Manual Service Pacific Crest

PDL HPB
Service Manual
PDL HPB Service Manual P/N M00746, Revision 1

Table of Contents
Chapter 1 - General Information and Safety ............................................................ 1

About this manual ........................................................................................................................... 2
Assumptions .................................................................................................................................... 2
Updating this manual ...................................................................................................................... 2
Related documentation .................................................................................................................... 2
Deciding what is serviceable ........................................................................................................... 2
Possible loss of warranty ................................................................................................................. 3
Removing and replacing parts ......................................................................................................... 3
Warnings and Cautions ................................................................................................................... 3
Electrostatic Discharge (ESD) ........................................................................................................ 3
ESD Prevention requirements ......................................................................................................... 4
Grounding requirements .................................................................................................................. 4
Protective flooring requirements ..................................................................................................... 4
Protective clothing requirements ..................................................................................................... 5
Packaging and shipping requirements ............................................................................................. 5
Training requirements ..................................................................................................................... 5
Personal grounding straps requirements ......................................................................................... 5
Grounded workbench requirements ................................................................................................ 5
Electrical equipment, tools, and soldering iron requirements ......................................................... 5
Test equipment requirements ........................................................................................................... 6
Setting up an ESD workstation ....................................................................................................... 6
Chapter 2 - Product History and Specifications ..................................................... 8

Product history ................................................................................................................................ 9
Initial release .................................................................................................................................. 9
2002-2003 release ........................................................................................................................... 9
2005 release ..................................................................................................................................... 9
Specifications ................................................................................................................................ 10
Physical specifications ............................................................................................................. 10
Electrical specifications ........................................................................................................... 10
Environmental specifications ................................................................................................... 10
Performance specifications ..................................................................................................... 10
General ................................................................................................................................. 10
Transmitter ........................................................................................................................... 10
Receiver................................................................................................................................ 10
Chapter 3 - Theory of Operation ............................................................................. 11

Circuit description ......................................................................................................................... 12
General .......................................................................................................................................... 12
Radio Modem Board (RFMOD) ................................................................................................... 12
PDL HPB Service Manual i P/N M00746 revision 1

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Interface .................................................................................................................................... 12
Table 1 – RFMOD pin-out descriptions – Connector J1 – AMPMOD interface................. 12
Table 2 – RFMOD pin-out descriptions – Connector J2 –Front panel I/O interface ........... 13
Microprocessor and Memory ................................................................................................... 14
Synthesizer and Dual Voltage Controlled Oscillators (VCO) .................................................. 14
Reference Oscillator ............................................................................................................ 14
A01655 family RFMOD ................................................................................................. 14
A00938 family RFMOD ................................................................................................. 14
Receiver ................................................................................................................................... 15
Transmitter ............................................................................................................................... 15
A01655 family RFMOD ...................................................................................................... 15
A00938 family RFMOD ...................................................................................................... 15
RF Power Amplifier Board (AMPMOD) ...................................................................................... 16
Interface .................................................................................................................................... 16
Table 3 – AMPMOD pin-out descriptions – Connector JP1 – RFMOD interface .............. 16
A01649 AMPMOD .................................................................................................................. 16
First stage ............................................................................................................................. 16
Second stage......................................................................................................................... 16
A00936/A00986 AMPMOD .................................................................................................... 17
First stage ............................................................................................................................. 17
Second stage......................................................................................................................... 17
Third (final) stage................................................................................................................. 17
Harmonic filter and antenna switching .....................................................................................17
I/O Interface Board ....................................................................................................................... 17
Table 4 – I/O PCBA pin-out descriptions – Connector J1 – RFMOD interface....................... 18
Table 5 – I/O PCBA pin-out descriptions - Connector J5 –AMPMOD Interface..................... 19
Push buttons ............................................................................................................................. 19
Numeric display ....................................................................................................................... 19
Indicator LEDs ......................................................................................................................... 19
Power regulation ...................................................................................................................... 19
Chapter 4 - Interfaces .............................................................................................. 21

User interfaces ............................................................................................................................... 22
DC power ...................................................................................................................................... 22
RS-232 interface ............................................................................................................................ 22
RF I/O ........................................................................................................................................... 22
Chapter 5 - Troubleshooting ................................................................................... 23

Setup and initial test ...................................................................................................................... 24
Connect to UUT ....................................................................................................................... 24
Print and save user settings ...................................................................................................... 24
PDL HPB Service Manual ii P/N M00746 revision 1

Table of Contents
Program test settings ................................................................................................................ 24

Perform initial RF tests ............................................................................................................ 24
Perform initial BER test ........................................................................................................... 25
Evaluate and interpret test results ............................................................................................. 25
Chapter 6 - Maintenance and Repair ...................................................................... 26

General maintenance and care ...................................................................................................... 27
Consumables ............................................................................................................................ 27
Disassembling the unit .................................................................................................................. 27
Disassemble front panel from enclosure .................................................................................. 28
Disassemble AMPMOD from enclosure .................................................................................. 29
Remove RFMOD from enclosure ............................................................................................ 30
Visually inspect seals .................................................................................................................... 32
RFMOD test points ....................................................................................................................... 33
Possible failure causes ................................................................................................................... 33
Unit won’t power up ................................................................................................................ 34
No display or LEDs.............................................................................................................. 34
All display segments lit when power button held ................................................................ 34
No response to serial port.......................................................................................................... 34
Synthesizer lock problems (E15, E16) .....................................................................................34
Low or no TX power ................................................................................................................ 34
No power on high or low ..................................................................................................... 34
No power on high, low power OK ....................................................................................... 34
Degraded or no RX .................................................................................................................. 35
Reassembling the unit ................................................................................................................... 35
Check and position enclosure gaskets....................................................................................... 35
Orient enclosure ........................................................................................................................ 35
Place board guides on RFMOD ................................................................................................ 35
Place front panel through enclosure .......................................................................................... 35
Insert RFMOD into enclosure ................................................................................................... 36
Assemble AMPMOD into enclosure......................................................................................... 38
Assemble front panel to enclosure ............................................................................................ 38
Leak test ......................................................................................................................................... 40
Final test ........................................................................................................................................ 40
Connect to UUT ........................................................................................................................ 40
Program test settings ................................................................................................................. 41
Perform bench tests ................................................................................................................... 41
Perform BER test ...................................................................................................................... 41
Restore customer settings.......................................................................................................... 41
Chapter 7 - Adjustments and Verification .............................................................. 43
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Adjustments .................................................................................................................................. 44
Frequency error ........................................................................................................................ 44
TCVCXO units (mid-2002 to current) ................................................................................. 44
Discrete reference crystal units (mid-2002 and older) ........................................................ 44
Modulation balance adjustment ............................................................................................... 45
Modulation (deviation) adjustment .......................................................................................... 45
Receiver sensitivity confirmation ............................................................................................. 45
RXA bias adjustment ............................................................................................................... 45
Performance verification ............................................................................................................... 46
Factory test procedures ................................................................................................................. 46
D00535, PDL HPB RFMOD Test Procedure ................................................................................ 47
D00564, PDL HPB Final Test Procedure ...................................................................................... 61
D00603, Vacuum Test Procedure .................................................................................................. 64
D00590, BER Test Procedure ........................................................................................................ 66
Chapter 8 - Assembly Drawings & Schematics ..................................................... 72

List of drawings ............................................................................................................................ 73
A02393 ASSY,PDL,HPB,35W,450,25K,AUTO,PWR,ON .......................................................... 74
A01649 ASSY,HPB,AMPMOD,LDMOS,35W,450 ..................................................................... 76
A01611 ASSY,PCB,HPB,AMP,LDMOS,35W,450 ...................................................................... 78
A01655 ASSY,HPB,PCB,RFMOD,100mW,450 .......................................................................... 80
A02457 ASSY,HPB,PCB,RFMOD,100mW,GEN ........................................................................ 83
A02413 ASSY, PDL,BASE, FRONT, PANEL,W/AUTO,PWR ON............................................ 84
A02388 ASSY,PDL,BASE,I/O BD,AUTO, PWR/ON ................................................................. 86
A00933 ASSY,PDL,BASE,CONN,RS232.................................................................................... 89
A00936 ASSY,PDL,BASE,AMPMOD,35W,450 ......................................................................... 90
A01387 ASSY,PDL,BASE,PCB,RF MOD, .................................................................................. 97
D00485 SCHM,PDL,BASE,RFMOD,450................................................................................... 102
D00668 SCHM,HPB,AMP,LDMOS,35W,UHF ......................................................................... 105
D00483 SCHM,PDL,BASE I/0 INTERFACE BD ...................................................................... 106
D00476 SCHEM,PDL,BASE,AMP,35W,UHF ........................................................................... 107
Chapter 9 - Service Software ................................................................................ 108

List of service software ............................................................................................................... 109
PDLCONF factory version ......................................................................................................... 109
PDLTEST .................................................................................................................................... 109
CDLEV ....................................................................................................................................... 109
BERTEST ................................................................................................................................... 109
Chapter 10 - Replacement Parts List .................................................................... 110

Top level assembly (A02393 family)........................................................................................... 111
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Model-specific subassemblies................................................................................................. 111

AMPMOD ................................................................................................................................... 112
Final assembly (A01649) ........................................................................................................ 112
Subassembly (A01611) ........................................................................................................... 112
RFMOD ....................................................................................................................................... 114
Model specific components..................................................................................................... 114
Generic RFMOD (A02457) .................................................................................................... 114
Front panel assembly.................................................................................................................... 119
I/O board ................................................................................................................................. 119
Manual Change Log................................................................................................ 121
PDL HPB Service Manual v P/N M00746 revision 1

Chapter 1
General Information and Safety
About this manual
Assumptions
Updating this manual
Related documentation
Deciding what is serviceable
Possible loss of warranty
Removing and replacing parts
Warnings and Cautions
Electrostatic Discharge (ESD)
ESD Prevention Requirements
Grounding requirements
Protective flooring requirements
Protective clothing requirements
Packaging and shipping requirements
Training requirements
Personal grounding straps requirements
Grounded workbench requirements
Electrical equipment, tools, and soldering iron requirements
Test equipment requirements
Setting up an ESD workstation
PDL HPB Service Manual 1 P/N M00746, Revision 1

About this manual
This service manual is a reference guide for service personnel at authorized Pacific Crest
Service Centers. It provides the necessary information to properly service, maintain, and repair
the Pacific Crest® PDL LPB radio modem.
Assumptions
This service manual assumes that the user has appropriate knowledge and understanding of:
• Mechanical design, electronic theory, and general service procedures
• Radio-frequency (RF) techniques and practices.
• Basic electronic test equipment such as volt-ohmmeters, oscilloscopes, generators, and
power supplies
• Specialized RF measurement equipment such as communication analyzers, spectrum
analyzers, and directional power meters
• The Microsoft Windows operating system
Updating this manual

Photographs, illustrations, specifications, and other details in this service manual were current
when the manual was released in March 2007. Any changes that may be needed will be
issued as supplementary or replacement pages, a Service Bulletin, other service information, or
as a revised volume of the manual.
Note – To keep a printed manual up to date, print any updates that you receive and insert them
at the relevant point in the manual.
Related documentation
Note – Read all Service Bulletins that relate to the PDL LPB before beginning service or repair.
To obtain the most recent Service Bulletins, contact Pacific Crest Corporation technical support
at [email protected].
Deciding what is serviceable

Assembly drawings in this service manual show the relationship between all assemblies that are
considered serviceable. Serviceable assemblies are defined as assemblies that can be repaired at
Pacific Crest Service Center level. The following factors determine whether an assembly is
serviceable:
• The tools required to complete the repair
• The time it takes to complete the work
• Availability of service parts

