD RANGE JUMPERS weed aae RUSO AUR EE al de ee are 5 4 TABLE OF CONTENTS GENERAL INFORMATION SECTION 1 GENERAL INFORMATION 1 1 SCOPE OF MANUAL This service manual includes installation circuit description servicing and alignment information for the Johnson 1100 VHF repeater Part No 242 1100 XXX 1 2 DESCRIPTION The Johnson 1100 is a VHF FM repeater which operates on a single channel in the 150 174 MHz range It is completely solid state and the transmitter is rated at 100 watts RF power output continuous duty The output from the duplexer if equipped is approxi mately 70 watts The 1100 can be ordered as a single user or a community repeater When used in a single user con figuration the repeate
3. 1 1 MP905 a Es 1 RED JUMPER 902 MP908 EP902 gt RED a d A 923 COAX 9900 POWER AMPLIFIER COMPONENT LAYOUT FIGURE 7 13 2936 1902 v 7 8 HW6 9 HW8 COAX TO 4985 1115 FILTER C956 BLK TO PIN 24 DO eg C955 RED TO PIN23 5 NOTE 2 SHIELD TO GND HW8 J901 _ HW 8 HW2 BLK TO GND 277777 INSULATOR 4902 4903 3 SEE DETAIL A BLK TO GND ON CARD RACK FH900 F900 RED TO EPI ON COVER C976 POWER AMPLIFIER AND FILTER COVER ASSEMBLY FIGURE 7 14 7 9 W503 c502 W517 JD A w502 JB 4 79 m O H R507 oi 8517 516 W5I5 N 514 w513 500 518 W505 JC 6523 DN R529 C508 X5l X50 X 34 x40 X48 1 52 43 5 5 1 CR505 CR504 ON R531 ER R533 w504 JB CALL GUARD COMPONENT LAYOUT FIGURE 7 15 DECODE R548 JD 22k 517 BUS 1 JB JC GE 3 502 505 wy OF 59 ee TT O g 2507 DECODE R505 R506 25k FREQ ADJ 805 2 abbr ha 4 502 BUS 3 el rem nF E 9
4. HR SERO ee oa GS bee RE 7 11 CONTROL CARD COMPONENT LAYOUT 7 12 CONTROL CARD SCHEMATIC 7 13 LEVEL ADJUST CARD COMPONENT 7 14 1 1 2 1 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 5 1 5 2 5 3 5 4 TABLE OF CONTENTS LEVEL ADJUST CARD SCHEMATIC 7 15 4 TONE CALL GUARD 7 16 CALL GUARD SCHEMATIC ene sey en eds 7 17 CW IDENTIFIER COMPONENT LAYOUT 7 18 CW IDENTIFIER SCHEMATIC ee px ER RR teed eae 7 19 LIST OF TABLES ACCESSORIES OPTIONS PE ee Ae UA 1 2 CALL GUARD FREQUENCIES 5 7 8 4 5253 2 ORIS bans 2 2 APPROXIMATE LOGIC LEVELS pe ter bte eos 4 2 SOUEECH VOLTAGES EI eege 4 3 RECEIVER AUDIO SIGNAL TRACING nes ac pide tees ey eas 4 4 IF AND LIMITER DISCRIMINATOR VOLTAGES 4 4 10 7 MHz UNMODULATED INJECTION POINTS
5. 5 4 OUIETING SBNSEDIVEDYA un za yusa EE 5 4 SINAD EE zu se wires ay Scents AL are Ud 5 4 ef RT GEES 5 5 CALL GUARDSQUELCH 5 5 TRANSMIT PERFORMANCE 5 5 5 TRANSMIT 2 2 2 0 0 0 0 0 2 2 4 5 5 TRANSMIT POWER OUTPUT 5 5 TRANSMIT DEVIATION Aout Ac en naan etal cesi onec 5 5 EIERE EE e EE 5 5 PARTS LIST 1100 REPEATER 150 160 2 6 1 1100 REPEATER 160 174 Ms 6 1 RECEIVER ists lis cand EEN 6 1 EXCITER e seo so EE sete Bikes ead Geel 6 5 POWER AMPLIFIER HE UNS 6 9 25A POWER SUPPLY cone bated b A ile 6 11 RECEIVER HARNESS Bae Sad SPEC Ede EE 6 12 EXCITER HARNESS EE 6 12 FILTER COVER ASSEMBLY 6 12 CARD RACK ASSEMBIGY EE 6 13 TESTCARD ee u tastes UE 6 13 CONTROL CARD EEN 6 13 LEVEL CARD tuts pix bti u E rer
6. 10 ohm 1 2W CC 220k ohm 10 1 2W CC 5 6 ohm 10 10W WW Ferroresonant transformer 572 0002 011 596 1108 011 575 0608 012 575 1606 008 575 0606 006 560 2104 006 018 0920 002 575 9614 012 013 0025 010 515 1006 001 542 5005 011 017 1828 003 017 1718 002 017 1719 003 559 9001 257 023 0030 014 576 0002 021 569 2010 270 569 1004 102 569 1504 100 569 1004 224 569 2010 569 592 3501 002 August 1996 Part No 001 1100 003 PARTS LIST 3 ins 1 gnd terminal strip 4 ins 1 gnd terminal strip 8 ft AC cord 3 18 black RECEIVER HARNESS 586 1001 022 586 1001 024 597 1001 002 PART NO 023 3823 002 Male contact 0 14 x 0 13 ferrite bead Pin receptacle EXCITER HARNESS 016 1932 002 517 2002 001 586 3002 015 PART NO 023 3823 011 Male contact Female contact 0 14 x 0 13 ferrite bead 016 1932 002 016 1931 002 517 2002 001 FILTER COVER ASSEMBLY PART NO 023 4111 061 0 56 pF 5 500V comp 1000 pF 20 feedthru 1000 pF 20 1kV feedthru 100 pF 5 50V N750 disc 33 pF 5 50V N150 disc 18 pF 5 350V underwood 40 pF 5 350V underwood 40 pF 5 350V underwood 40 pF 5 350V underwood 18 pF 5 350V underwood 100V 6A rectifier 17V 5 zener Hot carrier diode 1N5711 Soldering terminal Connector shield Soldering terminal 1 4 heatshrink tubing Molded handle Rib lock standoff 6 ring terminal 16 14 wire Black plastic tubing Terminal lug 2104 10 August 1996
7. 20 16V YSS disc 47 pF 5 50V N750 disc 130 pF 5 50V NPO disc 270 pF 5 50V N750 disc 01 20 16V 55 disc 1 20 16V YSS disc 1 9 15 7 pF vertical PC mt 1 9 15 7 pF vertical PC mt 39 pF 5 50V N330 disc 39 pF 5 50V N330 disc 9 pF 5 100V 1DM10 300 pF 5 100V 1DM10 9 pF 5 100V 1DM10 300 pF 5 100V 1DM10 100 pF 5 50V N150 disc 3 pF 5 500V composition 01 20 16V YS disc 9 pF 5 50V 150 disc 1000 pF 20 50V YSU disc 510 3262 681 510 2245 689 510 3208 104 510 2575 109 510 3210 104 510 1203 103 510 1203 103 510 1203 103 510 3210 103 510 2023 569 510 4116 471 510 3210 104 510 3202 222 510 4006 005 510 3210 103 510 3220 470 510 3213 131 510 3220 271 510 3210 103 510 3210 104 187 0109 005 187 0109 005 510 3218 390 510 3218 390 510 0202 910 510 0202 301 510 0202 910 510 0202 301 510 3216 101 510 9502 309 510 3210 103 510 3216 910 510 3204 102 82 pF 5 100V 1DM15 prep 510 0201 820 01 pF 20 16V Y 5S disc 1 8 pF 5 50V NPO disc 01 20 16V YSS disc 3 pF 5 500V composition 10 pF 20 50V YSU disc 1000 pF 20 50V Y SU disc 3 3 10 15V submin 3 3 10 15V submin 01 20 16V YSS disc 510 3210 103 510 3213 189 510 3210 103 510 9502 309 510 3202 100 510 3204 102 510 2073 339 510 2073 339 510 3210 103 1 10 35V submin 1 pF 10 35V submin 5 6 20 15 molded 1 uF 10 35V submin 510 2575 109 510 2575 109 510 2023 5
8. HW603 SCREW 4 HW604 WASHER 4 HW602 NUT 4 5600 HW600 NUT CR603 S602 SWITCH BLK TO 5602 HW6OI 2 560 TRANSMIT LED MP600 USED FOR VARIABLE TIME DELAY OPTIONAL CONTROL CARD COMPONENT LAYOUT FIGURE 7 17 7 12 TIME OUT TIMER R606 100k R602 Sec R6IO 22k 629 CR604 865 560 ACCESS SWITCH GROUND I 1 dh oe OPEN TONE Kell 9 1 SQUELCH SWITCH 16 gt FROM SQUELCH INVERTER ON LEVEL CARD 6 R652 jg CALL GUARD SWITCH LINE 9 9 FROM CALL GUARD SWITCH ON CALL GUARD CARD PINI5 COL C BASE STATION CONTROL NOT USED IN REPEATERS QUTPUT FROM NOR GATE TO TRANSMIT AUDIO SWITCH ON LEVEL CARD PINS XMIT SWITCH TO XMIT SWITCH JI PIN IO 9 6 REG FROM LEVEL CARD 20 COL A LIMITED AUDIO TO GUARDS TO BANDPASS FILTERS ON CALL GUARD CARD PIN I3 COL C FILTERED CALL GUARD AUDIO OUTPUT IN EXCITER 20 23 TO CALL GUARD SWITCH ON LEVEL CARD PIN 25 0 6 VP P Oe3 VP P Oe AUDIO IN FROM AUDIO CALL GUARD SWITCH ON LEVEL CARD PINI5 COL A Ae MLM 224 R620 100k R657 220k NOTES ALL RESISTOR VALUES IN OHMS UNLESS OTHERWISE SPECIFIED 2 ALL CAPACITOR VALUES IN MICROFARADS UNLESS OTHERWISE 3 DC VOLTAGES MEASURED WITH NO SIGNAL BEING RECEIVEDe VOLTAGES MEASURED TRANSMIT VO
9. NO os ASE Rae OER ER EIS 5 1 EE 5 1 325 VALUES 2k uha scuta data Ao cA Eee 5 2 CALL GUARD RANGE JUMPERS 5 4 LIST OF FIGURES REPEATER BLOCK DIAGRAM 2 2 RECEIVER BLOCK DIAGRAM sober pete POET T PME 3 3 TRANSMITTER BLOCK DIAGRAM 3 5 CONTROL CARD BLOCK DIAGRAM 3 8 LEVEL ADJUST CARD BLOCK 3 10 CALL GUARD CARD BLOCK DIAGRAM 3 12 MICROPHONE SUBSTITUTE ee an haad Pledge t ied 4 6 RECEIVER DESENSE TEST SETUP 4 9 RECEIVER TROUBLESHOOTING 4 10 TRANSMITTER TROUBLESHOOTING 4 11 RECEIVER TEST SETUP s deci odas soit otto Ld sb etu estero 5 1 TRANSMIT TEST SETUP 5 2 CALL GUARD CARD ALIGNMENT 5 5 4 RECEIVER ALIGNMENT 5
10. 1 Confirm the Exciter is putting out approximately 17W 2 Measure the DC voltage on the collector of Q901 with the transmitter unkeyed Typically 15 7V DC 3 Unsolder the supply side of L901 4 Connect a DC ammeter between L901 and the removal point 5 The DC current should be about 3 3 5A with 100W RF output 4 7 5 TESTING Q902 Q903 AND Q904 Any one or a combination of the following may be used to check Q902 Q903 and Q904 Be sure the Exciter is delivering approximately 17W to the PA WARNING DO NOT TOUCH POWER AMPLIFIER COMPONENTS WHILE TRANSMITTING BECAUSE RF BURNS MAY RESULT 1 Temperature Method a Key the transmitter for a short time to allow the tran sistors to heat b Unkey the transmitter and briefly touch the transis tor cases If one is cold it probably is not conducting and may be defective 4 Power Change Method a Key the transmitter b Briefly short the suspected transistor s base and emitter with the blade of a screwdriver August 1996 Part No 001 1100 003 c Ifthe power output drops significantly the transistor is probably operating properly d If the power output does not drop the transistor is probably bad and must be replaced 5 Isolation Method a Unsolder the final s base legs and their associated equalizing resistors b Temporarily reconnect each transistor s base indi vidually c Each transistor should have about 33W RF output p
11. 1 1 REPEATER CABINETS EE 1 2 MICROPHONE haya ean pus Modo Ee du 1 2 FACTORY CUSTOMER SERVICE 1 2 PRODUCT WARRANTY Rud ur RA ER PR netur ies iae 1 2 FACTORY RETURNS od ae reed eg wass Ede EEN 1 3 REPLACEMENT PARTS ud eh ERROREM EE OU CREATE ERE TERR e esc nan MED 1 3 INSTALLATION HERGES 2 1 115 230V AC OPERATION DEE 2 1 INSTALLATION EE 2 1 REPEATER START UP eege EE 2 1 CIRCUIT DESCRIPTION GENERAL dena Dee a elas veda ates 3 1 RECEIVER hoe GG ADE eee Maa APR A OEE CARES Re Bowe aed EN ea eii 3 1 DC POWER SUPPLY sudu an pa eun dated 3 1 HELICAL FILTER FIRST MIXER ka adie aie See ERE be Oa Rae eee 3 1 OSCILLATOR SECOND TRIPLER INJECTION AMPLIFIER 3 1 10 7 MHz CRYSTAL FILTER AND 10 7 MHz 3 2 SECOND OSCILLATOR SECOND MIXER ere e e EE 3 2 FIRST IF AMPLIFIER SECOND IF AMPLIFIER 3 2 LIMITER DISCRIMINATOR dA A 3 2 AUDIO PRE AMPLIFIER CALL GUARD FILTER 3 2 AUDIO DRIVE
12. pF 10 35V tantalum 1 10 35V tantalum 1 pF 10 35V tantalum 1 pF 10 35V tantalum 6 8 20 35V tantalum CR700 11V 5 1W zener CR701 Si diode 1N4448 CR702 Si diode 1N4448 500 Receptacle EP700 Red ribbed lock feedthru HW700 1 4 32 x 0 094 hex nut NPB HW701 1 4 6 32 panhead taptite MP700 PC board bracket MP701 Knob machined 0 425 long 510 2575 109 510 3204 102 510 3210 103 510 2245 689 510 2575 109 510 3204 102 510 2575 109 510 3208 104 510 2245 689 510 2575 109 510 3202 332 510 3202 332 510 2245 229 510 3202 332 510 3202 332 510 2245 229 510 2575 109 510 2245 229 510 2575 109 510 2575 109 510 2575 109 510 2575 109 510 2575 109 510 2575 109 510 2575 109 510 2245 689 523 2503 110 523 1500 883 523 1500 883 586 3503 001 260 0202 901 560 9043 012 575 0606 008 017 2007 013 032 0767 022 0700 Si NPN power audio 2480 576 0002 026 701 Si NPN gen purp 92 Q 702 Q 703 Si NPN gen purp TO 92 Si NPN gen purp TO 92 576 0003 053 576 0003 053 576 0003 053 DESCRIPTION Si NPN gen purp TO 92 Si NPN gen purp TO 92 Si NPN gen purp TO 92 Si NPN gen purp TO 92 Si NPN gen purp TO 92 Si NPN gen purp TO 92 200k ohm 1 8W PC trim pot 27k ohm 4596 1 4W 100k ohm 5 1 4W ohm 5596 1 4W 100k ohm 5 1 4W 200k ohm 1 8W PC trim pot 100k ohm 5 1 4W CF ohm 5 1 4W 1k ohm 5 1 4W CF 15 ohm 10 1 2W CC 10k ohm volume pot 1k
13. 1 mcg 81 Bees x 24 E 21 2211 1210 SR ks x b ZE ZE i PEU amp AUDIC JS OUTPUT J5 EXT SPKR LS3 5 H pee neces E E E 24 23 33 32 34 28 9 10 1 2 3 4 6 7 22 35 19 17 25 26 27 31 LEVEL CARD CALL GUARD RECEIVER PIN 20 CALL GUARD AUDIO SQUELCH GATE LOCAL AUDIO ADJUST 7 11 AUDIO 12 AUDIO 1 SQUELCH CONTROL SQUELCH CONTROL LOCAL AUDIO OUTPUT LOCAL SPEAKER MIC AUDIO SWITCH 07010 AUDIO TRANSMIT SWITCH 0709 CH TRANSMITTER PIN 10 PTT TRANSMIT AUDIO CALL GUARD AUDIO LEVEL AMP 0794 LEVEL ADJUST AUDIO SWITCH 07018 TRANSMIT AUDIO LEVEL ADJUST TRANSMIT AUDIO SWITCH U701A CALL GUARD FILTER Q705 Q706 CALL GUARD AUDIO LEVEL ADJUST CALL GUARD AUDIO SWITCH U701D CALL GUARD SWITCH CONTROL 0707 PIN 14 PIN 16 PIN 9 CONTROL CARD CALL GUARD CARD BUFFER AMP LIMITER 06018 GUARD 1 0501 13 CALL GUARD AUDIO COMPRESSOR 0607 0608 0609 06014 CALL GUARD LOW PASS FILTER CALL GUARD 0603 2 0502 CALL GUARD 3
14. CR403 Hot carrier diode 1N5711 CR404 Hot carrier diode 1N5711 CR405 Ge diode 1N67A CR406 12V 5 1W zener 10 Male contact EP300 Soldering terminal EP301 Soldering terminal 016 0104 003 EP302 Black varnished tubing 042 0240 500 EP306 Insulator pad w adhesive back 574 5005 110 EP308 0 055 teflon tubing 058 0053 515 016 1932 002 016 0104 004 L 206 L 320 L 321 L 322 L 345 L 347 20 uH 150mA filter choke 542 5007 011 0 22 0 37 pF inductor violet 542 1006 117 1 choke 542 3502 005 uH choke 542 3502 005 0 22 0 37 uH inductor violet 542 1006 117 coil space wound brown 542 1012 111 EP375 EP376 EP377 Spacer TO 39 1 2 coil shield 3 8 coil shield 574 9001 001 578 0002 002 578 0002 001 L 349 L 350 L 351 RF coil space wound brown RF choke 542 1012 111 542 3006 002 543 1015 025 0 115 0 16 variable ind 2 5T ferrite choke 2 5T ferrite choke 2 5 ferrite choke 2 5T ferrite choke EP400 0 14 x 0 14 x 0 07 bead EP401 Battery contacts EP402 0 03 teflon tubing EP403 0 08 teflon tubing EP405 0 14 x 0 14 x 0 07 bead EP407 0 375 x 0 375 ferrite bead 517 2002 005 016 2052 101 058 0053 510 058 0053 520 517 2002 005 517 2002 003 L 375 L 376 L 377 L 378 517 2005 005 517 2005 005 517 2005 005 517 2005 005 MPO002 Transmitter shield MP004 Exciter insulator 10 Standoff 1 Heat sink MP303 Crystal clip MP313 Connector shield MP377 Spacer TO 39 017 1977 011
15. DUPLEXER OR COMBINING EQUIPMENT Connect the signal generator to the receiver antenna jack and connect a 50 ohm dummy load to the RF output jack of the transmitter Repeat the test and if the result is normal the duplexer or combining equipment may be improperly tuned or defective TRANSMITTER If the preceding test still resulted in abnormal desensitization the transmitter may be emitting exces sive spurious radiation 4 10 DETERMINING EFFECTIVE SENSITIVITY If the repeater is operating in a congested area where many high level RF signals are present the effective sensitivity may be less than that obtained using the standard bench check procedure To deter mine the effective sensitivity of the repeater perform the following test August 1996 Part No 001 1100 003 SERVICING 1 Check the quieting sensitivity of the receiver using 4 Determine the effective sensitivity using the follow the standard bench check procedure detailed in the ing formula Performance Tests in Section 5 4 Perform the test with the antenna combining equipment if used and Eff Sens Bench X Antenna 50Q load record the results 2 Connect the test setup shown in Figure 4 2 using the capacitive coupler as described in Sections 4 9 2 EXAMPLE and 4 9 3 Check the sensitivity using a 50 ohm dummy load connected to the capacitive coupler Bench Check Sensitivity 0 4 20 dB Quieting and record the results transmitter may be key
16. EFJohnson 1100 SERIES REPEATER 150 174 MHz 115 230 VAC 25 100 Watts Part No 242 1 00 xxx JOHNSON Fifth Printing August 1996 Supersedes 001 1100 002 JOHNSON 1100 150 174 MHz REPEATER SERVICE MANUAL 115 230V AC OPERATION 25 100 WATT RF OUTPUT PART NO 242 1100 xxx Copyright 1979 by the Johnson Company The E F Johnson Company designs and manufactures two way radio equipment to serve a wide variety of communications needs E F Johnson produces equipment for the mobile telephone and land mobile radio services which include business indus trial government public safety and personal users E EFJohnson LAND MOBILE PRODUCT WARRANTY The manufacturer s warranty statement for this product is available from your product supplier or from the E F Johnson Com pany 299 Johnson Avenue Box 1249 Waseca MN 56093 0514 Phone 507 835 6222 WARNING This device complies with Part 15 of the FCC rules Operation is subject to the condition that this device does not cause harmful interference In addition changes or modification to this equipment not expressly approved by the E F Johnson Company could void the user s authority to operate this equipment FCC rules 47CFR Part 15 19 DO NOT allow the antenna to come close to or touch the eyes face or any exposed body parts while the radio is transmitting DO NOT operate the radio near electrical blasting caps or in an explosive atm
17. pany you will hear a brief message informing you of numbers that can be entered to reach various depart ments This number may be entered during or after the message using a tone type telephone If you have a pulse type telephone wait until the message is fin ished and an operator will come on the line to assist you When you enter some numbers another number is requested to further categorize the type of informa tion you need You may also contact the Customer Service Department by mail Please include all information that may be helpful in solving your problem The mailing address is as follows Transcrypt International Inc Customer Service Department 299 Johnson Avenue P O Box 1249 Waseca MN 56093 0514 1 8 FACTORY RETURNS Repair service is normally available through local authorized Johnson Land Mobile Radio Service Centers If local service is not available the equipment can be returned to the factory for repair However it is recommended that you contact the Customer Service Department before returning equipment because a ser vice representative may be able to suggest a solution to the problem so that return of the equipment would not be necessary Be sure to fill out a Factory Repair Request Form 271 for each unit to be repaired whether it is in or out of warranty These forms are available free of charge by calling the repair lab see Section 1 7 or by requesting them when you send a unit in for r
18. v N 77 777 v rh wo WO wo wo 6 10 PIN 5 RN e mee ue 2 Ee M K E OPTIONAL SWITCHES 2 MON x X35 13 RS RI R7 E 202k 10k O AAA CALL GUARD 5 DISABLE CONTROL TO REMOTE pyg 858 0507 10k DECODER PIN 18 SCH 3058 SOFROMRX 83 20 x33 TO RPTR LEVEL 8515 e 9 a ADJUST PIN 12 PIN 7 o d o X33 10k Q506 si E 3058 0507 CONTROL TO 3058 AUDIO CARD 515 X24 REMOTE R4 AUDIO PIN 9 PIN 6 MN p MN NK m X14 ch 2 x28 10k Q506 54 1 3058 w514 9 24 N 6 p Es Se x6 RB 202k 10k o v o x10 E 0505 x53 5 ush s w516 10k RI 2 2k 3058 Ke SWITCH TO CR503 ANODE 9 0 Nv O 0 o gt Se Dt BUS 1 513 s 23 10k IN 5 TO R527 CR503 PINS eman asa 2505 DECODER PIN 17 3058 PI DC REMOTE SWITCHING TES ALL RESISTORS ARE IN OHMS AND CAPACITORS iN MICROF ARADS JNLESS OTHERWISE SPECIFIED 0501 0502 4 IS AND PIN 11 IS GROUND CALL GUARD SCHEMATIC FIGURE 7 16 GRN TO TO YEL TO 560 560 5600 BLK TO ORN TO BLK TO
19. 018 1007 001 013 1139 028 016 2180 001 032 0589 001 013 1198 001 539 0005 001 HW002 6 32 panhead taptite 1 4 575 0606 008 HW0046 32 x 0 078 nut NPB 560 2106 008 HW0056 0 018 NPB lockwasher int 596 2106 009 HW006 4 40 x 0 375 panhead philips 575 0604 012 HW0104 40 panhead philips screw 575 0604 010 HW015 Rubber grommet 778 574 1006 002 HW019 Shoulder screw 013 1350 002 HW020 Transistor nut 013 1396 001 HW021 6 32 panhead philips ZPS 575 1606 012 HWO022 1 4 28 x 0 109 NPB hex nut 560 9040 012 HW023 3 8 32 x 0 094 NPB hex nut 560 9062 016 HW024 5 8 24 x 0 094 SPB hex nut 560 9078 028 NPOO1 Exciter 150 160 MHz label 001 Exciter 150 174 MHz label 559 9001 237 559 9001 239 001 Banana plug sub assembly 023 0030 014 320 Si NPN VHF UHF amp osc 576 0003 051 August 1996 6 7 Part No 001 1100 003 PARTS LIST DESCRIPTION Si NPN VHF UHF amp osc Si NPN 1 GHz amp TO 72 1W 175 MHz amp TO 39 2W 175 MHz amp RO 39 Si PNP 80V 7A TO 220 Si PNP 80V 7A TO 220 NPN gen purp 2N3904 13W VHF amp SOE 30W amp NPN gen purp 2N3904 Si PNP 80V 7A TO 220 NPN gen purp 2N3904 Si PNP 50 MHz amp TO 92 NPN gen purp 2N3904 7 5 ohm 5 7W WW 100k ohm 5 1 4W CF 150 160 MHz 15k ohm 5 1 4W CF 160 174 MHz 22k ohm 5 1 4W CF 100k ohm 5 1 4W CF 100k ohm 5 1 4W 2 7 ohm 5 1 4W 82k ohm 5 1 4W 82k ohm 5 1 4W CF 10k ohm 5 1 4W 82k ohm 5 1 4W CF 10k ohm 5 1 4W 1k ohm 5
20. 50V N750 disc 160 174 MHz 56 pF 5 50V N750 disc 56 pF 5 50V 750 disc 56 pF 5 50V 750 disc 150 160 MHz 47 pF 5 50V N750 disc 160 174 MHz 56 pF 5 50V N750 disc 56 pF 5 50 N750 disc 56 pF 5 50V N750 disc 150 160 MHz 47 pF 5 50V N750 disc 160 174 MHz 18 pF 5 50V N750 disc 160 174 MHz 22 pF 5 50V N750 disc 33 pF 5 50V 750 disc 150 160 MHz 22 pF 5 50 N750 disc 160 174 MHz 10 pF 5 50V N750 disc 150 160 MHz 18 pF 5 50V N750 disc 160 174 MH2 47 pF 5596 50V N750 disc 01 20 50V YSU disc 10 uF 25V aluminum 01 uF 20 50V Y5U disc 1000 pF 20 50V 50 disc 10 25V aluminum 5 pF 5 50V 750 disc 150 160 MHz 1 8 pF 5 50V NPO disc 160 174 MHz 22 pF 5 50V 750 disc 160 174 MHz 10 pF 5 50V 750 disc 160 174 MHz 56 pF 5 50V 750 disc 150 160 MHz 15 pF 5 50V N750 disc 150 160 MHz August 1996 Part No 001 1100 003 PART NUMBER 510 3220 560 510 3220 560 510 3220 560 510 3220 470 510 3220 560 510 3220 560 510 3220 560 510 3220 470 510 3220 560 510 3220 560 510 3220 560 510 3220 470 510 3220 180 510 3220 220 510 3220 330 510 3220 220 510 3220 100 510 3220 180 510 3220 470 510 3202 103 510 4006 002 510 3202 103 510 3202 102 510 4006 002 510 3220 509 510 3213 189 510 3220 220 510 3220 100 510 3220 560 510 3220 150 SYMBOL PART NUMBER DESCRIPTION NUMBER 6 10 C 976 EP407 EP901 EP903
21. 586 3502 002 142 0102 004 016 1929 001 016 1929 001 016 1929 001 016 1929 001 016 1929 001 542 1007 002 016 1929 002 016 1929 003 542 3502 001 542 1012 001 542 1012 001 542 3502 003 542 3504 689 542 3502 002 542 3502 002 542 5007 001 032 0589 001 017 2097 001 013 1198 001 017 2013 001 559 9001 236 576 0006 009 576 0003 029 576 0003 002 576 0003 058 576 0003 058 576 0003 058 576 0002 027 576 0003 058 1996 001 1100 003 PARTS LIST PART SYMBOL DESCRIPTION NUMBER NUMBER DESCRIPTION NPN 65W 6A TO 220 NPN 65W 6A TO 220 Si NPN VHF UHF amp osc Si NPN FM osc mul TO 92 Si NPN FM osc mul TO 92 Si NPN FM osc mul TO 92 2 7k ohm 5 1 4W 470 ohm 5 1 4W CF 8 2k ohm 5 1 4W 2 7k ohm 5 1 4W CF 10k ohm 5 1 4W CF 150 ohm 5 1 4W 4 7k ohm 5 1 4W CF 2 2k ohm 5596 1 4W 10k ohm 5 1 4W 820 ohm 5 1 4W 10k ohm 5 1 4W CF 100 ohm 5 1 4W 6 8k ohm 5 1 4W 3 3k ohm 5 1 4W 10k ohm 5 1 4W ohm 5 1 4W 6 8k ohm 5 1 4W 1k ohm 5 1 4W CF 3 3k ohm 5 1 4W CF 10k ohm 5 1 4W CF 1k ohm 5 1 4W 6 8k ohm 5 1 4W CF ohm 5 1 4W 10 ohm 5 1 4W CF 100k ohm 5 1 4W CF 10k ohm 5 1 4W CF 10 ohm 5 1 4W 100 ohm 5 1 4W CF 820k ohm 5 1 4W 39k ohm 5 1 4W CF 1M ohm 5 1 4W CF 330k ohm 5 1 4W CF 15k ohm 5 1 4W CF 10k ohm 5 1 4W CF 10k ohm 5 1 4W CF 120k ohm
