IC-FR5000_IC-FR5100_serv.pdf

S-14425XZ-C1 Jun. 2008 VHF FM REPEATER This service manual describes the latest service information for the IC-FR5000 IC-FR5100 VHF FM REPEATER at the time of publication. NEVER connect the repeater to an AC outlet or to a DC power supply that uses more than specifed. This will ruin the repeater. DO NOT expose the repeater to rain, snow or any liquids. DO NOT reverse the polarities of the power supply when connecting the repeater. DO NOT apply an RF signal of more than 20 dBm (100 mW) to the antenna connector. This could damage the repeaters front-end. To upgrade quality, any electrical or mechanical parts and internal circuits are subject to change without notice or obligation. MODELVERSION CH. SPACING (kHz) TX POWER FREQUENCY RANGE IC-FR5000 USA-017.5/15/30 50 W 136174 MHzEXP-0112.5/25.0 IC-FR5100EUR-0112.5/20.0/25.0 25 W Be sure to include the following four points when ordering replacement parts: 1. 10-digit Icom parts numbers 2. Component name 3. Equipment model name and unit name 4. Quantity required 1110003491 S.IC TA31136FNG IC-FR5000 MAIN UNIT 5 pieces 8820001210 Screw 2438 screw IC-FR5000 Top cover 10 pieces Addresses are provided on the inside back cover for your convenience. Icom, Icom Inc. and logo are registered trademarks of Icom Incorporated (Japan) in the United States, the United Kingdom, Germany, France, Spain, Russia and/or other countries. ORDERING PARTS 1. Make sure the problem is internal before disassembling the repeater. 2. DO NOT open the repeater until the repeater is disconnected from its power source. 3. DO NOT force any of the variable components. Turn them slowly and smoothly. 4. DO NOT short any circuits or electronic parts. An insulated tuning tool MUST be used for all adjustments. 5. DO NOT keep power ON for a long time when the repeater is defective. 6. DO NOT transmit power into a Standard Signal Generator or a Sweep Generator. 7. ALWAYS connect a 50 dB to 60 dB attenuator between the repeater and a Deviation Meter or Spectrum Analyzer when using such test equipment. 8. READ the instructions of test equipment throughly before connecting a test equipment to the repeater. REPAIR NOTES INTRODUCTIONCAUTION UNIT ABBREVIATIONS: F=FRONT UNIT M=MAIN UNIT CN=CONNECT UNIT CONTENTS SECTION 1 SPECIFICATIONS SECTION 2 INSIDE VIEWS SECTION 3 DISASSEMBLY INSTRUCTION SECTION 4 OPTIONAL UNIT INSTALLATION SECTION 5 CIRCUIT DESCRIPITON 5-1 RECEIVER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-2 TRANSMITTER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-3 OTHER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-4 CPU (M: IC20) PORT ALLOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SECTION 6 ADJUSTMENT PROCEDURES 6-1 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2 FREQUENCY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-3 TRANSMIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-4 RECEIVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 SECTION 7 PARTS LIST SECTION 8 MECHANICAL PARTS SECTION 9 BOARD LAYOUTS SECTION 10 BLOCK DIAGRAM SECTION 11 VOLTAGE DIAGRAM FRONT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 MAIN UNIT (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 MAIN UNIT (2/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 MAIN UNIT (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 CONNECT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 1 - 1 SECTION 1 SPECIFICATIONS M GENERALFR5000FR5100 Frequency coverage136174 MHz Conventional channelsmax. 