Chapter 1
Possible loss of warranty
If a Pacific Crest product is not serviced properly, or if it is repaired by someone other than an
authorized technician, the manufacturer’s warranty on the product will become void. To prevent
loss of coverage, always comply exactly with the instructions in this service manual.
Removing and replacing parts

To disassemble and reassemble the PDL HPB:
1. Consult the diagrams in Chapter 8, Assembly Drawings & Schematics.
2. Carefully follow the procedures described in Chapter 6, Pacific Crest Corporation
Maintenance and Repair.
If you need to replace a part, see Chapter 10, Replacement Parts List.
Warnings and Cautions

Note – An absence of specific alerts does not mean that there are no safety risks involved.
Always follow the instructions that accompany a Warning or Caution. The information they
provide is intended to minimize the risk of personal injury and/or damage to the equipment. In
particular, observe safety instructions that are presented in the following formats:
Warning – A Warning alerts you to a likely risk of serious injury to your person and/or
damage to the equipment. A warning identifies the nature of the risk and the extent of
possible injury and/or damage. It also describes how to protect yourself and/or the
equipment from this risk. Warnings that appear in the text are repeated at the front of the
service manual.
Caution – A Caution alerts you to a possible risk of damage to the equipment and/or loss
of data. A Caution describes how to protect the equipment and/or data from this risk.
Electrostatic Discharge (ESD)

The PDL HPB was constructed in an ESD-protected environment. Many of the semiconductor
devices in the instrument are susceptible to ESD damage.
ESD is generated in many ways. For example, it can be the result of simple contact, the
separation of materials, or the normal motion of people working with the device. Depending on
the magnitude of the charge, device substrates can be punctured or destroyed by contact with, or
by mere proximity to, a static charge. The result can be immediate destruction, early failure of
the device, or degradation of device performance.
To prevent static damage or destruction:
• Take adequate precautions when you handle or service equipment that contains static-
sensitive devices.
• Only attempt to service the circuitry in a static-sensitive device if you are thoroughly
familiar with industry-accepted techniques for handling such devices.

• Always take adequate measures to prevent the buildup of static charge on work surfaces
and on persons handling the PDL HPB.
ESD Prevention Requirements

Everyday friction and the separation of materials generate static electricity. Static electricity and
its associated electrostatic discharge (ESD) damages sensitive components and assemblies.
Since the service operations carried out in service manuals can expose the sensitive internal
components to static electricity, it is important that effective ESD controls are part of the service
process. This section describes how to prevent ESD damage to sensitive components and
assemblies.
Workshop Electrostatic Protected Area (EPA)
All repairs on Pacific Crest devices must be performed in an Electrostatic Protected Area (EPA).
When setting up an EPA, take the following measures to ensure it is correctly set up and used:
• Determine the requirements for the establishment of protected areas and ground
workbenches.
• Clearly identify the EPA by signs and tapes on the floor.
• Restrict access to the EPA to people who are properly trained.
• If an instrument has to be moved outside of the EPA during the repair, for example, for
distance measuring tests, first rebuild the equipment with all protecting covers.
• Certify the adequacy of protected areas and grounded workbenches before they are used.
• Document certification-testing procedures and data.
• Ensure the use of protective personal clothing and proper personal grounding at all
necessary points, where ESD-sensitive items are handled outside their protective
packaging.
• Establish and conduct training programs to ensure that all personnel, who handle ESD-
sensitive items, have received the necessary training and have required the necessary
skills.
Note – Personnel who are qualified in ESD/EPA requirements must carry out and approve the
design and installation of an EPA.
Grounding requirements
Technicians, visitors, equipment, and exposed surfaces must be properly grounded in the
EPA.Devices that cannot be grounded in the EPA (for example, a computer, monitor, and
keypad) should be placed at least40-50 cm away from the EPA.
Some typical grounding examples are:
• EPA with protective floor
When performing system tests requiring workspace larger than a single bench, Pacific
Crest recommends that the EPA consists of a protective floor. See Figure 3.5
• EPA limited to the working bench
When the repair can be completed on the workbench, the EPA can be limited to the
workbench.
• EPA for field maintenance

Chapter 1
For field maintenance, a protected area could consist of an area away from static
generators and equipped with:
– a personal wrist grounding strap
– a portable protective work mat
– ESD-protective packaging for parts
Protective flooring requirements

Protective flooring materials are available in conductive, static-dissipative, and anti-static
carpeting; vinyl sheeting; vinyl floor tiles; and terrazzo.
Use conductive adhesives to apply conductive vinyl flooring. Do not wax hard-surfaced flooring
because waxed surfaces are highly resistive and prone to static generation.
Protective clothing requirements

Wear conductive shoes, shoe covers, or heel grounders to discharge static from people when
conductive floors are used. These items only need to be worn in the ESD-protected areas and
should be kept clean to avoid malfunction. People sitting at workbenches in an ESD-protected
area should use ESD-protected work chairs.
Packaging and shipping requirements

Follow these procedures:
• Ensure that all ESD-sensitive items, which are submitted for shipping, have been
packaged in ESD-protective packaging.
• Remove items from the interim packaging only at an ESD-grounded workbench. Observe
the handling guidelines.
Training requirements
• Personnel shall be trained to effectively operate the materials, equipment, and procedures
in accordance with the ESD requirements.
• The EPA should be checked at least once year.
Personal grounding straps requirements

Personnel who handle ESD-sensitive items should wear a skin-contact wrist strap. The strap
rapidly dissipates personal static charges safely to ground and equalizes personal static levels
with those of the work surfaces. Alternatively, personal grounding methods could be used, for
example, conductive shoes, conductive chairs, and ESD-protected floors.
Grounded workbench requirements

Workbenches that have contact with ESD-sensitive items must have an ESD-protective work
surface over the area where ESD-sensitive items are placed. Workbench surfaces must be
connected to the ground through a ground cable.
An ESD field service workbench kit consists of a dissipative mat, a common point grounding
cord, and a personal wrist strap with a cord.

Electrical equipment, tools, and soldering iron requirements
Soldering irons, solder pots, or flow soldering equipment should be hard grounded or direct-
current insulated from the power line. Other electrical power equipment that comes into contact
with ESD-sensitive items should also be grounded. All hand-held tools should be ESD
protected.
Test equipment requirements

Ensure that all test equipment that has exposed metallic surfaces is electrically connected
through a grounded plug to the test-equipment power system or other hard ground. To avoid risk
of personal injuries, immediately fix or remove faulty test equipment or tools that are used in
electrical service work.
Setting up an ESD workstation

1. Unroll the ESD field service workstation kit and place it, pocket side up, on the
workbench.
2. Remove the mat grounding cable from the mat pocket.
3. Snap the end of the mat grounding cable onto the common point ground connection on
the mat.
4. Connect the other end of the cable to an electrical earth ground, such as a third wire utility
ground, a cold water pipe, or a ground rod.
5. Use the common point ground connection to plug the wrist strap cable into the mat
grounding cable.

Chapter 1
Note – Put on the wrist strap. The wrist strap must fit snugly. To adjust it, unclasp the buckle
latch, adjust the size, and re-clasp the latch.
It is now safe to handle components and printed circuit assemblies on the mat.
Note – Always repackage all ESD-sensitive components before you disconnect the wrist strap.

Chapter 2
2 Product History and Specifications
Product history
Initial release
2002-2003 release
2005 release
Specifications
Physical specifications
Electrical specifications
Environmental specifications
Performance specifications
General
Transmitter
Receiver

Product History and Specifications
Product history
Initial release
PDL HPB was initially released in 1999 as a single model covering 450-470 MHz, with 25 kHz
occupied bandwidth, PCC p/n A00939. This was quickly followed by additional versions
covering 410-430 and 430-450 MHz. Several OEM versions were subsequently released using
the same hardware.
All these units were built using the A00938/A00987/A00988 series RFMOD (RF/Modem)
assemblies, and the A00936/A00985/A00986 series AMPMOD (35W RF Amplifier Module)
assemblies.
2002-2003 release
In late 2002, PCC developed a more efficient AMPMOD using LDMOS FET RF power
transistors in place of the previous bipolar type. The decreased RF input power requirements of
this new AMPMOD necessitated minor changes to the RFMOD assembly for compatibility.
New top level part numbers were assigned for PCC branded units at that time. Existing OEM
branded units retained their part numbers but were revised to use the new AMPMOD and
RFMOD. New OEM units were subsequently added using new part numbers.
2005 release
In 2005, the previously optional “auto-power-on” feature was made standard and a new series of
top level part numbers was issued for all units.
Specifications
Physical specifications
Size 6.23"W x 2.77"H x 6.58"L (15.8 cm W x 7.0 cm H x 16.7 cm L)
Weight 3.22 lbs. (1.46 Kg)
Electrical specifications
Power supply 9-16 VDC
Power consumption Quiescent/Receive 1.9 W
Transmit (low power) 13 W
Transmit (high power, LDMOS RF amplifier) 100 W
Transmit power (pre-2003, bipolar RF amplifier) 135 W
Environmental specifications
Shock and vibration Per ANSI/ASAE EP455
Protection Per IEC 144/855420 I.P. 66 Dust-tight and watertight
Operating temperature -22° to 140° F (-30° to 60° C)
range
Storage temperature -67° to 185° F (-55° to 85° C)
range

Chapter 2
Performance specifications
General
Serial port interface 1200 to 38400 baud operation with 1 start, 8 data, optional parity, and one
stop bit
Modem transmission 19,200 or 9,600 bits per second (Four-level FSK)
rate 9,600 or 4,800 bits per second (GMSK)
Transmission Transparent, packet switched, auto-repeater, fast asynchronous, Trimtalk™,
Protocols Trimmark II/IIe™.
Modulation Gaussian Minimum Shift Keying (GMSK) with BT of 0.5 (4800, 9600 bps link
rate)
Four-level FSK (9600, 19200 bps link rate)
Transmitter
RF power 2 W (nominal), 35 W +/- 1 dB
Output impedance 50 Ohms
Modulation distortion < 5%
Transmitter attack < 18 mS
time
Spurious and < -55 dBc
harmonic FM
FM hum and noise < -40 dB
Receiver
Sensitivity -116 dBm or better (12 dB SINAD)
Adjacent channel -60 dB
selectivity
Conducted spurious < -65 dBm
Carrier detect attack 2 mS
time

Chapter 3
3 Theory of Operation
Circuit description
General
Radio Modem Board (RFMOD)
Interface
Table 1 – RFMOD pin-out descriptions Connector J1 – Amp Interface
Table 2 – RFMOD pin-out descriptions Connector J2 – Front Panel I/O Interface
Microprocessor and Memory
Synthesizer and Dual Voltage Controlled Oscillators (VCO)
Reference Oscillator
A01655 family RFMOD
A00938 family RFMOD (Pre-2003)
Receiver
Transmitter
A01655 family RFMOD
A00938 family RFMOD (pre-2003)
RF Power Amplifier Board (AMPMOD)
Interface
Table 3 – AMPMOD pin-out descriptions, connector JP1 – RFMOD Interface
A01649 AMPMOD
First stage
Second stage
A00936/A00986 AMPMOD
First stage
Second stage
Third (final) stage
Harmonic filter and antenna switching
I/O Interface Board
Table 4 – I/O PCBA pin-out descriptions Connector J1 –RFMOD Interface
Table 5 – I/O PCBA pin-out descriptions Connector J5 –AMPMOD Interface
Push buttons
Numeric display
Indicator LEDs
Power regulation

