500-2 Service Manual
Contents
1. 126 C313 417 424 GRM188R61C105K 142 1120631056051 0603 CHIP AO1D 11 C429 C430 C504 C505 C535 C710 C969 143 GRM2165C1H200J 144 1120732005091 0805 CHIP C 20pF AO1D 1 C130 C5 C23 C56 C127 C200 145 1120731066031 0805 CHIP C 10uF GRM21BR61A106K 14 2122 519 527 C940 956 970 146 147 1120721047081 CHIP TAN 211 104 035 2 12 18 148 1120721057051 CHIP TAN 1pF TEESVP1C105M8R 1 C15 149 1121021066051 CHIP TAN 10uF TEESVA1C106K8R 1 C964 TEESVB20J107M8 150 1121221077021 CHIP TAN 100uF R 1 C337 151 CERAMIC TRIMMER 152 1130110000001 TZY2Z100A001R00 1 TC1 CAP 10pF 153 154 155 INDUCTOR L1 L7 L10 L19 L103 L206 156 1170660100001 0603 FERRITE CHIP BLM18AG601S 10 L402 L403 L500 L904 157 1170722100001 0805 FERRITE CHIP BLM21PG221S 4 L104 L105 L501 1502 158 1170760000001 0805 FERRITE CHIP BLM21PG600S 1 L107 SMALL FIXED 159 1140618N28001 MLG1608B8N2S 1 L119 INDUCTOR 8 2nH SMALL FIXED 160 1140611505001 MLG1608B15NJ 1 L102 INDUCTOR 15nH SMALL FIXED 161 1140611805001 MLG1608B18NJ 2 L6L101 INDUCTOR 18nH SMALL FIXED 162 1140612205001 MLG1608B22NJ 4 121110012021212 INDUCTOR 22nH SMALL FIXED 163 1140712205001 C2012C22NJ 1 L14 INDUCTOR 22nH 164 1140611015001 PARETE MLG1608BR10J 2 L9L11 INDUCTOR 100nH SMALL FIXED 165 1140712215001 C2012. Installing Removing the Belt Clip Use the 2 screws M2 5x8 0 supplied with the radio and fix these screws on the holes in the radio clip and into the holes in the aluminum case If you want to remove the clip from the radio just unscrew them and remove the clip you can put the screws back to make sure you do not loose them 13 500 2 Service Manual d Installing Removing the Chassis PCB 14 500 2 Service Manual l 1 2 8 4 5 Remove the antenna channel selector and power volume knob and two screws under the channel selector and volume knob Screw off the two screws at the bottom of the radio by a hexagon screwdriver Pry up the aluminum shell by peaking a straight screwdriver in the cross slot at the bottom of the aluminum shell and then pull out the surface shell after placing the aluminum shell inclined to the back but please be careful not to snap off the cable of the speaker Screw off the 11 screws on the PCB by a cross screwdriver Unsolder the endpoints of the antenna LI I key board and speaker by an electric iron then remove the main board After the disassembly above you can carry out corresponding reparation and debugging according to the actual malfunction 15 500 2 Service Manual l Exploded View of the Parts 16 500 2 Service Manual 10 H 12 13 No Parts No Description Qty 1 604CU50001001 Cabinet asm 1 2 2010CU6000
3. the power 5V controlled by power down mode is the supply power of frequency synthesizer 25 500 2 Service Manual 5 7 MCU Unit CTCSS DCS OUT IC403 MCU 9 8304MHz CTCSS DCS IN 5 9 Schematic Diagram for MCU Unit MCU Unit controls the operation of every unit to realize all functions of the 500 2 Communication with external PC State data access Control PLL for the generation receiving and transmitting of local oscillation frequency Access to the current channel state Control LED status indicator Control power supplied condition of every unit Detect action of every function key Produce CTCSS signal Produce DCS signal Produce power controlled signal Finish CTCSS decoding Finish DCS decoding Squelch detection and control Control voice prompt content Memory FLASH Channel data voice data and other function setting data and parameter adjustment data 26 500 2 Service Manual l CTCSS DCS signal coding and decoding CTCSS DCS signals from MCU pin22 and pin18 output are sent to VCO and TCXO for modulation respectively after filtering by R500 R501 C500 C501 and R504 R503 C920 C921 CTCSS DCS signals from receiver are sent to MCU pin52 for decoding and then MCU test if there are CTCSS DCS signals with the same setting of the station to decide whether open the speaker or not CTCSS continuous tone control squelch system hereinafter referred to as CTCSS is a kind of squelch cont
4. 6 R138 R507 R202 R306 51 1090418450001 0402 CHIP 180kO RC0402JR 07180K 2 R322 R411 R414 R415 52 1090422450001 0402 CHIP 220kO RC0402JR 07220K 6 R421 R423 39 500 2 Service Manual 40 53 1090427450001 0402 CHIP R 270kO RC0402JR 07270K R16 R18 R316 R317 54 1090433450001 0402 CHIP 330 RC0402JR 07330K R8 R400 55 1090439450001 0402 CHIP 390 0 RCO402JR 07390K R315 56 1090447450001 0402 CHIP R 470kO RC0402JR 07470K 6 R983 R984 57 1090468450001 0402 CHIP R 680kO RC0402JR 07680K R208 R912 R922 58 1090475450001 0402 CHIP 750 RC0402JR 07750K R505 R528 59 1090410550001 0402 CHIP R 1MQ RC0402JR 071M0 7 R231 R304 R950 60 1090418550001 0402 CHIP R 1 8MQ RC0402JR 071M8 1 R512 61 62 1090600050001 0603 CHIP 100 RC0603JR 070R 5 NE 63 109064R750001 0603 CHIP R 4 70 RC0603JR 074R7 2 R332 R959 64 1090610050001 0603 CHIP R 100 RC0603JR 0710R 7 R334 R412 R417 65 1090622050001 0603 CHIP 220 RC0603JR 0722R 3 R109 R111 R218 66 1090647050001 0603 CHIP 470 RC0603JR 0747R 4 R121 R128 212 R220 67 1090610150001 0603 CHIP R 1000 RC0603JR 07100R 3 R14 R31 R403 68 1090622150001 0603 CHIP 2200 RC0603JR 07220R 2 R215 R402 69 1090627150001 0603 CHIP R 2700 RCO603JR 07
5. FET 189 1040002136201 TRANSISTOR 25 1362 3 0305 Q406A 0406 190 1040002461701 TRANSISTOR 25 4617 5 4 08 00 0501 0502 191 1040002498801 TRANSISTOR 25C4988FRTR Q102 102 1 101 192 1040002506601 TRANSISTOR 25C5066 V 7 PO Q201 Q503 193 1040000012301 TRANSISTOR DTA123JE TL 1 Q408 194 1040000014301 TRANSISTOR DTA143ZETL 2 Q504 Q902 195 1040000014401 TRANSISTOR DTA144EE TL 2 Q109 Q303 500 2 Service Manual l 196 1040000011401 TRANSISTOR DTC114EE TL 3 5 0400 0401 0106 0108 0200 0304 4 4 197 1040000014402 TRANSISTOR DTC144EE TL 14 DE Q907 Q908 Q910 Q911 Q912 Q914 198 1040000000301 TRANSISTOR UMG3NTR 2 0404 0407 199 1050000230201 FET 512302 1 C307 200 1050002182401 FET 25 1824 4 0302 Q500 0901 0913 201 1050000001201 FET RDO1MUS2 T113 1 Q105 202 1050000004601 FET RFMO4UGP 1 Q107 203 1050000250801 FET 25 508 1 52 1 C4 204 1050000331801 FET 3SK318 2 0202 0203 205 206 207 1020620130201 LDO XC6201P302MR 2 2 404 208 1020620150201 LDO XC6201P502MR 1 IC902 209 1020000150301 PLL IC MB15E03SL 1 210 1020000258001 FLASH IC W25080BVSIG 1 10401 FM 211 1020000313601 GT3136 1 IC200 DEMODULATOR 212 1020000521202 MICROPROCESSOR R5F212B8SNFP 1 IC403 OPERATIONAL 213 1020000210001 NJM2100V 1 IC500 AMPLIFIER O