22. A Vk CR505 1 810 id R511 c512 R539 6 8 2001 1 100k 1 77 52 1 E p C514 SEA 1 e 247 9V 8542 1M AUDIO SWITCH R546 1M B SR 9 NO 4 ENCODED AUDIO QUI ge BEER 1 Roa 7 11 gt ron omm ER A R4 512 2 F w X53 Geen T T EE 1 9 L e EAS Ca 2 i ur S O x54 5 4 VEER E Mee Ja W x55 REH EE bn pp 5 4 0 x56 6 6 d D x6 x7 x8 R 6 511 x17 X18 x19 x20 x21 x27 x28 x29 x30 x32 33 4910 x40 X42 X44 X45 X47 d C 5 gt O 9 Ou 0506 9 9 0507 9 0508 3058 3058 3058 ee 7 o f 77 77 X12 x13 x22 X23 x24 Se e X26 x52 X36 x3 x38 x39 x48 X49 x50 X52
23. BUS 4 501 m a E a o R508 lt R501 woi R503 NA U501C 470 820k 9 224 ANY U501B E 2217 U501A Mu 224 B 4206 2 e ned 502 R504 8 1 4 Tk 820k 5 2 H 1 2 x3 X4 x51 ez R511 45V 1 5 R51 1 6 8510 4 SH M 8513 ji 1k CR501 20 Dom CDI Q505 503 505 6 8 ES 1 5500 CALL GUARD R515 R518 EEEF S ES 100k mE eer rA a 5501 j R516 OPERATE TEST ik Q501 Q502 f eo Owo 3017 7001 9 10 13 R524 8517 R519 DE CODE 15k SWITCH 508 ANV 2 77 7 WEN W O OPTIONS Mo E WO TO PIN 8 DECODE SWITCH 15 5 eg Si p OPTIONAL WIRE QUIS Eee ENCODE CE NEM R549 JD Se 22k 518 JB Je 2 0 2 504 503 5 gt m d WST5 i0 0507 8 0 0 gt R535 ENCODE 8535 R534 25k FREQ ADJ 30 9k 30 9k 45 4 O W514 IO 0506 5 WM vv C509 el WEIS X25 d TP502 TO R2 X10 396 R529 A U502C 470k B 6 2 9502 224 R530 6532 D 320k A Ga R538 CR504 caog 10k R545 gt R544 10 e
24. EP904 HW002 4 40 x 0 375 panhead phil TT 1000 pF 20 1kV feedthru 510 3149 102 0 375 x 0 375 ferrite bead Insulator 0 055 teflon tubing 0 055 teflon tubing HW005 4 40 panhead philips screw HW006 4 40 x 0 025 panhead phil TT HW007 4 40 x 0 375 panhead phil TT HWOOS 4 washer NPB HW009 0 225 ID flat washer NPB L 901 L 902 L 903 L 904 MP901 MP903 MP908 MP910 911 999 0901 Q 902 Q 903 Q 904 R 901 R 902 R 903 R 904 R 905 R 906 R 907 R 908 U 901 1 5T ferrite choke 1 5T ferrite choke 2 5T ferrite choke 1 5T ferrite choke PA heatsink Heatsink Standoff PA shield insert PA cover universal heatsink PA shield insert univ heatsink PA 150 160 MHz label 40W 175 MHz amp 40W 175 MHz amp 40W 175 MHz amp 40W 175 MHz amp 27 ohm 10 1W CC 56 ohm 10 1W CC 10 ohm 10 1W 10 ohm 10 1W CC 10 ohm 10 1W CC 10 ohm 10 1W CC 27 ohm 10 1W CC 0 56 10W PC board 517 2002 003 018 1005 004 058 0053 515 058 0053 515 575 0604 012 575 0604 010 575 0604 008 575 0604 012 596 2404 009 596 9410 014 517 2005 003 517 2005 003 517 2005 005 517 2005 003 015 0868 102 016 2112 002 013 1188 007 017 2081 021 017 2081 111 017 2081 121 559 9001 238 576 0004 021 576 0004 021 576 0004 021 576 0004 021 569 1006 270 569 1006 560 569 1006 100 569 1006 100 569 1006 100 569 1006 100 569 1006 270 569 2010 568 035 0206 001 PARTS LIST PAR
25. Place a frequency monitor pickup loop near T210 and monitor the oscillator frequency 2 Adjust C269 to the channel frequency minus 10 7 MHz NOTE The value of C217 can be changed to set the oscillator frequency to within the tuning range of C269 see Table 5 2 Table 5 2 C271 VALUES Description Part Number 27 pF 5596 N220 510 3017 270 33 pF 5 220 510 3017 330 39 pF 45 N220 510 3017 390 5 2 3 FRONT END AND IF AMPLIFIERS 1 Connect a signal generator set to the channel fre quency modulated with a 1 kHz tone at 5 kHz deviation to the antenna jack 2 Set the test panel switch to position 3 TP203 August 1996 Part No 001 1100 003 ALIGNMENT AND PERFORMANCE TESTS 3 Adjust C101 through C105 L106 T211 L204 L205 and T201 through T204 for maximum voltage while decreasing the generator output 4 Retune C101 C105 for maximum quieting 5 Retune T211 T201 T203 and T204 for best SINAD NOTE DO NOT retune L204 and L205 5 2 4 DISCRIMINATOR 1 Connect an AC VTVM across 3 ohm dummy load plugged into the external speaker jack on the card rack or connect an AC VTVM to the audio output jacks 2 Adjust T205 for a maximum meter indication sig nal generator output on channel modulated with 1 kHz tone at 5 kHz deviation 5 3 TRANSMITTER ALIGNMENT 1 Loosen the two screws holding the transmitter and its mounting bracket in place 2 Place the assembly toward you and remove the top co
26. REMOTE KEYING 3 9 37 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 TABLE OF CONTENTS RECEIVE CALL GUARD AUDIO CIRCUITS 3 9 ENCODED CALL GUARD 3 10 TRANSMIT AUDIO CIRCUITS LOCAL 3 11 SOUELCH ADJUSTMENT 3 11 CALL GUARD SQUELCH CARD 3 11 GENERAL EE EEN 3 11 DECODE AUDIO INPUT EEN 3 11 DECODE BUFFER AMPLIFIER 05034 BANDPASS FILTER 503 50 3 11 THRESHOLD DETECTOR U503D BANDPASS FILTER U503B US03C 3 12 ENCODE SWITCH 0504 AND AUDIO SWITCH 5500 3 12 ENCODE MODE Sans AE Ee 3 12 SERVICING LEE eee 4 1 PERIODIC CHECKS 22 E T E EE erte See 4 1 VISUAL INSPECTION 4 1 SCHEMATICS AND COMPONENT LAYOUTS 4 1 REPLACEMENT PARTS 4 1 SERVICE AND ALIGNMENT TOOLS
27. SERVICING 5 PIN MICROPHONE CONNECTOR PN 117 5505 111 e TO AUDIO GENERATOR om 54 OUTPUT TERMINALS TRANSMITTER KEYING SWITCH SWITCH STANDARD BANANA PLUG Figure 4 1 MICROPHONE SUBSTITUTE 4 6 6 POWER CONTROL Table 4 8 TRANSMITTER AUDIO SIGNAL TRACING 1 Measure and compare the voltages in Table 4 9 with those in the power control section Signal Voltage Table 4 9 POWER CONTROL VOLTAGES Measured AT Volts RMS Volts P P Crystal IN Crystal OUT U301 Measured At Volts DC Volts DC pin 4 390mV 0 8V Q402 pin 5 87mV 250mV Base 0 8V 0 8V pin 9 0 9V 5 2V Q403 pin 10 2 1V 4 3V Emitter CR303 CR304 200mV 0 5V Base C306 R310 24mV 40mV Collector R320 R324 0 9V 5 2V Q400 R324 C321 480mV 2 6V Base Test Conditions Inject a 1 kHz audio signal at 4 5 kHz Collector deviation on J2 pin 1 Transmitter keyed and transmit crys Q401 tal was removed Emitter Base Collector U401 pin 2 4 6 5 FIRST SECOND RF AMPLIFIERS PRE x DRIVER P pin 5 6 1 With the transmit crystal inserted measure and 7 compare the voltage readings on Q347 Q375 and pin 12 Q376 with those listed in Table 4 10 pin 13 pin 14 2 With the transmit crystal removed measure and compare the voltage reading with those listed in Table 4 10 August 1996 Part No 001 1100 003 4 6 SERVICING Table 4 10 EXCITER VOLTAGE READINGS IN Vieasure At Q320 RMS VDC VDC
28. The transmitter may momentarily key and damage to the power amplifier could result The same power supply can be used for 115 or 230V AC power sources If the power supply needs to be converted to operate on the other power source rewire the transformer and change fuse F1 as shown on the schematic and wiring diagrams in the back of this manual However if a change between 50 and 60 Hz power sources is necessary a different transformer is required INSTALLATION 2 3 INSTALLATION 1 Install the antenna coaxial cable through the access holes in the front or back baseplates of the repeater cabinet Connect the cable to the duplexer or to the transmitter and receiver depending on the type of installation Connect the power supply to AC power NOTE Because most repeater installations require several hundred feet of coaxial cable it is very impor tant that the cable be a high quality product Failure to use a high quality cable may result in large power losses and poor repeater performance 2 4 REPEATER START UP Connect the AC power cord and set the various controls on the cards as follows Call Guard Card Set the Encode switch to OFF and the switches on the PC board to ON if the respective Call Guard squelch is being used Control Card Set Repeat switch to ON and the Access switch to TONE Level Card The Call Guard Level control and Transmit Audio Level control are factory set or are adjusted during r
29. control on the Level Adjust card for threshold squelch just quieted 2 Set the signal generator to the receive channel fre quency modulated with 1 kHz tone at 3 kHz devi ation 3 Increase the signal generator output until the squelch opens which should open lt 0 25 p V 5 4 4 CALL GUARD SQUELCH 1 Set the squelch adjust control on the Level Adjust card for threshold squelch and the access switch to tone 2 Set the RF signal generator on the receiver channel frequency modulated with the Call Guard tone 67 250 Hz at 600 Hz deviation 3 Increase the generator output to 0 5 uV and the squelch should open 4 Repeat this procedure for each of the Call Guard tones 5 5 TRANSMIT PERFORMANCE TEST Set the repeat switch to off and the access switch to open on the Control card The encode switch on the Call Guard card should be off 5 5 1 TRANSMIT FREQUENCY 1 Set the communications monitor to the transmitter frequency and key the transmitter 2 The transmitter frequency should be within 5 PPM 20 000590 5 5 2 TRANSMIT POWER OUTPUT Key the transmitter Power output should be 100W without duplexer after one minute of continu ous transmission NOTE If the optional duplexer is used there is nor mally up to 1 dB power loss or up to 30W with an input of 100W not including any power reflected from the duplexer input 5 5 3 TRANSMIT DEVIATION 1 Set the repeat switch to on and the
30. encode or tone generating mode so the correct fre quency can be set During normal repeater operation this switch is set to the OFF position so all four Call Guard circuits are in the decode mode An ON OFF switch for each Call Guard circuit is located on the PC board to allow a Call Guard circuit to be disabled 3 7 2 DECODE AUDIO INPUT The Call Guard audio signal is from the receiver audio preamplifier stage on J211 The receive audio and subaudible Call Guard tone is fed from the receiver on J200 pin 20 to Level Adjust card pin 11 in the card rack In the Level Adjust card the signal passes through audio switch U701B to Level Adjust card pin 15 and on to Control card pin 14 The signal is then passed through lowpass filter U603 This filter attenuates frequencies above 300 Hz and passes the Call Guard tone frequencies From the lowpass filter the signal is fed to buffer amplifier U601B and a diode limiter circuit that changes the Call Guard signal from a sine wave to a square wave The square wave Call Guard signal is then fed to Call Guard card pin 13 NOTE The following circuit description applies to all four Call Guard circuits Call Guard circuit number three is used for discussion purposes 3 7 3 DECODE BUFFER AMPLIFIER 0503 BANDPASS FILTER U503B U503C The Call Guard audio input signal on pin 13 is coupled by C514 to buffer amplifier U503A pin 2 The buffer amplifier provides isolation between the bandpass filte
31. ohm 1 1 8W 10 ohm 5 1 4W CF ohm 1 1 8 10k ohm 5 1 4W CF 100k ohm 5 1 4W CF 10k ohm 5 1 4W CF 15k ohm 1 1 8W MF 100k ohm 1 1 8W MF 270k ohm 5 1 4W CF 100k ohm 5 1 4W CF 470k ohm 5 1 4W CF 470k ohm 5 1 4W CF 820k ohm 5 1 4W CF 820k ohm 5 1 4W CF 30 9k ohm 1 1 8 15k ohm 1 1 8W MF 25k ohm multi turn trim pot 10k ohm 1 1 8W 10k ohm 1 1 8W MF 10k ohm 1 1 8W MF ohm 1 1 8W 1k ohm 1 1 8W MF 10 ohm 5 1 4W 1k ohm 1 1 8W MF 10k ohm 5 1 4W CF 100k ohm 5 1 4W CF 10k ohm 5 1 4W CF 15k ohm 1 1 8W MF 100k ohm 1 1 8W MF 270k ohm 5 1 4W CF 100k ohm 5 1 4W CF 470k ohm 5 1 4W CF 470k ohm 5 1 4W 820k ohm 5 1 4W CF 820k ohm 5 1 4W CF 390k ohm 5 1 4W CF ohm 5 1 4W 390k ohm 5 1 4W CF 1 ohm 5 1 4W CF 390k ohm 5 1 4W CF 1k ohm 5 1 4W CF 390k ohm 5 1 4W CF 22k ohm 5 1 4W CF 22k ohm 5 1 4W CF 22k ohm 5 1 4W CF PART NUMBER 569 0520 401 569 0520 301 569 0520 301 569 05 13 100 569 0520 301 569 05 13 103 569 05 13 104 569 05 13 103 569 0520 418 569 0520 501 569 05 13 274 569 05 13 104 569 05 13 474 569 05 13 474 569 05 13 824 569 0513 824 569 0520 448 569 0520 418 562 0108 253 569 0520 401 569 0520 401 569 0520 401 569 0520 301 569 0520 301 569 0513 100 569 0520 301 569 05 13 103 569 05 13 104 569 05 13 103 569 0520 418 569 0520 501 569 05 13 274 569 05 13 104 569 0513 474 5
32. pin 9 5 6V 80mV pin 10 5 6V pin 11 8 7V 150mV Q204 Emitter 1 1V Base 1 8V 15mV Collector 7 2 3 0 0203 Emitter 1 1V Base 1 7V Collector 7 2V 100mV At 455 kHz Test Conditions No RF input to the receiver 4 5 5 SECOND MIXER SECOND OSCILLATOR 10 7 MHZ AMPLIFIER 1 Inject unmodulated 10 7 MHz and 455 kHz signals at the points indicated in Table 4 5 and compare readings 2 Measure and compare the DC voltages on Q202 Q214 and Q215 with those listed in Table 4 6 Table 4 5 10 7 MHz UNMODULATED INJECTION POINTS Injected At Q202 Base Collector Q215 Base Collector Q101 Drain Level Quieting dB 20 455 kHz 20 455 kHz 20 10 7 MHz 20 10 7 MHz 20 10 7 MHz SERVICING Table 4 6 2nd MIXER 2nd OSC 10 7 MHz AMP Measured At Q202 Emitter Base Collector Q214 Emitter Base Collector Q215 Emitter Base 3 4V Collector 15 6V Test Conditions No RF into receiver 4 5 6 OSCILLATOR TRIPLER TRIPLER INJEC TION AMPLIFIER FIRST MIXER Volts DC Volts RMS IV 1 6V 8 6V 5 2V 5 3V 2 7V 1 Measure and compare voltages on Q211 Q213 Q102 and Q101 with those listed in Table 4 7 Table 4 7 INJECTION STRIP AND FIRST MIXER IN RF Volts RMS Measured At Q211 Emitter Base Collector Q213 Emitter Base 2 1V 2 2V 8 7V 1 9V 1 1V 9 3V 0 5V Collector TP204 Q102 Emitter Base Collector TP205 Q101 Source 3 2V Drain 15 6V Test Con
33. 001 576 0003 017 576 0006 009 576 0003 058 576 0003 058 576 0003 058 569 0513 222 569 0513 103 569 0513 103 569 0513 222 569 0513 103 569 0513 102 569 0513 474 569 0513 474 569 0513 102 569 0513 824 569 0513 824 569 0520 448 569 0520 418 562 0108 253 569 0520 401 569 0520 401 569 0513 391 569 0520 401 PARTS LIST PART NUMBER SYMBOL NUMBER DESCRIPTION 5 501 TP500 TP501 TP502 U 501 U 502 ohm 1 1 8W ohm 1 1 8 10 ohm 5 1 4W CF 100k ohm 5 1 4W 1k ohm 5 1 4W CF 10k ohm 5 1 4W CF 10k ohm 5 1 4W 15k ohm 1 1 8W MF 100k ohm 1 1 8W MF 270k ohm 5 1 4W CF 100k ohm 5 1 4W ohm 5 1 4W 10k ohm 5 1 4W CF 10 ohm 5 1 4W CF 10k ohm 5 1 4W CF 10 ohm 5 1 4W 470k ohm 5 1 4W CF ohm 45 1 4W 390k ohm 5 1 4W 390k ohm 5 1 4W CF 30 9k ohm 1 1 8W 15k ohm 1 1 8W 25k ohm multi turn trim pot 10k ohm 1 1 8W MF 10k ohm 1 1 8 10k ohm 1 1 8W 100k ohm 5 1 4W CF 1 2k ohm 5 1 4W CF 1M ohm 5 1 4W CF ohm 1 1 8W ohm 1 1 W 10 ohm 45 1 4W 1M ohm 5 1 4W CF 1M ohm 5 1 4W 22k ohm 5 1 4W CF 22k ohm 5 1 4W CF 470k ohm 5 1 4W CF Sub miniature switch PC mt DPDT slide switch Tip jack vertical PC mount Brown vertical tip jack 08 Red vertical tip jack 08 Quad op amp 224 Quad op amp 224 569 0520 301 569 0520 301 569 0513 100 569 0513 10
34. 012 C612 0047 uF 200V foil 510 1201 472 0093 16 cable clamp 572 0001 002 C613 0015 uF 200V foil 510 1201 152 HW0104 x 0 015 lockwasher int NPB 596 2104 008 C614 015 pF 10 250V flat foil 510 1203 153 HWO015 Wire tie 574 9008 001 C615 560 pF 5 100V 1DM15 510 0201 561 HW016 1 8 self threading nut CPS 560 1818 014 616 6 8 20 35V tantalum 510 2245 689 C617 1000 pF 20 50V YSU 510 3204 102 J001 Male conn housing w insert 117 0336 103 618 6 8 20 35V tantalum 510 2245 689 J003 3 6 mm jack enclosed 515 2001 011 C619 1 pF 20 35V tantalum 510 2245 109 7004 Red banana jack 108 0902 001 C620 01 pF 20 16V YSS cer disc 510 3210 103 J005 Black banana jack 108 0903 001 621 6 8 20 35V tantalum 510 2245 689 622 6 8 20 35V tantalum 510 2245 689 LS003 Speaker assembly 023 3409 001 C623 6 8 uF 20 35V tantalum 510 2245 689 624 15 pF 10 15V tantalum 510 2073 150 1 Microphone mounting bracket 017 2003 011 625 6 8 320 35V tantalum 510 2245 689 2 Card guide 574 9015 001 C626 1000 pF 20 50V YSU cer 510 3204 102 C627 1000 pF 20 50 50 510 3204 102 001 1kohm 5 1 4W CF 569 05 13 102 C628 1 20 35 tantalum 510 2245 109 629 1000 pF 20 SOV 50 510 3204 102 0001 PC board 035 0351 002 C630 47 pF 20 15V dipped 510 2243 470 631 4700 pF 20 50V YSU 510 3202 472 TEST CARD 632 1 2090 35 tantalum 510 2245 109 023 3823 022
35. 10 ohm 5 1 4W 1k ohm 1 1 8W MF 10k ohm 5 1 4W 100k ohm 5 1 4W 10k ohm 5 1 4W 15k ohm 1 1 8W 100k ohm 1 1 8W 270k ohm 5 1 4W 100k ohm 5 1 4W CF 470k ohm 5 1 4W 470k ohm 5 1 4W 820k ohm 5 1 4W CF 820k ohm 5 1 4W 30 9k ohm 1 1 8W 15k ohm 1 1 8W MF 25k ohm multi turn trim pot 10k ohm 1 1 8W MF 10k ohm 1 1 8W MF 10k ohm 1 1 8W MF ohm 1 1 8W 1k ohm 1 1 8W MF 10 ohm 5 1 4W 270k ohm 5 1 4W CF 100k ohm 5 1 4W 470k ohm 5596 1 4W 470k ohm 5 1 4W CF 820k ohm 5 1 4W CF 820k ohm 5 1 4W CF 30 9k ohm 1 1 8 15k ohm 1 1 8W MF 25k ohm multi turn trim pot ohm 1 1 8W ohm 1 1 8 569 05 13 274 569 05 13 104 569 05 13 474 569 05 13 474 569 05 13 824 569 05 13 824 569 0520 448 569 0520 418 562 0108 253 569 0520 401 569 0520 401 569 0520 401 569 0520 301 569 0520 301 569 05 13 100 569 0520 301 569 05 13 103 569 05 13 104 569 0513 103 569 0520 418 569 0520 501 569 0513 274 569 0513 104 569 05 13 474 569 05 13 474 569 05 13 824 569 05 13 824 569 0520 448 569 0520 418 562 0108 253 569 0520 401 569 0520 401 569 0520 401 569 0520 301 569 0520 301 569 0513 100 569 0513 274 569 0513 104 569 0513 474 569 0513 474 569 0513 824 569 0513 824 569 0520 448 569 0520 418 562 0108 253 569 0520 401 569 0520 401 10k ohm 1 1 8 MF ohm 1 1 8W
36. 160 MHz 5 1 pF 5 50V N150 disc 160 174 MHz 1000 pF 20 50V Y5U disc 56 pF 5 500V comp 5 1 pF 5 50V N150 disc 8 2 pF 5 50V N150 disc 12 pF 5 50V N750 disc 150 160 MHz 8 2 pF 5 50V N750 disc 160 174 MHz 1 pF 5 500V comp 01 uF 20 16V YSS disc 5 1 pF 5 50V 150 disc 2 pF 5 500 comp 01 20 16V YSS disc 1000 pF 20 50 YSU disc 01 20 16V Y5S disc 5 6 20 35V tubular 1000 pF 20 50V YSU disc 56 pF 5 50V N750 disc 160 174 MHz 1000 pF 20 50V 50 disc 27 pF 5 50V N750 disc 22 pF 5 50V N750 disc 56 pF 5 50V N750 disc 150 160 MHz 47 pF 5 50V N750 disc 160 174 MHz 56 pF 5 50V N750 disc 01 20 50V YSU disc 27 pF 5 SOV N750 disc 150 160 MHz 56 pF 5 50V N750 disc 01 uF 20 50V YSU disc 1000 pF 20 50V Y 5U disc 5 6 UF 20 35V tubular 56 pF 5 50V N750 disc 56 pF 5 50V N750 disc 01 20 50V YSU disc August 1996 Part No 001 1100 003 510 3216 430 510 3216 560 510 0201 301 510 3202 101 510 3216 689 510 3216 519 510 3204 102 510 9502 568 510 3216 519 510 3216 829 510 3220 120 510 3220 829 510 9502 109 510 3210 103 510 3216 519 510 9502 209 510 3210 103 510 3204 102 510 3210 103 510 2005 569 510 3204 102 510 3220 560 510 3204 102 510 3220 270 510 3220 220 510 3220 560 510 3220 470 510 3220 560 510 3202 103 510 3220 270 510 3220 560 510 3202 103 510 3204 102 510 2005 569 510 3220 560 510
37. 3 2 TRANSMIT AUDIO STAGES Transmit audio from the level adjust card is applied through C302 and R301 to first audio ampli fier U301A pin 6 The amplified audio goes from U301A pin 5 through C303 and R304 to U301B pin 3 The series RC network C303 and R304 forms a pre emphasis network This network gives the audio signal part of the required 6 dB per octave pre emphasis A high level of modulation is maintained by a logarithmic compression amplifier U301B CR301 CR302 R305 and C304 This is accomplished by effectively vary ing the resistance of the feedback path from U301B pin 4 to U301B pin 3 The gain of U301B is initially set by R305 With a low level of audio fed back to U301B pin 3 CR301 and CR302 do not conduct This effectively increases gain With a high level of audio fed back to U301B pin 3 CR301 CR302 conduct This effec tively decreases the feedback loop resistance decreas August 1996 Part No 001 1100 003 3 4 ing gain of U301B The result is a constant audio output level regardless of input audio level Capacitor C304 helps to roll off the high frequency response The amplified and compressed audio goes from U301B pin 4 through C305 to limiter circuit R307 CR303 CR304 R308 and R309 Diodes CR303 and CR304 limit the audio to prevent overmodulation This is done by partially forward biasing CR303 and CR304 to approximately 0 5V with voltage divider R307 R308 and R309 When the positive peak aud
38. 3 3 5 FIRST RF AMPLIFIER SECOND RF AM PLIFIER The output of Q346 is coupled by C358 C359 to the base of first RF amplifier 0347 test point volt age is rectified by CR347 and filtered by R359 C368 The amplified output is taken off the collector of Q347 and coupled through C361 L351 and a section of microstrip to the base of second RF amplifier Q375 The collector current of Q375 is controlled by the power control circuit This regulates the transmitter s RF power output August 1996 Part No 001 1100 003 CIRCUIT DESCRIPTION 3 3 6 PREDRIVER DRIVER FINALS The output of Q375 is taken off the collector and coupled through a section of microstrip C383 and another section of microstrip to the base of predriver Q376 The output is taken off the collector and fed through a section of microstrip C397 and a coaxial cable to the PA assembly The power amplifier assembly contains the driver finals power sense thermal sense circuitry and the lowpass filter The signal from the exciter is fed through microstrip to the base of driver Q901 The output of Q901 is taken off the collector and fed to three paralleled finals Q902 Q903 and Q904 The output of the finals is fed through microstrip C931 length of coax and a lowpass filter to either a duplexer or an antenna 3 3 7 POWER CONTROL The power control circuit processes two separate inputs to control the transmitter RF power output One input is a sample of the ou