Theory of Operation
Circuit description
This section provides theory of operation for each of the three major subassemblies of the HPB.
General
The main subassemblies of the PDL HPB are the radio modem board (RFMOD), the RF power
amplifier board (AMPMOD) and the I/O interface board. These boards are manufactured using
a combination of surface mount and through-hole technologies, and are interconnected with
various cable assemblies. All boards are independently tuned and can be interchanged, with
certain restrictions as detailed below.
Radio Modem Board (RFMOD)
Interface
The radio modem board is interconnected with the other system boards over 4 interfaces. The
interfaces are presented via connectors marked on the PCB with a "J" designation. Refer to the
assembly drawings in Chapter 8 for connector locations.
The radio modem board interfaces to the RF Amplifier board over connector J1. The radio
modem board interfaces to the I/O board over connector J2. Connectors J3 and J4 provide the
RF interface to the RF Amplifier board. Pin-out descriptions, including signal direction and
information concerning signal levels are presented in Tables 1 and 2.
Table 1 – RFMOD pin-out descriptions Connector J1 – Amp Interface
Pin # Name Description Direction

1 GND Ground
2 GND Ground
3 UNREG Unregulated power, 9-16 VDC Input
4 PCNTL Amplifier power control signal Output
5 AMPWR Amplifier power supply, 9-16 VDC Output
6 USW Unregulated power (pre-relay) from RFMOD Input
7 TAMP Amplifier temperature sense Input
8 ISENSE- Amplifier negative current sense Input
9 ISENSE+ Amplifier positive current sense Input
10 KEYAMP Amplifier enable signal (Low = Enabled) Output
11 HI/LO Amplifier power output select (Low = Low, High = Output
High)
12 GND Ground
13 HILOSW Amplifier power select switch input Input

Chapter 3
Table 2 – RFMOD pin-out descriptions Connector J2 – Front Panel I/O Interface
Pin# Name Description Direction

1 GND Ground
2 GND Ground
3 UNREG Unregulated power, 9-16 VDC, supplied from I/O Input
Board
4 UNREG Unregulated power, 9-16 VDC, supplied from I/O Input
Board
5 GND Ground
6 PWRBUT Power button closure detect, active low Input
7 GND Ground
8 SPIDAT Display latch serial data Output
9 DISPCLK Display latch clock Output
10 GND Ground
11 TXD1 Serial data out to modem (not used) Input
12 RXD1 Serial data from modem to DTE (not used Output
13 RTSD1 Request to send data to modem (not used) Input
14 CTSD1 Clear to send data to DTE (not used) Output
15 TXD2 Serial data out to modem port 2 (not used) Input
16 RXD2 Serial data from modem port 2 (not used) Output
17 RTSD2 Request to send data to modem port 2 (not used) Input
18 CTSD2 Clear to send data to DTE port 2 (not used) Output
20 RXD3 Serial data from modem to DTE port 3 (not used) Output
23 TXD0 Serial data out to modem DTE port 0 Input
24 RXD0 Serial data from modem to DTE port 0 Output
25 GND Ground
26 DCD Data carrier detect Output
27 USW Unregulated power (pre-relay) from AMPMOD Input
28 CHNBUT Channel button closure detect, active low Input
29 +8V Regulated power supply input Input
30 +8V Regulated power supply input Input

Theory of Operation
Microprocessor and Memory
A microprocessor implements the firmware logic for the control and monitoring of the modem
and RF circuitry. The processor accesses the firmware that is located in a 32 k byte FLASH
memory. System memory consists of approximately 32 k bytes of SRAM. Configuration
parameters are stored in the microprocessors on-chip EEPROM.
Synthesizer and Dual Voltage Controlled Oscillators (VCO)

The synthesizer and dual VCO provide a programmable RF frequency output that is used for
driving the transmitter and the local oscillator of the receiver. The synthesizer is designed for
low phase noise required for worldwide regulatory standards. The VCO and reference oscillator
are modulated directly from the baseband signal during transmission.
The synthesizer integrated circuit contains the programmable dividers and PLL components for
the VCO control. The synthesizer is loaded via a serial interface with data that configures the
divider and control circuits to generate the appropriate frequency.
The synthesizer takes input from the 18 MHz reference oscillator and from the VCO. A
synthesizer locked output indicates to the microprocessor that the synthesizer is locked “on-
channel.” This signal is used to inhibit transmission if the synthesizer fails to lock.
Separate VCOs are used for receive (RX) and transmit (TX) functions. The RX VCO includes a
high-Q ceramic resonator as part of its tank circuit. This RX VCO is designed for extremely
low phase noise operation and quick lock time at the local oscillator frequency. The separate
TX VCO is optimized for quick lock and low phase noise operation at the TX frequency. The
TX VCO is modulated directly from the baseband signal. A potentiometer is used to adjust for
the correct balance between the TX VCO and reference oscillator modulation.
Reference Oscillator
A01655 family RFMOD

The reference oscillator circuit consists of a surface mount voltage controlled, temperature
compensated crystal oscillator module operating at 18 MHz (reference designator X2.)
Frequency adjustment is achieved by varying DC reference voltage at the oscillator’s control
voltage input (X2 pin 1.) This reference voltage is sourced from an 8 bit DAC (reference
designator U13) under firmware control, and is combined with the transmit baseband
modulating signal at U7A, then low pass filter U7C before being applied to the reference
oscillator.
The reference oscillator is used by the synthesizer to generate the local oscillator (LO) and
transmit signals. The reference oscillator is also multiplied by three to provide the LO for the
second stage mixer. The first LO operates at 54.45 MHz above the channel RX frequency. The
second LO is fixed at 54 MHz.
A00938 family RFMOD (Pre-2003)

The oscillator circuit consists of a crystal oscillator that operates at 18 MHz. A precision
temperature sensor is used to digitally compensate the oscillator for changes in temperature. A
crystal dependent look-up table and input from the temperature sensor produces the proper bias
voltage to maintain stability within 2.5 ppm. Note that crystals are color coded with a dot to
indicate the proper look-up table.

Chapter 3
The reference oscillator is coarse frequency adjusted with a variable capacitor (VC3). Fine
frequency adjustment is performed under firmware control. Instructions for frequency
adjustment are found in Chapter 7.
Receiver
The receiver is a double conversion superheterodyne with intermediate frequencies at 54.45
MHz and 450 kHz. RF input from the Amplifier board is fed to the J3 connector. The front end
is protected during transmission by a diode protection circuit (D1). Two triple section helical
bandpass filters reject out of band interference. The front end is designed to accommodate an
input frequency band of 20 MHz. The front-end LNA is switched on during quiescent and
receive modes of operation.
The mixer multiplies the buffered RX VCO signal (RF channel frequency + 54.45 MHz) by the
RF input signal to produce the 54.45 MHz IF. The mixer output is fed to a matched pair of
crystal filters CF1 and CF2. Variable capacitors adjust the amplitude and phase response of the
crystal filter section. These adjustments are critical to receiver operation and should not be
disturbed. A transistor (Q7) amplifies the signal to the required level for the IF/detector IC.
The second conversion stage, second IF filter, and baseband detection is provided in the
MC3371 IF/detector IC. The 54 MHz second LO, sourced from the oscillator circuit, multiplies
the first IF signal resulting in a second IF at 450 kHz. The second IF is filtered using two
ceramic bandpass filters. Quadrature coil L6 centers the detector at the IF frequency, and is
adjusted for nominal 1.4 VDC as specified in the chip's datasheet. The baseband output is
nominally 1V peak to peak for +/-4 kHz RF deviation of the incoming signal. This chip also
provides a Received Signal Strength Indicator (RSSI) that is used by the microprocessor to
indicate a carrier present state.
Transmitter
The transmitter produces the low level RF power that drives the input of the RF amplifier board.
Frequency modulation of the transmit signal occurs in the synthesizer and reference oscillator
circuits. The TX VCO operates at the channel frequency, and modulation (TXA) is applied at
R104. R107 sets modulation balance for optimum transmitted waveform. The TX VCO signal
is amplified by two class A and one class AB stages, all powered by the KEYAMP signal
(nominally +7.5VDC).
A01655 family RFMOD

The RF signal is amplified to approximately +27 dBm by Q10, and then attenuated and matched
to 50 Ohms by the pi-section attenuator R158, R159, and R160. The resulting +20 dBm RF
signal is output at J4.
A00938 family RFMOD (pre-2003)

The RF signal is amplified to approximately +27 dBm by Q10, then matched to 50 Ohms by
VC2. The resulting +27 dBm RF signal is output at J4.

Theory of Operation
RF Power Amplifier Board (AMPMOD)
Interface
The RF power amplifier board interfaces with the other system boards, the user equipment and
antenna over 5 interfaces. The interfaces are presented via connectors marked on the PCB with
a "J" designation. Refer to the assembly drawings in Chapter 7 for connector locations.
Table 3 provides the pin-out descriptions for JP1, the interface to the radio modem board.
Table 3 – AMPMOD pin-out descriptions, connector JP1 – RFMOD Interface
1 GND Ground
2 GND Ground
3 UNREG Unregulated power, 9-16 VDC Output
4 PCNTL Amplifier power output control signal Input
5 AMPWR Amplifier power supply, 9-16 VDC Input
6 USW Unregulated, pre-relay, power supply, 9-16 VDC Output
7 TAMP Amplifier temperature sense Output
8 ISENSE- Amplifier negative current sense Output
9 ISENSE+ Amplifier positive current sense Output
10 KEYAMP Amplifier enable signal (Low = Enabled) Input
11 HI/LO Amplifier power output select (Low = Low, High = Input

High)
A01649 AMPMOD
First stage
The first stage amplifier Q1 takes the +10 dBm RF input from the RFMOD assembly and
amplifies it by approximately 14 dB. Stage gain is controlled by varying the gate bias voltage
via VR1. Isolated test point TP1 is used to monitor the bias voltage during adjustment. The
voltage measured at TP1 must not exceed 1.75 VDC for safe operation. Higher bias voltages
may damage Q1.
When low power operation is selected via the rear panel switch, PIN diodes D5, D7, D6, and D3
are turned off via the HI/LOW signal from the RFMOD, and the 2.5 Watt RF output from Q1 is
fed via the microstrip line to the harmonic filter. D4 and D8 are turned on by KEYAMP, and
the harmonic filter output is routed to the antenna port.
Second stage
When high power operation is selected, D5, D7, D6, and D3 are turned on, and the RF output
from Q1 is applied to the gate of Q2. This stage has approximately 11.5 dB gain. Gate bias is

Chapter 3
set by VR2 and monitored at TP2. The voltage measured at TP2 must not exceed 2.1 VDC for
safe operation. Higher bias voltages may damage Q2.
The 35 Watt RF output from Q2 is routed to the harmonic filter and antenna port.
A00936/A00986 AMPMOD
First stage
The first stage amplifier Q4 takes the +27 dBm RF input from the RFMOD assembly and
amplifies it by 8 to 10 dB. The stage is operated in class C and input matching is adjusted via
VC1. The gain and output level of this stage is controlled by varying the collector voltage of Q4
via power control amplifier Q5. Q5 is driven by PCNTL under microprocessor control.
In Low Power (2W) mode, HI/LO is at ground potential, causing PIN diodes D5 and D7 to
appear open and routing the 2W signal to coax cable W1W2, with matching adjusted via VC3.
Likewise D3 and D6 appear open, routing the signal from W1W2 to the input of the harmonic
filter and thus to antenna connector J2.
In High Power (35W) mode, HI/LO is driven near +8VDC, the above switching diodes are
turned on and the 2W signal is routed to the second stage (Q1). Likewise the output of the final
stage (Q2) is routed to the input of the harmonic filter.
Second stage
The second stage (Q1), also operating in class C, nominally provides 6 dB gain. Drive is fed to
Q1 via D5 (biased on by HI/LO). Collector current for this stage is supplied via FET switch Q6
from incoming power at protection relay K1. Q6 is turned on by Q3 when logic “low” is
applied by the radio modem board to AMPPWR.
Third (final) stage

The output of Q1 is fed to the third stage amplifier (Q2), which also operates in class C and
nominally provides 5 dB gain. Q2 collector current is also supplied via Q6 (as with the second
stage), passing through current sensing resistor R5. The voltage developed across R5,
proportional to Q2 current, is fed to terminals ISENSE- and ISENSE+ for use by the power
control circuitry. Inductor L7 and capacitors C39, C40, C41, and C42 match Q2 collector
impedance to the 50-ohm input of the harmonic filter.
Harmonic filter and antenna switching

Inductors L8, L9, L10 and capacitors C43, C44, C45, and C46 constitute the harmonic filter.
Antenna switching is accomplished via PIN diodes D4 and D8. In the receive condition,
KEYAMP is at ground potential, causing D4 and D8 to appear open and routing the incoming
RF signal from the antenna port to the RX input of the RFMOD via J4. When transmitting,
KEYAMP is driven near +8VDC, turning on D4 to route the TX path from the harmonic filter
to the antenna port, while D8 shunts RF power not suppressed by L19/C59 to protect the
receiver front end. L12 provides a static dissipative path to ground for the antenna port.