6. FM IC goes to the analog port of the microprocessor IC403 1C403 determines whether to output sounds from the speaker by checking whether the input voltage is higher or lower than the preset value To output sounds from the speaker IC403 sends a high signal to the MUTE and AFCO lines and turns IC302 on through Q302 Q304 and Q305 Audio Power Amplification The audio power amplifying circuit consists of IC302 and the peripheral components The signals are amplified by audio power amplifier to drive the speaker after collecting the receiving audio signals voice signals and warning tone signals The warning tone has no volume limitation When AFCO is high level Q304 is on 302 begins to work and the speaker sounds Speaker Impedance 160hm CTCSS Signal filtering The audio signals after demodulation in IC200 may contain CTCSS continuous tone control squelch system or DCS digital squelch signals The spectrum component of CTCSS DCS is 67 to 250Hz The filtering circuit composed of IC301 can filter out signals except CTCSS DCS spectrum which makes MCU decode the CTCSS DCS more accurately 5 3 Transmitter Tx Transmitter Power Amplifier Q101 Q102 Q105 Q107 ANT SW LPF Figure 5 5 Schematic Diagram for Power Amplifier and Antenna Switch 22 500 2 Service Manual The modulated RF signals from VCO are amplified by Q101 0102 and Q105 before the power amplification in Q107 Gate bias of Q105 and Q107 is controlled by APC
7. NIM2900V NIM2900V 2SC4617 25 4617 AMP gt LIMTER gt LPF gt LPF Tr Tr 500 2 BLOCK DIAGRAM Size Number Revision 4 VER 1 0 Dac Sh File Drawn By 2 3 4 5 6 3 8 5002 SCHEMATIC DIAGRAM 500 2 Service Manual Appendix 1 Abbreviations AMP amplify amplifier ANT Cantenna APC Cautomatic power control BPF band pass filter gt CTCSS continuous tone control squelch system DCS Digital code squelch DEMOD demodulation HPF high pass filter IDC instantaneous deviation control IF intermediate frequency LED Light Emitting Diode LNA Clow noise amplifier LPF Clow pass filter MCU micro control unit MIC microphone MOD modulation MONI monitor PLL phase lock loop PTT push to talk RX receiver SPK speaker TCXO Temperature Compensated Crystal Oscillators TX transmitter UL un lock VCO voltage control oscillator 51 500 2 Service Manual Appendix 2 Main Technical Indexes Technical Parameters 500 2 7 1 General Specification Frequency 400 470 MHz Number of channels 16 Channel separation W 25 kHz M 20KHz N 12 5kHz Working temperature 30 60 Antenna Impedance 500 Frequency Stability
8. PFD in IC1 The error signal is filtered by low pass filter before changing the VCO frequency to the set value in VCO it is locking N Fyco Fr N Division Frequency VCO Oscillation Frequency Fr Reference Frequency Lock lost detection When PLL is out of lock IC pin14 will output low level signal to MCU and then MCU prohibit transmitter from transmitting with a warning tone Q8 the power filter can provide PLL with more purified power to reduce the noise of frequency synthesizer 5 5 Voice Circuit The station is equipped with Voice Prompt Function which is very useful during night or under dark condition The speaker will voice the current channel number when changing the channel every time because of the voice memory chip 1C401 which stores channel voice prompts 5 6 Power Supply The station use lithium battery 7 4V 1300mAh while transmitter amplifier circuit Q105 Q107 and receiver audio amplifier IC302 use battery directly for power supply and other circuits use regulated voltage 5V and 3V IC404 micro power voltage stabilizer of LDO provides power of heavy current for the station together with Q10 and Q30 IC902 5V LDO Q405 5T switch controlled by MCU 5T supply power for the front end of transmitter Q408 5R switch controlled by MCU 5R supply power for the units such as RF amplification mixing IF processing and audio signal processing Q910 5C switch controlled by MCU 5C
9. turns to rapid charging Charging process checking battery voltage battery temperature rise AV charging time max Battery temperature 9 5 LED Status Table LED Status RED GREEN Standby battery 0 25 ON not installed 4 5s OFF charging ON Charging ON completed Error 0 25 ON 0 2s OFF 49 500 2 Service Manual Chapter 10 Block and Schematic 50 2 3 4 5 6 8 04068 MBISEO3SL DAT 400 470MHz PLL lt IPLL LE M QI00 D100 D200 0101 0102 0105 0107 D101 ANT 251508 5066 25 5066 MA2S077 25 5066 2504988 2SK3475 07 HVUI31 Loop TR RE RE RE RE NT F gt gt 5R gt Filter gt gt sw s
10. 02 38 85MHz 12302 5 AFPA 19 500 2 Service Manual l Figure 5 2 Receiver section configuration Front End of Receiver Signals from the antenna are filtered by BPF which consists of C235 C236 C233 C604 C252 C951 C234 C255 C260 L211 L209 L208 D201 D202 and D204 via RX TX switch 0101 D102 and D103 After being filtered out the useless out of band signals the signals are amplified by LNA consisting of Q203 and external components Signals from LNA are filtered again by BPF which consists of C228 C226 C238 C229 C227 C239 C947 C259 C948 1214 L204 L203 0905 D206 and D206 before entering the 1st mixer Q202 The PWM wave is output by MCU composed of 58 foot and then commutated to adjustable voltage after filtering to change the capacity of varactor diode D905 D203 D206 D201 D202 and D204 to control the center frequency of BPF 1 mixer The first IF 51 65MHz signal is produced after mixing of the receiving signal from LNA and the 1 local oscillation signal from frequency synthesizer The first IF signal is filtered out adjacent channel and other useless signals by crystal filter XF201 IF Circuit The 1 IF signal from crystal filter is amplified by the first IF amplifier Q201 before processing of IC in IF 200 GT3136 IF IC consists of the 2 mixer 2 local oscillation IF amplifier limiter frequency discriminator and noise amplifier Frequency 12 8MHz produced by TCXO X1 is amplified and then selects
11. 0432736051 0402 CHIP C0 027uF AO1D 1 C524 GRM155R71C333K C318 C320 C321 C423 125 1120433336051 0402 CHIP C0 033uF 5 A01D C503 GRM155R71C473K 126 1120434736051 0402 CHIP C0 047uF AO1D 3 C319 C511 C514 C1 C4 C30 C58 C104 C113 C131 C156 C207 C209 C210 C211 C213 GRM155R61A104K C256 C302 C303 C322 127 1120431046031 0402 CHIP C 0 1uF 31 A01D C327 C400 C419 C522 C525 C902 C905 C911 C914 C915 C918 C925 C943 C960 128 1120431056031 0402 CHIP C 1uF GRM155R61A105K 8 C310 C413 C903 C904 E15D C923 C926 C949 C959 129 GRM1885C1H1ROB 130 1120631P00091 0603 CHIP 1pF 7046 4 C135 C151 C154 C155 GRM1885C1H1R5B 131 1120631P50091 0603 CHIP C 1 5pF 7046 1 C149 GRM1885C1H2R0B 132 1120632P00091 0603 CHIP C 2pF 201D 3 C142 C144 C147 GRM1885C1H3ROB 133 1120633P00091 0603 CHIP C 3pF Z01D 2 C136 C153 GRM1885C1H5ROB 134 1120635P00091 0603 CHIP C 5pF 7046 2 C140 C150 GRM1885C1H180J 135 1120631805091 0603 CHIP C 18pF 1 C111 A01D GRM1885C1H270J 136 1120632705091 0603 CHIP C 27pF AO1D 2 C118 C138 GRM1885C1H680J 137 1120636805091 0603 CHIP C 68pF AO1D 1 C145 GRM188R71H471K 138 1120634716091 0603 CHIP C 470pF AO1D 2 C114 1213 GRM188R71H102K 139 1120631026091 0603 CHIP C 1000pF AO1D 3 C39 C42 C119 GRM188R71H104K 140 1120631046091 0603 CHIP C 0 1uF AO1D 3 C331 C333 C335 GRM188R71C474K 141 1120634746051 0603 CHIP C 0 47uF AO1D 1 C931 43 500 2 Service Manual l