39. 3 3k ohm 5 1 4W 470 ohm 5 1 4W CF 22k ohm 5 1 4W CF 100k ohm 5 1 4W 10k ohm 5 1 4W 2 7k ohm 5 1 4W 1 5k ohm 5 1 4W CF 1 5k ohm 5 1 4W CF 56 ohm 5 1 4W CF 56 ohm 5 1 4W 1 2k ohm 5 1 4W CF 200 ohm thermistor 200 ohm thermistor 569 0513 683 569 0513 822 569 0513 123 569 0513 394 569 0513 184 569 0513 102 569 0513 102 569 0513 222 569 0513 182 569 0513 222 569 0513 104 569 1504 221 569 0513 270 569 1504 221 569 0513 270 569 2003 278 569 0513 100 569 0513 223 569 2503 229 569 2003 278 569 0513 470 569 0513 223 569 0513 152 569 0513 102 569 1006 390 569 0513 473 569 0513 473 569 0513 273 569 0513 273 569 0513 101 569 0513 101 569 0513 101 569 0513 332 569 0513 471 569 0513 223 569 0513 104 569 0513 103 569 0513 272 569 0513 152 569 0513 152 569 0513 560 569 0513 560 569 0513 122 569 3001 003 569 3001 003 300 301 301 400 C 001 002 003 090 C 091 10mm 10 7 MHz IF xformer 10mm 455 kHz IF xformer 10mm 455 kHz IF xformer 10mm 455 kHz IF xformer 10mm 455 kHz IF xformer Input driver transformer 10mm 150 MHz transformer 10mm 150 MHz transformer 10mm 150 MHz transformer 18 75 MHz ph mod xformer 3 ins 1 gnd terminal strip Red vertical tip jack 08 Red vertical tip jack 08 Red vertical tip jack 08 PC board front end PC board RGC FM IF system Quad op amp 3301 RG 188A U coax cable RG 188A U coax cable Crystal s
40. 3220 560 510 3202 103 6 6 01 20 50V Y5U disc 15 pF 5 50V N750 disc 150 160 MHz 56 pF 5 50V N750 disc 160 174 MHz 22 pF 5 50V N750 disc 22 pF 5 50V N750 disc 150 160 MHz 18 pF 5 50V N750 disc 160 174 MHz 12 pF 5 50V N750 disc 150 160 MHz 27 pF 5 50V N750 disc 150 160 MHz 56 pF 5 50V N750 disc 1000 pF 20 50V YSU disc 33 pF 5 50V N750 disc pF 20 35V dip 1 pF 20 35V dip 1 pF 20 35V dip 220 16V aluminum 1000 pF 20 50V YSU disc 33 pF 5 SOV N750 disc 33 pF 5 50V 750 disc 100 pF 20 50V YSU disc 33 pF 5 50V N750 disc 1000 pF 20 50V YSU disc 5 6 20 35V tubular 100 pF 20 50V YSU disc 100 pF 20 50V YSU disc 047 uF 20 16V YSS disc 33 pF 5 50V N750 disc 33 pF 5 50V N750 disc 1000 pF 20 50V YSU disc 33 pF 5 50 N750 disc 15 10 15V submin 33 pF 5 50V 750 disc 33 pF 5 50V N750 disc 1 20 16V YSS disc 39 pF 5 50V N750 disc Casting 581B G Connector mounting plate Diode 1N881 1N645 Diode 1N881 1N645 Si diode 1N4448 510 3202 103 510 3220 150 510 3220 560 510 3220 220 510 3220 220 510 3220 180 510 3220 120 510 3220 270 510 3220 560 510 3204 102 510 3220 330 510 2245 109 510 2245 109 510 2245 109 510 4116 221 510 3204 102 510 3220 330 510 3220 330 510 3202 101 510 3220 330 510 3204 102 510 2005 569 510 3202 101 510 3202 101 510 3210 473 510 3220 330 510 3220 330 510 3204
41. 4 1 DRAWER REMOVAL Nel teats Lr 4 1 INTEGRATED CIRCUIT SERVICING 4 1 CMOS HANDLING 5 4 1 SERVICING TECHNIQUES 4 2 TRANSISTOR 4 2 REPLACING TRANSISTORS SOLDERED 5 4 2 LOCALIZING PROBLEM DEFECTIVE ASSEMBLY 4 3 INTRODUCTION Pe cee hn RR enee 4 3 RECEIVE TROUBLESHOOTING 4 3 DC SUPPLY VOL CAGES Selena esce suns b ou u Meee 4 3 SOUBLCH Deo quM 4 3 AUDIO ee E 4 3 LIMITER DISCRIMINATOR FIRST AND 5 4 4 SECOND MIXER SECOND OSCILLATOR 10 7 MHz 4 4 OSCILLATOR TRIPLER TRIPLER INJECTION AMPLIFIER FIRST 4 5 TRANSMIT 5 4 5 GENERA EE 4 5 DC SUPPLY
42. 5 1 4W CF 270k ohm 5 1 4W 5 6k ohm 5 1 4W 47k ohm 5 1 4W CF 470k ohm 5 1 4W CF August 1996 Part No 001 1100 003 576 0002 046 576 0002 046 576 0003 051 576 0003 002 576 0003 002 576 0003 002 569 0513 272 569 0513 471 569 0513 822 569 0513 272 569 0513 103 569 0513 151 569 0513 472 569 0513 222 569 0513 100 569 0513 821 569 0513 103 569 0513 101 569 0513 682 569 0513 332 569 0513 103 569 0513 102 569 0513 682 569 0513 102 569 0513 332 569 0513 103 569 0513 102 569 0513 682 569 0513 102 569 0513 100 569 0513 104 569 0513 103 569 0513 100 569 0513 101 569 0513 824 569 0513 393 569 0513 105 569 0513 334 569 0513 153 569 0513 103 569 0513 103 569 0513 123 569 0513 274 569 0513 562 569 0513 473 569 0513 474 6 4 68k ohm 5 1 4W 8 2k ohm 5 1 4W CF 12k ohm 5 1 4W CF 390k ohm 5 1 4W CF 180k ohm 5 1 4W CF 1k ohm 5 1 4W CF ohm 5 1 4W 2 2k ohm 5596 1 4W 1 8k ohm 596 1 4W 2 2k ohm 5 1 4W 100k ohm 5 1 4W CF 220 ohm 10 1 2W 27 ohm 5 1 4W 220 ohm 10 1 2W 27 ohm 5 1 4W 27 ohm 5 1 2W WW 10 ohm 5 1 4W CF 22k ohm 5 1 4W CF 2 2 ohm 5 1 2W WW 27 ohm 5 1 2W WW 47 ohm 5 1 4W CF 22k ohm 5 1 4W 1 5k ohm 5 1 4W CF ohm 5 1 4W 39 ohm 10 1W CC 47k ohm 5 1 4W CF 47k ohm 5 1 4W CF 27k ohm 5 1 4W CF 27k ohm 5 1 4W CF 100 ohm 5 1 4W CF 100 ohm 5 1 4W CF 100 ohm 5 1 4W CF
43. 715 9 5 6 R729 Q705 713_ C714 Ok 0 82k 35 3058 3300pF CHEN TP701 0706 1 5 3058 R731 R754 2 5 10k 2 8X 265 R761 C716 10k 22k T 05 d 735 02 138 0708 3058 7 ke SOURCE 9 6 REGULATOR 9700 138 SOURCE 223 ES e A L 701 R708 R709 R755 Min 001 1k 15 FH 138 Z R m Ze dem 6 8 coz 703 rh T 78700 105 77 96 720 NOTES CH 1 ALL RESISTORS IN OHMS AND CAPACITORS MICROF ARADS _ 8721 UNLESS OTHERWISE SPECIFIED ES Jor 2 0701 PIN 7 15 GROUND 9 0702 3 3058 5 DC VOLTAGES MEASURED IN STANDBY MODE 0703 VOLTAGES MEASURED IN TRANSMIT MODE WITH CALL GUARD 027 3058 DC VOLTAGES MEASURED IN TRANSMIT MODE WITH ENCODE CALL GUARD AUDIO 0 77 1 ALL VOLTAGES SINE WAVES AND Mi A CELIVER iV MGDULAT A CALL GUARD AT E600 STATION 5vP F R727 15k m R725 ANN 9 i lt lt TP700 100k e 7 2 el Q704 pee 3058 8743 15 0 7 77 R728 C708 22K 6 8 0 24 LEVEL ADJUST CARD SCHIEMATIC FIGURE 7 20 CALL GUARD 2 CALL GUARD 528 w514 GRN TO 5500 w509 508 W5IO JUMPER C W537 PIN 7 JUMPER B JUMPER A JU
44. Base 0 68V 1 9V 2 4V Emitter 0 21V 227 217 Collector 1 9V 8 2V 8 3V TP301 1 5V Q345 Base 0 47V 1 0V 2 2V Emitter 2 0V 1 5V Collector 3 0V 14 9V 15 1V TP302 LIN 0346 1 6V 0 6V 1 0V Emitter 0 06V 2 3V 0 3V Collector 2 2V 13 1V 15 3V TP303 0 2V Q347 Base 0 3V 0 5V 0 6V Collector 3 0V 11 6V 15 2V Q375 Base Collec 0 47V tor 1 5V 15 7V 15 7V Q376 Base 1 0V Collector 4 6V Power at 7313 17 Watts Test Conditions Voltage readings are with reference to 17W output 4 7 POWER AMPLIFIER TROUBLESHOOTING 4 7 1 COMPONENT REPLACEMENT When a component needs replacing it can be accessed from the component side of the power ampli fier board When replacing components on certain areas of the board care must be taken to prevent leads from touching the heat sink under the PC board An insula tor is installed between the PC board and the heat sink but it covers only a portion of the board The remain der of the board is mounted by electrically conductive standoffs which keep the component leads from becoming grounded The standoffs also provide a path to ground for the PC board 4 7 Transistors Q901 through Q904 may be removed _ by first removing each transistor s two mounting screws The transistor s flanges may now be unsol dered and the transistor can be removed NOTE When reinstalling 0901 through 0904 make sure there is adequate heat sink compound on the mounting base of the transistor This can
45. CF 470k ohm 5 1 4W 10k ohm 5 1 4W 47k ohm 5 1 4W CF 330 ohm 41096 1 2W ohm 5 1 4W 50k ohm 1 8W PC trim pot 2 2k ohm 5 1 4W CF 10k ohm 5 1 4W CF 1k ohm 5 1 4W 1k ohm 5 1 4W CF 10k ohm 5 1 4W CF ohm 5 1 4W 3 3k ohm 5 1 4W 1k ohm 45 1 4W 1 5k ohm 5 1 4W 200 ohm thermistor 200 ohm thermistor Thermistor RF transformer brown RF transformer green 2 2 ins 1 gnd terminal strip TP301 TP302 TP303 TP304 Red vertical tip jack Red vertical tip jack Red vertical tip jack Red vertical tip jack PC board transmitter Quad op amp 3301 PC board power thermal RF 188A U coax cable 569 05 13 104 569 05 13 103 569 0520 401 569 0520 301 569 0513 274 569 0513 104 569 1504 101 569 0513 103 562 0005 503 569 0513 104 569 0513 123 569 0513 474 569 0513 103 569 0513 473 569 1504 331 569 0513 102 562 0005 503 569 0513 222 569 0513 103 569 0513 102 569 0513 102 569 0513 103 569 0513 102 569 0513 332 569 0513 102 569 0513 152 569 3001 003 569 3001 003 569 3001 001 592 5022 101 592 5022 109 586 1001 020 105 2202 211 105 2202 211 105 2202 211 105 2202 211 035 0256 001 544 2005 001 035 0355 080 597 3002 003 X 302 X 303 DESCRIPTION Crystal socket Crystal socket POWER AMPLIFIER PARTS LIST 126 0110 014 126 0110 014 PART NO 023 4111 260 150 160 MHz PART NO 023 4111 360 160 174 MHz A 001 C901 9
46. CR600 Diode 1N881 1N645 523 1500 881 01 Receptacle 586 3503 001 CR601 Si diode 1N4448 523 1500 883 EP002 Right angle pin male 586 3504 021 CR602 Si diode 1N4448 523 1500 883 CR603 Red LED 549 4001 001 U 001 PC board extender card 035 0355 010 CR604 Si diode 1N4448 523 1500 883 CR605 Diode 1N881 1N645 523 1500 881 August 1996 6 13 Part No 001 1100 003 PARTS LIST EP500 Receptacle HW000 Panel mount LED socket HW600 1 4 32 x 0 094 hex nut NPB HW601 1 4 6 32 panhead taptite HW602 2 56 x 0 063 nut NPB HW603 2 56 panhead philips ZPS HW6042 x 0 013 lockwasher int NPB HW605 Panel mount LED socket MP600 PC board bracket Q 600 Si NPN gen purp TO 92 Si NPN gen purp TO 92 Si PNP 50 MHz amp TO 92 Si NPN Darlington TO 92 Si NPN gen purp TO 92 Si NPN gen purp TO 92 Si NPN Darlington TO 92 J FET 4 12k switch TO 92 J FET low noise RF TO 92 Si PNP 50 MHz amp TO 92 10 ohm 5 1 4W CF 100k ohm 5 1 4W ohm 5596 1 4W 100k ohm 5 1 4W CF 1k ohm 5 1 4W CF ohm 5 1 4W CF 100k ohm 5 1 4W CF 2 2M ohm 5 1 4W CF 1k ohm 5 1 4W CF 10k ohm 5 1 4W CF 22k ohm 5 1 4W CF 10k ohm 5 1 4W CF 1k ohm 5 1 4W CF 10k ohm 5 1 4W CF 1k ohm 5 1 4W CF 180k ohm 5 1 4W CF 10k ohm 5 1 4W CF 100k ohm 5 1 4W CF 100k ohm 5 1 4W CF 1k ohm 5 1 4W CF 100k ohm 5 1 4W CF 330k ohm 5 1 4W CF 390k ohm 5 1 4W CF 270k ohm 5 1 4W CF PART NUMBER 586 3503 001 550 0006 100 5
47. GUARD AUDIO CIR CUITS Level Adjust card pin 12 is connected to the col lector of squelch gate Q208 When an on channel signal is received the collector of Q208 goes high This places a high on the base of Q703 The collector of Q703 goes low which places a low on Level Adjust card pin 16 and Control Card pin 10 A low is also placed on the base of Q702 The collector of Q702 rises and U701B pin 12 goes to 9 6V This closes U701B and the Call guard audio from the receiver is coupled through R742 C721 U701B and C722 to Level Adjust card pin 15 This pin goes to the Call Guard lowpass filter on the Con trol Card The Control Card processes Call Guard audio and feeds it to Call Guard card pin 13 and Level Adjust card pin 23 From pin 23 the Call Guard audio is coupled through U701D normally closed by a high on U701D pin 5 to Call Guard level adjust R705 From R705 the audio is coupled to level amplifier Q704 The output on the collector is coupled through C709 to Level Adjust card pin 22 August 1996 Part No 001 1100 003 CIRCUIT DESCRIPTION CALL GUARD CG AUDIO AUDIO 5 RX CG AUDIO 07018 INVERTER INVERTER SQ GATE SQ GATE RX AUDIO IN TRANSMIT RX AUDIO OUT AUDIO SWITC TX SWITCH 01A SQ CONTROL CALL GUARD FILTER Q705 Q706 LOCAL MIC AUDIO MIC AUDIO SWITCH U701C TRANSMIT SWITCH Q709 LOCAL PTT TX PTT OUT TX AUDIO OUT CALL GUARD AUDIO SWITC 07010 CG AUDIO OU
48. M CR403 HI LO POWER SWITCH 8426 420 CHAN 2 OSC R337 C336 CHANI OSC 8338 C536 THERMAL SENSE R400 C400 E 4n 5 NOTES POWER SENSE R4h C 408 21 CAPACI i ty ALL RESISTORS ARE IN OHMS ITORS ARE IN MICROFARAOS TRANSMIT KEY LINE R374 8360 2 1L 3 UNLESS OYHERWISE SPECIFIED t 4 TRANSMIT AUDIO C302 2 DENOTES FREQUENCY RANGE TEMPERATURE COMPENSATION OR SEMICONDUCTOR MATCHING SEE TABLE BELOW CALL GUARD AUDIO J30 901 904 TRANSISTORS 575 0004 02 1 1 510 3020 560 510 3020 50 NOT USED pr Kiem 510 3020 560 510 3020 560 510 020 560 510 020 560 510 320 560 510 3020 560 NOT USED 12 021 9 510 3079 560 510 3020 560 510 3020 560 XMIT TP302 RCV TP204 50 14 20 NOT USED 510 3020 180 NOT USED NOT USED 510 2020 100 NOT USED NOT USED NOT USED T 510 3013 189 510 3016 588 NOT USED 510 3020 220 510 120 220 NOT USED NOT USED 510 3020 100 510 020 560 510 00 50 NOT USED NOT USED NOT USED 510 2020 19 NOT USED NO USID 160 174 IRW MOTOROLA 28 510 3020 470 510 3020 560 19 25 TP303 RCV TP205 3 OC VOLTAGES TAKEM WITH CRYSTAL REMOVED AUDIO VOLTAGES ARE RMSe des 4 Oe 3VRF FIRST RF AMPLIFIER 3e0 VRF 05647 VRF SECOND RF AMPLIFIER 30b the Casa Seet
49. PC mt SPST pushbutton switch August 1996 Part No 001 1100 003 586 3503 001 575 0606 010 550 0006 100 576 0002 027 576 0003 058 576 0003 017 576 0003 017 576 0003 058 576 0006 009 576 0007 001 569 0513 105 562 0004 204 569 1502 154 569 0513 103 569 0513 103 569 0513 103 569 0513 105 562 0004 204 569 1502 154 569 0513 103 569 0513 103 569 0513 103 569 0513 104 569 0513 104 569 0513 103 569 0513 103 569 1504 101 569 0513 103 569 0513 102 569 0513 471 569 0513 562 569 0513 103 569 0513 471 562 0004 503 569 0513 333 569 0513 474 569 0513 104 569 0513 474 569 0513 102 569 0513 474 583 3001 211 583 4007 001 6 20 Quad 2 input NOR Quad 2 input NOR Quad 2 input NOR 12 bit binary counter 4040B 12 bit binary counter 4040B Bi polar PROM 1k PC board IC socket 544 3001 103 544 3001 103 544 3001 103 544 3014 040 544 3014 040 544 9050 010 035 0355 065 515 5008 002 SECTION 7 SCHEMATIC DIAGRAMS AND COMPONENT LAYOUTS CARD RACK MOTHER BOARD OPTION OPTION OPTION CG CG CG CG CONTROL ADJ N G O N COLUMN 1 CARD RACK WIRING DIAGRAM FIGURE 7 1 7 1 REPEATER WIRE HARNESS USED WITH TONE REMOTE 12 10 35 9 32 5 11 10 4 EH E 920 J1 96 RECEIVER i 30 gt 22 j 22 SUN 35 55 i KE Ze 33 14 D 2 6 E mcos Be To pn bad DA P
50. TI SH BLK WHT GRN 10 120 7 3 POWER HWIT 2 HWIO 4 HW6 3 CABLE SEE DETAIL B 7 Em EP28 MP3 MP2 LI E FH2 F2 C 1 2 TE gt 1 eve EP28 POWER SEE DETAIL 4 CABLE J2 HW8 2 HW4 2 4 2 EM HW 2 HW22 2 HW22 2 HWI2 2 2 HW23 2 25A POWER SUPPLY COMPONENT LAYOUT TOP FIGURE 7 4 29 5 CHARGER OPTION TB2 HW4 BLK WHT GRN FHI SEE DETAIL F 25 POWER SUPPLY COMPONENT LAYOUT BOTTOM FIGURE 7 5 J3 TO TRANSCEIVER TEST JACK RECEIVER OSC TRIPLER TEST POINT TP204 TRANSMIT 2ND DOUBLER TEST POINT TP302 8 TRANSMIT FIRST DOUBLER TEST POINT RECEIVER IF TEST POINT TP203 TRANSMIT FIRST RF AMPLIFIER TEST POINT 19 RECEIVER INJECTION AMPLIFIER TEST POINT TP205 gt 9 13 8 VDC SWITCHED 4308 ot 1567 RECEIVE 1367 VDC XMIT 4304 20 NOT USED 28 EXTERNAL METER TEST SWITCH SCHEMATIC FIGURE 7 6 FOLDOUT gt GRY BRN TO ORN RED MPiOI 2 PINI 4200 2 4200 JUMPER JUMPER ORN TO CATHODE OF CR209 RED TO BLK PIN2 OF TBI WHT RED TO PIN 25 J200 TINNED JCT EP201 COAX SHIELD WHT BLK TO RIO3 RIO4 TO TOGND PINS 4200 RECE
51. drops to near ground potential and current flows through LED CR506 and R584 The Call Guard switch line output on Call Guard card pin 15 is the voltage drop across Q505 and CR506 approximately 2 2V 3 7 5 ENCODE SWITCH 0504 AND AUDIO SWITCH S500 Encode switch Q504 is turned on in the decode mode by removing the base voltage through 5500 This effectively shorts the feedback path of the Call Guard to AC ground which prevents the Call Guard from oscillating 3 7 6 ENCODE MODE When the Call Guard circuit is in the encode mode 55004 connects contacts 6 and 4 placing the output of the Call Guard circuit to pin 4 In 5500 contacts 12 and 10 are connected placing a high posi tive voltage on the base of Q504 and it turns off A portion of the Call Guard output is now fed back through R558 R557 to U503A pin 3 This positive feedback causes the Call Guard to oscillate at the bandpass frequency The amplitude of the oscillations is controlled by a voltage divider and limiter circuit made up of R591 R592 CR512 and CR513 The diodes are connected on one side to the DC input line which presents a ground for AC signals The output of the oscillator is from U503B pin 7 and fed through S500 pins 4 and 6 to the encoded Call Guard output line on Call Guard card pin 4 The oscillator frequency is measured at TP503 or encoded on the transmit signal and measured from the RF output The encode audio switch Q508 is turned on in the enc
52. k nt 36 Di Lowe CA 47097 1 5 9 4 A h s 3 1345 345 tgs 2 7 tex C334 470 346 ne 00 364 C365 242666 TP302 Ew Sas T 7 P300 20F 1459 caga sd PIN25 R397 PING 10k R350 525 9v REG 10k 432 1 Ee 8 leO VRE 406 VR 1 d PREORIVER VRF on sor 2408 c39 mm w H Bd Y be r con V UN 1 Best Dee C392 396 KE 948 E377 azer 56 pF 909 c fez cs D se mei 2 2 sare 500 119 0 8 97 400 1 2 i 15 7 92 Ar F900 19 7 SLOW BLOW 1 l 224295 EP405 2021 2 15 p 5 7 227 047 1540 04241457 330 1429 1 g MLM224 1009F POWER CONTROL R401 FORWARO POWER 9 8 8416 H Toc 100k ge R EC EP405 EP405 Dr 77 GC 8415 PIM 23 zl EP403 n 470k 400 ror 7 TO Mi LO POWER PIN2 C420 5 001 se 403 6402 C408 2409 33pF IOF 33pf Loo HI LO POWER SWITCH srg
53. ohm 5 1 4W CF ohm 5 1 4W 10k ohm 5 1 4W 200k ohm 1 8W PC trim pot 10k ohm 5 1 4W 100k ohm 5 1 4W CF 200k ohm 1 8W PC trim pot 100k ohm 5 1 4W 100k ohm 5 1 4W CF ohm 5 1 4W 10k ohm 5 1 4W 100k ohm 5 1 4W CF 4 7k ohm 5 1 4W CF 10 ohm 5 1 4W CF 100k ohm 5 1 4W 10k ohm 5 1 4W CF 33k ohm 5 1 4W 2 2k ohm 5 1 4W CF 82k ohm 10 1 4W 330k ohm 5 1 4W CF 10k ohm 5 1 4W CF 10k ohm 5 1 4W CF 330k ohm 5 1 4W 82k ohm 10 1 4W 2 2k ohm 5 1 4W CF 10 ohm 5 1 4W CF 10k ohm 5 1 4W CF ohm 5 1 4W 100k ohm 5 1 4W CF PARTS LIST 576 0003 053 576 0003 053 576 0003 053 576 0003 053 576 0003 053 576 0003 053 562 0004 204 569 0513 273 569 0513 104 569 0513 102 569 0513 104 562 0004 204 569 0513 104 569 0513 102 569 0513 102 569 1504 150 562 0016 005 569 0513 102 569 0513 103 569 0513 103 562 0004 204 569 0513 103 569 0513 104 562 0004 204 569 0513 104 569 0513 104 569 0513 103 569 0513 103 569 0513 104 569 0513 472 569 0513 100 569 0513 104 569 0513 103 569 0513 333 569 0513 222 569 1502 823 569 0513 334 569 0513 103 569 0513 103 569 0513 334 569 1502 823 569 0513 222 569 0513 100 569 0513 103 569 0513 103 569 0513 104 August 1996 001 1100 003 PARTS LIST DESCRIPTION 10k ohm 5 1 4W CF 10 ohm 5 1 4W CF 10 ohm 5 1 4W 15k ohm 5 1 4W CF ohm 5
54. to Figure 5 1 for a suggested test setup For troubleshooting purposes receiver troubles can be quickly isolated to the defective stage by fol lowing the receiver troubleshooting flow chart see Figure 4 3 or by proceeding as follows 4 5 1 DC SUPPLY VOLTAGES 1 Measure the DC voltage on the cathode of CR208 and the positive lead of C260 They should be within 5 of those listed below Positive lead of C260 Cathode of CR209 15 7V DC 9 0V DC 4 3 4 5 2 SQUELCH 1 With no signal into the transceiver measure the DC voltage on the collector of Q208 J209 while rotat ing squelch control R717 The squelch control can be adjusted through a hole on the level adjust card in the card rack 6 6V DC DC Counterclockwise Clockwise With no signal into the receiver measure the noise on U201 pin 6 with an oscilloscope Typically 500 mV P P of noise Measure and compare the voltages in the squelch section with those in Table 4 2 Table 4 2 SQUELCH VOLTAGES Measured Volts P P At U202C VDC Squelched VDC Unsquelched pin 1 0 5V 0 5V 5 SON 4 5V 4 5V pin 6 20 mV 0 5V 0 5V U202D pin 2 0 5V 0 5V pin 3 100 mV 0 5V 0 5V pin 4 2 0V 4 2V 4 2V Q208 base 0 7V 0 2V collector 0 6V 6 7V Test Conditions No RF into receiver Squelch control set as indicated 4 5 3 AUDIO 1 With the receiver unsquelched measure the voltage at the base of Q207 Typical
55. 01 902 901 903 905 906 907 908 909 C 910 C 910 911 912 C 912 913 914 914 915 916 916 917 Filter cover assembly 12 pF 5 50V N750 disc 150 160 MHz 22 5 50V N750 disc 160 174 MHz 15 pF 5 50V N750 disc 150 160 MHz 10 pF 5 50V N750 disc 160 174 MHz 33 pF 5 50V N750 disc 160 174 MHz 56 pF 5 50V N750 disc 1000 pF 20 50V Y 5U disc 56 pF 5 50V N750 disc 56 pF 5 50V N750 disc 56 pF 5 50V N750 disc 56 pF 5596 50V N750 disc 150 160 MHz 68 pF 5 50V N750 disc 160 174 MHz 56 pF 5 50V N750 disc 56 pF 5 50V 750 disc 150 160 MHz 47 pF 5 50V N750 disc 160 174 MHz 56 pF 5 50V 750 disc 150 160 MHz 56 pF 5 50V N750 disc 150 160 MHz 47 pF 5 50 N750 disc 160 174 MHz 56 pF 5 50V N750 disc 150 160 MHz 56 pF 5 50V N750 disc 150 160 MHz 47 pF 5 50V N750 disc 160 174 MHz 56 pF 5 50V N750 disc 150 160 MHz 023 4111 061 510 3220 120 510 3220 220 510 3220 150 510 3220 100 510 3220 330 510 3220 560 510 3202 102 510 3220 560 510 3220 560 510 3220 560 510 3220 560 510 3220 680 510 3220 560 510 3220 560 510 3220 470 510 3220 560 510 3220 560 510 3220 470 510 3220 560 510 3220 560 510 3220 470 510 3220 560 August 1996 001 1100 003 PARTS LIST 56 pF 5 50V N750 disc 56 pF 5 50V N750 disc 56 pF 5 50V N750 disc 150 160 MHz 47 pF 5
56. 05 adjusts the detector and is tuned for maxi mum undistorted audio output 3 2 8 AUDIO PRE AMPLIFIER CALL GUARD FILTER Detected audio from U202 is coupled through C235 to the de emphasis network C230 C255 C237 R233 R234 and R232 This network provides a 6 dB per octave de emphasis from 300 3000 Hz The gain of U202A is determined by the ratio of the feedback resistance and its input resistance The feedback path contains C247 used to roll off amplification of fre quency over 3 kHz The output of U202A is coupled by C252 and C254 to the inverting input of Call Guard filter U202B The components make U202A act as a high pass filter with a low frequency roll off of approxi mately 300 Hz to remove Call Guard tones The audio output from U202A pin 10 is coupled through C246 to J200 pin 11 This pin goes to the transmit audio circuit and to local volume control on the Level Adjust card in the card rack 3 2 9 AUDIO DRIVER AUDIO OUTPUT The output of the local volume control is fed to J200 pin 12 and coupled by C250 and R247 to the base of audio amplifier Q206 Base bias for Q206 is developed across R262 and fed through 252 to the base of Q206 Negative feedback capacitor C259 helps high frequency roll off response The audio is directly coupled from Q206 to the base of audio driver Q207 The output of Q207 is taken off the col lector of Q207 and applied to the primary of T206 the input transformer to a Class B push pull au