Theory of Operation
I/O Interface Board
The I/O Interface Board interfaces with the other system boards over two connectors. The
connectors are marked on the PCB with a "J" designation. The following illustration shows the
position of the connectors:
Tables 4 and 5 present the pin-out information for each connector. Connector J1 interfaces to
the Radio Modem board. Connector J5 interfaces to the serial port connector (LEMO) on the
power amplifier module.
Table 4 – I/O PCBA pin-out descriptions Connector J1 –RFMOD Interface

1 GND Ground
2 GND Ground
3 UNREG Unregulated power input (9-16 VDC) Output
4 UNREG Unregulated power input (9-16 VDC) Output
5 GND Ground
6 PWRBUT Power button closure detect, active low Output
7 GND Ground
8 SPIDAT Display latch serial data Input
9 DISPCLK Display latch clock Input
10 GND Ground
11 TXD1 Serial data out to modem (not used) Output
12 RXD1 Serial data from modem to DTE (not used Input
13 RTSD1 Request to send data to modem (not used) Output
14 CTSD1 Clear to send data to DTE (not used) Input
15 TXD2 Serial data out to modem port 2 (not used) Output
16 RXD2 Serial data from modem port 2 (not used) Input
17 RTSD2 Request to send data to modem port 2 (not used) Output

Chapter 3
18 CTSD2 Clear to send data to DTE port 2 (not used) Input
20 RXD3 Serial data from modem to DTE port 3 (not used) Input
23 TXD0 Serial data out to modem DTE port 0 Output
24 RXD0 Serial data from modem to DTE port 0 Input
25 GND Ground
26 DCD Data carrier detect Input
27 USW Unregulated power (pre-relay) from AMPMOD Output
28 CHNBUT Channel button closure detect, active low Output
29 +8V System 8 VDC regulated power supply Output
30 +8V System 8 VDC regulated power supply Output
Table 5 – I/O PCBA pin-out descriptions Connector J5 –AMPMOD Interface

1 +UNREG Unregulated power from AMPMOD Input
2 GND Ground
3 SGND3 RS-232 ground
4 TX5 RS-232 TX data Input
5 RX5 RS-232 RX data Output
Push buttons
Two momentary push buttons are located on the interface board. One is used to control power,
and the other is used to change the channel or to select a channel operating mode (AutoBase™
or AutoRover™). The push buttons interface with the microcontroller and are debounced in
firmware. The operation of the channel button is virtually instantaneous. The operation of the
power button requires that the button be depressed for a 2 second period to turn the unit off.
Numeric display
A seven-segment plus decimal point LED is used to display the channel of operation and other
run-time information. A shift register loaded by the microprocessor drives the display. For
power conservation purposes, the display is only illuminated in response to the channel or
power buttons being pressed. During power-up, all segments flash on briefly.
Indicator LEDs
Four indicator LEDs are present to display radio operating status. A shift register loaded by the
microprocessor drives the LEDs. The LEDs are:
TX - indicates a transmission in progress
RX - indicates that an RF carrier is present (does not indicate that data is present, but rather that
a signal of sufficient strength to be considered is present)

Theory of Operation
Amp Power - indicates that the high power output is selected (change this by the toggle switch
available on the rear of the unit. This LED will flash if an amplifier overheating condition is
noted.
System Power - indicates that the unit is powered and operational. This LED will flash to
indicate a low external power situation if supply voltage drops below 10 volts. If the supply
voltage drops below 9 volts the system will not remain on.
Power regulation
The I/O interface board provides regulation for the main system power and provides the
interface protection circuitry to prevent damage due to reverse power connection and over
voltage conditions. A linear power regulator provides +8 VDC to the RF Modem board. The
regulator is heat sunk to the front panel.
Three regulators on the RFMOD provide +5 VDC for the digital and baseband sections, and for
the receive (RX) and transmit (TX) sections. The RX and TX regulators are switched on and
off by the microprocessor under firmware control, to enable the RX and TX functions.

Chapter 4
Interfaces
User interfaces
DC power
RS-232 interface
RF I/O
This chapter details the user interfaces of the PDL HPB.

Interfaces
User interfaces
There are 2 rear panel connectors on the HPB. A standard BNC connector is used for the
antenna connection. A 5 pin connector is used for both power and serial port connections.
DC power
DC power from 9-16 Volts is applied via pins 1 (+) and 2(-) of the rear panel PWR/DATA
connector (J1.) This connection normally terminates at a 2 pin SAE connector for all PCC-
supplied power/data cable assemblies. The unit is designed to produce full 35 Watt RF output
with 13.6 VDC applied. Lower voltages will reduce RF power output. Units with A01649
AMPMOD may consume up to 7.5 Amperes of current. Older units with A00938/A00986
AMPMOD may consume up to 9 Amperes. The power source and associated cabling must be
able to provide this current without significant voltage drop for high power operation.
RS-232 interface
The RS-232 interface uses only the signals TXD, RXD, and SGND (signal ground) and
occupies the remaining 3 pins of J1. RXD appears at pin 3, SGND at pin 5, and TXD at pin 5.
Other RS-232 handshaking signals such as RTS, CTS, DTR, and DSR are not implemented.
RF I/O
Transmitted and received RF signals flow through BNC coaxial connector J2. This connection
is designed to work properly with a load impedance of 50 Ohms resistive, such as a properly
tuned antenna system or a “dummy” load used for testing.

Chapter 5
Troubleshooting
Setup and initial test
Connect to UUT
Print and save user settings
Program test settings
Perform initial RF tests
Perform initial BER test
Evaluate and interpret test results
This chapter describes how to set up and perform the initial tests for HPB.

Chapter 5
Setup and initial test
Connect to UUT
1. Connect A00470 programming cable 2 pin SAE connector to power supply.
2. Connect A00470 DB-9 connector to T00018 adapter.
3. Connect T00018 adapter to PC serial port.
4. Connect A00470 5 pin Lemo connector to UUT Power/Data port.
5. Connect BNC RF cable to communications analyzer RF I/O port and to UUT antenna
connector.
Print and save user settings

1. Run PDLCONF (Factory version.)
2. Load settings via Power-On Capture method.
3. Print user settings using “Print” button at left of screen.
4. Display memory map using Memory Map tab.
5. Print memory map using “Print” button on Memory Map tab.
6. Save resulting printouts with the repair documents.

1. On the Serial Interface tab, select Protocol “Packet Switched.”
2. Set port baud rate to 9600 with no parity.
3. On the Radio Link tab, select GMSK modulation.
4. Select Link Rate 9600 Baud (for 25 kHz units) or 4800 Baud (for 12.5 kHz units.)
5. Program these settings.
6. Close the modem.
Perform initial RF tests
Caution – Avoid transmitting continuously on high power for longer than necessary to perform the
required measurements, particularly when testing units in unknown operating condition. Extended high
power transmission may generate excessive heat, and may cause damage to components, particularly if
faults exist in the unit under test.
Configure the communications analyzer to monitor at the frequency shown in the TX column for
Channel 0 in the configuration printout. Set the analyzer to display the modulation scope.
2. Run PDLTEST.
3. Connect to the UUT by selecting the appropriate COM port.
4. Set the UUT rear panel High/Low switch to High power.
5. Select Modulation “GMSK” and Channel “Middle.”
6. Select TX Function “Carrier.”
7. Click “Start TX.”
8. Observe that the TX LED on the UUT front panel illuminates.

Chapter 5
9. Record the transmitted RF power and frequency error from the analyzer display. Check
that the frequency is stable within a few tens of Hertz.
10.If frequency error exceeds +/- 200 Hz, adjust using the Frequency Up or Down button as
appropriate. Record the corrected value.
11.Click “Stop TX.”
12.Set the UUT rear panel High/Low switch to Low power.
13.Select TX Function “Random.”
14.Click “Start TX.”
15.Record the transmitted RF Power and modulation from the analyzer display. Observe the
demodulated waveform for anomalies.
17.Configure the communications analyzer to generate with no modulation at the frequency
shown in the RX column for Channel 0 in the configuration printout.
18.Set the generator amplitude to -120 dBm.
19.While observing the UUT RX LED, slowly increase the generator amplitude until the RX
LED illuminates. Record the amplitude and check that it is within +/- 2 dB of the
appropriate value for the current squelch setting.
Perform initial BER test

1. Run PDLCONF and connect to the UUT.
2. Select “Factory Defaults” and program the UUT.
3. Close the modem and exit PDLCONF.
4. Place the UUT in the BER Test Fixture and connect the Data/Power and RF connections.
Turn on the UUT. Close the test fixture’s shielded enclosure.
5. Run the BER test per procedure D00590 (Chapter 7.)
6. Save the resulting printout with the repair documents.
Evaluate and interpret test results

Failure of any of the above tests will indicate a direction for troubleshooting to proceed.
If the unit passes these tests, it may be necessary to look further for possible intermittent
conditions, or to contact the end user to obtain more information, such as operating conditions
when the failure occurs. In some cases the user settings may be incompatible with other units in
a system, or the problem may be caused by faulty antenna, batteries, or cables in the user’s
system.

Chapter 6
6 Maintenance and Repair
General maintenance and care
Consumables
Disassembling the unit
Disassemble front panel from enclosure
Disassemble AMPMOD from enclosure
Remove RFMOD from enclosure
Visually inspect seals
RFMOD test points
Possible failure causes
Unit won’t power up
No display or LEDs
No response to serial port
Synthesizer lock problems (E15, E16)
Low or no TX power
No power on high or low
No power on high, low power OK
Degraded or no RX
No RX LED, no data
RX LED normal, no data
Degraded sensitivity
Reassembling the unit
Check and position enclosure gaskets
Orient enclosure
Place board guides on RFMOD
Place front panel through enclosure
Insert RFMOD into enclosure
Assemble AMPMOD to enclosure
Assemble front panel to enclosure
Leak test
Final test
Connect to UUT
Perform bench tests
Perform BER test
Restore customer settings

Chapter 6
General maintenance and care
Consumables
Two removable seals (assembly drawing A02393, item 10, PCC p/n C01397) must be replaced
whenever the case bracket (item 9) is removed and re-installed, such as when performing the
leak test. These seals are intended for one-time use only.
The rubber “bumpers” (item 2, PCC p/n F00471) should be replaced if visibly worn or
deformed, or if the unit fails the leak test.
Disassembling the unit

The HPB is constructed of 3 major assemblies: Front Panel and I/O board, RFMOD board, and
AMPMOD assembly. With care, it is possible to remove these assemblies from the enclosure
without disconnecting any connections.