12. 04X Ear phone cabinet 1 3 2020CU500004X O ring P5X1 5 2 4 304060250001X Volume screw M6X0 75X2 5 special shape brass 1 5 2010CV600006X Volume knob black 1 6 304070250001X Volume screw M7X0 75X2 5 special shape brass 1 7 2010CU600007X Encoder knob black 1 8 7100500240471 Anntenna 1 9 2030CU600003X SMA RF socket 1 10 2020CU500003X O ring 7X1 5 1 11 2010CU600005X radio top cover black 1 12 2020CU500002X 2 PIN power socket washer 1 17 500 2 Service Manual 13 301250607001X machine screw M2 5X6 0 black Ni plate 2 14 7110CLP02001 CLP 02 clip asm 1 15 70600CB03001 Battery CB 03 OR CB 05 70600CB05001 1 16 301200807001X Machine screw M2 0X8 0 2 17 2030CU500001X AL cabinet polishing ADC 12 1 18 1010500200102 Main PCB 1 19 2020CU500001X cabinet waterproof ring 1 20 301200407001X machine screw M2 0X4 0 14 Exchangeable part list No Parts No Description Qty 604CU50001001 Cabinet asm 1 2010CU500001X Radio front cabinet black 1 2 2010CU600010X Light guider clear PC 1 3 2010CU600002X PTT plastic key black 1 4 2010CU600003X Ear phone plastic plug 1 5 2010CU600008X Ear phone cover black 1 6 2020CU600001X PTT silicon key block 1 7 306003301001X air filter nylon weave 1 8 1211361601001 Speaker P36mm 1 9 2040CU600004X mic air filter 7 0 4 5 0 2 1 10
13. 2 5 Battery Standard Lithium ion Battery 1300mAh 7 4V Configuration Dimension WxLxH 97 5 mm x53 5 mmx31 mm Weight 7 2 Receiving part Sensitivity 12dB SINAD 230g With battery and antenna 0 25 V W 0 28uV N Adjacent channel selectivity W 2 70dB N 260dB Intermodulation immunity gt 70dB 50 100kHz Audio Output Power 1W 160 Audio distortion lt 5 7 3 Transmitting part Transmitting Power 4W Modulation Mode F3E Clutter and Harmonics 36dBm lt 1GHz 30dBm gt 1GHz 300 3000 2 Adjacent power Residual W s 45 dB N lt 40dB 300 3000Hz Audio distortion lt 5 W 270dB N 260dB Max Frequency Offset W S 5kHz M st4kHz N lt 2 5kHz 52 500 2 Service Manual l Appendix 3 Troubleshooting No Problems Solutions The radio cannot e Battery pack may not be installed properly Remove the 4 be switched on or battery pack and install it again no display after Battery power may be insufficient Recharge or replace switched on the battery pack Me battery e The battery life is finished please replace it with a new 2 consume quickly battery pack after charging O The frequency or CIC55 0C5 signaling are not hear other identical and please reprogram it 3 e Make sure the setting of the selective signaling 5 Tone members in your group in he RX
14. 2020CU600004X Mic waterproof washer 1 11 2010CU600009X Battery locker black 1 12 2030CU600004X Spring 2 3X10 5 0 25 2 604CU50001002 AL cabinet asm 1 2030CU500001X AL cabinet 1 2 2010CU600005X Radio top cover black 1 3 2020CU500001X Cabinet waterproof ring orange 1 4 2020CU500002X Power socket washer 1 5 301250607001X Machine screw M2 5X6 0 2 2010CU600006X Volume knob 2010CU600007X Encoder knob 7110CLP02001 CLP 02 Clip 18 500 2 Service Manual l Chapter 5 Circuit Description 5 1 Frequency configuration The reference frequency of frequency synthesizer is provided by 12 8 2 crystal oscillator 1 TCXO The receiver adopts quadric mode first IL 1 38 85 2 and the second IL is 450kHz The first local oscillation signal of the receiver is produced by frequency synthesizer and the second local oscillation signal selects the 3 harmonics of 12 8MHz of crystal oscillator X1 TCXO The signal of transmitter is produced by frequency synthesizer directly 450kHz UR 12300 12302 SP AF AMP LPF HPF 38 4MHz Q1 TCXO gi 12 8 MHz MIC AMP Q105 Q107 IC500 D101 D102 Q203 Q202 38 85MHz Q201 Figure 5 1 Frequency configuration 5 2 Receiver Rx The receiver is double conversion superheterodyne designed to operate in the frequency range of 400 to 470MHz The frequency configuration in Fig 2 450MHz XF201 Q203 Q2
15. 23 33 1090468250001 0402 CHIP R 6 8kQ RC0402JR 076K8 R523 R972 34 1090482250001 0402 CHIP R 8 2kO RC0402JR 078K2 R339 R410 R426 R15 R33 R140 R308 R327 R432 R435 R501 35 1090410350001 0402 CHIP R 10kQ RC0402JR 0710K 16 R502 R503 R511 R516 R913 R920 R928 R964 36 1090412350001 0402 CHIP 12kQ RC0402JR 0712K 2 R117 R312 37 1090415350001 0402 CHIP 15 RC0402JR 0715K 3 R526 R527 R955 38 1090418350001 0402 CHIP 18kQ RC0402JR 0718K 3 R305 R529 R919 R321 R500 R504 R5 39 1090422350001 0402 CHIP R 22kQ RC0402JR 0722K 7 oe R925 R927 R958 R508 R513 R514 R51 40 1090433350001 0402 CHIP RC0402JR 0733K 8 R519 R520 R929 R963 41 1090439350001 0402 CHIP RC0402JR 0739K 2 R313 R915 R22 R107 R118 R126 42 1090447350001 0402 CHIP 47kQ RC0402JR 0747K 11 R141 R307 R320 R330 R917 R921 R968 43 1090451350001 0402 CHIP R 51kQ RC0402JR 0751K 1 R524 44 1090456350001 0402 CHIP R 56 RC0402JR 0756K 2 R216 R605 45 1090468350001 0402 CHIP R 68kQ RC0402JR 0768K 1 R602 46 1090482350001 0402 CHIP 82kQ RC0402JR 0782K 3 R11 R543 R918 47 1090491350001 0402 CHIP 910 RC0402JR 0791K 1 R300 R6 R21 R146 R221 R318 R323 R325 R341 R401 48 1090410450001 0402 CHIP R100kQ RC0402JR 07100K 14 R408 R533 R541 R603 R961 49 1090412450001 0402 CHIP 1200 RC0402JR 07120K 2 R30 R340 R134 R135 R136 R137 50 1090415420001 0402 CHIP R 150kQ RCO402DR 07150K
16. 270R 3 R102 R139 R154 70 1090647150001 0603 CHIP R 4700 RC0603JR 07470R 2 R535 R969 71 1090656150001 0603 CHIP R 5600 RC0603JR 07560R 1 R20 72 1090618250001 0603 CHIP R 1 8kO RC0603JR 071K8 1 R534 73 1090622250001 0603 CHIP R 2 2kO RCO0603JR 072K2 1 R144 74 1090627250001 0603 CHIP R 2 7kQ RC0603JR 072K7 1 R209 75 1090610350001 0603 CHIP R 10kQ RC0603JR 0710K 2 R35 R214 76 1090647350001 0603 CHIP R 47 RC0603JR 0747K 2 R125 R338 77 1090668350001 0603 CHIP R 68kQ 0603 0768 1 R962 78 1090610450001 0603 CHIP 100 0 RC0603JR 07100K 2 R601 R604 79 1090615420001 0603 CHIP 150kO RCO603DR 07150K 1 R133 80 1090618450001 0603 CHIP 1800 RC0603JR 07180K 1 R145 81 1090618550001 0603 CHIP R 1 8MQ RC0603JR 071M8 1 R517 82 83 1090700050001 0805 CHIP 100 RC0805JR 070R 1 R127 84 85 10910R3950001 1206 CHIP R 0 390 RC1206JR 07R39 3 R130 R131 R132 86 87 1101147300001 Adjustable resistance EVM2NSX80BQ4 1 VR501 47kO 47K 88 89 90 CAPACITOR 500 2 Service Manual d GRM1555C1HR50B 91 112043 500091 0402CHIPCO5pF 27 C40 49 GRM1555C1H1ROB 92 1120431P00091 0402 CHIP C 1pF C226 238 GRM1555C1H1R5B 93 1120431P50091 0402 CHIP 1 5pF C41 7018 GRM1555C1H2ROB 94 1120432P00091 0402 CHIP C 2pF 29 6951 GRM1555C1H3ROB 95 1120
17. 2CR22J 1 L109 INDUCTOR 220nH SMALL FIXED 166 1140612215001 MLG1608SR22J 4 116 L17 L207 L901 INDUCTOR 220nH SMALL FIXED 167 1140713315001 C2012CR33J 1 L200 INDUCTOR 330nH 44 500 2 Service Manual l 45 SMALL FIXED MLF1608AR47KTO 168 1140624716001 1 L4 INDUCTOR 0 47uH 00 SMALL FIXED 169 1140715615001 C2012CR56J 1 L201 INDUCTOR 560nH SMALL FIXED 170 1140625616001 MLF1608DR56KT 1 LS INDUCTOR 0 56 LI SMALL FIXED 171 1140711025001 C2012C1R0J 1 12 INDUCTOR 1 SMALL FIXED 172 1140623326001 MLF1608A3R3KT 1 L902 INDUCTOR 3 34H L110 L112 L113 L114 173 1152R351R6041 AIR CORE COIL 4T E20 35 1 6 4TR 9 L203 L204 L208 L209 L214 174 1152R351R6081 AIR CORE COIL 8T ER0 35x1 6x8 1 L106 175 176 DIODE 177 1030000137201 DIODE 155372 1 0500 178 1030000022201 DIODE DAN222TL 1 D501 179 1030000013101 DIODE HVU131TRF 1 D101 180 1030000211101 DIODE MA2S111TX 2 D6D7 D1 D100 D102 D103 181 1030000207701 DIODE 25077 5 D200 HT19 2132SURC H 182 1030019213201 LED RED HH 1 D400 183 1030019213202 LED GREEN 19 21325 2 D401 D402 VARIABLE D201 D202 D203 D206 184 1030000035001 CAPACITANCE HVC350BTRF 5 D905 DIODE VARIABLE 185 1030000127801 CAPACITANCE 1 278 1 DS DIODE VARIABLE 186 1030000132501 CAPACITANCE 1 V325 2 10204 DIODE 187 188 TRANSISTOR