32 ch Type of emissionWide16K0F3E Middle14K0F3E Narrow11K0F3E/11K0F7E/11K0F7D/11K0F7W/ 8K50F3E (EXP-01 only) 8K50F3E Digital4K00F1E/4K00F1D/4K00F3E Antenna impedance50 (Nominal) Operating temperature range 22F to +140F (30C to +60C)25C to +55C Power supply requirement (nominal) 13.6 V DC (Negative ground)13.2 V DC (Negative ground) Current drain (Approx.)Receiving 500 mA (stand-by), 1900 mA (max. audio) Transmitting 15 A (at 50 W) 8.0 A (at 25 W) Dimensions (Projections not included) 19 (W)3 1532 (H)10 14 (D) in.483 (W)88 (H)260 (D) mm Weight (Approx.)12 Ib 5 17/32 oz.5.6 kg M TRANSMITTERFR5000FR5100 Output power50 W 25 W ModulationVariable reactance frequency modulation Max. frequency deviationWide5.0 kHz Middle4.0 kHz Narrow2.5 kHz Frequency stability0.5 ppm 0.2 kHz Spurious emissions80 dB typ. 0.25 W (1 GHz), 1.00 W (1 GHz) Adjacent channel powerWide76 dB typ. 76 dB typ. Middle76 dB typ. Narrow69 dB typ. 70 dB typ. Digital65 dB typ. 66 dB typ. Audio harmonic distortion1% typ. (at AF 1 kHz 40% deviation) Intermodulation attenuation40 dB min. Audio frequency response+2 dB to 8 dB of 6 dB/oct. Wide/Middle from 300 Hz to 3000 Hz Narrow from 300 Hz to 2550 Hz FM Hum and noise (300 Hz3000 Hz, 750 s) Wide52 dB typ. Narrow49 dB typ. Audio input impedance (Microphone)600 1 - 2 M RECEIVERFR5000FR5100 Receive systemDouble-conversion superheterodyne system Intermediate frequencies1st IF: 46.35 MHz, 2nd IF: 450 kHz SensitivityWide/Narrow0.3 V typ. at 12 dB SINAD10 dBV max. at 12 dB SINAD Wide/Middle/Narrow10 dBV max. at 12 dB SINAD Digital0.25 V typ. at 5% BER0 dBV emf max. at 1% BER (PN9) Squelch sensitivity (at threshold)0.25 V typ. Adjacent channel selectivityWide80 dB typ. (TIA-603-B) 85 dB typ. (TIA-603) 86 dB typ. Middle83 dB typ. Narrow56 dB typ. (TIA-603-B) 77 dB typ. (TIA-603) 77 dB typ. Digital66 dB typ. (EN 301 166, 400 Hz 1%) 63 dB typ. (EN 301 166, PN15 5%) 67 dB typ. Spurious responseAnalog90 dB80 dB typ. Digital90 dBV emf90 dB Vemf typ. IntermodulationWide78 dB typ. 72 dB typ. Middle72 dB typ. Narrow78 dB typ. 71 dB typ. Digital75 dBV emf typ.76 dBV emf typ. Hum and noiseWide52 dB typ. Middle Narrow50 dB typ. Digital66 dB typ. Audio output power (at 5% distortion with a 4 load) 4.0 W typ.3.5 W min. Audio output impedance4 Specifications are measured in accordance with TIA603B (for Wide and Narrow) or EN 300 166 (Digital) for FR5000. Specifications are measured in accordance with EN 300 086 (for Wide, Middle and Narrow) or EN 301 166 (Digital) for FR5100. All stated specifications are subject to change without notice or obligation. 2 - 1 SECTION 2 INSIDE VIEWS RX VCOs MAIN UNIT (TOP VIEW) MAIN UNIT (BOTTOM VIEW) Power SW (VCC line) (Q57) 8V regulator (8V line) (IC27) AF AMP (IC34) FUNCTION (Ref.No.) 2nd IF filter (Wide) (FI1) 2nd IF filter (Narrow) (FI2) CPU (IC20) 5V regulator (DSP5V line) (IC39) CPU clock (X5) PLL IC (TX lopp) (IC3) TX VCOs Optional digital unit slot TX power AMP (IC22) 1st mixer (DBM) (D62, L27, 32) 5V regulator (CPU5V) (IC30) 5V regulator (+5V line) (Q41) EEPROM (IC21) DSP (IC12) AF SW (IC35) PLL IC (RX loop) (IC4) Ref. OSC (X1) Level converter (IC26) 8V regulator (T8V line) (Q45) D/A converter (IC20) Discriminator (X3) IF IC (IC5) FUNCTION (IC40) Liner codec (IC8) 2 - 2 FRONT UNIT FRONT CPU (IC503) CLOCK OSC (X501) LCD DRIVER (IC500) ANALOG SW (IC506) AF POWER AMP. (IC509) SPEAKER SW (Q508) 3 - 1 SECTION 3 DISASSEMBLY INSTRUCTION 1. Removing the front panel q Unscrew 11 screws from the top cover. 