57. 1 This leaves less current available for Q375 and the RF output power decreases until the power amplifier cools to a safe temperature If the power amplifier section gets extremely hot the resistance of RT902 decreases even more This causes the voltage on U401A pin 14 to go even higher When this DC level gets to approximately 6 8V CR402 conducts This applies a positive DC voltage to the inverting input of U401C This also results in the power output decreasing but since both inputs to U401C are involved the amount of power decrease is even more This is done to ensure that the power output decreases especially if R412 or R420 are turned up to a high level When the high low power switch is not used no voltage 15 applied to the junction of R426 and C420 This allows 0403 to turn on which turns on 0402 With the collector of Q402 essentially at ground potential a voltage divider consisting of R420 and R421 is placed in the input circuit of U401C The high power adjustment is made with R420 When the high low power switch is used with the power fail beep alarm installed normally no volt age is applied to the junction of R426 and C420 as pre viously discussed When the AC power fails and the battery takes over approximately 12V is applied to the junction of R426 and C420 This turns off Q403 which turns off Q402 With Q402 shut off the high power adjustment voltage divider is removed from the inverting input circuit of U401C T
58. 1 4W 100k ohm 5 1 4W CF 10 ohm 5 1 4W 1k ohm 5 1 4W CF 10k ohm 45 1 4W 10 ohm 5 1 4W 100k ohm 5 1 4W CF 100k ohm 5 1 4W CF 100k ohm 5 1 4W CF 100k ohm 5 1 4W CF 10k ohm 5 1 4W 10k ohm 5 1 4W 100k ohm 5 1 4W CF 100k ohm 5 1 4W 100k ohm 5 1 4W CF 10k ohm 5 1 4W CF Black feedthru terminal PC board Quad analog switch 569 05 13 103 569 05 13 100 569 0513 100 569 0513 153 569 0513 102 569 05 13 104 569 05 13 100 569 05 13 102 569 05 13 103 569 0513 100 569 05 13 104 569 0513 104 569 05 13 104 569 05 13 104 569 05 13 103 569 05 13 103 569 05 13 104 569 0513 104 569 05 13 104 569 0513 103 260 0203 001 035 0355 040 544 3014 016 TYPE A CALL GUARD CARD PART NO 023 3823 056 1 10 35 tantalum pF 100V polycarb pF 100V polycarb 6 8 20 35V tantalum 1000 pF 20 50 YSU cer 1 uF 20 35 tantalum 1 pF 20 35V tantalum 1 pF 20 35 tantalum 1 pF 100V polycarb 1 pF 100V polycarb 6 8 uF 20 35V tantalum 1000 pF 20 SOV YSU cer 1 uF 20 35 tantalum 33 pF 5 50 NPO cer disc 3 3 pF 10 15V tantalum 1 uF 10 35V tantalum Ge diode 1N67A August 1996 Part No 001 1100 003 510 2575 109 510 1015 104 510 1015 104 510 2245 689 510 3204 102 510 2245 109 510 2245 109 510 2245 109 510 1015 104 510 1015 104 510 2245 689 510 3204 102 510 2245 109 510 3213 330 510 2073 339 510 2575 109 523 1500 067 SY
59. 1 4W CF 100k ohm 5 1 4W CF 100k ohm 5 1 4W CF 68k ohm 5 1 4W 27k ohm 5 1 4W CF 150 160 MHz 15k ohm 5 1 4W 160 174 MHz 68k ohm 5 1 4W CF 82k ohm 5 1 4W CF 1k ohm 5 1 4W CF 1k ohm 5 1 4W CF 150k ohm 5 1 4W 1k ohm 5 1 4W CF 50k ohm 1 8W PC trim pot 27k ohm 5 1 4W CF 50k ohm 1 8W PC trim pot 27k ohm 5 1 4W CF PART NUMBER 576 0003 051 576 0003 029 576 0004 008 576 0004 03 1 576 0002 021 576 0002 021 576 0003 058 576 0004 051 576 0004 072 576 0003 058 576 0002 021 576 0003 058 576 0003 017 576 0003 058 569 2007 759 569 05 13 104 569 0513 153 569 05 13 223 569 0513 104 569 05 13 104 569 05 13 272 569 05 13 823 569 05 13 823 569 0513 103 569 05 13 823 569 0513 103 569 0513 102 569 0513 104 569 0513 104 569 05 13 683 569 05 13 273 569 05 13 153 569 05 13 683 569 05 13 823 569 0513 102 569 05 13 102 569 05 13 154 569 05 13 102 562 0004 503 569 05 13 273 562 0004 503 569 05 13 273 SYMBOL PART NUMBER DESCRIPTION NUMBER 470 ohm 5 1 4W 27k ohm 5 1 4W CF 56k ohm 5 1 4W CF 33k ohm 5 1 4W CF 33k ohm 5 1 4W 47k ohm 5 1 4W CF 47k ohm 5 1 4W CF 100 ohm 5 1 4W CF 27k ohm 5 1 4W CF 27k ohm 5 1 4W CF 470 ohm 5 1 4W CF 470 ohm 5 1 4W 6800 ohm 5 1 4W CF 150 ohm 5 1 4W 1 8k ohm 5 1 4W 10 ohm 5 1 4W CF 10k ohm 5 1 4W CF 100 ohm 5 1 4W CF 10 ohm 5596 1 4W 3 3k ohm 5 1 4W CF 220 ohm 5 1 4W C
60. 102 510 3220 330 510 2073 150 510 3220 330 510 3220 330 510 3210 104 510 3220 390 015 0805 522 017 1666 003 523 1500 881 523 1500 881 523 1500 883 PARTS LIST PART SYMBOL NUMBER NUMBER CR304 Si diode 1N4448 CR307 9 1 5 zener CR318 Ge diode 1N67A CR320 Ge diode 1N67A CR321 Varicap diode SMV1628 523 1500 883 523 2503 919 523 1500 067 523 1500 067 523 0009 034 J 301 HWO25 1 4 0 315 x 1 2 washer HWO32 4 40 x 0 094 NPB nut HW033 4 40 panhead philips ZPS 596 4514 020 560 2104 008 575 1604 010 Solderless pin 586 3502 002 CR322 CR323 CR345 CR346 CR347 CR350 CR400 CR401 CR402 Varicap diode SMV 1628 6 2 5 1W zener Ge diode 1 67 Ge diode 1N67A Ge diode 1 67 17V 5 1W zener 6 2V 5 1W zener 9 1V 5 1W zener 6 8V 5 1W zener 523 0009 034 523 2503 629 523 1500 067 523 1500 067 523 1500 067 523 2503 170 523 2503 629 523 2503 919 J 304 J 305 J 306 J 307 J 308 J 309 J 310 J311 Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 523 2503 689 J311 Male conn housing w insert 117 0336 103 523 1500 014 J312 Female conn housing w insert 117 0436 103 523 1500 014 J313 UHF female coax TBO 142 0102 004 523 1500 067 J314 Jack 013 0025 010 523 2503 120 J315 Pinreceptacle 586 3002 015
61. 150 174 MHz 1 5 MHz 43 H x 22 W x 15 D Optional HD for local operation and test 115V AC 230V AC Parts 15 21 74 90 and 16F3 Continuous 25A fuse 0 35 mV 12 dB SINAD 90 dB 0 25 mV 100 dB 100 dB 80 dB 0 5 Watt local 60 dB squelched 5 PPM 22 F to 140 F 2 5 PPM 22 F to 140 F 50 Ohms nominal 8 Ohms 100 Watts Continuous 70 dB 16KOF3E 5 kHz at 77 F 100 at 1 kHz 50 dB minimum 5 PPM 20 F to 140 F 2 5 PPM 20 F to 140 F 5 at 1 kHz 3 kHz deviation 50 Ohms INSTALLATION CIRCUIT DESCRIPTION SECTION 3 CIRCUIT DESCRIPTION 3 1 GENERAL The Johnson 1100 is a VHF full duplex multi tone repeater see Figure 2 1 The unit is powered by a 115 230V AC power supply The incoming signal is fed from the receive section of the duplexer to the receiver The audio output of the receiver is then fed to the card rack A portion of the Card Rack processes the audio and turns on the exciter The RF output of the exciter is coupled to the power amplifier and to the optional duplexer and the antenna The repeater can also be controlled by the optional tone remote console Refer to the appropriate schematic diagram or block diagram while following the circuit description 3 2 RECEIVER 3 2 1 DC POWER SUPPLY DC power is applied to the receiver 15 7V DC line at J200 pin 35 This line supplies power to the audio output stages 9 1V regulator first mixer 10 7 MHz IF amplif
62. 3 1500 067 523 1500 067 523 2503 919 523 1500 067 013 1393 001 016 1932 002 574 5005 110 042 0240 770 013 1302 001 013 1302 001 013 1302 001 013 1302 001 013 1302 001 013 1302 001 013 1302 001 260 0002 001 260 0001 001 018 1080 002 574 5008 001 574 5008 001 517 2002 004 517 2002 001 575 0606 008 560 2106 008 596 2106 009 575 0604 010 575 0604 012 013 1350 002 575 1606 012 560 9078 028 560 1810 022 575 1606 008 575 4506 008 596 9400 004 DESCRIPTION Male conntr housing w insert Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Solderless pin Female coax UHF TBO Helical inductor Helical inductor Helical inductor Helical inductor Helical inductor 0 115 0 14 WH variable induct Helical inductor Helical inductor 1 uH 10 choke 5 8 6 variable inductor 5 8 6 WH variable inductor 50 5 choke 6 8 WH 10 RF choke 20 uH 5 choke 20 HH 5 choke 20 150 mA filter choke Crystal clip Front end shield Connector shield IF shield Receiver label 150 174 MHz J FET low noise RF TO 92 Si NPN 1 GHz amp TO 72 Si NPN FM osc mul TO 92 NPN gen purp NPN gen purp NPN gen purp Si NPN audio driverMPS U01 NPN gen purp PARTS LIST 117 0336 103 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002 586 3502 002
63. 4 569 05 13 102 569 0513 103 569 0513 103 569 0520 418 569 0520 501 569 0513 274 569 0513 104 569 0513 102 569 0513 103 569 05 13 100 569 0513 103 569 0513 100 569 0513 474 569 05 13 102 569 0513 391 569 0513 391 569 0520 448 569 0520 418 562 0108 253 569 0520 401 569 0520 401 569 0520 401 569 0513 104 569 0513 122 569 0513 105 569 0520 301 569 0520 301 569 0513 100 569 0513 105 569 0513 105 569 05 13 223 569 05 13 223 569 05 13 474 583 3001 211 583 3003 001 105 0860 001 105 2208 211 105 2202 211 544 2020 001 544 2020 001 6 17 4 TONE CALL GUARD CARD PART NO 023 3823 050 Switch harness assembly 1 pF 10 35V tantalum 1 100V polycarbon 100V polycarbon 6 8 20 35V tantalum 1000 pF 20 50V YSU cer 1 20 35V tantalum 1 20 35V tantalum 1 10 tantalum uF 100V polycarbon 1 100V polycarbon 6 8 20 35V tantalum 1000 pF 20 SOV YSU cer 1 20 35 tantalum 1 420 35V tantalum 1 10 35 tantalum 1 uF 100V polycarbon 1 uF 100V polycarbon 6 8 20 35V tantalum 1000 pF 20 50V YSU 1 20 35 tantalum 1 20 35 tantalum 1 10 35V tantalum 1 100V polycarbon 1 100V polycarbon 6 8 20 35V tantalum 1000 pF 20 SOV YSU cer 1 uF 20 35V tantalum 1 20 35V tantalum 33 pF 5 50V NPO cer disc 1 10 35 tantalum Diode 1N881 1N645 Diode 1N881 1N
64. 448 6 2V 5 1W zener Red LED Si diode 1N4448 Si diode 1N4448 Si diode 1N4448 Part No 017 2007 015 510 1203 104 510 2033 338 510 3261 102 510 3261 102 510 3261 102 510 2033 338 510 2245 689 510 3261 102 510 4003 005 510 1203 124 510 1203 124 510 2245 109 510 2245 109 510 2245 109 510 4006 006 523 1500 883 523 2503 629 549 4001 001 523 1500 883 523 1500 883 523 1500 883 August 1996 001 1100 003 PARTS LIST PART NUMBER SYMBOL NUMBER EP500 Receptacle HW001 1 4 6 32 panhead taptite HW003 Panel mount LED socket Q 001 Q 003 Q 004 Q 005 Q 006 Q 007 Si NPN audio driver MPS UOI Si NPN gen purp TO 92 Si NPN 50 MHz amp TO 92 Si PNP 50 MHz amp TO 92 Si NPN gen purp TO 92 J FET low noise RF TO 92 Si NPN Darlington To 92 1M ohm 5 1 4W CF 200k ohm 1 8W PC trim pot 150k ohm 10 1 4W 10k ohm 5 1 4W CF 10k ohm 5 1 4W CF 10k ohm 5 1 4W 1M ohm 5 1 4W CF 200k ohm 1 8W PC trim pot 150k ohm 10 1 4W 10k ohm 5 1 4W CF 10k ohm 5 1 4W 10k ohm 5 1 4W CF 100k ohm 5 1 4W CF 100k ohm 5 1 4W CF 10k ohm 5 1 4W CF ohm 5 1 4W 100 ohm 41096 1 2W 10k ohm 4596 1 4W 1k ohm 5 1 4W CF 470 ohm 5 1 4W CF 5 6k ohm 5 1 4W CF 10k ohm 5 1 4W CF 470 ohm 5 1 4W CF 50k ohm 1 8W PC trim pot 33k ohm 5 1 4W CF 470k ohm 5 1 4W CF 100k ohm 5 1 4W CF 470k ohm 5 1 4W CF ohm 5 1 4W 470k ohm 5 1 4W CF Sub miniature switch
65. 5 CONTROL CARD 3 5 1 GENERAL Refer to Figures 3 3 and 7 2 for block diagram layouts of the card rack and control card The repeater control card contains circuitry that can be put into two categories Transmit Control circuits Call Guard circuits While going through the circuit description refer to the control card schematic Figure 7 18 3 5 2 TRANSMIT CONTROL CIRCUITS NOTE While going through the transmit control cir cuits initially assume the receiver is receiving an on channel signal with the proper Call Guard tone The circuitry that causes various voltages on the input pins 10 the control card are discussed in the appropriate sections of this service manual When a properly encoded signal is received pins 15 and 16 go low This places a low through repeater switch S601 and R601 to the base of Q600 With S601 in the OPEN position a Call Guard tone is not needed to operate the repeater A Call Guard tone is needed in the TONE position A low is also applied from pin 15 through R652 to NOR gate 0602 pin 9 low is not U602A pins 9 10 and 11 In order to key the transmitter a low is also needed on U602A pin 12 With S600 in the OFF position U602A pin 11 will always be high and the transmitter cannot be keyed The base station control line Control Card pin 21 is not used in the repeater When a low is applied to the base of Q600 it turns off This causes a positive pulse to be coupled throu
66. 56pF 1904 C922 2 906 2 10 157V POWER SENSE R910 casa 199 56 100 L9 L92 1915 499 1009F an 2 973 4OpF E 1902 D 4 PS 2 core THERMAL SENSE C955 RED PIN 23 THERMAL FOLDBACK INTER COMNECT HARNESS SCHEMATIC 025 1000 070 SWITCHED 13 8 VOC 4308 1 TEST JACK 1547 VOC 1348 VOC RYC 4304 SEMICONDUCTOR oC oB oE Q320 0321 576 0003 051 0350 9400 9402 576 0003 9403 576 0003 017 9901 9902 9903 9904 576 0004 021 4 1 24 cose I I I 4905 te I 904 ES ASING IS BOTTOM VIEW UNLESS OTHERWISE INDICATED VIEW Q345 576 0003 029 Q346 Q347 576 0004 031 0348 0349 0401 576 0002 021 0375 576 0004 051 9376 576 0004 018 544 2005 001 TRANSMITTER SCHEMATIC DIAGRAM FIGURE 7 12 _ 2 6976 RED TO tP90 EPI ON TO COVER 4 955 9 2900 TO 9 C95 VIEW FROM PC BOARD SIDE DETAIL A po ee ee SS lt lt lt lt lt 1 1 1 I i 1 I 1 COAX 2 FILTER
67. 60 9043 012 575 0606 008 560 2102 006 575 1602 008 596 2102 006 550 0006 100 017 2007 011 576 0003 058 576 0003 058 576 0003 017 576 0007 001 576 0003 058 576 0003 058 576 0007 001 576 0006 051 576 0006 009 576 0003 017 569 0513 100 569 0513 104 569 0513 102 569 0513 104 569 0513 102 569 0513 102 569 0513 104 569 0513 225 569 0513 102 569 0513 103 569 0513 223 569 0513 103 569 0513 102 569 0513 103 569 0513 102 569 0513 184 569 0513 103 569 0513 104 569 0513 104 569 0513 102 569 0513 104 569 0513 334 569 0513 394 569 0513 274 SYMBOL PART NUMBER DESCRIPTION NUMBER 330k ohm 5 1 4W CF 390k ohm 5 1 4W CF 180k ohm 5 1 4W CF 330k ohm 5 1 4W CF 330k ohm 5 1 4W CF 330k ohm 5 1 4W 390k ohm 5 1 4W CF 330k ohm 5 1 4W CF 150k ohm 10 1 4W 10k ohm 5596 1 4W 10k ohm 5 1 4W CF 10 ohm 5 1 4W CF 22k ohm 5 1 4 CF 470k ohm 5 1 4W CF 4 7k ohm 5 1 4W CF 2 2k ohm 5 1 4W CF 8 2k ohm 5 1 4W CF 270k ohm 5 1 4W CF 270k ohm 5 1 4W CF ohm 5 1 4W 2 7k ohm 5 1 4W CF 18k ohm 5 1 4W 2 7k ohm 5 1 4W CF 1k ohm 5 1 4W CF 1k ohm 5 1 4W CF 10 ohm 5 1 4W 100k ohm 5 1 4W 10k ohm 5596 1 4W 10k ohm 5 1 4W CF 220k ohm 5 1 4W 47k ohm 5 1 4W CF ohm 5 1 4W 1M ohm 5 1 4W CF 220k ohm 5 1 4W CF 220k ohm 5 1 4W CF 10 ohm 5 1 4W Slide switch DPDT Slide switch DPDT SPST pushbutton switch PC board Quad op am
68. 645 Diode 1N881 1N645 Diode 1N881 1N645 Red LED Red LED Red LED Red LED Si diode 1N448 Si diode 1N448 Si diode 1N448 023 3823 051 510 2575 109 510 1015 104 510 1015 104 510 2245 689 510 3204 102 510 2245 109 510 2245 109 510 2575 109 510 1015 104 510 1015 104 510 2245 689 510 3204 102 510 2245 109 510 2245 109 510 2575 109 510 1015 104 510 1015 104 510 2245 689 510 3204 102 510 2245 109 510 2245 109 510 2575 109 510 1015 104 510 1015 104 510 2245 689 510 3204 102 510 2245 109 510 2245 109 510 3213 330 510 2575 109 523 1500 881 523 1500 881 523 1500 881 523 1500 881 549 4001 001 549 4001 001 549 4001 001 549 4001 001 523 1500 883 523 1500 883 523 1500 883 August 1996 001 1100 003 PARTS LIST 511 Si diode 1N448 CR512 Si diode 1N448 CR513 Si diode 1N448 CR514 Si diode 1N448 CR515 Si diode 1N448 500 Receptacle HW501 1 4 6 32 panhead 502 1 4 32 x 0 094 hex nut NPB HW504 Panel mount LED socket HW505 Panel mount LED socket HW506 Panel mount LED socket HW507 Panel mount LED socket 500 Bracket MP501 Knob machined 425 long Q 500 Q 501 Q 502 Q 503 Q 504 Q 505 Q 506 Q 507 Q 508 R 500 R 501 R 502 R 503 R 504 R 505 R 506 R 507 Si PNP 50 MHz amp TO 92 Si NPN Darlington TO 92 Si PNP 50 MHz amp TO 92 Si NPN Darlington TO 92 Si PNP 50 MHz amp TO 92 Si NPN Darlington TO 92 Si PNP 50 MHz amp TO 92 Si NPN Darlington TO 92 Si PN
69. 69 510 2575 109 1 10 50V submin 510 3109 104 1 10 50V submin 510 3109 104 10 50V submin 510 3109 104 1 10 50V submin 510 3109 104 August 1996 Part No 001 1100 003 6 2 DESCRIPTION 1 Casting CH002 Connector mounting plate CH202 Front cover casting 101 Ge diode 1N67A CR201 Ge diode 1N67A CR203 Ge diode 1N67A CR204 Ge diode 1N67A CR205 Ge diode 1N67A CR206 Ge diode 1N67A CR207 Ge diode 1N67A CR208 Ge diode 1N67A CR209 9 1V 5 1W zener CR212 Ge diode 1 67 1 Helical tuning cup Male contact Insulated pad adhesive backed Black ext plastic tubing Helical coil form Helical coil form Helical coil form Helical coil form Helical coil form Helical coil form Helical coil form Standoff terminal red Standoff terminal white Crystal pin insulator long slot Compression washer 77 CS Compression washer 77 CS 0 138 x 0 070 ferrite bead Ferrite bead 14 x 13 HW002 6 32 panhead taptite 1 4 HW004 6 32 x 078 NPB nut HW005 Lockwasher int 6 x 018 NPB HW0064 40 panhead philips screw HW007 4 40 x 375 panhead phil TT HW019Shoulder screw HW021 6 32 panhead philips ZPS HW024 5 8 24 x 094 hex nut SPB HW028 Tension lock nut CPS HW0306 32 panhead philips ZPS HW101 6 32 panhead slot nylon screw HW200 Teflon flat washer 015 0805 503 017 1666 003 017 1703 011 523 1500 067 523 1500 067 523 1500 067 523 1500 067 523 1500 067 523 1500 067 52
70. 69 0513 474 569 05 13 824 569 05 13 824 569 05 13 394 569 05 13 102 569 05 13 394 569 05 13 102 569 05 13 394 569 05 13 102 569 05 13 394 569 05 13 223 569 05 13 223 569 05 13 223 SYMBOL NUMBER R 598 S 500 5 501 S 502 S 503 S 504 TP501 TP502 TP503 504 505 500 501 502 503 504 DESCRIPTION 22k ohm 5 1 4W CF Switch Sub miniature switch PC mt Sub miniature switch PC mt Sub miniature switch PC mt Sub miniature switch PC mt Brown vertical tip jack 08 Red vertical tip jack 08 Orange vertical tip jack 08 Yellow vertical tip jack 08 Tip jack vertical PT mount PC board Quad op amp 224 Quad op amp 224 Quad op amp 224 Quad op amp 224 PARTS LIST 569 05 13 223 583 2036 007 583 3001 211 583 3001 211 583 3001 211 583 3001 211 105 2208 211 105 2202 211 105 2206 211 105 2207 211 105 0860 001 035 0355 050 544 2020 001 544 2020 001 544 2020 001 544 2020 001 CW IDENTIFIER CARD PART NO 023 3823 330 PC board bracket assembly 1 pF 10 250V flat foil 33 10 35V molded tant 1000 pF 20 1 5 1000 pF 20 1 YSS 1000 pF 20 1 55 cer 33 10 35V molded tant 6 8 20 35V tantalum 1000 pF 20 1 55 cer 100 10 alum electrolytic 12 uF 10 25V flat foil 12 uF 10 25V flat foil 1 20 35V tantalum 1 uF 20 35V tantalum 1 20 35V tantalum 150 pF 25V alum electrolytic Si diode 1N4
71. 8 515 3007 002 515 3007 002 013 0025 010 016 2019 001 016 2019 001 016 2019 001 016 2019 001 017 2081 103 534 1004 031 534 1004 032 534 1005 035 013 1198 001 023 0030 014 569 0513 104 569 3001 001 597 3002 003 597 3002 003 597 3002 003 PARTS LIST PART SYMBOL NUMBER NUMBER CARD RACK ASSEMBLY CONTROL CARD PART NO 023 3823 020 PART NO 023 3823 030 Chassis assembly 023 3773 001 600 Harness 023 3823 031 Harness assembly 023 3823 021 Microphone connector assem 117 5205 102 C600 1000 pF 20 50V YSU ceram 510 3204 102 Post 586 3504 001 601 6 8 20 35V tantalum 510 2245 689 Black ext plastic tubing 042 0240 770 602 6 8 20 35V tantalum 510 2245 689 Contact assembly male 023 1932 002 C603 100 pF 10V alum electrolytic 510 4003 005 0 14 x 0 13 ferrite bead 517 2002 005 C604 100 pF 20 50V YSU ceram 510 3202 101 605 6 8 uF 20 35V tantalum 510 2245 689 HW 002 6 32 panhead taptite 1 4 575 0606 008 606 1 pF 10 35 tantalum 510 2575 109 HW003 6 32 panhead philips ZPS 575 1606 012 607 6 8 12096 35V tantalum 510 2245 689 HW004 6 32 x 0 078 nut NPB 560 2106 008 C608 0047 uF 200V foil 510 1201 472 HW0056 x 0 018 lockwasher int NPB 596 2106 009 C609 0015 uF 200V foil 510 1201 152 HW006 4 40 panhead philips 575 1604 010 C610 015 10 250V flat foil 510 1203 153 HW007 4 40 x 0 094 nut NPB 560 2104 008 C611 560 pF 5 100V 1DM15 510 0201 561 HW008 4 40 panhead philips ZPS 575 1604
72. 9 2770 AWW AUDIO J1 PIN 9 18 gt mi ett ee ife 2749 0723 10 LOCAL MIC AUDIO 18 4 8757 100k 19 6v 20 gt 1 e E R745 gt 10k R744 MIC KEY 14 gt EE eck 027 EXCITER KEY 19 vw 5 ue Sie 138 J1 PIN 35 21 M MC Eege R742 6221 CG AUDIO FROM RX 10 n PIN 20 A emen R711 gt Ik SE een 704 C705 1 77 722 lt 1 AUDIO TO CONTROL CARD DONC RUPES TT NN LPF COL B PIN 14 15 gt 714 SQ SW FROM RX 100 Ji PIN 21 12 gt UD 2 AAA 50 SW TO NOR GATE 16 M PN ON CONTROL CARD COL B PIN 16 CG AUDIO EXCITER S UD ES n ee J1 PIN 22 wa 24 b 2 2 S CALL GUARD lt R758 SWITCH gt 100k 2724 FILTERED AUDIO Kales 07018 FROM CONTROL CARD n CG AUDIO COMPRESSOR 23 DS SE d 7277 COL B PIN 23 SQUELCH ADJUST Rx SQ CONTROL Jt PIN 5 gp R717 200k 7 ENCODE AUDIO IN 2 4 FROM CG CARO COL PIN 4 R736 2010 TRANSM T ia MEM t MEM f 5 Su y AUDIO S Da SWITCH T 25 EE 2 720 8724 C710 330k Ge 22 io 1 5 B 5300 L R733 2 S 350k 48 4 8 3 9
73. AND GROUND ON PIN 7 902 576 0003 002 DC VOLTAGES IN INJECTION STRIP MEASURED WITH XTAL REMOVED 576 0003 029 Q203 Q204 4 INDICATES SQUELCHED DC READINGS Q206 0208 5 FACTORY SELECTED VALUE 979 0095 01 A UNMODULATED INPUT LEVEL IN pV WHICH PRODUCES 9212 204 QUIETINGe 279798903705 A 1007 MHz UNMODULATED SIGNAL LEVEL IN pV INJECTED THROUGH pF CAPACITOR WHICH PRODUCES 20 db AUDIO QUIETINGe EXCEPT 455KHz INJECTION SIGNAL e JA PEAK TO PEAK AUDIO VOLTAGES PRODUCED BY INPUT SIGNAL AT ANTENNA JACK MODULATED WITH IKHz 5KHz DEVIATION AUDIO OUTPUT LEVEL SET FOR 2WATTS INTO E 4 PEAK NOISE VOLTAGES MEASURED WITH NO 0209 0210 U202 SIGNAL INPUTe 576 0002 029 544 2002 007 544 2005 00 INJECTION STRIP VOLTAGES ARE 7 5 N k Wee een 2 2 25 80 1000 0 8 7 0 2 LIMITER 4 4 ZOND MIXER FIRST IF SECOND IF UISCRIMINATOR AUDIO CALL GUARD FILTER 2 CA3089 PRE R231 Jan oureur 220 2200 1 330k 232 205 C253 MHz E 00 10 pF 4 201 246 TP202 TP203 46 c 77 L FILTER 1202 1204 5 4 1 J213 8 R225 8246 816 6 18k I casa 1908 e XMIT AUDIO 1 9 P 215 18 i 241 R233
74. D OFF TEST 0 SEE TABLE FOR TIMING RANGE DESIRED voraces 4 Ul U2 AND U3 HAVE 5 SUPPLY ON PIN 14 AND GROUND ON PIN 7 DC VOLTAGE U4 US AND U6 HAVE 5 VOLT SUPPLY 16 AND GROUND ON PIN 8 DC VOLTAGES TAK TEST POSITION 7 19 JUNTER PROGRAMED MEMORY 5 SWITCH DIGITAL COUNTER RIS DEVIATION TEST R32 5 S OPERATE 84 12 pes AUDIO SWITCH AUDIO OSCILLATOR OUTPUT ES SWITCH DEVIATION ADJUST 2 08 R27 50k Cla ZN WITH FLUKE 8000A TIMING TIMING CHART A ERATE SWITCH IN OPERATE POSITIONe TME RANGE CONNECTION JUMPER TAKEN WITH TIMING LED S TAKEN WHEN IDENTIFYINGe EN WITH TEST OPERATE SWITCH IN PIN U5 TO CRI ANODE PIN 15 05 CRI ANODE PIN 14 05 TO CRI ANODE CW IDENTIFIER SCHEMATIC FIGURE 7 24 EFJohnson E 1100 Series Includes revisions through Part 001 1 100 003 8 96mwp Printed in U S A