18. 3 harmonics 38 4MHZ as the second local oscillator signal source The second IF signals 450kHz are generated after signals mixing of the second local oscillation 38 4MHz and the first IF 38 85MHz in 200 Audio signals are demodulated and outputted by IC200 after the second IF signals are amplified and limited 200 and then filtered by ceramic filter 450kHz 20 500 2 Service Manual 450KHz Noise 38 85MHz AF out Figure 5 3 Schematic Diagram for IF System Receiving Audio Signal Processing The audio processing circuit of receiver consists of IC300 and the peripheral circuit Voice signals from IC200 are sent to IC301 CTCSS signaling filter circuit and IC300 D respectively after amplified in IC300 C After that the signals are removed of the HF and LF components after amplification de emphasis and filtering by other units of IC300 and only audit components from 300 to 3000Hz can be sent to audio power amplifier IC302 after amplified in Q300 and adjusted by volume potentiometers IC300A IC300B IC300C IC300D Q300 Q301 From CTCSS DCS To MUC Figure 5 4 Schematic Diagram for Audio Processing of Receiver 21 500 2 Service Manual l Squelch Circuit Part of the AF signal from the 200 enters the FM again and the noise component 15 amplified and rectified by a filter and an amplifier to produce a DC voltage corresponding to the noise level The DC signal from the
19. 32 236 237 253 112 1120434716091 0402 CHIP 470pF 63 A01D C254 C257 C402 C403 C406 C410 C411 C414 C416 C427 C506 C517 C526 C528 C532 C601 C602 C604 C606 C607 C906 C927 C928 C938 C950 C957 C958 C966 C982 GRM155R71H681K 113 1120436816091 0402 CHIP C 680pF 0 2 510 C513 C43 C116 C123 C314 GRM155R71H102K C407 C521 C609 C610 114 1120431026091 0402 CHIP C 1000pF 13 A01D C706 C912 C916 C922 6932 115 1120433326091 0402 CHIP 3300pF 2 155 71 332 0500 C509 C512 C920 Pr A01D C929 GRM155R71H392K 116 1120433926091 0402 CHIP C 3900pF 1 c502 GRM155R71H472K 117 1120434726091 0402 CHIP C 4700pF C 1 C204 GRM155R71H562K 118 1120435626091 0402 CHIP 5600 _ 1 c308 GRM155R71H682K 119 1120436826091 0402 CHIP 6800 _ 4 C309 C501 C921 C930 GRM155R71H822K 120 1120438226091 0402 CHIP 8200 _ 1 C300 C19 C20 C37 C128 C201 C214 C217 C220 C221 C305 C306 C312 C316 C330 C334 C336 C418 GRM155R71E103K 121 1120431036071 0402 CHIP 0 01uF AO1D 34 C420 C421 C422 C425 C508 C515 C603 C924 C934 C935 C936 C937 C939 C961 C962 C963 C967 0402 CHIP C GRM155R71E183K 122 1120431836071 1 C301 0 018uF A01D 42 500 2 Service Manual l GRM155R71E223K 123 1120432236071 0402 CHIP C0 022uF A12D 2 C518 C520 GRM155R71C273K 124 112
20. 433P00091 0402 CHIP 3pF C45 654 C233 C409 GRM1555C1H3R6B 96 1120433P60091 0402 CHIP C3 6pF 20 C38 GRM1555C1H4ROB 97 1120434P00091 0402 CHIP C 4pF m C44 GRM1555C1H5ROB 98 1120435P00091 0402 CHIP C 5pF MA C215 GRM1555C1H6ROB C53 C105 C222 C234 99 1120436P00091 0402 CHIP 6pF 7018 C239 GRM1555C1H7ROB 100 1120437P00091 0402 CHIP C 7pF C108 Z01D GRM1555C1H8ROB 101 1120438P00091 0402 CHIP C 8pF s C219 C227 C229 GRM1555C1H9ROB 102 1120439P00091 0402 CHIP C 9pF 20s C235 GRM1555C1H100J C9 C14 C16 C36 C412 103 1120431005091 0402 CHIP C 10pF 7018 C415 C516 GRM1555C1H220J 104 1120432205091 0402 CHIP C22 C28 C100 GRM1555C1H330J 105 1120433305091 0402 CHIP C33 C35 C202 C212 C255 GRM1555C1H470J 106 1120434705091 0402 CHIP 27 C10 107 1120835605001 o402 CHIP sor C208 C259 C338 C947 7018 C948 GRM1555C1H680J 108 1120436805091 0402 CHIP 20 C51 C252 GRM1555C1H101J C2 C6 C31 C134 109 1120431015091 0402 CHIP 100pF 7018 C910 GRM155R71H221K 205 C206 C529 530 110 1120432216091 0402 CHIP 220pF A01D C531 C533 GRM155R71H331K 111 1120433316091 0402 CHIP C330pF 0 17 C26 41 500 2 Service Manual l 7 C24 C25 C27 C46 C48 C52 C55 C57 C101 102 103 106 107 109 110 120 121 125 129 132 139 141 143 157 203 218 224 228 231 GRM155R71H471K 2
21. 500 2 Service Manual 500 2 Service Manual 500 2 Service Manual 500 2 Service Manual Contents Chapter 1 General Chapter 2 Radio Overview Chapter 3 Mode Introduction Chapter 4 Disassembly For Repair Chapter 5 Circuit Description Chapter 6 PCB Layout Chapter 7 Adjustment Chapter 8 Bill Of Materials Chapter 9 Charger Chapter 10 Block and Schematic Appendix 1 Abbreviations Appendix 2 Main Technical Indexes Appendix 3 Trouble Shooting 500 2 Service Manual l Chapter 1 General 1 1 Introduction This manual applies to the service and maintenance of 500 2 radios and is for the engineers and professional technicians that have been trained by our company In this manual you can find all the information of product service Our company reserve the rights to modify the product construction and specification without notice in order to enhance product performance and quality Read this manual before repairing the product 1 2 Attention Safety Do not touch the antenna connector with your skin directly Do not reverse the power polarities Do not turn on the radio before the antenna and load connection is completed Do not contact the damaged antenna when transmitting or may make lightly burning on the skin Electromagnetism Interference It s prohibited to use or repair the radio in the following places Hospital health center air port Any area with a potentially explosive atmosphere e g fuel and chemical sto
22. 600 radio top cover PC ABS 2950 CU600 volume knob black ABS 700 243 244 2010CU600007A 2010CU600008A CU600 encoder knob black ABS 700 CU600 ear phone cover black TPU 245 2010CU600009A CU600 battery locker black PC ABS 2950 246 2010CU600010A CU600 light guider clear PC 247 2020CU600001A CU600 PTT silicon key block 60A 50 high spring silicon 248 2020CU500001A CU500 cabinet waterproof ring orange 40 50 high spring silicon 249 2020CU600004A CU600 mic waterproof washer 60A 50 high spring silicon 250 2020CU500002A 2 PIN power socket washer 60A 50 high spring silicon 251 2020CU500003A 1 5 waterproof ring high spring silicon 252 2020CU500004A 5X1 5 waterproof ring high spring silicon 253 2030CU500001A CU500 AL cabinet polishing ADC 12 254 255 256 2030CU600002A 2030CU600003A 2030CU600004A CU600 battery metal locker SUS304 polishing SMA RF socket spring P2 3X10 5 0 25 spring steel Ni plate 257 2040CU500001A 2 PIN power socket 4502 258 2040CU600002A CU600 PTT metal dome plate 259 306003301001A air filter nylon weave 260 2040CU600004A mic air filter 7 0X4 5X0 2 gt 47 500 2 Service Manual 261 304060250001A encoder screw M7X0 75 special shape brass 262 304070250001A volume screw M6X0 75 spec