3. Removing the MAIN UNIT q Unscrew 9 screws, and remove the cover. (If you are going to install an optional unit, see page 4-1 for the installation.) 2. Removing the MAIN UNIT assembly q Uscrew 5 screws which settles the MAIN UNIT assembly. P0P1P2P3P4 P0P1P2P3P4 P0P1P2P3P4 PWRTXRX PWRTXRX PWRTXRX w Unscrew 7 screws from the front panel. e Disconnect the cable from the MAIN UNIT assembly, and remove the front panel. w Turn the MAIN UNIT assembly upside down. (To be continued to next page) 3 - 2 MAINMAIN J9J9J9 J4J4 Unscrew ANT case Unsolder ANT case Flat cable Disconnect Disconnect BlackBlackBlackBlack RedRedRedRed W4 W4 Unsolder 2 points Unsolder 4 points Unscrew Clip 15 screws w Unsolder 2 points at the ANT cases. e Unscrew 4 screws from the ANT cases, and remove them. r Disconnect the flat cabe from J4 and the speaker cable from J9. t Unsolder 2 points at the bottom of ANT connectors. y Unsolder 4 points at the PA module leads. u Unscrew 2 screws from W4. i Remove the clip from the side of chassis. o Unscrew 15 screws from the MAIN UNIT, then take off the MAIN UNIT PCB from the chassis. 4 - 1 SECTION 4 OPTIONAL UNIT INSTALLATION PWRTXRX q Disassembly the repeater until the MAIN UNIT is exposed. (See the page 3-1) w Modify the patterns on the MAIN UNIT as below. e Remove the protective paper of optional unit, and install it to the J1 as below. A and F; Cut the patternB; Short the pattern r Replace the cover, screws, etc. to recover the whole assembly. NOTE: When uninstalling the scrambler unit Be sure to recover the disconnected or connected points, otherwise no TX modulation or AF output is available. Install UT-109R or UT-110R as follows. 5 - 1 SECTION 5 CIRCUIT DESCRIPTION 5-1 RECEIVER CIRCUITS RF BPF CIRCUITS RX signals from the RX antenna connector (J11) are passed through the 1st stage of BPF (D28, 29, 31, 32, L44, 47) then amplified by the RF AMP (Q36). The amplified RX signals are passed through the 2nd stage of BPF (D28, 29, 31, 32, L44, 47) to remove unwanted signals for good image response then applied to the 1st mixer (L27, 32, D62). Being mixed with 1st LO signals from the RX VCO, the RX signals are converted into the 46.35 MHz 1st IF signal. The 1st and 2nd stage of the BPFs are tuned to the pass band frequency by tracking voltage “T1” and “T2” from the DAC (IC17). The gain of low noise RF AMP (Q36) is controlled by the AGC circuit (Q39, D27) according to the RX signal strength. IF FILTER/IF AMP CIRCUITS The 1st IF signal from the 1st mixer (L27, 32, D62) is amplifi ed by the buffer AMP (Q63, 64, 71) and 1st stage of IF AMP (Q19) then fi ltered by crystal fi lter (FI3 or FI4), and then applied to the IF IC (IC5). The crystal fi lters (FI3 or FI4) are switched by the “NWC1” signal from the CPU (IC20) according to the RX mode; Wide (Middle), Narrow or Digital. Being mixed with the 2nd LO, the 1st IF signal is converted into the 450 kHz 2nd IF signal. The 2nd IF signal is passed through the external ceramic filter (FI1 or FI2), then FM- demodulated by the internal quadrature detector with discriminator (X3). The demodulated AF signals are amplifi ed by the AF AMP (IC36), and applied to the LINER CODEC (IC8). The AF signals are converted into the digital audio signal then processed by the DSP (IC12) then recovered to the analog audio signals. The ceramic filter (FI1 or FI2) is switched by the “NWC2” signal from the CPU (IC20) according to the RX mode; Wide (Middle), Narrow or Digital. The 