75. DM20 100 pF 20 50V 50 disc 01 uF 20 16V 55 disc 20 16V 55 disc uF 10V Y5U comp disc 22 pF 5 100V 1DM10 4700 pF 20 50V YSU disc 1 10V 50 comp disc 10 pF 5 100V 1DM15 prep 1 20 16V YSS disc 10V 50 comp disc 047 uF 10 35V submin 1000 pF 20 50V 50 disc 01 pF 20 16V YSS disc 510 0202 100 510 3202 102 510 4110 470 510 3213 829 510 3213 110 510 3210 103 510 0202 270 510 0202 680 510 0202 390 510 3210 104 510 9502 309 510 3209 224 510 2033 228 510 3210 104 510 0208 152 510 3210 103 510 3209 224 510 3210 104 510 0208 152 510 0202 150 510 0202 150 510 3210 103 510 3209 224 510 3210 104 510 0208 152 510 3202 101 510 3210 103 510 3210 104 510 3208 104 510 0202 220 510 3202 472 510 3208 104 510 0201 100 510 3210 104 510 3208 104 510 2575 477 510 3204 102 510 3210 103 100 pF 5 100V 1DM15 prep 510 0201 102 1500 pF 5 NPO axial multi 510 3541 152 220 16V aluminum 510 4006 004 100 pF 5 100V 1DM15 510 0201 102 100 pF 5 100V 1DM15 prep 510 0201 102 DESCRIPTION 680 pF 50V 5 ceramic 6 8 20 35 dip prep 1 10V 50 comp disc 1 10 35V submin 1 20 16 YSS disc 01 10 250V flat foil 01 uF 10 250V flat foil 01 pF 10 250V flat foil 01 20 16V 55 disc 5 6 20 15V molded 470 uF 16V aluminum 1 20 16V YSS disc 2200 pF 20 50V YSU disc 1000 16V aluminum 01
76. F 56 ohm 5 1 4W 150 ohm 5 1 4W CF 3 3k ohm 5 1 4W CF 150 ohm 5 1 4 CF 10k ohm 5 1 4W CF 10k ohm 5 1 4W CF 10k ohm 5 1 4W CF 680 ohm 5 1 4W CF 1k ohm 5596 1 4W CF 56 ohm 10 1W CC 2 7k ohm 5 1 4W CF 2 7k ohm 5 1 4W CF 47 ohm 5 1 4W CF 1k ohm 5 1 4W CF 10 ohm 51096 1 2W 150 160 MHz 56 ohm 10 1 2W CC 160 174 MHz 56 ohm 10 1 2W CC 56 ohm 10 1 2W CC 56 ohm 10 1 2W CC 150 160 MHz 1 5k ohm 5 1 4W CF 1k ohm 1 1 8W MF 100k ohm 5 1 4W CF 1k ohm 1 1 8W MF 569 0513 471 569 05 13 273 569 05 13 563 569 05 13 333 569 05 13 333 569 05 13 473 569 05 13 473 569 05 13 101 569 05 13 273 569 05 13 273 569 05 13 471 569 05 13 471 569 05 13 682 569 0513 151 569 05 13 182 569 05 13 100 569 0513 103 569 0513 101 569 0513 100 569 05 13 332 569 05 13 221 569 05 13 560 569 0513 151 569 05 13 332 569 0513 151 569 05 13 103 569 05 13 103 569 0513 103 569 05 13 681 569 05 13 102 569 1006 560 569 05 13 279 569 05 13 279 569 05 13 470 569 0513 102 569 1504 100 569 1504 560 569 1504 560 569 1504 560 569 1504 560 569 0513 152 569 0520 301 569 0513 104 569 0520 301 August 1996 Part No 001 1100 003 6 8 DESCRIPTION 100k ohm 5 1 4W ohm 5 1 4W 10k ohm 1 1 8W MF ohm 1 1 8W 270k ohm 5 1 4W CF 100k ohm 5 1 4W CF 10 ohm 10 1 2W CC 10k ohm 5 1 4W CF 50k ohm 1 8W PC trim pot 100k ohm 5 1 4W 12k ohm 5 1 4W
77. HT BRN TO PIN I 4311 BLK TO PIN33 YEL TO PIN II J312 WHT BLU TO JCT C260 L206 WHT VIO up 17 4311 GRN TO 43018 GRY ORN TO WHT GRY WHT TO PIN IO PINS 9312 PINI3 PIN22 BLU TO WHT VIO RED COAX PIN2 J312 EP375 TO Q40l C TO C90 TO x C386 GD MP377 WHT YEL TO EP376 PIN T J312 TRANSMITTER BOARD COMPONENT LAYOUT FIGURE 7 10 WHT BRN TO PIN 24 GRN TO WHT RED TO PING PIN 23 4511 WHT VIO x TO TO C384 PIN 55 POWER CONTROL BOARD COMPONENT LAYOUT FIGURE 7 11 7 6 INJECT 2 Oel VRMS 1206 PINI J2 pss Jail AUDIO 4304 N ege 2 RECEIVE ES SWITCH FIRST AUOIO SECOND AUOD THIRO AUDIO SPLATTER LE 1 1 304 129 00k WV R302 TEND gt S cR205 3511 22k UR ER JE Ss C369 CR Sak RS C301 R304 4 5 6 207 PX 0 68 VRF 15 4047 2 R 4 R39 y EU ex 5 6 RSE 5 9v REG 330 PILIS 27 OSCILLATOR DOUBLER CHAN 1 le9 VRF 4306 4309 FIRST OOUBLER DOUBLER 0 47 VRE ngar 3 0 VRF 4031 2e2VRF eG VRF 2 238 ye Sel pert 345
78. IVER BOARD FIGUR 36 PIN JACK ORN WHT BRN ORN TO JCT WHT YEL TO JUMPER PINI OF TBI R273 R282 PIN 27 J200 R208 6212 E 1242 3203 15 8 OO YEL TO 4200 RED GRN TO BLU TO VIO TO BLU VIO TO PIN4 OF TBI PINI2 J200 PINS J200 2 J200 20 J200 8192 QI02 BASE MPONENT LAYOUT 7 7 8104 LIO6 R102 mies clos 9102 EMITTER EPIO8 BARE TO 105 BARE TO C286 EPII2 RED TO 9V REG 10 _DETAIL A DETAIL B 0102 COLLECTOR RED WHT TO PIN 26 4200 SEE DETAIL A COAX TO L202 SEE DETAIL FRONT END STRIP COMPONENT LAYOUT FIGURE 7 8 7 4 0 4 FIRST MIXER ees 1 ls C104 5 750 12 O Se L E EE 420 2202 1203 1547 V N Oe3RF XTAL FREQ CHANNEL FREQ 1047 MH 9 le8RF le4 RF Oe9 RF Oe92RF 5 CH2 NOT USED em C278 OSCILLATOR TRIPLER Ge BN p25 INJECTION AMF CH2 270 IC 27 L108 1 9 G uc x 33 156 SEMICONDUCTOR BASING IS BOTTOM VIEW UNLESS OTHERWISE INDICATED CS 6 5 NOTES oD ot le UNLESS OTHERWISE SPECIFIED ALL RESISTORS ARE IN OHMS 0202 0213 0207 AND CAPACTORS ARE IN MICRO FARADS 576 0006 009 Q214 Q215 576 0002 027 2 IC U202 HAS SUPPLY VOLTAGE ON PIN 14
79. LTAGES MEASURED WITH TRANSMITTER TIMED OUT FACTORY SELECTABLE 4 ALL AC WAVEFORMS ARE SINE WAVES UNLESS SHOWN OTHERWISE AC MEASUREMENTS TAKEN WITH RECEIVER RF INPUT OF 100pV MODULATED WITH A CALL GUARD AT 600Hz DEVIATIONe TRANSMIT CONTROL AND DEL AY TRANSMIT SWITCH R6I9 REPEATER GATE INVERTOR 5 MCI4002CP 0602 B 9 6 V Oel VP P 07 VP P 0047 Seat GUARD AUDIO COMPRESSOR IOOk SCH MC330I R638 6 U6OI A R639 202k Bed VP P lt SVP P BEER CALL GUARD LIMITER 9 FILTERS S U 4 224 8 60 weus 823 6 2 13 R628 s 330k 4 ran 447 6 8 1644 58645 48646 R627 2 68 R642 27k 18 27k 330k 0047 66 3 633 ce 6 8 210 001 CONTROL CARD SCHEMATIC FIGURE 7 18 RED TO 70 LJ 5 TE YEL TO R710 GRN TO R710 BRN TO TP 701 VOL POT VOL CALL GUARD EP700 ER OI SQUELCH MP700 ADJUST HWTOI 2 LEVEL ADJUST CARD COMPONENT LAYOUT FIGURE 7 19 BLK TO R710 VOL POT R723 10k D Y VOLUME CONTROL OUT 7 gt j mem R712 10k RX AUDIO J1 PIN 11 8 m ANA H 25 R713 R713 22k 22k 2716 rh XE SCH R R722 FROM CONTROL 100k NOR GATE COL B PIN 9
80. MBOL PART NUMBER DESCRIPTION NUMBER 6 16 CR002 CR500 CR501 CR502 CR503 CR504 CR505 EP500 Ge diode 1N67A Si diode 1N4448 Si diode 1N4448 Diode 1N881 1N645 Red LED Si diode 1N4448 Si diode 1N4448 Receptacle HW501 1 4 6 32 panhead taptite HW502 2 56 x 0 063 nut NPB HW503 2 56 panhead philips ZPS HW504 Wire tie HW505 Panel mount LED socket 500 500 500 501 502 503 504 505 506 507 001 002 003 004 005 007 500 R 501 R 502 R 503 R 504 R 505 R 506 R 507 R 508 R 509 R 510 R 511 PC board bracket PC board Si PNP 50 MHz amp TO 92 Si PNP 50 MHz amp TO 92 Si NPN Darlington TO 92 Si PNP 50 MHz amp TO 92 J FET low noise RF TO 92 Si NPN gen purp TO 92 Si NPN gen purp TO 92 Si NPN gen purp TO 92 2 2k ohm 5 1 4W 10k ohm 5 1 4W CF 10k ohm 5 1 4W CF 22k ohm 5 1 4W CF ohm 5 1 4W 1k ohm 5 1 4W CF 470k ohm 5 1 4W CF 470k ohm 5 1 4W CF 1k ohm 5 1 4W CF 820k ohm 5 1 4W 820k ohm 5 1 4W CF 30 9k ohm 1 1 8W 15k ohm 1 1 8W 25k ohm multi turn trim pot 10k ohm 1 1 8W 10k ohm 1 LSW 390k ohm 5 1 4W 10k ohm 1 1 8W MF 523 1500 067 523 1500 883 523 1500 883 523 1500 881 549 4001 001 523 1500 883 523 1500 883 586 3503 001 575 0606 008 560 2102 006 575 1602 008 574 9008 001 550 0006 100 017 2007 014 035 0355 056 576 0003 017 576 0003 017 576 0007
81. MHz RG 400 3 ft N PL 259 597 3004 001 PART NO 023 4111 101 Crystal comp 023 4245 001 Front end assembly 023 4091 001 Crystal comp kit 023 4246 001 Receiver board assembly 023 3706 021 Transmit crystal 521 0000 000 Receiver harness assembly 023 3823 002 Receive crystal 521 6000 000 Bracket front end 017 1641 001 1100 REPEATER 160 174 MHz PART NO 242 1100 241 33 pF 5 50V NPO disc 510 3013 330 33 pF 5 50V NPO disc 510 3013 330 25A power supply 110V 60Hz 023 3341 012 15 pF 5 50V N150 disc 510 3016 150 Card rack assembly 023 3823 020 5 1 pF 5 50 150 disc 510 3216 519 Test card 023 3823 022 1000 pF 500V feedthrough 510 3151 102 Control card assembly 023 3823 030 1000 pF 20 50V Y5U disc 510 3002 102 Level adjust card assembly 023 3823 040 1000 pF 20 50V YSU disc 510 3002 102 August 1996 6 1 Part No 001 1100 003 PARTS LIST 10 pF 5 100V 1DM10 1000 pF 20 50V 50 disc 47 uF 10V radial aluminum 8 2 pF 5 50V NPO disc 11 pF 5 50V NPO disc 01 20 16V YSS disc 27 pF 5 100V 1DM10 68 pF 5 100V 1DM10 39 pF 5 100V 1DM10 1 20 16V 55 disc 3 pF 5 500V comp 22 YST disc 22 UF 10 35V molded tant 1 pF 20 16V YSS disc 1500 pF 5 500V 4DM20 01 uF 20 16V YSS disc 22 3V 5 disc 20 16 YSS disc 1500 pF 5 500 4DM20 15 pF 5 100V 1DM10 15 pF 5 100V 1DM10 01 UF 20 16V YSS disc 22 uF YST disc 20 16V 55 disc 1500 pF 5 500 4
82. MPER C JUMPER D W513 JUMPER B 8526 24 Hr w502 N R529 RED 5500 w512 JUMPER A 531 WHT BLU JUMPER w532 BLU JUMPER w525 WHT RED TO 5500 9 W530 500 LJ PIN A wemmer JUMPER D W539 WHT YEL TO JUMPER C YEL TO S500 JUMPER A JUMPER B WHT ORN TO JUM 5500 PIN II PIN 5 S500 PIN IO w527 w522 w504 w520 521 JUMPERD W526 CALL GUARD 4 CALL GUARI WO BRN 5500 PIN 2 CR504 W536 JUMPER D MP50I KNOB HW502 NUT HW503 SET SCREW CGI LED CR504 CR505 CR506 CR505 T cG2 501 2 LED MP500 CR507 w529 WHT TO S500 PIN B w524 WHT BRN TO 5500 PINS W533 WHT GRY JUMPER W534 GRY JUMPER 516 CR507 T gt EmA LED w5I7 JUMPER B PER C ORN TO S500 PIN 4 518 W503 w 5 4 TONE CALL GUARD COMPONENT LAYOUT FIGURE 7 21 7 16 4 1 Y 01 CALL GUARD SW ENCODED CALL GUARD 1 I ont AMF 7 CALL GUARD 1 NOTES 1 AMPS ON PIN 4 GROUND PIN 11 BANDPASS FILTER p JD 2 ALL RESISTORS ARE OHMS AND CAPACITORS IN A 3 DC VOLTAGES MEASURED WI
83. OPHONE This is a high impedance microphone used for repeater testing 1 6 PRODUCT WARRANTY The warranty statement for this transceiver is available from your product supplier or from the Warranty Department Transcrypt International Inc 299 Johnson Avenue Box 1249 Waseca MN 56093 0514 August 1996 Part No 001 1100 003 This information may also be requested by phone from the Warranty Department as described in Section 1 7 The Warranty Department may also be contacted for Warranty Service Reports claim forms or any questions concerning warranties or warranty service by dialing 507 835 6222 1 7 FACTORY CUSTOMER SERVICE The Customer Service Department of the E F Johnson Company provides customer assistance on technical problems and the availability of local and factory repair facilities Regular Customer Service hours are 7 30 a m 5 30 p m Central Time Monday Friday The Customer Service Department can be reached using one of the following telephone numbers Toll Free 800 328 3911 From within continental United States only International 507 835 6911 FAX 507 835 6969 E Mail First Initial Last Name transcrypt com You need to know the name of the person you want to reach Example dthompson G transcrypt com NOTE Emergency 24 hour technical support is also available at the 800 and preceding numbers during off hours holidays and weekends When your call is answered at E F Johnson Com
84. P 50 MHz amp TO 92 470k ohm 5 1 4W CF 470k ohm 5 1 4W 820k ohm 5 1 4W 820k ohm 5 1 4W CF 30 9k ohm 1 1 8W 15k ohm 5196 1 8W 25k ohm multi turn trim pot 10k ohm 1 1 8W 10k ohm 1 1 8W MF 10k ohm 1 1 8W ohm 1 1 8W ohm 1 1 8 MF 10 ohm 5 1 4W ohm 1 1 8 ohm 5 1 4W 100k ohm 5 1 4W CF 10k ohm 5 1 4W CF 15k ohm 1 1 8W MF 100k ohm 1 1 8W August 1996 Part No 001 1100 003 PART NUMBER 523 1500 883 523 1500 883 523 1500 883 523 1500 883 523 1500 883 586 3503 001 575 0606 008 560 9043 012 550 0006 100 550 0006 100 550 0006 100 550 0006 100 017 2007 012 032 0767 022 576 0003 017 576 0007 001 576 0003 017 576 0007 001 576 0003 017 576 0007 001 576 0003 017 576 0007 001 576 0003 017 569 0513 474 569 0513 474 569 0513 824 569 0513 824 569 0520 448 569 0520 418 562 0108 253 569 0520 401 569 0520 401 569 0520 401 569 0520 301 569 0520 301 569 0513 100 569 0520 301 569 0513 103 569 0513 104 569 0513 103 569 0520 418 569 0520 501 SYMBOL PART NUMBER DESCRIPTION NUMBER 270k ohm 5 1 4W 100k ohm 5 1 4W 470k ohm 5 1 4W 470k ohm 5 1 4W CF 820k ohm 5 1 4W 820k ohm 5 1 4W CF 30 9k ohm 1 1 8W 15k ohm 1 1 8W 25k ohm multi turn trim pot 10k ohm 1 1 8W MF ohm 1 1 8W MF 10k ohm 1 1 8W ohm 1 1 8W ohm 1 1 8W
85. Part No 001 1100 003 510 9502 568 510 3149 102 510 3149 102 510 3220 101 510 3016 330 510 0016 018 510 0016 040 510 0016 040 510 0016 040 510 0016 018 523 0015 001 523 2503 170 523 1500 014 016 0104 004 032 0576 001 016 0104 004 042 0241 555 032 0362 001 260 0102 001 586 0001 010 042 0240 770 586 0005 110 13 EP015 EP407 EP911 EP912 6 ring terminal 16 14 wire 14 16 wire contact 0 375 x 0 375 ferrite bead Connector Connector F900 5A 125V slow blow MDX HWO01 1 4 28 x 0 109 hex nut NPB HW002 Fiber washer insulator HW003 4 40 x 0 094 nut NPB HW004 3 8 32 x 0 094 hex nut NPB HW005 0 5 OD nylon snap bushing HW006 4 40 panhead philips screw HW007 4 40 panhead philips ZPS 10 1 4 x 0 025 lockwasher int 11 1 4 x 0 018 flat washer SPB J 900 J901 J 902 N connector panel mount N connector panel mount Jack L 910 L 911 L 912 L 913 Inductor Inductor Inductor Inductor MPO001 5 MP006 MP007 MP313 Heatsink filter cover Fuse body 9835 Know 99531 2 washer 9955 Fuse spring 1A1853 Connector shield P903 Banana plug subassembly R910 100k ohm 5 1 4W CF RT900 Thermistor W 901 W 904 W 999 RG 188A U coax cable RG 188A U coax cable RG 188A U coax cable 586 0001 010 534 1004 037 517 2002 003 023 3313 001 013 1426 001 534 0001 008 560 9040 012 596 4414 016 560 2104 008 560 9062 016 574 0001 005 575 0604 010 575 1604 020 596 2114 015 596 9103 01
86. R AUDIO OUTPUT 3 2 SQUELCH AMPLIFIER SQUELCH FILTER U202D SQUELCH 3 3 TRANSMITTER RA EU E ERE ee d ay a TT PENSIO 3 4 DC POWER SUPPLY TRANSMIT SWITCH Rr e ew etd e Boni EC Sus 3 4 TRANSMIT AUDIO STAGES xc reati xx eet None os e a e Ea RR TP Y CHA Rr RTO d 3 4 TRANSMIT OOSCILLATOR DOUBLER 3 4 FIRST DOUBLER SECOND DOUBLER LOCARE RT 3 5 FIRST RF AMPLIFIER SECOND RF 3 5 PREDRIVER DRIVER FINALS ess ka Pea wien dusk s 3 6 POWER CONTROL Seele OR Qe GC aod dae ea pans os 3 6 POWER SUPPLY Cid a SSA Red dos a e 3 6 CONTROL CARD eege 3 7 GENERAL asc REIR OV URP eeu vacua ies eS S Up TOY ean Quy Paca 3 7 TRANSMIT CONTROL CIRCUITS 555 lt yams REGIE OM ai E RR RR see ch 3 7 CALL GUARD SQUELCH CIRCUITS ayudo do we oS Oat te ue ete E E RC es 3 8 LEVELADIUST CARD ERI EE 3 0 GENERAL IS ente hd aud du M ra 3 9 REGULATOR a qud etta EE e oer us acie 3 9 TRANSMIT AUDIO CIRCUITS
87. R234 a 252 VOLUME ar Prot Par be Ka C221 4 2 o 4 4 0 5 113 0 5 12 1 4 C225 ZS a 94 1 8224 S 4 c230 255 A czas C213 R216 1222 CR20I c23 2 2 nese R244 R245 Ost i 33k Sech s 2233 R240 12k 390k P28 1200 R223 d Gei P33 200 Air 9 REG 10 165 8 8 0 2 0 SECOND OSC SQUELCH CR208 GATE c2 R242 J 0 2 nw i e 1 MC3301 P26 2200 o0 4 TP205 SQUELCH R235 SQUELCH 4209 120k 5 2 25 242 SQUELCH SWITCH OUTPUT 21 4200 Bos 2 001 001 CR206 S 0 5 CR205 6249 8236 R248 R200 R251 79 Kg 2 2 270 295 150 200 2 2 236 47 001 cR209 9V REG Se ILI dean Sei L 15 R266 15 7 39 RV P5 3200 TO SQUELCH CONTROL gt L206 25 54 p35 200 gt c260 2 8 0 1140 AUDIO OUTPUT AN 8 0 PT 1200 P8 200 CR207 045 0648 00 1825 J212 AUDIO DRIVER 259 Te TO LOCAL SPEAKER 0022 27 N 4 9 14 6 256 0 6 2 5 6 9 145 28256 R260 27 100k R262 2 2 47 R259 225 22k 1 15 7 FROM LOCAL AUDIO VOLUME CONTROL gt 3200 gt RECEIVER SCHEMATIC DIAGRAM FIGURE 7 9 WHT TO EP377 6 PINS J312 WHT BLK TO PIN2 431 7 2 W
88. R553 10 AV m 1 E me 1 285 2550 2001 DISABLE A 4 SWITCH C NCODE SWITCH R558 GE 22 GUARD 10k SWITCH VIN 3 0 1 1 U503D RA 12 224 z 42 SE 3 0 i 00 0502 0504 d EH OR 0508 THRESHOLD 1 10k 4 We 576 0003 017 UT e 0901 0505 0505 0507 576 0007 011 ENCODE ADS UNLESS OTHERWISE SPECIFIED GARD AUDIO IN WAVE DECOLE OF BUFFER Y R522 470k Wy R521 05024 470k 2 224 446 1 xt 1 4 6 LU 5 R590 ENCODE 390 f ES R536 cem m ANN 5 EE y a 21255 eem oz lt 1505 9 6 T Tin 1 2 ENCODF AUDIO SWITCH gt 1 2 R585 177 1 mr an deg i ape Kee at A ee 6 L SE BUFFER AMP 4 C521 Te 1 R564 a I 470k SE en 27 USO4A 4704 2 224 22 R593 446 1 1k 5500 a Se iw 4 6 i ee 406 47 NEA 4 390 DE SWITCH Nen i 2578 100k 2 M CATHODE ae 16576 Ki 1k 5 25 155 R504 CR507 1 4001 001 4 CALL GUARD 2 BANDPASS FIL
89. T NUMBER SYMBOL DESCRIPTION NUMBER DESCRIPTION 25A POWER SUPPLY 110V AC 60 Hz PART NO 023 3341 012 HW008 10 32 panhead philips ZPS HW009 10 32 panhead philips ZPS HW010 8 32 x 0 125 CPS nut HW011 0 018 lockwasher int ZPS HW012 10 shakeproof washer HW013 4 x 0 015 lockwasher int NPB HW014 1 4 0 315 x 1 2 washer HW015 1 4 28 x 0 109 hex nut NPB HW016 4 40 panhead philips ZPS HW017 1 4 x 0 025 lockwasher int HWO018 Rubber grommet HW019 8 32 U type nut CPS HW020 Backing plate HW021 3 8 32 x 0 094 nut NPB HW022 6 32 panhead philips ZPS 575 1610 020 575 1610 036 560 1108 011 596 1106 009 596 1110 012 596 2104 008 596 4514 020 560 9040 012 575 1604 020 596 2114 015 574 0002 014 560 1808 004 013 1479 001 560 9062 016 575 1606 012 1 Bracket 017 2121 001 C 001 C 002 C 003 C 004 C 005 55000 uF aluminum 033 20 50V YSU disc 55000 uF aluminum 1000 pF 20 1kV feedthru 10 uF 370V AC oil filled 510 4028 002 510 3002 333 510 4028 002 510 3149 102 510 1014 001 001 Circuit breaker 534 2006 002 Chassis 017 1951 012 001 6 8V 5 1W zener 2 6 8V 5 1W zener 50V 20A rectifier 4 50V 20A rectifier 007 200V 1 rectifier 1N4003 CRO10 50V 20A rectifier 001 002 003 004 005 006 007 008 009 029 031 032 001 001 Connector 1 4 stud mtng mica w
90. T CG AUDIO IN CALL GUARD CG ENCODE Figure 3 4 LEVEL ADJUST CARD BLOCK DIAGRAM 3 6 5 ENCODED CALL GUARD AUDIO When the Call Guard card is in the ENCODE mode it is necessary to make sure that a received Call When the Call Guard card is placed in the Guard tone is not simultaneously retransmitted with ENCODE mode encoded Call Guard audio is cou the encoded tone A portion of the encoded Call pled to Level Adjust card pin 4 The Call Guard audio Guard audio is coupled from Level Adjust card pin 4 is then coupled by C700 to encode level adjust R700 through C717 and R738 to a voltage doubler consist through R701 C706 to the base of level amplifier ing of CR701 and CR702 The output of the voltage Q704 Collector output is coupled through C709 to doubler is a positive voltage that is applied to the base Level Adjust card pin 22 of Q707 This causes the collector of Q707 and U701D pin 5 to go low to disabled and no received Call Guard audio is retransmitted August 1996 Part No 001 1100 003 3 10 CIRCUIT DESCRIPTION 3 6 6 TRANSMIT AUDIO CIRCUITS LOCAL KEYING The repeater can be brought up at the site by key ing the local microphone Level Adjust card pin 14 goes to ground and the base of Q709 goes to OV to place a high on the collector the base of Q708 and U701C pin 13 The microphone audio switch closes to allow the local microphone audio to be coupled to the Call Guard filter 0602 on the Control card contains two 4 inp
91. TER PREG ADJ 1 1 Patt ecole R528 10k AAA U502C _ 05028 1 224 8 4 5 4 5 s 4 6 R530 208 5 10k K532 i 4e6V lk e e e ovs S 853 250 6 8 1 SWITCH R537 A 10k U502D 224 105401 14 0 L gt T 540 THRESHOLD DETECTOR CALL GUARD 4 BANDPASS FILTER Sat MF ad R598 22k 4 ES JB d ro R569 R567 R568 30 9 X eve 1 2 IP 04 508 5502 DISABLE SWITCH ace CR507 504 DISABLE SWITCH 4 sUARD SCHEMATIC FIGURE 7 22 Wa R2 CODE SPEED ADJ GRN TO S2 PIN ORN TO 52 WI YEL U5 CODE TIMING AI PIN 1 14 15 81 4 tc L LOOAV I LNUNOdNOO DILL LNIOT MO 6 00533 CIO 31VH3ddO ia c gt o m m DIGITAL CODE SPEED CLOCK I5 TO 25 Hz NOTES XMIT SWITCH PIN I9 4 TO 8Hz TIMING CLOCK PIN PIN 24 PIN 20 TIMING REGULATOR INDICATOR RI8 AUDIO TO XMITER PIN 18 l ALL RESISTOR VALUES ARE IN OHMS UNLESS OTHERWISE SPECIFIED 5 DC VOLTAGES TAKI Ze ALL CAPACITOR VALUES ARE IN MICRO FARADS UNLESS OTHERWISE SPECIFIED LE
92. TH ENCODF SWITCH OFF NO 7 0 R506 4 DC VOLTAGE A CALL GUARD AUDIO INPUT 6504 8505 25 FREQ ADJ d 305 30 06 X DC VOLTAGE IN THE ENCODE MODE EE 5 DEDEDE MODE VOLTAGES MEA D WII A Fri et MODULATED WITH CALL GUARD 606 GEVIAT JUMPERS JB JC JD DETERMINE FREQUENCY RANGE Ne LI 65273 He 10017 QUT j OUT OUT 73 90 Hz OUT our OUT pO AO 73790 Hz OUT OL N OUT 905125 Lou 091 cul 125 187 gt _ OUT IN pour ree 588 DPR 2 390 5 512 1 5 vm 1 777 777 S R516 CALL GUARD FNCODF SWITCH SC GC AA 9 6 13 0501 224 R520 AG i 100k Q501 DA 5 soc E 9 7001 2 R519 uc 4 0 5 270 Se 1 3 THRESHOLD 9 501 21 DETECTOR ABLE AGL SWITCH RSIR 100k SR 22 36 EEN EE e Mer 2 Ca EE D Sen EE AL y Ip SIGMAL MM a ER SC B ux GN EE EET oe gt E PR L E 4 E b R597 Log 22k JD l 0 R548 1 25k FREQ ADJ ell ek oe TF503 R550 5 10k w ARN 5 FMI 1 APA lt 8551 10k 2 R554
93. The output of Q215 is taken off the collector and coupled through R295 to crystal filter Z201 An impedance match between Q215 and Z201 is provided by R295 This crystal filter has a bandwidth of 15 kHz at the 6 dB points 3 2 5 SECOND OSCILLATOR SECOND MIXER Second oscillator Q214 is a modified Colpitts oscillator with the feedback controlled by C263 and C264 Crystal Y203 functions as a parallel resonant element and oscillates at either 11 155 MHz high side injection or 10 245 MHz low side injection High side injection is used in most units low side injection is optional The signal from the second oscillator is coupled to the base of second mixer Q202 through C209 and C206 The output of second mixer 0202 is tuned to 455 kHz the difference of the two signals on the base The output is coupled from T207 through C215 to the base of IF amplifier Q203 3 2 6 FIRST IF AMPLIFIER SECOND IF AMPLI FIER The output of first IF amplifier Q203 is coupled to the base of second IF amplifier Q204 through T203 and C221 The output of Q204 is coupled to limiter discriminator U201 by T204 An IF test voltage is rectified by CR201 and coupled to TP203 3 2 7 LIMITER DISCRIMINATOR The IF amplifier limiter detector and audio pre amplifier circuitry are contained in U201 The detec tor operates as a quadrature type which means that a August 1996 Part 001 1100 003 90 phase shift audio recovery process is used Induc tor T2