23. M waveform are sent to VCO and TCXO for modulation the HF components of DCS signals are modulated by VCO while the LF components by TCXO after filtered the HF components over 300Hz in low pass filter composed by RC CTCSS DCS signals from receiver are sent to MCU for decoding and then MCU test if there are DCS codes with the same setting of the station to decide whether open the speaker or not 28 500 2 Service Manual Table 5 2 DCS Coding Schedule 023 114 174 315 445 631 025 115 205 331 464 632 026 116 223 343 465 654 031 125 226 346 466 662 032 131 243 351 503 664 043 132 244 364 506 703 047 134 245 365 516 712 051 143 251 371 532 723 054 152 261 411 546 731 065 155 263 412 565 732 071 156 265 413 606 734 072 162 271 423 612 743 073 165 306 431 624 754 074 172 311 432 627 5 8 Description of Semiconductor Devices The distribution of each pin goes as the table 5 3 Table 5 3 Definition of CPU Base Pin Pin No Port Name l IC ARINE Function Name Level 1 APCSW P33 O H APC switch 2 PTT P34 I L switch input Connect this pin to VCC via a 4 7K MAPE resistor Burn 29 500 2 Service Manual 4 SK1 P43 L SIDE KEY1 input 5 SK2 P44 L SIDE KEY2 input 6 RESET L CUP res
24. PERATIONAL 214 1020000290201 NJM2902V 1 IC300 AMPLIFIER OPERATIONAL 215 1020000290401 NJM2904V 2 IC100 IC301 AMPLIFIER AUDIO 216 1020000282201 TDA2822D 1 IC302 PROCESSOR IC 217 218 OTHERS CHIP CRYSTAL 219 1221009830402 5032SMD glass 1 X400 RESONATOR 3225VCTCXO 12 8 220 1221012800002 TCXO 1 X1 MHz 38 85MHz CRYSTAL 221 1080000388501 5 2 5 2 1 201 FILTER 222 1010500200102 500 2 PCB 500 2 02 1 ELFY450G 223 1080000045001 Ceramic Filter 1 CF201 or LTWC450G 224 225 1080004502401 Discriminator JTM450C24 1 CD200 226 1212602762201 MIC ELEMENT PF0 6027P 62 2dB 1 MIC500 46 500 2 Service Manual l 227 1102210300001 RP08110SNAX V02 0000 POWER SWITCH VR401 228 1061001010001 RE1001BA V01 000 1 ROTARY SWITCH 401 229 1230525200801 2 5 PJ D2008K 4501 230 1230535302701 5 03 5 PJ D3027 J500 231 232 1010600200202 1211361601001 CU600 KEY PCB SPEAKER CU600pttV03 PCB 36 160 1W gt gt 233 234 235 236 STRUCTURE 237 2010CU500001A CU500 radio front cabinet black 238 2010CU600002A CU600 PTT plastic key black PC ABS 2950 239 2010CU600003A CU600 ear phone plastic plug black PC ABS 2950 240 2010CU600004A CU600 ear phone cabinet PC ABS 2950 241 242 2010CU600005A 2010CU600006A CU
25. SB port Figure 3 1 3 on the power of the computer 500 2 Service Manual l 4 Turn on the power of the interphone Click on 500 Programming software icon to perform the program 6 Inthe main menu of the programming software click on Read to read the parameters of the radio into the computer click on Write to write the parameters set in the computer into the radio e Caution 1 Before editing for the first time the data should be read from the interphone and properly backed up 2 If the edited data cannot work normally after being written into the interphone please open the backup data and rewrite them 3 Model Information is the important information of the interphone and should not be altered Test Mode According to Figure 3 1 connect the radio to the computer with the special programming cable Warning Before entering the Test Mode please first connect a high frequency load of 50 ohm to the antenna port of the radio or connect the radio a certain test instrument With the 500 Programming Software you can enter the adjustment status in Computer Test Mode to adjust the following parameters of the radio 1 Frequency stability 2 RF transmitting high power 3 RF transmitting Middle power 4 RF transmitting Low power 5 Maximum TX voice deviation 60 VOX1 Tight 7 VOX10 8 2 5tone deviation 9 DTMF deviation 10 deviation 11 DCS LTR balance 12 DCS deviation 13 LSD d
26. Squelch Mode is proper uM Beyond the radio efficient communication range Other voices from non group e Change the CTCSS DCS tone and make sure change 4 members are the tone on all radios in your group heard on the Please set 5 Tone selective signaling on the channel channel e Make sure the antenna is well connected 5 Communication e sure the antenna is the originally supplied one range is too small Check if the battery power is in the normal state Ask your local dealer to adjust the squelch level Make sure the PTT button has been pressed completely 6 Unable to Battery power may be insufficient Recharge or replace transmit the battery pack Transmitting frequency has not been set on the channel and the radio has been remote killed e Battery power may be insufficient Recharge or replace 7 Noise is too loud the battery pack Beyond the efficient communication range 53
27. circuit so the output power of transmitter can be controlled conveniently by changing the gate bias voltage APC Automatic Power Control gt 0105 0107 IC100A IC100B Q109 III gt To 0105 0107 0 3952 3 To MCU Figure 5 6 Schematic Diagram for APC Circuit R130 R131 and R132 are power amplification current detector IC100A 1 power amplification current sampling amplifier and IC008 1 power comparison amplifier The power amplification current and IC100A output will increase with oversized output power of transmitter When the output voltage of IC100B decreases the bias voltage of Q105 and 0107 will decrease finally the output power of transmitter will decrease or vice versa Thus the output power of transmitter will keep stable under any different working condition MCU can set the power by changing the voltage input to IC1008 Audio Signal Processing of Transmitter MIC MIC Amp Pre Emphasis IC500B 0502 Q501 Q4 IC500A 12 8MHz Figure 5 7 Schematic Diagram for Audit Circuit of Receiver 23 500 2 Service Manual The audio signal processing circuit of Transmitter consists of IC500 and the peripheral components Voice signals from MIC are sent to VCO for modulation together with CTCSS DCS after amplification limitation and filtering circuit consists of 0500 0501 and Q503 The signal amplitude 1 reduced to ensure no distortion in case of oversized MIC signal Q504 the power sw
28. djustment 7 3 Adjustment 7 3 1 VCO Adjustment Close Power saving Mode Set receiving frequency to low frequency point see Table 7 2 and in the receiving state test voltage of PD by DMM and adjust fine tuning capacitor TC1 TC2 to get CV voltage of 1 0V 0 2V Set transmitting frequency to high frequency point refer to Table 7 2 press PTT and test voltage of PD by DMM which shall less than 4 0V Table 7 2 High Intermediate Low Frequency Point of All Models Low Frequency Intermediate High Frequency Point Frequency Point Point 500 2 400 100 MHz 435 100 MHz 469 975 MHz 7 3 2 Frequency stability Double click to enter Frequency Stability in Test Mode Manual to achieve the rated transmitting frequency by adjusting the number from 0 to 255 lt 100 2 7 3 3 RF transmitting power High power Adjusts the transmitting power to 3 8 4 2W in the computer 5 frequency points including Highest High Med Low lowest Middle Power Adjust the transmitting power to 1 8 2 2W in the computer Low Power Adjust the transmitting power to 0 8 1 2W in the computer 7 3 4 Voice deviation Maximum voice deviation Signal source MOD 1kHz 120mV LPF 15kHz Adjust the max frequency deviation in the computer adjustment mode 35 500 2 Service Manual d mode 3 9kHz 4 5kHz wideband 3 2kHz 3 9kHz median band between 1 8kHz 2 3kHz narrowband 2 5 TONE DTMF MSK Deviation Ad