Chapter 6
Disassemble front panel from enclosure
Using a 3/32” hex driver, remove the 8 socket screws from around the perimeter of the front
panel.
The front panel should drop free of the rubber bumper. In some circumstances the panel may
stick to the bumper slightly. Use a fingernail or miniature screwdriver to loosen the panel.
Take care not to damage the panel or bumper. Avoid causing stress to the ribbon cable and
power/data cable attached to the I/O board.

Chapter 6
Disassemble AMPMOD from enclosure
Using a 3/32” hex driver, remove the 8 socket screws from around the perimeter of the
AMPMOD heat sink. Note that 4 screws are between fins of the heat sink.
The AMPMOD assembly should drop free of the rubber bumper. In some circumstances the
panel may stick to the bumper slightly. Grasp the heat sink fins and gently pull or tilt the
AMPMOD away from the bumper. Take care not to damage the heat sink or bumper. Avoid
causing stress to the cables attached to the AMPMOD.

Chapter 6
Remove RFMOD from enclosure
Move the AMPMOD 1-2 inches away from the enclosure. Tilt the front panel assembly away
from the enclosure to allow access to the RFMOD board. Carefully push the front edge of the
RFMOD using fingers only, so that the RFMOD moves slowly toward the rear of the enclosure.
As the RFMOD emerges from the rear of the enclosure, carefully tilt the front panel assembly
into the enclosure front. Avoid creating stress to the attached cables. Continuing in this way,
remove the RFMOD and feed the front panel through the enclosure. Be careful not to lose the
four rubber RFMOD board mounts.

Chapter 6

Chapter 6
Visually inspect seals

The 2 rubber bumpers have embossed ridges in the flat section (both sides) which are
compressed between the front panel or heatsink and the enclosure body. Check that these ridges
are smooth and undamaged, with no foreign matter attached. If any damage or foreign matter is
visible, replace the bumper.

Chapter 6
RFMOD test points
Test Point # Test Point Definition
TP1 E clock of microprocessor, 2.4576 MHz
TP2 TX data clock of GMSK modem IC
TP3 RXA analog voltage, post filter, for GMSK demodulation
TP4 TXA offset voltage from DAC, after scaling network
TP5 RX signal to noise value, post filter, of GMSK modem IC
TP6 TXA signal, post baseband filtering and offset voltage
TP7 RF Signal - 1st IF mixer output, before IF filter
TP8 RF Signal – 2nd IF signal from phase detector IC
TP9 RF Signal – 1st IF signal after IF filter

TP10 Steering voltage for receiver VCO
TP11 RF Signal – local oscillator for 2nd IF, fixed at 54Mhz
TP12 RXA analog voltage, before baseband filtering
TP13 +8V DC supply voltage from U4 pin 8
TP14 +5V DC supply voltage for digital section from U4 pin 1
TP15 RXA analog voltage, post filter, for 4LFSK demodulation
TP16 RX eye pattern test point for 4LFSK (enable with SETRXEYE command to view)
TP17 +5V DC supply voltage for analog section from U21 pin 1
TP18 +5V DC supply voltage for analog section (receive only) from U22 pin 1
TP19 +5V DC supply voltage for analog section (transmit only) from U23 pin 1
TP20 TP20 Received Signal Strength Indicator (RSSI), before scaling amplifier
TP21 PCNTL – analog voltage controlling AMPMOD RF power output
TP22 Transmit current sensor output (see schematic)
TP23 RFMOD temperature sensor output
Possible failure causes

This section lists possible causes for common failures. It is not possible to list all conceivable
failures or their causes. Any particular failure mode may have several possible causes. The
following information is intended as a general guide to troubleshooting. Use standard RF
troubleshooting techniques to locate individual failed components.
Make all possible observations before drawing conclusions that a part has failed. For example,
if the unit does not transmit, does it draw normal TX current, or not? If so, the RF amplifier
stages may be working, but RF power is not reaching the antenna port. If not, the problem lies
elsewhere.

Chapter 6
Unit won’t power up
No display or LEDs
• Open power connection
• Failed +8V regulator (U1 - A02388)
• Failed +5V regulator (U4 - A01655)
All display segments lit when power button held
• Corrupted firmware
• Failed microprocessor clock
• Failed microprocessor
No response to serial port

• Open serial port connection
• Failed U6 - A02388
• Failed U9 - A01655
Synthesizer lock problems (E15, E16)

• Reference oscillator failure
• Open feedback loop
• Flux contamination (VCO section)
• Failure of +5VRX or +5VTX (NOTE: firmware switches +5VTX off if TX lock not
detected within ~100 ms)
Low or no TX power
No power on high or low

• Open RF connection
• Failed Q1 - A01649
• Failed D4 - A01649
• No KEYAMP voltage from RFMOD
• No PCNTL voltage from RFMOD
No power on high, low power OK
• Failed Q2 - A01649
• Failed D3 - A01649
• Open connection to, or failed, HI/LO switch
WARNING – Pre-2003 units: If it is necessary to replace the AMPMOD in units manufactured prior to 2003
(A00936 AMPMOD) with a new A01649 AMPMOD, while retaining the unit's original A00938 family RFMOD, the
RFMOD must be modified to reduce its TX RF output power from 0.5 to 0.1 Watt. If this is not done, damage to
the replacement A01649 AMPMOD will occur. See the procedure D00744NR in Chapter 8 for instructions.
Likewise, if replacing an A00938 series RFMOD with a new A01655 family RFMOD, while retaining the unit's
original A00936 AMPMOD, the new A01655 family RFMOD must be modified to increase its TX RF output
power from 0.1 to 0.5 Watt. If this is not done, the AMPMOD will have extremely low or no RF power output. To

Chapter 6
perform this modification, remove R158 and R159 from the new A01655 RFMOD, and replace R160 with a short
wire jumper flush with the PCB.
Component level repair of A00936 AMPMOD assemblies in the field is not recommended. It is more cost
effective to replace the AMPMOD.
Degraded or no RX
No RX LED, no data
• Failed 2nd LO path (Q9 or Q8 - A01655)
• Failed U15 - A01655
• Failed 1st LO (U19 - A01655)
RX LED normal, no data
• RXA DC bias out of spec
• Failure in RXA path (U7 - A01655)
• Failed U3 - A01655 (GMSK) or U27 - A01655 (4LFSK)
Degraded sensitivity
• Failed U18 - A01655 (reduced gain) (NOTE: check D1 - A01655 and D8, C37 - A01649
to ensure failure does not recur)
• Alignment issues
Be aware that the above is only a brief outline of things to check when some possible failures
occur.
Reassembling the unit
Check and position enclosure gaskets

Ensure that the enclosure front and rear gaskets are clean and undamaged, or replace if
necessary. Place the gaskets on the front and rear openings of the enclosure. Be sure that they
are fully seated.
Orient enclosure
The location of the s/n label on the bottom side of the enclosure serves as a guide to proper
orientation. Place the enclosure, bottom side down, with the front facing left.
Place board guides on RFMOD

Place the 4 rubber board guides at the 4 corners of the RFMOD assembly.

Chapter 6
Place front panel through enclosure
Holding the front panel assembly at an angle, insert it into the rear of the enclosure and gently
“fish” the assembly through the enclosure to the front. Do not pull the front panel all the way
through the enclosure at this time. Be careful not to disturb any connections. It may be easier to
hold the front panel still while moving the enclosure around it.

Chapter 6
Insert RFMOD into enclosure
While the front panel assembly is partially out of the enclosure front, gently insert the 2 rubber
board guides at the front of the RFMOD into the enclosure channels. Be sure that the
power/data cable from the front panel assembly is routed below the RFMOD. Do not allow this
cable to become pinched.
Carefully push the RFMOD into the enclosure while gently moving the front panel assembly
through the enclosure front opening.

Chapter 6
When the 2 board mounts at the rear of the RFMOD reach the enclosure rear opening, ensure
that they enter the enclosure channel correctly.
Push the rear board mounts gently until the front board mounts are approximately 1/4” from the
enclosure front opening. Check that all board mounts are positioned correctly.
Assemble AMPMOD to enclosure

Carefully bring the AMPMOD assembly up to the rear of the enclosure. Orient the attached
cables so that they loop into the space above the RFMOD. Take care that no wiring can become
pinched. Insert the 4 “inner” screws into the holes between heat sink fins and partially tighten
so that the AMPMOD is “snug” to the enclosure. Insert the remaining 4 screws and tighten all
screws beginning with the center 4 and then the outer 4.

Chapter 6
Assemble front panel to enclosure
Carefully bring the front panel assembly up to the front of the enclosure. Orient the cabling so
that it cannot become pinched. Insert the screws and tighten to 8 inch-pounds torque.

Chapter 6
Leak test
Perform the leak test by performing the steps below, using the leak test fixture T00090. See
procedure D00603 (Chapter 7) for more details.
• Place transparent tape over the BNC connector and 2 of the 3 side mounting holes.
• Cover the 3rd side hole of the UUT with the suction cup of the fixture.
• Turn the air vacuum valve (on top of tester) CW to apply vacuum to the UUT.
• Turn the vacuum ON/OFF switch (on front of tester) to the “ON” position (left).
• While drawing a vacuum on the UUT, observe the system gauge reads > 15 in/Hg.
• Turn the vacuum ON/OFF switch to the “OFF” position (right).
• Start the stopwatch to begin a 15 second time period.
• If UUT drops below 10 in/Hg during the 15-second time period then the UUT fails.
• When the test is completed, replace the two screw seals (PCC p/n C01397) with new parts.
Insert the screws through the two end holes of the bracket, then place the seals on the
screw threads with the open edge facing away from the bracket (toward the HPB
enclosure.) Apply one drop of Loctite 242 to the threads of each screw. Attach the
bracket to the HPB enclosure, and tighten the two screws to 8 inch-pounds torque.

Chapter 6
Final test
This section describes the necessary tests to be performed when the HPB has been repaired and
reassembled, and before it is returned to the user.
Connect to UUT
1. Connect A00470 programming cable 2 pin SAE connector to power supply.
2. Connect A00470 DB-9 connector to T00018 adapter.
3. Connect T00018 adapter to PC serial port.
4. Connect A00470 5 pin Lemo connector to UUT Power/Data port.
5. Connect BNC RF cable to communications analyzer RF I/O port and to UUT antenna
connector.