450 kHz 2nd IF signal is amplifi ed by IC7 then applied to the DSP (IC12) via ADC (IC9), and digital-demodulated. The processed digital signal is converted into the analog audio signal by the LINEAR CODEC (IC8). AF AMPLIFIER CIRCUITS The AF signals from the LINEAR CODEC are amplifi ed by the AF AMP (IC36) and level-adjusted by DAC (IC2), then applied to IC28 via IC29 to be power-amplifi ed. SIGNALING (DECODE) The Continious Tone (CTCSS/DTCS), Single Tone (5-Tone/ DTMF/CW_ID) signals in the demodulated AF signals are decoded in the DSP (IC8). 5-2 TRANSMITTER CIRCUITS MODULATION CIRCUITS The demodulated signals are applied to the MIC AMP (IC25). The amplified Demodulated signals are passed through the SW IC (IC35) which selects the source of Demodulated signals from J5 (from MIC) and from D-SUB connector (DEXM). The Demodulated signals from the SW IC are amplifi ed by an AMP (IC1) then applied to the LINEAR CODEC IC (IC8) where the Demodulated signals are converted in to the digital audio signals. The converted digital audio signals are processed (pre- emphasis, limit, etc.) by the DSP (IC12), then recovered to the analog audio signals by LINER CODEC IC (IC8). The AF signals are amplifi ed by IC1 and level-adjusted by Electronic VR (IC2), then applied to the TX VCO and TCXO (X1) as the modulation signals. SIGNALING (ENCODE) The Continious Tone (CTCSS/DTCS), Single Tone (5-Tone/ DTMF/CW_ID) signals are encoded, and mixed with Demodulated signals in the DSP (IC12). YGR/PA CIRCUITS The output signals from TX VCOs are amplified to the level required for the PA module by pre-AMPs (Q37, 38), then amplifi ed by the PA module (IC22) to obtain TX output power. The power-amplifi ed TX signal is passed through the ANT SW (D44) and LPF (for harmonics removal) then applied to the TX antenna. APC CIRCUIT D45, D48 and D49 detect the TX power, and the detected voltage is applied to the IC23 in APC circuit. Comparing the detected voltage which is in proportion to the TX power and power setting voltage as the reference voltage, IC23 adjusts the bias voltage of PA module (pin 2: VGG terminal) and pre- AMP (Q38) to control the TX power. 5 - 2 5-3 FREQUENCY SYNTHESIZER CIRCUITS RX PLL CIRCUIT The RX PLL IC (IC4) outputs resulting signal; phase-comparison of reference signal (15.3 MHz) from the TCXO (X2) and fedback OSC signal from the RX VCO. The phase-difference signal is passed through the active loop fi lter (Q11, 14) and applied to the RX VCO as the lock voltage. The voltage of RX LV (lock voltage) is adjusted to appropriate one by “RX LVA” signal. A portion of reference frequency signal (15.3 MHz) from the TCXO (X2) is passed through the tripler (Q2) to extract 3rd harmonic, then applied to the IF IC (IC5). RX VCO There are 2 VCOs; VCO for lower band (Q21, D8, 16, L17) and higher band (Q20, D7, 15, L20), and these VCOs (=OSC freq.) are switched by the VCO SW (Q26, 30). The OSC frequencies of these VCOs are adjusted (=Locked) to desired one by the RX LV signal (Lock Voltage). The output signals of these VCOs are applied to the 1st mixer (L27, 32, D62) via buffer (Q25). A portion of output signal from the buffer (Q25) is applied to the doubler (Q32) to extract 2nd harmonic, then applied to the PLL IC (IC4) via the LPF. TX PLL CIRCUIT TX PLL IC (IC3) outputs resulting signal; phase-comparison of reference signal (15.3 MHz) from the TCXO (X1) and fedback OSC signal from the TX VCO. The phase-difference signal from the PLL IC (IC3) is passed through t