29. e table can be substituted by integrated tester HP8920 HP8921 33 500 2 Service Manual MICJACK Figure 7 1 External Speaker microphone Interface Definition 7 2 Adjustment Items Some detection and adjustment shall be made to the station technical data after changing the components during the maintenance The debugging introduction of some related circuits goes as follows Some parameters of the product can be adjusted by use of 500 Programming Software of our company The adjustable parameters are as follows 1 Frequency stability 2 RF transmitting high power 3 RF transmitting Middle power 4 RF transmitting Low power 5 Maximum TX voice deviation 6 VOX1 Tight 7 VOX10 8 2 5 tone deviation 9 DTMF deviation 10 deviation 11 DCS LTR balance 12 DCS deviation 13 LSD deviation 14 CTCSS 67 0Hz deviation 15 55 254 1 2 deviation 16 Battery warning level 17 RX Sensitivity 18 DCS RX middle level 19 RX squelch 9 open level 20 RX squelch 9 close level 21 RX squelch 1 open level 22 RX squelch 1 close level 23 RSSI 120dBm 24 RSSI 70dBm 34 500 2 Service Manual Steps for adjustment 1 Enter Computer Test Mode by selecting Test Mode in main menu of 500 Programming Software 2 Select the items to be adjusted in choice menus and then adjust the parameters by function keys on the computer keyboard 3 Exit Computer Test Mode after a
30. ector input 45 ENC1 P32 I Channel selector input 46 ENC2 P13 I Channel selector input 47 ENC3 P12 Channel selector input 48 VOX P11 AN9 VOX level input 49 BATT P10 I AN8 Battery voltage input 50 AFCO 00 0 L Audio Amplification Power 51 SPKSW P01 O L Audio amplifier control 52 DCS_IN P02 I AN5 CTCSS DCS input Recording level input 53 NC 54 BUSY P04 I AN3 Busy level input 55 TOPKEY P62 I L TOPKEY input 56 RXMUTE P61 O H RX audio mute 57 RSSI PO5 AN2 Received Signal Strength Indicator input 58 PCTV P06 0 APC BPF control output 59 AVSS GND 60 DTMF P07 0 DA1 DTMF Beep output 61 VREF 3V 62 AVCC I 3V 63 MC P37 O 64 RX_W N P53 O H RX Wide Narrow switch Table 5 4 Functional description of semiconductor device Item Model Function Description IC1 MB15E03 Frequency Synthesizer 100 NJM2904 APC Voltage Comparison Driving 200 GT3136 Receiver 274 Local Oscillation 2 IF Amplification Limitation Demodulation Noise Amplification IC300 NJM2902V Receiver demodulated signal Amplification Filtering IC500 NJM2100V MIC Amplification Limitation Filtering IC 302 TDA2822D Audio Frequency Power Amplification 401 25080 FLASH Channel Frequency Data Storage Function Setting Parameter Debug Mode Parameter IC 403 R5F212BCSNFP MCU 31 500 2 Service Manual Chapter 6 500 2 PCB Lay
31. et Burn 7 XOUT 0 MCU clock 8 VSS GND 9 XIM I MCU clock 10 VCC 3V 11 BSHIFT P54 0 L Beat shift switch 12 F CS P53 0 L FLASH chip select output 13 F DI P52 0 FLASH data in 14 F_CLK P51 O FLASH serial clock output 15 F_DIO P50 FLASH data input output 16 NC P27 0 17 VCCN P26 0 Frequency regulation output PWM 18 DCSTCXO P25 0 CTCSS DCS output PWM 19 PLL_CLK P24 0 H PLL clock Output 20 PLL_DAT P23 0 PLL data Output 21 PLL_EN P22 0 L PLL enable 22 DCSVCO P21 0 CTCSS DCS output PWM 23 PLL_UL P20 I H PLL unlock detect pin 24 RXVCO P17 0 L TX RX VCO selection H RX 25 BEEP_AF P16 O Local Beep Control Pin 26 RXDO P15 I Serial data 27 TXDO P14 O Serial data 28 GLED P86 O H Green LED 29 RLED P85 0 L Red LED 30 NC P84 0 31 TDIN P83 TRFI TONE data input Alarm switch control LI Controlled by 32 ALARMC P82 0 L Volume Switch L Emergency siren maximum volume 33 DEV2 P81 O Voice deviation adjustment 2 34 DEV1 P80 0 Voice deviation adjustment 1 35 NARROW P60 0 L 12 5KHz 36 MIDDLE P45 0 L 20KHz 37 TXD1 P66 0 Reserved 38 RXD1 P67 Reserved 39 MIC_MUTE P65 O L MIC mute L MIC mute 40 5TC P64 O H Transmitting power control 41 EXTPTT P63 L External PTT switch input 42 SAVE P31 O H Battery power control H Power save 30 500 2 Service Manual 43 5RC P30 O H Receiving power control 44 ENCO P36 I Channel sel
32. eviation 14 CTCSS 67 0Hz deviation 15 55 254 1 2 deviation 16 Battery warning level 17 RX Sensitivity 18 DCS RX middle level 19 RX squelch 9 open level 20 RX squelch 9 close level 21 RX squelch 1 open level 22 RX squelch 1 close level 500 2 Service Manual 23 RSSI 120dBm 24 RSSI 70dBm Firmware Upgrading Mode The radio is equipped with an internal FLASH ROM it can be upgraded if required 1 Connect the radio to the PC with a proper programming cable then power on the radio 2 Run computer programming software 3 Select the right com port you connected and the upgrading firmware and then click on E P to start downloading 4 Turn off the radio and exit the programming software 500 2 Service Manual l Chapter 4 Disassembly For Repair The radio is a kind of sophisticated communication equipment with small and fine mechanical structure You should assemble and disassemble it carefully during the maintenance process The Instruction for assembly and disassembly are as follows Installing Removing the Battery Pack To install the battery please place it into the groove on the top of the radio chassis about 5mm away from latch If the radio has the belt clip installed you will have to press one side of the clip to raise it and slide the battery in proper position Press the battery with your fingers and push the battery until you hear a latch click the battery is now instal
33. ial shape brass machine screw M2 0X4 0 PB Ni plate 263 301200407001A 14 nylok blue patch machine screw M2 0X8 0 six lobe pan 264 301200807001A 2 Ni plate nylok blue patch machine screw M2 5X6 0 PB black 265 301250607001A 2 Ni plate 266 306006005001A mic washer 6 0X0 5mm soft PVC 1 267 268 269 270 48 500 2 Service Manual Chapter 9 CP 02 Charger 9 1 General Description Function intelligent rapid charging Applicable battery CB 05 1300mAh 7 4V Li ion battery Battery type identification External Input power supply DC12 0 5V 500mA ripples lt 500 9 2 Operating environment Temperature 5 C 2 C 55 2 Humidity 95 40 9 3 Safety requirements In accordance with safety requirements of CCC CE and UL etc 9 4 Technical Specifications Current 600 50 Max charging time 300 minutes Max Battery temperature 55 C Specified voltage of charged battery Nickel hydrogen battery recovery the battery when the voltage lt 3 7V pre charging when the voltage lt 6 4 0 1V when the battery voltage reaches 6 4 0 1V the charging turns to rapid charging When the battery voltage reaches 8 35V the battery will be deemed as full and the charging will be stopped Li ion battery pre charging when the voltage lt 6 4 0 1V when the battery voltage reaches 6 4 0 1V the charging