3. On the Serial Interface tab, select Protocol “Packet Switched.”
4. Set port baud rate to 9600 with no parity.
5. On the Radio Link tab, select GMSK modulation.
6. Select Link Rate 9600 Baud (for 25 kHz units) or 4800 Baud (for 12.5 kHz units.)
7. Program these settings.
8. Disconnect from the modem by clicking "Close.".
Perform bench tests

1. Configure the communications analyzer to monitor at the frequency shown in the TX
column for Channel 0 in the configuration printout. Set the analyzer to display the
modulation scope.
2. Run PDLTEST.
3. Connect to the UUT by selecting the appropriate COM port.
4. Set the UUT rear panel High/Low switch to High power.
5. Select Modulation “GMSK” and Channel “Middle.”
6. Select TX Function “Carrier.”
7. Click “Start TX.”
8. Observe that the TX LED on the UUT front panel illuminates.
9. Record the transmitted RF power and frequency error from the analyzer display. Check
that the frequency is stable within a few tens of Hertz.
10.If frequency error exceeds +/- 200 Hz, adjust using the Frequency Up or Down button as
appropriate. Record the corrected value.
12.Set the UUT rear panel High/Low switch to Low power.
13.Select TX Function “Random.”
14.Click “Start TX.”
15.Record the transmitted RF Power and modulation from the analyzer display. Observe the
demodulated waveform for anomalies.

Chapter 6
17.Configure the communications analyzer to generate with no modulation at the frequency
shown in the RX column for Channel 0 in the configuration printout.
18.Set the generator amplitude to -120 dBm.
19.While observing the UUT RX LED, slowly increase the generator amplitude until the RX
LED illuminates. Record the amplitude and check that it is within +/- 2 dB of the
appropriate value for the current squelch setting.
Perform BER test

1. Run PDLCONF and connect to the UUT.
2. Select “Factory Defaults” and program the UUT.
3. Disconnect from the modem by clicking "Close" and exit PDLCONF.
4. Place the UUT in the BER Test Fixture and connect the Data/Power and RF connections.
Turn on the UUT. Close the test fixture’s shielded enclosure.
5. Run the BER test per procedure D00590 (Chapter 7.)
6. Save the resulting printout with the repair documents.
Restore customer settings

3. Refer to the user settings printed during “Setup and initial test” (Chapter 5.)
4. Restore each individual setting which has been changed to that shown in the original
printout, unless an invalid setting was determined to be the cause of the original failure.
5. Program the settings into the HPB.
6. Print the restored settings and memory map and file with other repair documents. Retain
for future reference.
The repaired HPB is now ready to be returned to the user.

Chapter 7
Adjustments and Verification
Adjustments
Frequency error
TCVCXO units (mid-2002 to current)
Discrete reference crystal units (mid-2002 and older)
Modulation balance adjustment
Modulation (deviation) adjustment
Receiver sensitivity confirmation
RXA bias adjustment
Performance verification
Factory test procedures
D00535 PROC,TEST,PDL,BASE,RFMOD
D00564 PROC,TEST,PDL,BASE,FINAL,35W
D00603 PROC,TEST,PDL,VACUUM
D00590 PROC,TEST,BER,MODEM TEST
This chapter describes the adjustments which may be necessary when performing repairs, as
well as the final tests which must be performed before the unit is returned to the customer.

Chapter 7
Adjustments
Unless otherwise stated, all adjustments are to be performed with the HPB in Packed Switched
protocol, with serial port set to 9600 Baud with no parity. Modulation type should be set to
GMSK at the highest available link rate.
Note – Except when making measurements of RF power output, it is best to keep the HPB
switched to low power via the rear panel switch for all adjustments and tests. This will avoid
potential overheating of both the HPB and power supply.
Frequency error
Frequency error should be checked any time a unit is serviced, and adjusted when the measured
error exceeds +/- 200 Hz.
TCVCXO units (mid-2002 to current)

• Set the communications analyzer to the frequency currently programmed into the HPB, in
monitor mode, with input from RF I/O.
• Connect the HPB antenna port to the analyzer RF I/O using the shortest practical 50 Ohm
coaxial cable. Connect the HPB serial port to the test bench PC serial port via the T00018
adapter.
• Run PDLTEST and connect to the HPB by selecting the appropriate serial port.
• Select “Carrier” in the TX function (Transmit block) of PDLTEST and click “Start TX.”
• Measure and record the frequency error as displayed by the analyzer.
• If the error is greater than +/- 200 Hz, adjust the error by using the Frequency Up/Down
buttons in the Adjustment block of PDLTEST.
• Program the new setting by using the “Program Adjustments” button of PDLTEST.
• Record the new frequency error after programming.
• When the adjustment is complete, stop transmitting by using the “Stop TX” button of
PDLTEST.
Discrete reference crystal units (mid-2002 and older)

• With the HPB disassembled, connect to the analyzer and serial port as described above.
• Run PDLTEST and connect to the HPB by selecting the appropriate serial port.
• Select “Clear” in the frequency adjustment block of PDLTEST.
• Select “Carrier” in the TX function (Transmit block) of PDLTEST and click “Start TX.”
• Measure and record the frequency error as displayed by the analyzer.
• If the error is greater than +/- 200 Hz, adjust the error by tuning VC3 on the RFMOD
using a non-metallic alignment tool.
• Record the new frequency error after adjustment
PDLTEST.
• Program the new setting by using the "Program Adjustments" button of PDLTEST.

Chapter 7
Modulation balance adjustment
Modulation balance should be checked if the transmitted modulation waveform is distorted, or
whenever components in the frequency synthesizer are replaced.
Set the communications analyzer to display the modulation oscilloscope.
• Run PDLTEST and connect to the HPB as described above.
• Select “Square” in the TX Function block of PDLTEST and click “Start TX.”
• The modulation scope should display a square wave of approximately 200 Hz.
• If the leading edge of the displayed square wave shows more than 10% overshoot or
undershoot, adjust the modulation balance by tuning R107 on the RFMOD with a small
non-metallic alignment tool.
PDLTEST.
• Check the modulation as described below and adjust if needed.
Modulation (deviation) adjustment

Modulation should be checked whenever the HPB is serviced and adjusted when out of spec. If
modulation balance adjustment is required, that must be performed first, and then modulation
adjustment should be performed.
Set the communications analyzer to display the modulation oscilloscope.
• Run PDLTEST and connect to the HPB as described above.
• Select “Random” in the TX Function block of PDLTEST and click “Start TX.”
• The modulation scope should display the transmitted random data.
• Measure and record the deviation as displayed by the analyzer. The current spec for
deviation is +/- 3.2 kHz for 25 kHz units, and +/- 1.6 kHz deviation for 12.5 kHz units.
• If the modulation is more than 0.2 kHz out of spec, adjust modulation by tuning R34 on
the RFMOD with a small non-metallic alignment tool.
• Measure and record the deviation as displayed by the analyzer.
Receiver sensitivity confirmation

This is a quick check to determine whether the receive sensitivity has been degraded by
component failure. Normally, if the HPB passes this quick check, and passes BER test in both
GMSK and 4LFSK, no adjustment should be required.
• With the HPB connected to the analyzer as described above, set the analyzer to generate
on the frequency programmed into the HPB.
• Vary the generated RF amplitude while observing the “RX” LED. Confirm that the RX
LED turns on within +/- 2 dB of the programmed digisquelch threshold (-114 dBm for
high sensitivity.)
• Confirm that the RX LED turns off when the generated amplitude is lowered 2 dB from
the above threshold.

Chapter 7
RXA bias adjustment
Checking and adjusting RXA bias should only be done if the HPB passes the above RX
sensitivity confirmation, but fails RX BER test. The frequency error adjustment above must be
performed prior to adjusting RXA bias.
• With the HPB connected to the analyzer as described above, set the analyzer to generate
with no modulation, at amplitude -80 dBm, on the frequency programmed into the HPB.
• Using a DMM, measure the DC voltage at TP3 on the RFMOD. The spec is 2.5 +/- 0.1
VDC.
• If the voltage is out of spec, adjust by tuning L6 on the RFMOD with a small non-metallic
alignment tool. Use extreme caution as the ferrite tuning core may be difficult to turn, and
is also brittle and easily damaged. The adjustment is quite sensitive, and requires a
delicate touch to perform correctly without damage to L6.
• Measure the DC voltage at TP15 and confirm that it is within +/- 0.1 VDC of the value
seen at TP3.
Performance verification
Perform the BER test as described in the procedure D00590 in this chapter. When the HPB
passes the BER test, and all the above parameters are within spec, performance verification is
complete. Print the BER test result, and file with the recorded values from above, with the
service documentation for the HPB.
Factory test procedures

The factory test procedures are included below for reference. It is normally not necessary to
perform these procedures when repairing the HPB. However, they may provide information
helpful in troubleshooting, and must be used to properly set up an UNTESTED replacement
PCB assembly. It is PCC’s intention to provide only TESTED replacement PCB assemblies.

PDL HPB RFMOD
D00535
TEST PROCEDURE
1. PURPOSE
This procedure is used to test and tune the RFMOD of the PDL base and match it with an
AMPMOD during manufacture or after repairs have been performed.
2. HISTORY
X01372 – July 26, 2000
X01403 – Sept 8, 2000
REV 08 - 430 Production release
Rev. 09 – ECN X01634
Rev. 10 – ECN X01639
Rev. 11 – Oct. 28, 2002, ECN X01753
Rev. 12 – ECN X01760
Rev. 13 – January 23, 2003, ECN X01713
Rev. 14 – Aug. 20, 2003, ECN X01874
Rev. 15 – October. 28, 2004, ECN X01963
Rev. 16 – October. 10, 2005, ECN X02118
3. REFERENCES
D00485 - SCHEM, PDL, BASE, RFMOD
D00560 – REP, TEST, PDL, BASE, RFMOD
A01649 – ASSY,HPB,AMPMOD,LDMOS,35W,410-470
4. REQUIRED EQUIPMENT
Communications Monitor (Motorola R2570A or equivalent)
Signal Generator (Tektronix CFG253 or equivalent)
DC Power Supply(12V,10A min.) with current meter (BK Model 1688 or equivalent)
Digital Volt Meter (HP34401A or equivalent)
Frequency Counter with 1X probe (Tektronix CMC251or equivalent)
Digital Oscilloscope – (TDS 340)
Personal Computer (PC) running windows 9X
Printer for the PC (HP 880C)
PDLCONF.EXE - factory version (current revision)
PDLTEST.EXE and C.EXE programs for modem test (current revision)
A00937 – ASSY,PDL,BASE,I/O INTFC
T00083 – TOOL,TEST,PDL,BASE,AMP SIMUL
T00084 – TOOL,TEST,PDL,BASE,EYE PATTERN GEN
T00038 – N to MCX cable (2 each)
T00076 - RF sniffer probe cable
Small (0.10”) flat head screwdriver (potentiometer adjusting tool)
Grounded probe for performing firmware loading (brain dead)
SINAD Audio filter and 1X probe
5. DEFINITIONS
UUT = Unit Under
Test DVM = Digital Volt Meter
TX DEVIATION = FM change in frequency measure 0 to Peak on a modulation scope.
Company Confidential Revision 16 Page 1 of 1

2005, Pacific Crest Corporation 10/10/2005
PDL HPB RFMOD
D00535
TEST PROCEDURE
6. PROCEDURE
6.1 Visual Inspection
Examine the UUT for visual defects. Look for missing components, wrong components, poor
solder joints, and damage that may have occurred in transit. Also look to verify the correct
assembly and revision.
RFMOD PCB No. E00050 Rev. 04 (Reference only)

PDL HPB RFMOD
D00535
TEST PROCEDURE
RFMOD Board (Reference only)
6.2 PCB Identification Sticker

Enter your initials, the date, frequency range, bandwidth, and status (New/Rework) of the UUT in
the appropriate spaces provided on the data sheet. On the bottom side of the UUT, attach a PCB
ID sticker with a bar code above J1. Record this number on the test report form.
6.3 Setup
Set the power supply to 13.6-13.8V DC.
Connect the configuration cable to the power supply.
Connect the other end of the configuration cable to the computer COM port.
Connect the UUT to the interface board (A00937) with the ribbon cable.
Connect the RFIO cable from the Communications Monitor to the receiver connector
labeled J3 (RFIN) of the UUT.
6.4 Load Firmware (brain dead)

Skip over this step if the firmware was previously loaded by an external supplier. The flash
memory IC (chip U10) will be identified with the firmware revision if this was done. If the revision
is old, use PDLCONF to upgrade to the current revision (this is faster). Verify that there is no
power being supplied to the UUT. The PC must be in DOS (full screen). Hold the ground probe
on the “BD” test point and apply power to the UUT. Remove the ground probe after this is done.
To load the firmware, type: BD Note: BD is a batch file that performs “BD-PDL <filename> <com
port = 1 or 2>”. The file name is the current revision of the .S19 file but you do not need to type
the extension. Do not run this software from Windows NT or 2000. It is recommended that you
close any other programs while loading firmware, especially GroupWise Notify, internet access or
other programs that may interrupt the processor.
Example: BD-PDL R938V607 2 (this loads R938V607.s19 into COM2) this process will take 45
seconds. Success will be indicated with the following:
P: . . . . .Done
V: . . . . . .Pass
Exit DOS by typing Exit. During the time that firmware is being loaded; proceed with procedure
steps 5.4 through 5.8. Indicate pass or fail on the report.
6.5 Configure the UUT
Turn OFF power to the UUT. From Windows (95, 98, NT or 2000), run the PDLTest program.