94. The transmitter oscillator dou bler can be set exactly on frequency by adjusting C325 CIRCUIT DESCRIPTION FIRST AUDIO COMPRESSOR AMP FILTER LOCAL MICROPHONE SECOND RF AMP PREDRIVER DRIVER POWER CONTROL AMPLIFIERS SPLATTER FILTER um TRANSMIT TCXO AUDIO IN b gt gt gt FREQ OSCILLATORY FIRST SECOND FIRST DOUBLER DOUBLER RF AMP gt FINAL gt POWER SWITCH POWER CONTROL E POWER V HARMONIC OPTIONAL FILTER DUPLEXER nr OUTPUT POWER CONTROL AMPLIFIERS HIGH LOW SENSE THERMAL FOLDBACK AMPLIFIERS Figure 3 2 TRANSMITTER BLOCK DIAGRAM The transmitter oscillator is a modified Colpitts using a fundamental crystal operating in the 18 7 21 8 MHz range Crystal frequency can be deter mined by the following formula Crystal Freq Channel Freq 8 The collector circuit of W320 is tuned to twice the crystal frequency by L320 L345 An oscillator test voltage is rectified by CR345 and filtered by R345 C363 3 3 4 FIRST DOUBLER SECOND DOUBLER The output of Q320 is coupled by C345 C347 to the base of first doubler Q345 The collector circuit of Q345 is tuned to twice the frequency of the signal on the base The output of Q345 is taken off the collector and coupled by C352 C353 to the base of second dou bler Q346 The collector circuit of Q346 is also tuned to twice its input frequency A test voltage is rectified by CR346 and filtered by R358 C366
95. U503 ACCESS SWITCH 5601 DISABLE SWITCH S600 CALL GUARD 4 0504 REPEATER SWITCH U602A PIN 15 ENCODE SWITCH 500 TIME OUT TIMER 0600 601 Q602 0603 TRANSMIT DELAY 9604 9605 U6028 TRANSMIT SWITCH 0606 PIN 19 CARD RACK BLOCK DIAGRAM FIGURE 7 2 See s 220 240 VAC 60 Hz 110 120 60 Hz NOTES A A A TI DETAIL 16 14 7 VDC ALL RESISTOR VALUES ARE IN OHMS AND ALL CAPACITOR VALUES ARE IN MICROFARADS UNLESS OTHERWISE SPECIFIED 25 AMPERE POWER SUPPLY VOLTAGES ARE WITH NO LOAD 342A FOR ASSEMBLY 023 3341 002 FOR ASSEMBLY 023 3341 Olle WHEN USED FOR 220V OPERATION FOR AC INPUT PRIMARY WINDINGS ARE IN PARALLEL FOR 220V AC INPUT PRIMARY WINDINGS ARE IN SERIES AS IN DETAIL A THIS BATTERY TAKEOVER AND CHARGE CKT IS OPTIONAL 023 3823 325 Jl 25 POWER SUPPLY SCHEMATIC FIGURE 7 3 Hw20 4 TI HWI 4 Hwi2 4 HW 20 4 HWIB 4 DETAIL C HW9 4 DETAIL A DETAIL B TBI BRN TI BLK WHT TI BLU BRN WHT TI BLK TI R4 TI GRN TO C4 YEL CR3 WHT HW 2 HWIG BLK HWI3 FHI CR7 9 R3 BLK WHT GRN HW7 6 CH A CH2 HW3 MOUNTING PANEL R2 CHI HW 19 6 Ti 220 230 VAC YEL DETAIL D DETAIL E DETAIL F BRN TI BLK GRN BLK WHT TI WHT BRN WHT
96. VOLTAGE AS a Sn ha 4 5 AUDIOS tos Se et tp ce pisa et el Dd 4 5 OSCILLATOR DOUBLER FIRST SECOND DOUBLER 4 5 FIRST SECOND RF AMPLIFIERS 4 6 POWER CONTROEG p 4 6 POWER AMPLIFIER 4 7 COMPONENT 4 7 POWER AMPLIFIER PC BOARD 1 4 7 CIRCUIT PROTECTION deg eege ueste G A gar AS 4 7 EE ee 4 8 TESTING 09020903 AND Q904 oben e 4 8 LEVEL ADJUST CONTROL AND CALL GUARD SQUELCH 5 4 8 GENBRAE sz M Ed ai dtes EE 4 8 CONTROL CARD NOR 0602 OPERATION 4 8 TABLE OF CONTENTS CHECKING RECEIVE 5 4 9 INTRODUCTION ENE MM 4 9 CAPACITIVE COUPLER cam tet aces dst iat bres adi 4 9 TESPPROCEDURE o
97. WITCHES ei Be 4 bw CALL GUARD 3 CALL GUARD 4 Figure 5 3 CALL GUARD CARD ALIGNMENT POINTS 5 4 RECEIVER PERFORMANCE TEST Set the repeat switch to off and the access switch to open on the Control card Connect an RF signal generator and set the receive channel frequency no output to the receiver subassembly antenna jack 5 4 1 QUIETING SENSITIVITY 1 Connect an AC VTVM across a3 ohm dummy load plugged into the external speaker jack or to the audio output jacks on the card rack panel 2 Set the squelch adjust control on the Level Adjust card fully counterclockwise 3 Set local audio control for 0 dB indication on the AC VTVM 4 Increase the RF signal generator output unmodu lated to 0 5 The AC VTVM indication should drop 20 dB or more 5 4 2 SINAD SENSITIVITY 1 Connect a distortion meter across 3 ohm dummy load or to the audio output jacks 2 Set the RF signal generator for an output of 0 35 on the receiver channel frequency modulated with 1 kHz tone at 3 kHz deviation ALIGNMENT AND PERFORMANCE TESTS 3 Adjust the local audio control for an output level of 0 77V RMS 200 mW 4 Adjust distortion meter for a 0 dB reference and null out the 1 kHz signal should occur at least 12 dB below the reference reading S N D N D 212 dB S Signal N Noise D Distortion 5 4 3 SQUELCH SENSITIVITY 1 With no signal input adjust the SQUELCH ADJ
98. and helps locate its source 4 9 2 CAPACITIVE COUPLER A capacitive coupler can be used to connect a sig nal generator to the antenna cable This coupler should provide 50 60 dB of isolation to adequately protect the generator from high level RF present on the cable Use a coupler such as a Bird Model 4275 or fabri cate one from a coaxial connector To do this remove the pin from one of the side terminals of the connector and shorten it until the required isolation is obtained 4 9 3 TEST PROCEDURE 1 Connect the test setup shown in Figure 4 2 The coupler should be inserted in the cable between the receive antenna and repeater or combining equip ment 2 Switch the REPEAT switch to OFF 3 Set the signal generator to the receive channel fre quency with an unmodulated output 4 Connect the generator and the antenna to the capac itive coupler The repeater transmitter should be unkeyed 5 Set the unmodulated generator output to obtain 15 dB of quieting 6 Switch the REPEAT switch to ON 7 Less than 2 dB quieting degradation should result CARD RACK RECEIVER EXCITER DUPLEXER CAPACITIVE COUPLER 3 POWER AMPLIFIER AF SIGNAL SUPPLY GENERATOR Figure 4 2 RECEIVER DESENSE TEST 5 UP 4 9 4 LOCALIZING CAUSE OF DESENSITIZA TION ANTENNA Substitute a 50 ohm dummy load for the transmit antenna and repeat the test If the result is normal the antenna or feedline may be defective
99. ap 1 9 15 7 pF vert mount cap 43 pF 5 50V NPO disc 43 pF 5 50V NPO disc 56 20 6V tubular 01 20 16V YSS disc 91 pF 5 100V 1DM10 300 pF 5 100V 1DM10 91 pF 5 100V 1DM10 300 pF 5 100V 1DM10 1000 pF 20 SOV YSU disc 01 uF 20 16V YSS disc 047 20 16V 55 disc 5 1 pF 5 50V N150 disc 82 pF 100V 1DM15 150 160 MHz 56 pF 5 100V 1DM15 160 174 MHz 470 pF 5 100V 1DM15 1000 pF 20 50 YSU disc 82 pF 100V 1DM15 1000 pF 20 50 YSU disc 33 pF 5 50V N150 disc 150 160 MHz 22 pF 5 50V N150 disc 160 174 MHz 1 8 pF 5 50V NPO disc PARTS LIST 510 4006 005 510 2005 569 510 3210 473 510 3208 104 510 3202 682 510 1203 104 510 2245 109 510 2245 109 510 3208 104 510 1201 472 510 0201 391 510 3208 104 510 2023 569 510 3204 102 510 0201 471 510 3210 473 510 3210 473 510 3121 471 510 3121 471 510 3204 102 187 0109 005 187 0109 005 510 3213 430 510 3213 430 510 2001 560 510 3210 103 510 0202 910 510 0202 301 510 0202 910 510 0202 301 510 3204 102 510 3210 103 510 3210 473 510 3216 519 510 0201 820 510 0201 560 510 0201 471 510 3204 102 510 0201 820 510 3204 102 510 3216 330 510 3216 220 510 3213 189 August 1996 Part No 001 1100 003 PARTS LIST PART NUMBER SYMBOL NUMBER DESCRIPTION 43 pF 5 50 150 disc 56 pF 5 50V N150 disc 300 pF 100 1DM15 150 160 MHz 100 pF 20 50V YSU disc 160 174 MHz 6 8 pF 5 50V N150 disc 150
100. asher Molded handle 10 16 14 AWG ring terminal Push on terminals Soldering terminal 1 4 ring terminal 16 14 AWG Black varnished tubing Terminal lug 2104 10 10 8 AWG ring terminal Connector shield 5A 250V SE slow blow fuse Fuse holder HKP HW000 Capacitor mounting bracket HW001 10 32 x 0 375 CPS nut HW002 4 40 x 0 094 NPB nut HW003 6 32 1 4 panhead taptite HW004 6 32 x 0 078 NPB nut HW005 9 16 ID rubber grommet HW006 Strain relief SV SVT 18 HW007 8 18 hex head sheet mtl ZPS 523 2503 689 523 2503 689 523 0016 500 523 0016 500 523 0501 002 523 0016 500 013 1426 001 023 3312 001 574 5005 008 032 0362 001 586 0001 002 586 3008 001 016 0104 004 586 0001 013 042 0240 500 586 0005 110 586 0001 027 032 0576 001 534 0002 030 534 1002 001 572 0002 005 560 1110 012 560 2104 008 575 0606 008 560 2106 008 574 0002 004 574 0003 002 575 3908 016 HW024 Capacitor mounting bracket HW025 8 x 0 02 lockwasher int CPS HW026 8 32 panhead philips CPS HW027 6 32 panhead philips ZPS HW030 6 32 panhead philips CPS HW032 4 40 x 0 063 nut NPB HW034 Cushion w adhesive backing HW035 10 32 panhead J 001 J 002 L 001 001 MP002 001 001 Q 001 R 001 R 002 R 003 R 004 R 010 T 001 Jack 125V AC receptacle w gnd 1 filter choke Rack panel Heatsink outer Heatsink inner 25A 120V AC 60 Hz label Banana plug subassembly Si PNP 80V 7A TO 220 27 ohm 10W 1k ohm 10 1 2W
101. ator NOTE Crystal compensating capacitor C291 is a fac tory selected part and is shipped with the crystal Frequency adjustment is provided at C269 and the range of adjustment can be extended by changing C271 see Section 5 2 2 The first oscillator crystal frequency can be deter mined by the following formula Crystal Freq Chnl Freq 10 7 MHz 9 The oscillator output circuit is coupled by T208 and T209 to the base of second tripler Q213 through capacitor C281 The tripler output signal is then cou pled through transformer T210 and capacitor C286 to the base of injection amplifier Q102 A tripler test voltage is rectified by CR212 and coupled to TP204 The tripler output is tuned by T210 The signal from injection amplifier Q102 is cou pled to the source of first mixer Q101 The output of Q102 is tuned by C108 and C109 A test voltage is rectified by CR101 and coupled to TP205 August 1996 Part No 001 1100 003 CIRCUIT DESCRIPTION 3 2 4 10 7 MHZ CRYSTAL FILTER AND 10 7 MHZ AMPLIFIER The output of Q101 is tuned to 10 7 MHz the difference of the incoming signal frequency and the output frequency of injection amplifier Q102 This difference frequency is fed through a length of coax L202 and C201 to the input of 2 pole crystal filter Z202 The crystal filter has a bandwidth of 5 kHz at the 3 dB points The output of Z202 is coupled through C202 T201 and C298 to the base of 10 7 MHz IF amplifier Q215
102. be done by applying heat sink compound to the transistor s mounting base and installing the transistor using the two mounting holes DO NOT SOLDER AT THIS TIME Remove the transistor and inspect the foot print on the heat sink Look for any air pockets and be sure there are no bare spots Do the same for the transistor s mounting base NOTE Power amplifier transistors Q901 through Q904 must be of the same type and manufacturer 4 7 2 POWER AMPLIFIER PC BOARD REMOV AL The power amplifier PC board can be removed by first removing the PA cover Unscrew the six screws holding the cover in place and remove the cover 2 Unsolder the coaxial input and output lines along with the DC input line on C976 3 Remove the eight mounting screws attaching Q901 through Q904 4 Remove the three screws holding the PC board in place and remove the board NOTE When reinstalling the PC board make sure there is adequate heat sink compound on the transistor bases and that the insulator between the PC board and heat sink is in place Also make sure that no compo nent leads touch the heat sink 4 7 3 CIRCUIT PROTECTION If a transistor is shorted in the power amplifier the 25A fuse in the power cable will open The fuse provides short circuit protection for the power ampli fier and must not be defeated since severe component or microstrip damage could result August 1996 Part No 001 1100 003 SERVICING 4 7 4 TESTING Q901
103. ctive Call Guard circuit is ON 4 Refer to Figure 5 3 for the ENCODE switch posi tion the frequency test point and the frequency adjustment pot for each of the four Call Guard circuits 5 Use one of the following procedures to set the fre quency to the required 0 5 tolerance Method 1 Connect a period counter to the proper test point and set it for the proper period count Period 1 Frequency in Hz Method 2 Compare the Call Guard frequency at the test point to a preset frequency from an audio generator by using a Lissajous pattern A digitally set generator is preferred over an analog generator because it can be more accurately set on frequency Connect the vertical input of an oscilloscope to the test point and the hori zontal input to the audio generator With the audio generator set to the Call Guard frequency adjust the proper frequency adjust pot to stop the rotation of the circular Lissajous figure Distortion of the circular pattern is caused by differences in amplitude and not frequency 6 Return the ENCODE switches to the OFF position The switches on the PC board should be in the ON position unless that particular Call Guard is not being used Table 5 4 CALL GUARD RANGE JUMPERS Frequency Range JA 65 73 Hz OUT 73 90 Hz OUT 90 125 Hz OUT 125 187 Hz OUT 187 251 Hz IN August 1996 Part No 001 1100 003 T o 502 TP502 R527 R527 CALL GUARD 2 5 ON OFF S
104. dio ampli fier A 180 shift of the audio signal applied to Q210 and Q209 is accomplished by putting the base circuits of the two transistors in the opposite portions of the secondary The transistors are biased slightly by a biasing network made up of R256 R255 R254 and R253 to prevent crossover distortion To provide tem perature stabilization R261 and R257 are in the emit ter circuits of Q210 and 0209 respectively Negative feedback is provided by C258 and R259 to further decrease distortion and shape the audio response R249 and C274 in series dampen oscillations caused by the inductive effects of the speaker CIRCUIT DESCRIPTION FIRST INJECTION OSCILLATOR 5 SECTION MIXER _ AMPLIFI TRIPLER HELICAL FILTER 0101 TRIPLER m ANTENNA A 1101 1105 Las Diren WE L101 L105 0212 08 10 7 MHz SECOND 10 7 MH 2 FAMPLIFER 07 MIXER SECOND CRYSTAL FILTER CRYSTALFILTER 0202 OSCILLATOR lt RS 0214 11 155 MHz 10 245 MHz _ TO TRANSMIT BALL GUARD CIRCUITS AUDIO TRANSMIT UTPUT CIRCUITS 455 kHz 455 kHz SERRE AUDIO CALL GUARD AMP REAMP ILTER AUDIO AUDIO 5 5 DRIVER DRIVER VOLUM CONTROL SPEAKER SQUELCH ER SQUELCH SQUELCH FILTER GATE Figure 3 1 RECEIVER BLOCK DIAGRAM 3 2 10 SQUELCH AMPLIFIER SQUELCH FIL TER SQUELCH GATE The operation of the squelch circuit depends upon the presence or absence of an on
105. ditions No RF into the receiver 2 2V 2 0V 9 3V 0 2V 4 6 TRANSMIT TROUBLESHOOTING 4 6 1 GENERAL The exciter can be removed from its mount for servicing by loosening the two screws holding it in place The exciter can now be removed from its mount the covers removed and turned over for easier servicing Refer to Figure 5 2 for suggested test setup For troubleshooting purposes exciter troubles can be quickly isolated to the defective stage by fol lowing the exciter troubleshooting flow chart see Fig ure 4 4 or by proceeding as follows 4 6 2 DC SUPPLY VOLTAGE 1 Measure the voltage on the cathode of CR350 A reading of 14V DC 5 should be read Key the exciter and measure the DC voltage at the cathode of CR307 A reading of 9V DC 5 should be measured 4 6 3 AUDIO Remove the transmit crystal and proceed as fol lows 1 Inject a 1 kHz audio signal at a level of 0 1 V RMS at microphone pin 1 on the card rack assembly A microphone substitution fixture see Figure 4 1 can be used Using an oscilloscope measure and compare the audio level with those listed in Table 4 8 4 6 4 OSCILLATOR DOUBLER FIRST SECOND DOUBLER With the transmit crystal inserted measure and compare the voltage readings on Q320 Q345 and Q346 with those listed in Table 4 10 With the transmit crystal removed measure and compare the voltage readings with those in Table 4 10 August 1996 Part No 001 1100 003
106. e 6 15 CALE GUARD CARD EE 6 16 ATONE CALL GUARD CARD EE EE 6 17 EE EENEG 6 19 1 1 2 1 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 5 1 5 2 5 4 3 1 3 2 3 4 3 5 4 2 4 3 5 1 5 2 5 4 5 5 7 2 7 3 7 5 7 6 7 8 7 9 7 10 7 11 7 12 7 13 7 14 7 15 7 16 7 17 7 18 7 19 TABLE OF CONTENTS SCHEMATIC DIAGRAMS AND COMPONENT LAYOUTS ACCESSORIES OPTIONS 1 2 CALL GUARD FREQUENCIES a eh MD EM M 2 2 APPROXIMATE LOGIC LEVELS 4 2 SOUELCH VOLTAGES wz EE Sete Angina D ELE 4 3 RECEIVER AUDIO SIGNAL TRACING 4 4 IF AND LIMITER DISCRIMINATOR VOLTAGES 4 4 10 7 MHz UNMODULATED INJECTION POINTS 4 4 2nd MIXER 2nd OSC 10 7 MHz AMP 4 5 INJECTION STRIP AND FIRST MIXER 4 5 TRANSMITTER AUDIO SIGNAL TRACING 4 6 POWER CONTROL VOLTAGES eye cee Be 4 6 EXCITER VOLTAGE READINGS 4 7 TEST PANEL SWITCH POSITIONS
107. eater are selected to meet specific parameters and are listed with E F Johnson part numbers To obtain maximum repeater performance always replace defective semi conductors with the same type parts 4 1 5 SERVICE AND ALIGNMENT TOOLS Only common service and alignment tools are required to service the repeater Use a low power sol dering iron 60 watts or less to prevent component damage from overheating and use rosin core solder containing 60 tin and 40 lead To remove solder when replacing a defective component use a desol dering aid such as braided solder wick bulb or plunger type suction tool Common straight pointed and hex tipped align ment tools are used for adjustments A kit containing all the alignment tools needed to adjust Johnson equipment is available from the Johnson Customer Service Department This kit Part No 115 0410 001 contains seven alignment tools plus two ceramic replacement tips Replacement Parts Price Book 4 1 6 DRAWER REMOVAL The drawers used in this repeater can be pulled out and tilted down for servicing or they can be easily removed Before removing a drawer or other subas semblies turn off power and unplug all cables note where each is attached To remove the drawer slide it out until the guide pins line up with the holes in the side rails and then lift it up and out of the cabinet Each drawer has a top and bottom cover that can be removed for servicing To remove the power ampli f
108. ed or Sensitivity with 500 load 400 HV 20 dB Quieting unkeyed Antenna Sensitivity 4000 20 dB Effective Sensitivity 0 4 X 4000 400 3 Connect the antenna to the coupler and check the sensitivity with no on channel signal present Effective Sensitivity 4 UN Record the results MEASURE RECEIVER LEAD OF C260 15 7V DC SUPPLY VOLTAGES CATHODE OF CR209 9V DC NO CHECK POWER SUPPLY INTERCONNECT CABLE AND 9V REGULATED LINE YES MEASURE 0208 SQUELCH CONTRO COLLECTOR J209 FULL CCW AND CW MEASURE REFER TO SCHEMATIC Wo eNO ee 0214 0204 W215 VOLTAGE READINGS CW 0 1 QUELCH ES CIRCUITS TROUBLESHOOT DEFECTIVE STAGE MEASURE NOISE U201 PIN6 YES MEASURE REFER TO SCHEMATIC Q211 0213 0102 0101 VOLTAGE READINGS NO TROUBLESHOOT DEFECTIVE STAGE NO YES REFER TO SCHEMATIC MEASURE OSCILLATOR FREQUENCY Figure 4 3 RECEIVER TROUBLESHOOTING FLOWCHART August 1996 Part No 001 1100 003 4 10 SERVICING EASURE TRANSMI KEY TRANSMITTER SUPPLY VOLTAGE CR350 CATHODE 14V DC CR307 CATHODE 9V DC NO CHECK POWER SUPPLY AND TRANSMIT SWITCH Q348 YES EASURE TRANSMITTER POWER OUTPUT CHECK POWER CONTROL VOLTAGES A A LII YES TRANSMITTER DEVIATION AND AUDIO SYMMETRY NO CHECK TRANSMITTER AUDIO CIRCUITS YES CHECK TRANSMITTER FREQUENCY NO CHECK TRANSMITTER OSCILLATOR Figure 4 4 TRANSMITTER TROUBLESHOOTING FLOWCHART Aug
109. epair Clearly describe the difficulty experienced in the space provided and also note any prior physical damage to the equipment Then include a form in the shipping container with each unit Your telephone number and contact name are important because there are times when the technicians have specific questions that need to be answered in order to completely identify and repair a problem When returning equipment for repair use a PO number or some other reference number on your paperwork in case you need to call the repair lab about your unit These numbers are referenced on the repair order and it makes it easier and faster to locate your unit in the lab GENERAL INFORMATION Return Authorization RA numbers are not nec essary unless you have been given one by the Field Service Department RA numbers are required for exchange units or if the Field Service Department wants to be aware of a specific problem If you have been given an RA number reference this number on the Factory Repair Request Form sent with the unit The repair lab will then contact the Field Service Department when the unit arrives 1 9 REPLACEMENT PARTS Johnson replacement parts can be ordered directly from the Service Parts Department To order parts by phone dial the toll free number as described in Section 1 7 When ordering please supply the part number and quantity of each part ordered Johnson dealers also need to give their account nu
110. epeater alignment Adjust the Local audio control as desired and adjust the Squelch Adjust con trol so the squelch opens and the transmitter keys when the desired signal level is received August 1996 Part No 001 1100 003 INSTALLATION ANTENNA POWER POWER RF DUPLEXER py RE SUPPLY AMPLIFIER OPTIONAL DC POWER nr CONTROL DC TEST EXCITER RECEIVER SQUELCH CONTROL AUDIO AND DG CARD RACK AUDIO AND DC CONTROL CONTROL ONE REMOTE RACK OPTIONAL y Q REMOTE CONSOLE Figure 2 1 REPEATER BLOCK DIAGRAM Table 2 1 CALL GUARD FREQUENCIES August 1996 Part No 001 1100 003 2 2 INSTALLATION CR1100 SPECIFICATIONS The following are general specifications intended for use in testing and servicing this repeater For current advertised specifi cations refer to the Marketing Specifications sheet Specifications are subject to change without notice GENERAL Frequency Range Channels Transmit Receive Separation Dimensions Microphone Power Source FCC Compliance Duty Cycle Circuit Protection RECEIVER Sensitivity Selectivity Squelch Sensitivity Spurious Image Rejection Intermodulation Audio Power Output Hum and Noise Frequency Stability Optional Input Impedance Speaker Impedance TRANSMITTER RF Power Output Duty Cycle Spurious and Harmonic Emissions Modulation FM Hum and Noise Frequency Stability Optional Audio distortion Load Impedance