34. itch of voice processing circuit controlled by MCU will give power supply to 500 only during transmission 4501 15 the socket for external MIC and the internal MIC will disconnect automatically when using external MIC but the internal PTT is still effective 5 4 PLL Frequency Synthesizer IC1 Q101 100 0200 1N Charge nr 9 To MCU VCCN MOD in Figure 5 8 Schematic Diagram for Frequency Synthesizer The 500 2 adopts PLL frequency synthesizer Frequency synthesizer consists of reference oscillator voltage controlled oscillator VCO programmable frequency divider PFD phase comparator and low pass filter LPF RX VCO Unit consists of 04 D2 D4 L14 C35 C41 C44 C45 and D1 Q5 TX VCO Unit consists of 04 D2 04114 C35 C41 C44 and C45 D5 is the modulation circuit of VCO MB15E03 is PLL integrated circuit and contains programmable parametric frequency divider PPFD programmable frequency divider PFD phase comparator and charge pump etc Low pass filter consists of R5 R7 R9 R10 C12 C15 and C18 Reference frequency is provided by X1 TCXO 12 8MHz Reference frequency of TCXO Temperature controlled Crystal Oscillator is divided by PPFD in IC1 to produce reference frequency of 5kHz or 6 25kHz controlled by MCU based on the set channel frequency 24 500 2 Service Manual The oscillation frequency of VCO is compared with reference frequency to produce error signal after divided by
35. just TONE DTMF MSK deviation in the computer adjustment mode 3 2 4 0 kHz wideband 3 0kHz 3 6kHz median band 1 8 2 3kHz narrowband VOX1 VOX10 Adjust VOX1 VOX10 microphone sensitivity in the computer adjustment mode VOX1 for 50mv and VOX10 for 5 mv 7 3 5 CTCSS DCS deviation DCS LTR balance Signal source LPF 300Hz Adjust DCS LTR balance in the computer adjustment mode Make the transmitting demodulation waveform be flat square wave DCS deviation Signal source LPF 300Hz Adjust DCS frequency deviation in the computer adjustment mode 0 50kHz 0 85kHz wideband 0 50kHz 0 65kHz medium band 0 25kHz 0 45kHz narrowband The waveform shall be good LSD deviation Reserved for the future CTCSS 67 0 254 1Hz deviation Signal source LPF 300Hz Adjust CTCSS deviation in the computer adjustment mode 0 50kHz 0 85kHz wideband 0 50kHz 0 65kHz medium band 0 25kHz 0 45kHz narrowband The waveform shall be good 7 3 6 Battery warning level Adjust the battery warning level in the computer adjustment mode Set the power supply voltage at 6 8V and press start and then end 7 3 7 Receive sensitivity 36 500 2 Service Manual Adjust the sensitivity in the computer adjustment mode Make the sensitivity of all frequency points the highest provided the sensitivity is the highest the better data 7 3 8 Squelch adjustment Adjust squelch in the computer adjustment mode Squelch 9 ope
36. led Removing the battery pack II you want to remove the battery from the radio first press the battery latch located on the bottom of the radio and then press down to slide the battery about 5mm to release the latch 10 500 2 Service Manual l Notice Do not short circuit the battery terminals or dispose the battery in fire Do not disassemble the battery case Installing Removing Antenna Channel Selector Power Volume Knob Screw the antenna out of the connector at the top of the radio by holding the bottom of the antenna and turn it counter clockwise until apart Using a smooth tool or a tool protected with cloth to hold or prize up form the bottom of channel selector or volume knob until apart then screw the two screws under the channel selector and volume knob using the special tool 11 500 2 Service Manual l Install external speaker MIC Open the cover of the jack for external speaker MIC and then insert the plug of the external speaker or microphone into the jack on the radio When inserting the accessory plug make sure it is properly aligned straight to avoid internal damage to the connector the radio 12 500 2 Service Manual CAE 2 A n LI mM E A I IL es 4 AA 1 we x SS AN 2 X A A ff 7 V j 7 y 22
37. n The signal level output is set to 118dBm wideband or 117dBm narrowband Automatically records the corresponding squelch level Squelch 9 close The signal level output is set to 120dBm wideband or 119dBm narrowband Automatically records the corresponding squelch level Squelch 1 open The signal level output is set to 124dBm wideband or 123dBm narrowband Automatically records the corresponding squelch level Squelch 1 close The signal level output is set to 126dBm wideband or 125dBm narrowband Automatically records the corresponding squelch level 7 3 9 RSSI adjustment RSSI 120dBm RSSI 70dBm The signal level output is set to 120dBm or 70dBm Automatically records the corresponding RSSI level Note Voltage for the aforesaid tests 7 5V 0 1V in room temperature 37 500 2 Service Manual Chapter8 500 2 BOM 5002 500 2 PARTS LIST va Component Parts Description Name Specificatio Ref No n 702 05002001 500 2 UNIT 500 2 portable 4 701 05002001 1 two way radio 500 2 packaging 5 605CU5000201 1 BOM 6 71200CT02001 CT 02 radio ring 1 7 70700CP02001 CP 02 rapid charger 1 CU500U1 ANTENNA CRAK435001010 8 7100500240471 1 about 160mm 400 470MHz 9 Power Supply DC 10 709CA02US001 CA 02 1 12V 500mA Lithium ion Battery 11 70600 05001 05 1 1300mAH 7 4V 12 13 500 2 p
38. ortable 14 701CU5002001 two way radio 15 16 RESISTOR R4 R7 R13 R419 R901 17 1090400050001 0402 CHIP ROO RC0402JR 070R 6 R914 R19 R26 R210 R211 18 1090410150001 0402 CHIP R 1000 RC0402JR 07100R 5 R530 19 1090415150001 0402 CHIP R 1500 RC0402JR 07150R 1 R27 20 1090433150001 0402 CHIP R 3300 RC0402JR 07330R 2 R108 R113 21 1090456150001 0402 CHIP R 5600 RC0402JR 07560R 1 R5 22 1090468150001 0402 CHIP R 6800 RC0402JR 07680R 1 R110 23 1090482150001 0402 CHIP R 8200 RC0402JR 07820R 2 R429 R532 R2 R9 R10 R222 R328 R407 R409 R413 R420 24 1090410250001 0402 CHIP R 1kQ RC0402JR 071K 16 R427 R433 R434 R932 R951 R952 R967 25 1090415250001 0402 CHIP R 1 5kQ RC0402JR 071K5 4 R112 R331 R521 R525 38 500 2 Service Manual l 26 1090418250001 0402 CHIP R 1 8kQ RC0402JR 071K8 4 R205 R329 R522 R908 R1 R226 R418 R536 27 1090422250001 0402 CHIP R 2 2kQ RC0402JR 072K2 5 R537 28 1090427250001 0402 CHIP 2 7kQ RC0402JR 072K7 2 R422 R428 R100 R103 R105 R106 29 1090433250001 0402 CHIP 3 3kQ RC0402JR 073K3 11 R203 R204 R303 R424 R425 R510 R548 30 1090439250001 0402 CHIP R 3 9kO RC0402JR 073K9 1 R201 31 1090447250001 0402 CHIP R 4 7kQ RC0402JR 074K7 4 R32 R416 R607 R909 R101 R301 R302 R324 32 1090456250001 0402 CHIP 5 RC0402JR 075K6 8 R326 R910 R914 R9