PDL HPB RFMOD
D00535
TEST PROCEDURE
The screen should appear like the one shown above.

Click on “Run PDLConf”. You will see a window popup asking if you want to program changes
before running PDLConf. Select "NO" at this time. The path for PDLConf.exe is: C:\program
files\pcc\factory\pdlconf.exe
Click "LOAD" and then apply power to the UUT when instructed by the screen prompt. A progress
bar will appear showing that the software is loading the current modem settings.
After the progress bar closes, click on the “Factory” tab and set the following (In Order):
• “Model” to “PDL Base”

• “Frequency” to desired range.
In the drop box for the choice of frequency range there are only three choices of 20MHz bands.
If the UUT is one of these bands, select the appropriate and click on "Set Factory Frequencies".
If the UUT is a 10MHz band, choose the band which it is a subset.
Example: If the UUT is a 450-460MHz or 460-470MHz unit, select 450-470MHz.
For these type of splits DO NOT Click "Set Factory Frequencies".
The frequencies will have to be entered manually from the frequency chart.
• “RF Power” to “35 Watts”
• “Channel Bandwidth” to 25 kHz
• Push the “Factory Initialize” button
• “Crystal” should be set to “None”
Push the “Clear User Fields” button.
For 10MHz band UUTs, use the frequency chart in Table 1 to enter the correct values.
• Push the “Set Factory Frequencies” button (only for 20MHz bands).
PDL HPB RFMOD
D00535
TEST PROCEDURE
• Push the “Program” button and answer “Yes” to the prompt After the Program progress bar
is complete push “Close” to prevent any further uploads or downloads to the UUT. The
PDLCONF program can be minimized at this time or the operator can push the “Exit” button to
exit the program. Indicate pass or fail on the report
TABLE 1: Frequency Chart
Channel Receive/Transmit Frequency Frequency Band Frequency
Frequency Band 410-430 430-450 MHz Band 450-470
MHz MHz
ch0 Middle Freq. 419.85 MHZ 439.85 MHz 459.85 MHz
ch1 Low Freq. 410.15 MHz 430.15 MHz 450.15 MHz
ch2 High Freq. 429.85 MHz 449.85 MHz 469.85 MHz
6.6 Verify 8V Supply

Turn on power to the UUT. Use the DVM to measure the 8V supply voltage at U4 pin 8 (TP13 on
fab revision 05 or higher). Indicate pass or fail on the report.
6.7 Verify 5V Digital
Measure the 5V regulator voltage at U4 pin 1(TP14 on fab revision 05 or higher). Indicate pass or
fail on the report.
6.8 Verify 5V Analog
Measure the 5V regulator voltage at U21 pin 1 (TP17 on fab revision 05 or higher). Indicate pass
or fail on the report.

PDL HPB RFMOD
D00535
TEST PROCEDURE
6.9 Verify +5VRX

Measure the 5V regulator voltage at U22 pin 1 (TP18 on fab revision 05 or higher). Indicate pass
or fail on the report.
6.10 Verify +5VTX
Run PDLTEST, select “Middle” channel, “Carrier Only” TX functions and push “Start TX” the
“Start TX” button. When done, push “Stop TX”. Measure voltage at TP19. Indicate pass or fail on
the report.
6.11 E-Clock Frequency
Use the frequency counter to measure the frequency at TP1. Indicate pass or fail on the report.
6.12 Frequency Error (using local oscillator leakage)
Configure the Communications Monitor to receive at the mid frequency of the desired band and
select the “ANT” port for the RFIO. Place the sniffer probe (cable T00076 - connected to the
antenna input port of the communications monitor) next to the mixer (U16) of the UUT. Run
PDLTest. Adjust frequency error valueusing UP and DOWN buttons. Table 2, shown below,
displays a list of LO frequencies for the mid frequencies of the various bands. Indicate pass or fail
on the report.
TABLE 2: LO Frequency Chart
6.13 RXA dc level

Configure the RF control of the communications monitor to GENERATE at mid frequency with no
modulation, set output power to -80 dBm via the RFIO port. Run PDLTEST, and click on mid
channel and ensure that the RFMOD is in receive mode. Adjust the variable inductor L6 while
reading the RXA voltage at the test points labeled TP3 and TP15 until the specified value is
achieved. Indicate pass or fail on the report.
6.14 IF Filter Tuning
Connect one end of a coaxial cable to the RFIO port on the Communications Monitor and the
other end to the Ant. Port of the UUT. Attach the Audio Filter and 1X probe to the SINAD port of
the Communications Monitor. Attach the RF sniffer coil (T00076) probe to the antenna port of the
Communications Monitor. Connect the output of the Signal Generator to the SQUARE WAVE IN
port on the Eye Pattern Generator (T00084).Connect the SYNCH OUT port on the Eye Pattern
Generator to the External Sync input on the Oscilloscope. Connect the MOD OUT port of Eye
Pattern Generator to the EXT MOD IN port of the Communications Analyzer. With the toggle
switch on the Eye Pattern Generator in the “Square Wave” position, set up the Signal Generator
to output a 1 kHz square wave and adjust the amplitude until a 4kHz deviation (8kHz p-p) trace is
viewed on the modulation scope display of the Communications Monitor Be sure that “External”
(in the Audio section of the cursor control of Communications Monitor) is set to Continuous (on) to
enable external modulation. Increase the generator power level to –80 dBm. Enable the EXT
MOD IN port being driven by the Signal Generator by pushing the “Cont.” (on) button in the Audio
section for the “External” setting on the Communications Analyzer. Confirm that the deviation of
the generated signal is correct for the BW of the UUT (12.5kHz or 25kHz RFMODs).

PDL HPB RFMOD
D00535
TEST PROCEDURE
Square Wave Method

Coarse tuning of the IF filter will be done with a square wave signal. Confirm that the toggle
switch on the Eye Pattern Generator is in the “Square Wave” position. On the UUT, adjust
variable capacitors VC1, VC4, and VC5, for the best square wave pattern by placing the
Oscilloscope probe on TP12. The square wave must be symmetrical and ripple after the single
overshoot peak is to be minimized. The rise time should be maximized.
On the PDLTest screen click on 4LFSK. Turn the toggle switch on the Eye Pattern Generator to
the “Eye Pattern” position. Make sure an eye pattern has maximized openings in the three level
crossing areas. Indicate pass or fail.
GOOD 4LFSK EYE PATTERN BAD 4LFSK EYE PATTERN

PDL HPB RFMOD
D00535
TEST PROCEDURE
6.15 CD Level Setting

Run the PDLTest program and click on Run CDLev, It will launch the CDLev program Click on
“Load” button. Set the communications monitor to generate at mid frequency
with an output power of –116dBm through the RFIO port. Push "Start Test" on the computer
screen and change the output power level when instructed. Fail unit if any level value is FF or if
the standard deviation of any measurement is higher than 5. Attempt to retest any bad data
points. The graph shown by CDLEV3 should approximate a straight line. Confirm that the "RX"
LED illuminates at the RF signal level for High Digisquelch. On completing the test Push the
“Program” button followed by the “Close Modem” button. Indicate pass or fail on the report.
6.16 12dB SINAD – middle frequency
*Note: All SINAD measurements should be done without the external Audio Filter.
The Communications Monitor should continue to generate at Middle frequency. With the AUD
screen, configure the Communications Monitor to generate a 1kHz sine wave with 3kHz of
deviation turned "on". With the DISP screen of the Communications Monitor, select SINAD
mode. Run PDLTEST, Push “Stop TX” (confirm not transmitting) and select “Middle” channel.
Place the SINAD probe at TP3 of the UUT. With the RF screen of the Communications Monitor,
lower the output power until a 12dB SINAD reading is obtained. Indicate pass or fail on the report.
6.17 12dB SINAD – low frequency

Change the frequency of the communications monitor to low frequency of the band. On the
PDLTEST screen, select “Low” channel. Adjust the output power of the Communications Monitor
until a 12dB SINAD reading is obtained at TP3. Indicate pass or fail on the report.
6.18 VCO Control RL
Without disturbing the above setup measure the VCO control voltage at TP10. Record the result
on the report. If the result is higher then min go to the middle frequency and adjust using VC6.
6.19 12dB SINAD – High frequency

PDL HPB RFMOD
D00535
TEST PROCEDURE
Change the frequency of the communications monitor to high frequency of the band. On the
PDLTEST screen, select “High” channel. Adjust the output power of the Communications Monitor
until a 12dB SINAD reading is obtained at TP3. Indicate pass or fail on the report.
6.20 VCO Control RH
Without disturbing the above setup measure the VCO control voltage at TP10. Record the result
on the report. If the result is lower then max go to the middle frequency and adjust using VC6.
6.21 TX RF Power Adjustment and Current Measurement
Connect the Amplifier Simulator (T00083) to the UUT at this time. Change the Communications
Monitor to MONITOR mode and select RF DISPLAY for the Display Meter and MODULATION
SCOPE for the display options. Move the RFIO cable from J3 (RFIN) to the bottom side of the
UUT to J4 (RFOUT).
Run PDLTest program. Set the communications analyzer to Monitor at the middle frequency. On
the PDLTest screen click on GMSK modulation, middle channel, Random Data for TX function
and click on start Tx. While transmitting, adjust VC2 until the RF power value is maximized.
Note: if the RFMOD board is a A01655, A01656 or A01657 assembly there is no
potentiometer to adjust and R160 (an 0805 component) must change for adjustments.
Increase Increase Nominal Decrease Decrease Decrease
RF 20% RF 10% Value RF 10% RF 20% RF 30%
R160 10O 13.3O 18.2O 22O 33O 51O
C00553 C02036 C02006 C02001 C00516 C00555
Record New resistor values (other than the original value) on the bottom of the report.
If more TX power is needed, remove C130 (450-470 MHz) and change the value of R160 again.
6.22 TX Current Measurement

Monitor supply current with the meter on the power supply. Indicate pass or fail on the report.
.
6.23 Square Wave – Middle Frequency: Tune for Modulation Balance
Run PDLTest program. Set the communications analyzer to Monitor at the middle frequency. On
the PDLTest screen click on GMSK modulation, middle channel, Square Wave for TX function
and click on start Tx. Tune the square wave for Modulation Balance by tuning R107. Tune R107
(TX modulation balance) for a flat square wave response with little or no overshoot and no ripple.
Stop Transmission by clicking on Stop Tx. Indicate pass or fail on the report.
6.24 Tune for Deviation
Make an initial adjustment of the deviation to 4 kHz (2kHz if this is a 12.5kHz channeled radio)
with potentiometer R34 on the UUT. Tune R34 for the required Deviation. Stop Transmitting
when done. Indicate pass or fail on the report
6.25 RF Power – Middle Frequency
Measure the RF output power at Middle Frequency. Record the value on the report.