111. eys If the ID is being transmitted the repeater can be accessed and the voice communication will be heard over the ID U701 is included in the kit to upgrade the soft ware if necessary Revision 208 or later software is required with the CWID The PROM can be factory programmed or pro grammed with the PROM Programmer II Part No 250 3020 200 August 1996 Part No 001 1100 003 GENERAL INFORMATION Table 1 1 ACCESSORIES OPTIONS Description Transmit 2 5 PPM TCXO 1 Receive 2 5 PPM TCXO 1 Transmit 5 PPM TCXO 1 Receive 5 PPM TCXO 1 Receiver Shield Kit Test Panel 4 Tone Call Guard Squelch Type A Call Guard Squelch Power Failure Alarm CW Identifier Card Heavy Duty Microphone 60 Indoor Cabinet 43 Outdoor Cabinet 60 Outdoor Cabinet Duplexer 150 162 MHz 162 174 MHz 522 522 1xxx xxx 521 Oxxx xxx 521 6xxx xxx 023 3823 080 023 3823 340 023 3823 050 023 3823 056 023 3988 001 023 3823 330 250 0740 200 023 3824 003 023 4061 001 023 4061 002 532 4001 006 532 4001 013 Part Number 1 The last six digits are determined by the frequency in MHz 1 5 2 REPEATER CABINETS The standard 30 inch cabinet does not have addi tional room for accessories The 43 or 60 cabinets are used when accessories such as a duplexer are installed The outdoor cabinet consists of three panels which install around the indoor cabinet to make it weather resistant 1 5 3 MICR
112. f the two pin junctions If the 9 6V regulated line tends to decrease both Q701 and Q700 turn on The emitter to collector resistance of Q700 decreases and it drops less volt age This compensates for the decrease in voltage of the regulated line If the regulated line tries to increase in voltage both Q701 and Q700 tend to turn off The emitter to collector resistance of Q700 increases and Q700 drops more voltage This increased voltage drop counteracts the increase in voltage on the regulated line 3 6 3 TRANSMIT AUDIO CIRCUITS REMOTE KEYING When the transmitter is brought up the output of U602A on the Control Card goes high This puts high on pin 9 of the Level Adjust card and on bilateral switch U701A pin 6 When U701A pin 6 goes high the switch closes and allows signals to pass The audio from the receiver is applied to pin 8 on the Level Adjust card through a resistor network and C720 to 701 pin 8 Local audio control R710 adjusts the received audio volume at the repeater site Level adjust pot R714 sets the amount of audio to the transmit audio circuitry The output on U7014A pin 9 is coupled through R724 C710 and C711 to Call Guard filter 0705 and Q706 These two transistors along with their associ ated components make up a highpass filter that removes signals of under 300 Hz The output is taken off the emitter of Q706 and coupled through C716 to pin 18 of the Level Adjust card 3 6 4 RECEIVE CALL
113. frequency RF car rier Without an on frequency signal input to the receiver high frequency noise is fed from the limiter discriminator to squelch amplifier U202C through R240 The level of noise is raised approximately 20 dB and fed to squelch filter U202D The squelch filter has a sharp roll off below 3 kHz The noise output is fed to a voltage divider network consisting of R237 R238 This network establishes the input level to squelch filter U202D The feedback circuit consists of C241 C242 and R235 These components allow U202D to act as a highpass filter The output is fed through C244 to a voltage rectifier doubler circuit made up of CR204 CR203 and C248 In this model receiver CR205 and C295 perform no function The positive DC voltage from the recti fier doubler is fed through R250 to the base of squelch gate Q208 turning it on The collector of Q208 goes low disabling local audio amplifiers Q206 and Q207 This low is also fed to the squelch circuits on the level adjust card The squelch potentiometer on the Level Adjust card sets the point at which Q208 conducts When an on channel signal is received there is no noise fed to the squelch amplifier the squelch filter or the rectifier doubler The base of the squelch gate goes to and 0208 turns off The collector voltage on Q208 rises and allows Q206 and Q207 to operate normally To prevent intermittent squelching when receiv ing a weak fading signal a hysteresis ci
114. frequency modulated with a 1 kHz tone at 5 kHz deviation Monitor the transmitter output with a deviation meter and adjust deviation control R324 on the Exciter TCXO for 5 kHz transmit deviation Reset the signal generator deviation level to 4 kHz Adjust XMIT AUDIO LEVEL R714 on the Level Adjust card for 4 kHz transmit deviation 5 3 5 CALL GUARD DEVIATION 1 Connect an RF signal generator to the receiver antenna jack Set the generator for 100 output on the receive channel frequency modulated with 150 Hz audio at 600 Hz deviation Monitor the transmitter output with a deviation meter and adjust Call Guard level control R705 on the Level Adjust card for 600 Hz transmit devia tion Turn off the signal generator modulation Remove the Level Adjust card and reinsert with an extender card Turn the ENCODE switch the Call Guard card to any encode position with a Call Guard frequency of 60 250 Hz Monitor the transmitter output and adjust R700 on the Level Card for 600 Hz 5 3 6 CALL GUARD TONE FREQUENCY AD JUSTMENT Refer to Figure 5 3 for Call Guard card alignment locations 1 Remove the Call Guard card from the card rack and reinsert with an extender card August 1996 Part No 001 1100 003 ALIGNMENT AND PERFORMANCE TESTS 2 Cut the frequency range jumpers as shown in Table 5 4 3 Check that the Call Guard switch on the PC board for each a
115. gh C602 and CR600 to the base of Q603 C603 is charged to approximately 9V and this voltage is applied to the base of Q603 and the collector goes low This places the positive end of C603 and 0602 pin 12 near ground potential The capacitor cannot dis charge through the base emitter junction of Q601 therefore the base of Q601 goes to approximately 8V This turns off Q601 and the collector goes high The base of Q603 also goes high to ensure it stays turned on C603 then begins discharging through R607 With all of the inputs to U602A low the output on U602A pin 13 goes high This high is applied through R613 to the base of Q604 and it turns on The emitter of Q604 also goes high charging C605 This high is passed through a resistor network to the base of Q605 and it turns on A low appears on the collec tor of Q605 and is applied to the inputs of NOR gate U602B This portion of U602 acts as an inverter and a high appears on the base of Q606 A low appears on the collector of Q606 that turns on CR603 and places a low on the transmit switch line on Control Card pin 19 to key the transmitter After approximately three minutes C603 in the time out timer circuit discharges through R607 to a point where Q601 turns on This places a low on the collector of Q601 and the base of Q603 The collector voltage on Q603 rises and places a high on U602A 12 The output of U602A 13 goes low to turn off Q604 This allows C605 to discha
116. his causes the input voltage on the inverting input of U401 to increase The output on 0401 7 decreases and tends to turn off Q400 The collector voltage on Q400 increases causing Q401 to conduct less This reduces the conduction of Q375 and reduces the RF power out put The low power adjustment is made with R412 3 4 POWER SUPPLY This supply consists basically of a ferroresonant transformer bridge rectifier and voltage regulator The ferroresonant power transformer is designed to accept a nominal input of 110 220V AC 15 and CIRCUIT DESCRIPTION provide a constant output of the secondary of 16V AC The output of the secondary is rectified by CR3 and CR4 The output of the rectifier is then fed to a shunt regulator circuit The initial load on the power supply is estab lished by R1 The base of Q1 is held at a constant 14V by zener diode CR1 and CR2 This places the emitter of Q1 at approximately 14 7V If the power supply output voltage tends to rise the conduction of Q1 increases This increases the current flow in the secondary of T1 which increases the voltage drop This increase in voltage drop opposes the output volt age increase If the output voltage tries to decrease the conduction of Q1 decreases There is now less of a voltage drop on the secondary of T1 This decrease in voltage drop offsets the decrease in output voltage To increase the regulation of Q1 CR7 is placed between the base and emitter 3
117. ier and the audio output stages Filter ing is provided by C1 C2 C260 L206 C296 L212 C297 L213 and C299 A regulated 9 1V is supplied to the remainder of the receiver by zener diode CR209 3 2 2 HELICAL FILTER FIRST MIXER The incoming on channel signal is coupled through a 5 section helical resonator and L106 to the gate of first mixer Q101 The individual cavities are tuned by C101 C105 These variable capacitors rep resent the variable spacing between the ends of their respective coils and ground The size and shape of the aperture between cavities determine the degree of cou pling and bandpass characteristics An impedance match between the helical resona tors and the gate of Q101 is provided by L106 and C106 First mixer Q101 mixes the incoming signal with the output of injection amplifier Q102 3 1 3 2 3 OSCILLATOR TRIPLER SECOND TRI PLER INJECTION AMPLIFIER Parts are included on the circuit board for two channel operation however only channel 1 is opera tional This has been done by hard wiring the emitter circuit of Q211 to ground The oscillator tripler is a modified Colpitts circuit with the collector of Q211 tuned to the third harmonic of the crystal frequency The oscillator output fre quency is tuned by R208 and T209 A passive tem perature compensation scheme is used with ther mistor RT201 controlling the effective capacitance of C291 which establishes the temperature compensa tion of the oscill
118. ier or power supply remove the mounting screws from the back of the cabinet mounting rail 4 2 INTEGRATED CIRCUIT SERVICING 4 2 1 CMOS HANDLING PRECAUTIONS Some of the integrated circuits used in this repeater are CMOS devices CMOS integrated cir cuits can be identified by a part number of 544 3x1x xxx Since these devices have very high open circuit August 1996 Part No 001 1100 003 SERVICING impedance they are particularly susceptible to dam age from static discharges Damaging static charges may be present even if static arcs are not observed When handling these devices observe the following precautions 1 Before touching the equipment or a CMOS device discharge any built up static charge on your body by touching a good earth ground 2 Ground all test equipment and make sure the solder ing iron tip is grounded Connect ground leads before connecting test probes 3 Leave the CMOS device in its conductive shipping packaging until it is inserted in the PC board Once the device is installed in the PC board it is protected by internal diode protection circuits so the chance of static damage is somewhat reduced A ser vice bench protection kit Part No 299 0026 001 can be ordered from the Service Parts Department This kit eliminates static build up on the body and includes a conductive mat wrist strap and a grounding strap with a 1M ohm resistor 4 2 2 SERVICING TECHNIQUES A good starting point when
119. io level exceeds 0 5V CR303 becomes reverse biased and limits the audio signal When the negative audio peaks exceed 0 5V CR304 becomes reverse biased and limits the audio The audio is coupled from the limiter through C306 R310 to U301C pin 11 U301C performs splat ter filtering and audio amplification The amplified and filtered audio is coupled from U301C pin 10 through C307 R313 that provide addi tional pre emphasis and R314 to U301D pin 8 U301D performs additional splatter filtering and audio amplification 3 3 3 TRANSMIT OSCILLATOR DOUBLER Channel one of the transmitter is used for the repeater however channel two can be used by grounding the emitter of Q321 Processed audio is taken from U301D pin 9 and coupled through C310 R320 R324 C321 and L321 to varactor diode CR321 Varying the amount of reverse bias applied to this type of diode the internal capacity is varied This varies the frequency of the varactor s associated crystal The varactor is reverse biased by the 6 2V regu lated line When audio is applied to the varactor the reverse bias voltage varies at an audio rate and this direct FM modulates the oscillator Deviation is adjusted by R324 on the TCXO circuit board and by R714 on the level adjust card Temperature compen sation is accomplished in the same manner as in the receiver The approximate frequency on which Y301 operates is determined by C327 and is peaked to the center range of C325
120. ly 023 3823 020 C977 100 pF 5 50V N750 disc 510 3020 101 Test card 023 3823 022 Control card assembly 023 3823 030 000 Cover 017 1626 030 Level adjust card assembly 023 3823 040 00 43 repeater cabinet assembly 023 3824 001 Receiver 150 174 MHz assem 023 4111 101 Exciter 150 160 MHzassem 023 4111 210 HW000 10 U type ZPS speed nut 560 1810 002 PA 150 160 MHz assembly 023 4111 260 HW000 1 4 20 HH flange ZPS screw 575 1914 012 HW000 1 4 20 HH flange ZPS screw 575 1914 016 100 pF 5 50V N750 disc 510 3020 101 HW000 10 TF pan head philips CPS 575 3610 032 HW000 Backing plate 013 1479 001 00 Cover 017 1626 030 00 43 repeater cabinet assembly 023 3824 001 name plate 559 0009 179 000 repeater 1100 label 559 0009 195 HW000 10 U type ZPS speed nut 560 1810 002 000 VHF 1100 repeater label 559 0009 196 HW000 1 4 20 HH flange ZPS screw 575 1914 012 000 Exciter label 559 3056 001 HW000 1 4 20 HH flange ZPS screw 575 1914 016 HW000 10 pan head philips CPS 575 3610 032 W 000 Harness 023 3823 070 HW000 Backing plate 013 1479 001 000 RG 400 3 ft N PL 259 597 3004 001 FCC name plate 559 0009 179 Y 000 Crystal comp 023 4245 001 000 VHF repeater 1100 label 559 0009 195 Y 000 Crystal comp kit 023 4246 001 000 VHF 1100 repeater label 559 0009 196 Y 000 Transmit crystal 521 0000 000 Exciter label 559 3056 001 000 Receive crystal 521 6000 000 Harness 023 3823 070 RECEIVER 150 174
121. ly 2 1V DC Inject a 1 kHz signal at 400 mV on 0201 pin 6 With the Local Audio volume control on the Level Adjust card set for maximum unclipped audio out put across the speaker load Typically or 4V RMS minimum Measure and compare the DC voltages in the audio circuit with those in Table 4 3 August 1996 Part No 001 1100 003 SERVICING Table 4 3 RECEIVER AUDIO SIGNAL TRACING Measured At U202A Volts RMS Volts P P pin 8 6 2V 0 5V pin 9 2 3V 4 2V U202B pin 11 0 5V pin 10 2 45V 6 8V 4 4V R710 R723 2 2V 6 1V Q206 Base 0 6V Collector 45mV 125mV 2 1V Q207 Base 45mV 125mV 2 4V Collector 1 1V 3 0V 14 6V Q209 Base 34mV 104mV 0 7V Collector 4 15V 11 6V 7 3V Q210 Base 4 15V 11 6V 21 Collector 24 5mV J212 0 41V Test Conditions No RF into receiver Squelch control set fully CCW 4 5 4 LIMITER DISCRIMINATOR FIRST AND SECOND IF 1 Inject an unmodulated 455 kHz signal at a level of 70 uV into TP202 using 6800 pF coupling capac itor 20 dB of quieting should be measured 2 Measure and compare the voltages on Q203 Q204 and U201 with those listed in Table 4 4 August 1996 Part No 001 1100 003 4 4 Table 4 4 IF AND LIMITER DISCRIMINATOR VOLTAGES Measured At U201 Volts DC Volts P P Noise pin 1 21 1 0V pin 2 2 1V pin 3 2 1V pin 6 1 0V pin 7 0 4V 100mV pin 8 5 4V 200mV
122. m ber If there is uncertainty about the part number include the designator C112 for example and the model number of the equipment the part is from You may also send your order by mail or FAX The mailing address is as follows and the FAX number is shown in Section 1 7 E F Johnson Company Service Parts Department 299 Johnson Avenue P O Box 1249 Waseca MN 56093 0514 1 10 INTERNET HOME PAGE The E F Johnson Company has a home page on the World Wide Web that can be accessed for informa tion on such things as products systems and regula tions The address is http www transcrypt com August 1996 Part No 001 1100 003 INFORMATION August 1996 001 1100 003 INSTALLATION SECTION 2 2 1 INTRODUCTION Although this equipment is carefully aligned at the factory shipment can upset some of the adjust ments so pre installation testing is recommended Complete the tests listed in the Performance Tests Sections 5 4 and 5 5 Site preparation and antenna installation is not within the scope of this manual Refer to the Dealer Guide To Site Preparation Part No 004 8000 100 for preliminary installation requirements Factory installation of repeaters is available Contact your sales representative for more information 2 2 115 230V AC OPERATION CAUTION Do not connect the power supply to AC power until an antenna or dummy load has been connected to the antenna jack
123. ocket Crystal socket 11 155 MHz 32 pF HC 18 10 7 MHz crystal filter PART NUMBER 592 5013 012 592 5006 005 592 5006 005 592 5006 005 592 5006 005 592 1015 001 592 5009 016 592 5009 016 592 5009 016 592 5009 023 586 1001 022 105 2202 211 105 2202 211 105 2202 211 035 0212 001 035 0314 001 544 2002 007 544 2005 001 597 3002 003 597 3002 003 126 0110 014 126 0110 014 519 0009 001 532 0007 002 10 7 MHz 2 pole crystal filter 532 0006 001 EXCITER PART NO 023 4111 210 150 160 MHz PART NO 023 4111 310 160 174 MHz Exciter harness assembly Transmitter bd 150 160 MHz Transmitter bd 160 174 MHz Power terminal assembly 33 pF 5 50V 150 disc 1000 pF 20 50V YSU disc 01 20 50V YSU disc 1000 pF 20 1kV feedthru 1000 pF 20 1kV feedthru 023 3823 011 023 3493 001 023 3493 002 023 4111 012 510 3016 330 510 3204 102 510 3202 103 510 3149 102 510 3149 102 6 5 SYMBOL NUMBER 1000 16V aluminum 5 6 20 35V tubular 047 20 16V YSS disc 10V YSU disc 6800 pF 20 50 YSU disc 1 pF 10 250V flatfoil 1 20 35V dipped 1 uF 20 35V dipped 1 uF 10V YSU disc 0047 200V foil 390 pF 5 100V 1DM15 uF 10V YSU disc 5 6 uF 20 15V molded 1000 pF 20 50V YSU disc 470 pF 5 100V 1DM15 047 20 16V YSS disc 047 20 16V YSS disc 470 pF 5 1500 50V 470 pF 5 N1500 50V 1000 pF 20 50V YSU disc 1 9 15 7 pF vert mount c
124. ode mode This shorts the Call Guard audio input line to ground This prevents any signals on the Call Guard audio input line from interfering with the oscillator s operation SERVICING SECTION 4 SERVICING 4 1 GENERAL 4 1 1 PERIODIC CHECKS Heavy duty cycles and the number of users that depend on the repeater make it especially important that regular preventive maintenance be performed Checks should include receiver sensitivity SINAD and transmitter frequency deviation and power out put The repeater should be checked monthly during the first six months of operation and quarterly thereafter 4 1 2 VISUAL INSPECTION Always give the repeater a visual inspection before attempting to isolate a problem Check for loose broken or pinched wires overheated or discol ored components and cold solder joints A defective solder joint may have excess solder too little solder or a dull uneven coloring 4 1 3 SCHEMATICS AND COMPONENT LAY OUTS Schematic diagrams and component layouts for all PC boards are located in Section 7 The compo nent layouts allow quick location and identification of components and test points 4 1 4 REPLACEMENT PARTS A replacement parts list with component part numbers is located in Section 6 Parts are listed alpha betically according to designator starting with the lowest number and are separated into sections identi fied by headings in boldface type Semiconductor devices used in the rep
125. osphere DO NOT operate the radio unless all the radio frequency connectors are secure and any open connectors are properly terminated DO NOT allow children to operate transmitter equipped radio equipment SAFETY INFORMATION Proper operation of this radio will result in user exposure below the Occupational Safety and Health Act and Federal Communi cation Commission limits The information in this document is subject to change without notice E F Johnson Company will not be liable for any misunder standing due to misinformation or errors found in this document Viking Head EFJohnson Logo and Call Guard are registered trademarks of the E F Johnson Company a subsidiary of Transcrypt International Inc All other company and or product names used in this manual are trademarks and or registered trademarks of their respective manufacturer 3 1 3 2 3 3 3 4 3 5 3 6 TABLE OF CONTENTS GENERAL INFORMATION SCOPE MANUAL Bee BEE CULO ERRARE 1 1 DESCRIPTION tend Kara Facts abate v ie 1 1 REPEATER IDENTIFICATION yo Sa ee yy re e E RR RN Vane Ea Er ra Y Rink epa 1 1 JOHNSON 1100 MODELS RR e Ra QE E ee 1 1 ACCESSORIES 22060 pal ERE Ua Rp e RR T 1 1 EXTERNAL CW IDENTIFIER 5 sda Sub aso eyed Kick pi vp
126. output is coupled by C619 and R638 to U601A pin 6 A portion of the output is taken off U601A pin 5 and coupled by C620 to the anode of CR605 and the base of Q609 When received tone is of too great an amplitude the negative peaks cause 0609 to conduct Filtering is provided by C261 and the gate of Q607 goes in a negative direc tion This turns on Q607 and shorts the excess signal to ground The processed Call Guard audio output is taken off U601A pin 5 and coupled through C607 to pin 22 on the Control Card This pin goes to the Call Guard level adjustment circuitry on the Level Adjust card 3 6 LEVEL ADJUST CARD 3 6 1 GENERAL Refer to Figures 3 4 and 7 2 for block diagram layouts of the Card Rack and Level Adjust card The Level Adjust card contains the 9 6V regula tor a portion of the transmit and audio Call Guard cir cuitry a portion of the transmitter control circuitry and the local audio and keying circuitry This card also contains various transmit audio and Call Guard audio level adjustments along with the receiver squelch adjustment 3 6 2 9 6V REGULATOR The regulator supplies 9 6V regulated DC to the cards in the repeater card rack An unregulated 15 7V is applied to pin 21 The base of Q701 is held at a constant 11V by CR700 The emitter base junction of Q701 is forward biased which forward biases the emitter base junction of Q700 The emitter of Q700 is approximately 1 4V less than the base of Q701 because o