39. out 32 8214 312 312 0501 EE EE ss ALE 8409 LJ es 5 5 e 500 2 Service Manual 7 1 Required Test Equipment Chapter 7 ADJUSTMENT Table 7 1 Number Name Parameter requirements 4 Computer Above P2 compatible IBM PC WINDOWS 98 ME 2000 XPOperating System 2 Programming 500 Programming software software Pregramming Special Serial USB CPL 01 programming cable 4 Dubbing cable CPL 02 5 DC regulator Output voltage 7 5V output electric current gt 5A Test range 0 5 10W Frequency range 100MHz 500MHz Resistance 500 SWR 1 2 Frequency range 0 1 600 2 Frequency 5 6 7 Star Frequency accuracy higher than 1x10 Sensitivity higher than 100mV 8 Frequency Frequency range DC 600MHz deviator Test range 0 5kHz 9 DMM Input resistance above 10MQ V DC capable of measuring voltage electric current and resistance 10 Audio signal Frequency range 2 3000Hz generator Output level 1 500mV 11 RF power Decrement 40db or 50db attenuator Receive power higher than10W 12 Standard signal Frequency range 10MHz 1000MHz source Output level 0 1uV 32mV 127dBm 17dBm Frequency range DC 20MHz 18 Oselloseope Test rangen10mv 20V Audio 14 Frequency Test range 10mV 10V voltmeter Recommend how to use item 6 7 8 10 11 and 12 which listed in th
40. rage and transport devices etc Any area of dynamite or exploder Change Components All the components used in repair service should be supplied by our company Other components of the same models available on the market are not surely able to use in this product and we do not guarantee the quality of the product using such components 1 3 Service All the products of our company are subject to the service warranty After sales service will be provided and the length of warranty is stated by our company The radio and its accessories are all in the warranty However in one of the following cases charge free service will be not available No valid service warranty or original invoice Malfunction caused by disassemble repair or reconstruct the radio by the users without permission Wear and tear or any man made sabotage such as mechanical damage burning or water 3 500 2 Service Manual l leaking Product serial number has been damage or the product trademark 15 difficult to identify Beyond the warranty time lifetime service 15 still available with paid And we also provide service components to service stations and staff 500 2 Service Manual l Chapter 2 Radio Overview 1 PTT PUSH TO TALK Button To make a call press and hold the PTT button then speak into the microphone in normal voice Release the PTT button to receive signals 2 Side Button 1 Programmable Button 3 Side Button 2 P
41. rogrammable Button 4 Channel Selector Rotate to select channel 1 16 5 Power Volume Knob Turn clockwise to switch on the radio Turn counterclockwise till a click is heard to switch off the radio Rotate to adjust the volume after turning on the radio 6 LED Indicator LED Indicates Status Alert Green LED lights when a carrier is detected in the current channel Red LED lights during transmission Orange LED flashes when receiving the Radio ID 5 Tone signaling or 2 Tone signaling or MDC signaling Green LED flashes when scanning Red LED flashes when low battery 7 Speaker Microphone Jacks Used to connect the optional speaker microphone 8 MIC Input Please keep your mouth about 10 cm 3 4 inches away from the microphone input to achieve the best voice quality If the distance is too far or too close to the radio it will affect the voice quality 500 2 Service Manual Programmable Button Function The dealer can program the Side Button 1 Side Button 2 and the Top Button with the following Optional functions None No Function Annunciation Selection Talkaround Call1 Cal12 Cal13 Call4 Lone Work Emergency Call Cancel Emergency Call Scan Noise Channel Delete Call Forward H M L Power Switch Squelch Adjust Monitor Momentary Call Cancel Monitor Call Cancel Squelch Off Momentary Call Cancel Squelch Off Call Cancel Lock Keyboard Battery Check Surveillance CTCSS Scan Forever Save CH CTCSS Scan Save CH 500 2 Ser
42. rol system with modulation on carrier and continuous sub audio signals as pilot tone If CTCSS function is set the call is available only at the same CTCSS frequency of both receiving and transmitting parties to avoid the disturbance of other signals The station has 39 groups of standard CTCSS frequency for your selection such as Table 5 1 CTCSS signals produced by MCU are sent to VCO for modulation after filtered the HF components over 300Hz in low pass filter composed by RC 27 500 2 Service Manual Table 5 1 CIC55 Frequency Table No Frequency No Frequency Frequency No Frequency Hz Hz Hz Hz 1 67 0 11 94 8 21 131 8 31 186 2 2 69 3 12 97 4 22 136 5 32 192 8 3 71 9 13 100 0 23 141 3 33 203 5 4 74 4 14 103 5 24 146 2 34 210 7 5 77 0 15 107 2 25 151 4 35 218 1 6 79 7 16 110 9 26 156 7 36 225 7 7 82 5 17 114 8 27 162 2 37 233 6 8 85 4 18 118 8 28 167 9 38 241 8 9 88 5 19 123 0 29 173 8 39 250 3 10 91 5 20 127 3 30 179 9 DCS signaling DCS Digital code squelch is a kind of continuous digital code modulated on carrier with voice signal and used for squelch control If DCS function is set the speaker is available only when receiving the same DCS code to avoid the disturbance of useless signals The station has 83 kinds of standard codes including positive and inverse code for your selection such as Table 2 DCS signals produced by MCU PW
43. vice Manual Chapter 3 Mode combinations Mode Introduction Mode Function How to access User Mode For normal use Power on Data Reading and writing 2 Receive instructions from Programming frequency data and other the PC mode functions PC Test Mode Used to tune the radio Receive instructions from Mode using the PC the PC Firmware Upgrades the software i Receive instructions from Upgrading when new features are the PC Mode added User Mode You can enter User Mode conventional communication mode by turning on the power switch Users in the mode can use the defined function of the radio Data programming mode Before leaving the factory the radio has been set in factory However due to different requirements of users functional parameters of the radio such as working frequency channels CTCSS DCS and auto scanning etc should be set again Therefore the company has specially designed a set of 500 Programming software with friendly interface convenient operation and visualized display for setting functional parameters of the radio Steps for setting the functional parameters of the interphone by computer are as follows 1 Install 500 Programming software on the computer 2 shown in the figure below connect the radio to the computer through a special serial or USB programming cable Radio Earphone Program port Programming cable Computer RS232 serial port U
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