127. ower 4 8 LEVEL ADJUST CONTROL AND CALL GUARD SQUELCH CARDS 4 8 1 GENERAL To isolate a problem to a specific stage on one of these cards refer to the card rack block diagram see Figure 7 2 and the appropriate schematic diagram Determine the signal path from the block diagram and then measure the DC and AC voltages as shown on the schematic 4 8 2 CONTROL CARD NOR GATE U602 OP ERATION On the Control card U602 contains two 4 input NOR gates The output from both U602A and U602B is high only when all the inputs are low When one or more of the inputs on each NOR gate is high its out put is low The transmitter is keyed if all four inputs at U602A are low This means that the squelch time out timer Call Guard squelch if used and the repeater disable signals must be low to key the transmitter The inputs to U602B must all be low to key the transmitter This puts a high on the output and turns on Q606 To unkey the transmitter the input to U602B goes high This produces a low on the output of U602B and Q606 turns off SERVICING 4 9 CHECKING RECEIVE DESENSITIZATION 4 9 1 INTRODUCTION Receiver desensitization is the loss of receiver sensitivity caused by high level off frequency signals that are applied to the receiver Some possible causes of desensitization are improperly tuned combining equipment or a transmitter generating excessive spuri ous radiation The following test measures desensiti zation
128. p 3301 Dual NOR gate CMOS 4002 Quad op amp 224 569 0513 334 569 0513 394 569 0513 184 569 0513 334 569 0513 334 569 0513 334 569 0513 394 569 0513 334 569 1502 154 569 0513 103 569 0513 103 569 0513 100 569 0513 223 569 0513 474 569 0513 472 569 0513 222 569 0513 822 569 0513 274 569 0513 274 569 0513 102 569 0513 272 569 0513 183 569 0513 272 569 0513 102 569 0513 102 569 0513 100 569 0513 104 569 0513 103 569 0513 103 569 0513 224 569 0513 473 569 0513 102 569 0513 105 569 0513 224 569 0513 224 569 0513 100 583 3003 001 583 3003 001 583 4007 001 035 0355 030 544 2005 001 544 3001 135 544 2020 001 August 1996 Part No 001 1100 003 700 701 702 703 704 705 706 707 708 709 C 710 C711 C712 C713 C714 C715 C716 C717 C718 C 720 C721 C 722 C 723 C 724 C 725 C 726 LEVEL ADJUST CARD PART NO 023 3823 040 1 pF 10 35V tantalum 1000 pF 20 50V YSU 01 20 16V YSS cer 6 8 20 35 tantalum 1 10 35V tantalum 1000 pF 20 50 YSU cer 1 10 35V tantalum 1 10V YSU cer disc 6 8 20 35V tantalum 1 pF 10 35 tantalum 3300 pF 20 50V YSU cer 3300 pF 20 50V YSU cer 2 2 20 35V tantalum 3300 pF 20 50 YSU cer 3300 pF 20 SOV YSU 2 2 20 35V tantalum 1 pF 10 35V tantalum 2 2 20 35 tantalum 1 pF 10 35V tantalum 1 pF 10 35V tantalum 1 pF 10 35V tantalum
129. plicable Table 4 1 APPROXIMATE LOGIC LEVELS Input Level Logic Low Max CMOS 5V Supply 10V Supply ECL August 1996 Part No 001 1100 003 Logic High Min Output Level Logic Low Max Logic High Min SERVICING Mounting Check to make sure that the transistor mount ing surface is clean and then apply a thin coat of silicon heatsink compound Insert the transistor and tighten it securely when applicable Solder the transistor using a generous amount of solder to provide good contact between the entire transistor tab and the microstrip Check that no solder bridges are present 4 4 LOCALIZING PROBLEM TO A DEFECTIVE ASSEMBLY 4 4 1 INTRODUCTION A problem with the repeater can usually be iso lated fairly quickly to a main subassembly such as the receiver or exciter drawer The following checks can be used to verify operation of the receiver and trans mitter Before proceeding with these checks make sure all the cables on the rear panel connectors are in place and that the power supply output voltage is approximately 14V Refer to the troubleshooting flowchart Figure 4 3 or to the following information to determine if the receiver is working properly 4 5 RECEIVE TROUBLESHOOTING The receiver can be removed from its mount for servicing by loosening the two screws holding it in place The receiver can now be removed from its mounting the covers removed and turned over for easier servicing Refer
130. r and the receiver audio preamplifier From U503A the signal is fed to the bandpass fil ter formed by U503B U503C and their associated components This is an adjustable active filter formed from operational amplifiers and has a bandpass of 2 5 Hz at Call Guard frequencies The bandpass fre quency is set by R548 and jumper wires A B C and D The location of the jumper wires is shown in Table 5 4 The ENCODE switch is used to set the Call Guard frequency August 1996 Part No 001 1100 003 CIRCUIT DESCRIPTION CALL GUARD CG AUDIO CG DECODE ENCODE SWITCH 500 CG ENCODE Figure 3 5 CALL GUARD CARD BLOCK DIA GRAM 3 7 4 THRESHOLD DETECTOR U503D BANDPASS FILTER U503B U503C The output of the bandpass filter is on 0503 pin 7 and fed to threshold detector U503C pin 13 The threshold level of the operational amplifier is set by the voltage divider consisting of R559 R560 With no signal input to the threshold detector U503C pin 13 is approximately 4 6V and pin 12 is approximately 4V Since the inverting input is at a higher level the output on U503C pin 14 is OV When the bandpass filter decodes a signal a sine wave input on 0503 13 is produced When the negative August 1996 Part No 001 1100 003 going alternation drops below the level on U503C pin 12 a positive pulse is provided on the output These pulses cause C520 to charge through CR502 and turn on Call Guard switch Q505 The collector
131. r is activated by the receiver s squelch circuitry or by a tone if the unit 15 equipped with the Retransmit Call Guard card The tone remote console Part No 250 45xx functions as a control point base station when used with the repeater When used in the community repeater configura tion the repeater is activated by any one of 16 possible Call Guard tones Each Call Guard card contains four tunable Call Guards see Table 1 1 1 3 REPEATER IDENTIFICATION The serial number is printed on an adhesive backed cloth attached to the inside of the cabinet The following table shows a breakdown of an identifica tion number Revision Manufacture Letter D Warranty Number Model Plant 1 1 1 4 JOHNSON CR1100 MODELS The following breakdown shows the part number scheme used for the Johnson CR1100 models 242 1100 X 0 BASE STATION 1 STANDARD UNIT 2 STANDARD UNIT 1 3 STANDARD UNIT 2 3 150 160 MHz 4 160 174 MHz 2 25 100 WATTS 1 WITH DUPLEXER 2 WITH TONE REMOTE 1 5 ACCESSORIES Refer to Table 1 1 for a listing of CR1100 repeater accessories options and their part numbers 1 5 1 EXTERNAL CW IDENTIFIER The CWID is a separate PC board option that pro vides automatic international Morse Code station call sign identification by superimposing coded audio onto the transmit modulation If voice communication is in process the ID is not transmitted until the repeater unk
132. rcuit made up of CR208 R242 is used In the unsquelched mode CR208 is forward biased This provides a shunt path to ground through R242 CR208 and C236 for some of the noise This effectively reduces the sensitivity of the squelch circuit to minor fades A greater change in the received noise is now required to squelch the radio To prevent the receiver from being unsquelched during short fades C245 is in the emit ter base circuit of Q208 August 1996 Part No 001 1100 003 CIRCUIT DESCRIPTION 3 3 TRANSMITTER 3 3 1 DC POWER SUPPLY TRANSMIT SWITCH B from the power supply is applied to the power amplifier assembly through P904 Transient voltage protection is provided by 17V zener diode CR902 Polarity protection is provided by CR901 If a nega tive potential is applied to the radio CR901 conducts and blows the power supply fuse A DC power cable containing a 5A fuse carries from the power amplifier to the exciter Inside the exciter B is applied directly to the collector of Q376 and to L206 in the transmit switching circuit In the receive mode transmit switch Q348 is turned off by a positive voltage on the base provided by R374 R360 This prevents the 13 8V transmit switch line from becoming activated In the transmit mode J1 pin 10 becomes grounded and 0348 turns on This supplies B volt age to the exciter circuitry except for Q375 Q376 The receive switch is inactive as the receiver is on all the time 3
133. rge through R615 R655 and the base emitter junction of Q605 After approximately three seconds Q605 turns off The collector voltage on Q605 increases and places a high on the inputs to U602B The output on U602B pin 1 goes low and turns off Q606 The collector volt age of Q606 rises and unkeys the transmitter and turns off CR603 The low on U602B pin 1 is also applied August 1996 Part No 001 1100 003 CIRCUIT DESCRIPTION RX CG AUDIO U603 SQ GATE REPEATER REPEATER SWITCH U602A RANSMIT DELA Q604 Q605 CALL GUARD BUFFER AMP MITER LOWPASS FILTER LI CG TONE U601B CALL GUARD AUDIO COMPRESSOR CG TONE Q607 Q608 Q609 U601A TO TX TIME OUT TIMER Q600 Q603 CG DECODE INVERTER SWITCH Q606 TX PTT OUT Figure 3 3 CONTROL CARD BLOCK DIAGRAM through R606 to the base of Q602 Q602 turns on and places a high positive voltage on the base of Q601 This holds Q601 on and the transmitter stays unkeyed In order to bring the repeater up again the remote oper ator must unkey the microphone that turns Q600 on The next signal with appropriate Call Guard tone that the repeater receives brings it up again The three minute transmit cycle can also be started again by using TIMER RESET switch S602 located on the front of the repeater control card This is a momentary contact normally open switch When the switch is depressed C602 discharges through R609 When the switch is released C602 cha
134. rges and passes a positive pulse through CR600 to the base of Q603 to reset the timing cycle The purpose of the delay selector is to keep the repeater up for a short period of time usually three seconds after a transmission This eliminates one of the squelch tails and prevents loss of signal between operators If the repeater has to come up between con versation exchanges the first part of each message August 1996 Part No 001 1100 003 could be missed Any one of three resistors can be chosen for the desired time delay In addition a provi sion has been made on the PC board for mounting a potentiometer 3 5 3 CALL GUARD SQUELCH CIRCUITS The audio output containing the Call Guard squelch frequencies from the receiver is fed from the level card to pin 14 on the control card The audio is then coupled by C606 R620 and C632 to the input of low pass filter U603 This filter is a quad operational amplifier which removes all frequencies above 300 Hz This leaves only the Call Guard tones at the out put on pin 14 The output of the limiter is coupled by C624 to Control Card pin 13 and goes to the Call Guard card The output of low pass filter U603D pin 14 is also fed to the Call Guard audio compressor through C618 and R637 This circuit ensures that the level of the Call Guard tone fed to the Level Adjust card is constant CIRCUIT DESCRIPTION The input to the compressor is on the gate of amplifier Q608 The source
135. s EE ER 4 9 LOCALIZING CAUSE OF DESENSITIZATION 4 9 DETERMINING EFFECTIVE SENSITIVITY 4 9 ALIGNMENT AND PERFORMANCE TESTS RAD 58 a AA ae N 5 1 RECEIVER ALIGNMENT 5 1 FIRST OSCILLATOR TRIPLER INJECTION 5 1 FIRST OSCILLATOR FREQUENCY 5 1 FRONTEND AND 5 5 1 DISCRIMINA TOR La E dede Pei 5 2 TRANSMITTER ALIGNMENT 5 2 OSCILLATOR DOUBLER 6 5 2 SECOND AMPLIFIER 22225 5 2 PRELIMINARY DEVIATION 5 3 TRANSMIT DEVIATION ee Ee eg 5 3 CALL GUARD 5 3 CALL GUARD FREQUENCY 5 3 RECEIVER PERFORMANCE 5
136. servicing integrated circuits is to measure steady state DC voltages Oper ational amplifiers which function as buffers or ampli fiers usually have a DC voltage on the input and out put that is half the supply voltage Others which function as comparators may have an output voltage that is near the supply voltage or 0 volts depending on which input is higher The steady state DC voltages of logic gates such as AND or OR gates can also be measured with a volt meter Check the output level produced by each input combination Troubleshooting operating digital cir cuits i e microprocessors is difficult because of the dynamic operation of these devices Table 4 1 shows the approximate logic levels for CMOS and TTL integrated circuits 4 3 TRANSISTOR SERVICING 4 3 1 REPLACING TRANSISTORS SOLDERED TO MICROSTRIP Use the following procedure to replace transistors that are soldered directly to PC board micro strip such as those on the power amplifier board Removal Remove the defective transistor and all excess solder on the microstrip Clean the mounting surface with alcohol or another solvent that does not leave a residue Do not apply solvent to Under wood capaci tors because it may cause dielectric breakdown and affect the value Tinning Lightly tin the underside of each transistor lead with solder Do not allow a thick build up of solder since this could cause case separation when the tran sistor is tightened when ap
137. squelch adjust control for threshold squelch 2 Set an RF signal generator to the receive channel frequency modulated with a 1 kHz tone at 5 kHz deviation at an output level of 100 3 Connect the signal generator to the receiver subas sembly antenna jack 4 Monitor the transmitter deviation meter Deviation should be 4 5 5 kHz 5 Decrease the signal generator to 4 kHz and the transmitter deviation should drop to 4 kHz reset deviation see Section 5 3 4 5 5 4 CALL GUARD SQUELCH 1 Set the encode switch on the Call Guard card to position 1 2 3 or 4 and key the transmitter 2 Deviation should be 600 Hz on the Call Guard fre quency Refer to Section 5 3 6 3 Repeat for each Call Guard tone 4 System deviation with Call Guard deviation should be 4 5 kHz 500 Hz August 1996 Part No 001 1100 003 ALIGNMENT AND PERFORMANCE TESTS Figure 5 4 RECEIVER ALIGNMENT POINTS E In val TF3 1 L320 5 R324 325 327 SE R412 LOW POWER HIGH POWER Figure 5 5 TRANSMITTER ALIGNMENT POINTS August 1996 Part No 001 1100 003 5 6 PARTS LIST SECTION 6 PARTS LIST DESCRIPTION DESCRIPTION 1100 REPEATER 150 160 MHz 000 Receiver 160 174 MHz assem 023 4111 101 PART NO 242 1100 231 000 Exciter 160 174 MHz assem 023 4111 310 000 160 174 MHz assembly 023 4111 360 25A power supply 110V 60Hz 023 3341 012 Card rack assemb
138. tput power taken from the output circuit just ahead of the lowpass filter The other input is a temperature indication produced by a thermistor located near the finals Under normal oper ating conditions only the RF power level input has an effect on the power output If the ambient temperature of the finals exceeds a certain level the power is cut back to protect the finals from damage A sample of the RF power output is coupled by C954 from the input to the lowpass filter and rectifier filter circuit CR903 R910 and C957 The DC voltage is applied through a voltage divider network to U401C pin 6 Thermistor RT400 is used to keep the reference voltage level on U401C pin 6 constant over temperature The thermal foldback circuit is controlled by the voltage drop across thermistor RT902 As the power amplifier temperature increases the resistance of RT902 decreases This results in a drop in the voltage level on U401A pin 13 The voltage level on U401A pin 14 increases since the input is on the inverting input When the output on U401A pin 14 is about 5 6V zener diode CR400 conducts and a voltage is added to the reference voltage on U401B pin 2 Since this is the inverting input the output of U401B pin 1 August 1996 Part No 001 1100 003 decreases causing the voltage level on U401C pin 5 to decrease The voltage level on U401C pin 7 also decreases which turns off Q400 The collector voltage on Q400 increases and turns off Q40
139. ust 1996 4 11 Part No 001 1100 003 SERVICING EE August 1996 Part No 001 1100 003 4 12 ALIGNMENT AND PERFORMANCE TESTS SECTION 5 ALIGNMENT AND PERFORMANCE TESTS 5 1 GENERAL A test panel is located on the card rack to provide a convenient location for measuring test point voltages during alignment Plug a high impedance voltmeter into the jacks provided and select the desired test point with the selector knob as shown in Table 5 1 Table 5 1 TEST PANEL SWITCH POSITIONS TP302 Transmit 2nd doubler TP302 Transmit 1st RF amp NONE TP205 Receiver injection amp J308 13 8V DC J304 15 7V DC RX 13 7V DC TX CARD RACK RECEIVER EXCITER DUPLEXER POWER AMPLIFIER prs POWER RF SIGNAL SUPPLY Figure 5 1 RECEIVER TEST SETUP 5 2 RECEIVER ALIGNMENT 1 Loosen the two screws holding the receiver and its mounting bracket in place 2 Pull the assembly toward you and remove the top cover 3 Set the Control card access switch to OPEN and the REPEAT switch to OFF 4 Connect the test equipment as shown in Figure 5 1 5 2 1 FIRST OSCILLATOR TRIPLER INJEC TION AMPLIFIER 1 Set the test panel switch to position 1 TP204 2 Adjust T208 T209 and T210 for a maximum volt age 3 Set the test panel switch to position 4 TP205 4 Adjust C108 and C109 for maximum voltage 5 Repeat the preceding steps 5 2 2 FIRST OSCILLATOR FREQUENCY AD JUSTMENT 1
140. ut NOR gates The output from both U602A and U602B is high only when all inputs are low When one or more of the inputs on each NOR gate is high the out put is low The transmitter is keyed if all four inputs to U602A low This means the squelch time out timer Call Guard if used and repeater disable sig nals must be low to key the transmitter The inputs to U603B must all be low for the out put to go high and turn on Q606 that keys the transmit ter To unkey the transmitter an input to U602B goes high the output goes low and Q606 turns off When the local microphone keys a high is on the base of 0708 and the collector goes low to Level Adjust card pin 19 to key the transmitter 3 6 7 SQUELCH ADJUSTMENT The middle contact on squelch adjust pot R717 is connected to CR206 in the receiver squelch circuit The lower the resistance of R717 more noise is required to turn on the squelch gate The higher the resistance of R717 less noise is required to turn on the squelch gate 3 7 CALL GUARD SQUELCH CARD 3 7 1 GENERAL Each Call Guard card contains four separate decode encode Call Guard circuits Each Call Guard circuit can be tuned to any subaudible tone squelch frequency and produce a low output when the correct tone is decoded These Call Guard circuits generate an encoded tone for test and alignment purposes A rotary switch on the front panel of the Call _ Guard card is used to switch each Call Guard to the
141. utput to the power ampli fier input ALIGNMENT PERFORMANCE TESTS Connect the wattmeter with a 250W VHF range to the power amplifier output DO NOT use the duplexer Power Switch Over Option NOT Used Preset R412 and R420 on the power control board fully counterclockwise Adjust R420 for 100W output power DO NOT re adjust R412 Power Switch Over Option is used Preset 412 and R420 on the power control board fully counterclockwise Apply 9V DC to the junction of C420 and R426 by soldering a jumper wire from that junction to the cathode of CR401 Adjust R412 for 25W output power Remove the jumper wire and adjust R420 for 100W output power DO NOT re adjust R412 5 3 3 PRELIMINARY DEVIATION ADJUSTMENT 1 the Control card set the REPEAT switch to ON and the ACCESS switch to OPEN On Level Adjust card set SMIT AUDIO LEVEL control R714 to maximum fully clock wise Set CALL GUARD LEVEL control R705 to mum fully counterclockwise Set SQUELCH ADJUST control R717 fully coun terclockwise The squelch should open and the transmitter should key up Set LOCAL AUDIO control R710 for background noise then re adjust R717 for threshold squelch The transmitter should unkey 5 3 4 TRANSMIT DEVIATION 1 Connect an RF signal generator to receiver antenna jack Set the generator for 100 output on the receiver channel
142. ver 3 Connect the test equipment as shown in Figure 5 2 5 3 4 OSCILLATOR DOUBLER MULTIPLIERS 1 Disconnect the Exciter coax from the PA input and connect wattmeter with 25W element and terminate with a 50 ohm dummy load 2 Set the test panel switch to position 2 TP301 3 Key the transmitter and tune L320 and L345 for maximum voltage 4 Set the test switch to position 1 TP302 5 Key the transmitter and tune T346 and L347 maximum voltage reading 6 Set the test switch to position 3 TP303 August 1996 Part No 001 1100 003 7 Key the transmitter and tune T348 and L349 fora maximum voltage reading 8 Tune L351 for maximum power output typically 17W 9 Place the frequency monitor s pickup loop near the load and put the transmitter on frequency by adjust ing C325 NOTE C327 is a factory selected component and can be replaced to bring the frequency within range of C325 see Table 5 3 Table 5 3 C325 VALUES Part Number 510 0001 220 510 0001 270 510 0001 330 510 0001 390 510 0001 430 510 0001 470 510 0001 560 510 0001 680 Description 22 pF 5 100V 1DM15 27 pF 45 100V 1DM15 33 pF 5 100V 1DM15 39 pF 5 100V 1DM15 43 pF 5 100V 1DM15 47 pF 5596 100V 1DM15 56 pF 5 100V 1DM15 68 pF 45 100V 1DM15 RF SIGNAL GENERATOR Figure 5 2 TRANSMIT TEST SETUP 5 3 2 SECOND RF AMPLIFIER 1 Turn off the transmitter disconnect the wattmeter and connect the Exciter o

EFJ 1100-series VHF Repeater Service Manual

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