PDL HPB RFMOD
D00535
TEST PROCEDURE
6.26 Square Wave - Low Frequency

Set the communications monitor to receive at ch1 (preset 01). Run PDLTEST, select “Low”
channel. Check the square wave response, DO not make any adjustments. All adjustments
to be made at mid frequency ONLY. Indicate pass or fail on the report.
6.27 RF power – Low Frequency

Measure the RF output power at Low Frequency. Record the value on the report.
6.28 TX VCO Control Voltage – Low Frequency

Use the DVM to measure the TX VCO control voltage at low frequency on TP10. Record the
result on the report. If the result is higher then min go to the middle frequency and adjust
using VC7.6.29 Square Wave - High Frequency
Select ch2 (preset 02) for high frequency. Run PDLTEST, select “High” Channel. Check for the
proper square wave response. DO not make any adjustments. All adjustments to be made at
mid frequency ONLY. Indicate pass or fail on the report.
6.30 RF power – High Frequency

Measure the RF output power at High Frequency. Record the value on the report.
6.31 TX VCO Control Voltage – High Frequency

Use the DVM to measure the TX VCO control voltage at high frequency on TP10. Record the
result on the report. If the result is lower then max go to the middle frequency and adjust using
VC7.
GMSK, BT = 0.5
"Keep Out" zones
6.32 Transmitter Eye Pattern

Use the digital oscilloscope to display the Modulation Output signal from the Communications
Monitor. Refer to the figure for an ideal, fully open, GMSK eye pattern. Indicate pass or fail on
the report.
6.33 High Low Switch

Toggle the High Low control switch and confirm that the LED on the front panel toggles also.
Indicate pass or fail on the report.

PDL HPB RFMOD
D00535
TEST PROCEDURE
6.34 Verify Temperature Circuit

On the PDLtest screen click on Temperature and look at the value that comes up on the
comments section of the screen. Indicate pass or fail on the report.
6.35 Verify KEYAMP
On the PDL Test screen click on random data and click on start Tx. And verify that the KEYAMP
indicator on the amplifier simulator is ON during transmission. Indicate pass or fail on the report.
6.36 Verify Power Control Circuit
While still transmitting, use the DVM to measure the voltage at TP21 to confirm that the current
sensor is working properly. Click on stop Tx to stop transmission. Indicate pass or fail on the
report.
6.37 Attach AMPMOD
Remove the AMPMOD simulator and attach the AMPMOD that will ship with this RFMOD.
Connect the antenna port to the RFin port of the modulation analyzer. Record the serial number
of the AMPMOD on the test report.
6.38 RF Low Power, Middle Frequency
Run PDLTest and select Modulation: GMSK, Channel: mid and Transmit: Carrier. Make sure
your high/low switch is set to Low. Then click on Start Tx. Observe the output power. Tune VR1, if
required, to get an output power of 2.5W. Remember that the voltage at TP1 cannot be lower
than 1.1V and cannot exceed 1.75V.
6.39 RF Low Power, Low Frequency
Run PDLTest and select Modulation: GMSK, Channel: Low and Transmit: Carrier. Make sure
required, to get an output power of 2.5W. Remember that the voltage at TP1 cannot be lower
than 1.1V and cannot exceed 1.75V.
6.40 RF Low Power, High Frequency
Run PDLTest and select Modulation: GMSK, Channel: High and Transmit: Carrier. Make sure
required, to get an output power of 2.5W. Remember that the voltage at TP1cannot be lower than
1.1V and cannot exceed 1.75V.
6.41 RF High Power, Middle Frequency

Run PDLTest.exe and Select Channel: Mid, Transmit: carrier, and click on start Tx. Observe the
output power on the modulation analyzer. Tune VR2 (between 2.05V - 2.1V) to achieve the
targeted output power of 35W +/-4W. Do not exceed 2.1V at TP2.
Click on stop Tx. to stop transmission. In case you are not able to set the output power within the
range specified, go back to section 6.38.
6.42 RF High Power, Low Frequency

Run PDLTest.exe and Select Channel: Low, Transmit: carrier, and click on start Tx. Observe the
targeted output power. Do not exceed 2.1V at TP2.
PDL HPB RFMOD
D00535
TEST PROCEDURE
range specified in the test report, go back to section 6.39. Also make sure that you do not violate
the low and high power max. and min. spec. as specified in the test report.
6.43 RF High Power, High Frequency

Run PDLTest.exe and Select Channel: High, Transmit: carrier, and click on start Tx. Observe the
targeted output power. Do not exceed 2.1V at TP2.
range specified in the test report, go back to section 6.40. Also make sure that you do not violate
the low and high power max. and min. spec. as specified in the test report.
Verify the above 5 steps if any adjustment was made to VR1 or VR2.
6.44 Tx. Spurs and DC current
Connect the antenna port of the AMPMOD to port J2 of the 30 dB coupler. Connect J1 to the
Communications Monitor, Connect J3 to a 50ohm load and connect J4 to the HP8591 Spectrum
analyzer. Run PDLtest.exe and transmit carrier at mid frequency. Observe the spectrum on the
spectrum analyzer. Confirm that no out of band oscillations are higher than 6 divisions during the
high RF power measurements. Indicate pass or fail on the test report.
Also observe the dc current drawn on the power supply. Note down the value in the test report.
Repeat the test for low and high frequency's.
6.45 RX Reflected Power

With the same setup as above connect the ampmod mcx-rx port J4 to a bird watt meter with a
500mW sensor in it. Connect the other end of the watt meter to a 50ohm load.
Run PDLtest.exe and set it to transmit a carrier at mid frequency.
Read the RX reflected power on the Bird Watt meter and record the
average RX Reflected power on the report sheet. Repeat the test at low and high frequency.
Package RFMOD
Turn off power to the UUT. Review test sheet for completeness and accuracy. Indicate the unit
test status by marking the report. Sign the test report. Leave the AMPMOD connected and place

PDL HPB RFMOD
D00535
TEST PROCEDURE
the RFMOD UUT in an electrostatic bag for safe storage.
7. TEST POINT LOCATIONS

The table and illustration below is of revision 05 of the fab. Older revisions will not correspond.
Test Point # Test Point Definitions
TP1 E clock of microprocessor, 2.4576 MHz
TP2 TX data clock of GMSK modem IC
TP3 RXA analog voltage, post filter, for GMSK demodulation
TP4 TXA offset voltage from DAC, after scaling network
TP5 RX Signal to Noise Value, post filter, of GMSK modem IC
TP6 TXA signal, post baseband filtering and offset voltage
TP7 RF Signal - IF Mixer output, before IF filter
TP8 RF Signal – 2nd IF signal from phase detector IC
TP9 RF Signal – IF signal after IF filter
TP10 Steering voltage for receiver VCO
TP11 Local Oscillator for 2nd IF, fixed at 54Mhz
TP12 RXA analog voltage, before baseband filtering
TP13 8V DC supply voltage from U4 pin 8
TP14 5V DC supply voltage for digital section from U4 pin 1
TP15 RXA analog voltage, post filter, for 4LFSK demodulation
TP16 RX Eye test point for 4LFSK (must enable with SETRXEYE command to view)
TP17 5V DC supply voltage for analog section from U21 pin 1
TP18 5V DC supply voltage for analog section (receiver only) from U22 pin 1
TP19 5V DC supply voltage for analog section (transmit only) from U23 pin 1
TP20 Received Signal Strength Indicator (RSSI), before scaling amplifier
TP21 Voltage for Power Control Circuit
TP22 Transmit current voltage sensor output (see schematic)
TP23 Temperature Sensor output

PDL HPB RFMOD
D00535
TEST PROCEDURE

PDL HPB Final Test
D00564
Procedure
1. PURPOSE
This procedure is used to test and tune the PDL High Power Base FINAL assembly.
2. HISTORY
Nov. 15, 1999 – Initial release
Nov. 18, 1999 – Revised spec
Jan. 27, 2000 – Changed test frequencies to reflect current defaults
Nov. 8, 2001 – Rev. 04 Revised spec Show use of PDLTEST
Feb. 4, 2002 – Rev. 05, X01634
Mar. 19, 2002 – Rev. 06, X01639
Oct 28, 2002 – Rev 07, X01753
Feb 25,2003 – Rev 08, X01811
Rev 09 – 18-Apr-03 – X01802
Rev 10 – 30-Jul-2003 – X01830
3. REFERENCES
D00563 – REP,TEST,PDL,BASE,FINAL,35W
D00603 - PROC,TEST,PDL,VACUUM
D00590- PROC,TEST, BER, MODEM TEST
D00670 – PROC,HPB LDMOS AMPMOD TEST
D00671 – REP,HPB LDMOS AMPMOD TEST
Communications Monitor (Motorola R2570A or equivalent)
DC Power Supply(12V,2A min.) with current meter (BK Model 1688 or equivalent)
Personal Computer (PC) running windows 9X
Printer for the PC (HP 880C)
PDLCONF.EXE - factory version (current revision)
PDLTEST.EXE and C.EXE programs for modem test (current revision)
Data/Power cable (A00470)
BNC(M) to BNC(M) RF Cables
30dB attenuator
HP8591A Spectrum Analyzer
5. PROCEDURE
5.1 Attach the UUT
Connect the UUT to a data/power cable. Connect the antenna port of the UUT to the RFIO
connector of the communications monitor. Run PDLTEST with the UUT in packet switched
mode.
5.2 Verify PWR LED and Displayed Channel

Turn on power to the UUT. Confirm that the correct channel is displayed and the PWR LED is
functioning properly. Indicate pass or fail on the report.
Company Confidential Rev 10 Page 1 of 3

2003, Pacific Crest Corporation 30-Jul-03
PDL HPB Final Test
D00564
Procedure
5.3 Frequency Error – Low RF Power

Configure the Communications Monitor to receive at the Local Oscillator frequency corresponding
to middle test frequency. Use PDLTEST to adjust the frequency error of the UUT to within the
specified range. Program the modem. Indicate pass or fail on the report. The table below
displays a list of Local Oscillator frequencies for the select bands.
TABLE : Local Oscillator Frequency Chart
Frequency Band: 410-430 MHz 430-450 MHz 450-470 MHz

Local Oscillator: 474.30MHz 494.30 MHz 514.30 MHz
5.4 TX LED
While transmitting, confirm the TX LED is functional. Indicate pass or fail on the report.
5.5 Verify TX Performance - Middle Frequency

Configure the communications analyzer to monitor the middle test frequency. Use PDLTEST to
select middle test frequency and Random Data for the UUT. Observe and record the results of
the following parameters while transmitting:
• RF output in the LOW power setting
• RF output in the HIGH power setting
• Deviation in the HIGH power setting
• DC Current in the HIGH power setting
5.6 Verify TX performance - Low Frequency

Configure the communications analyzer to monitor the low test frequency. Use PDLTEST to
select low test frequency and Random Data for the UUT. Observe and record the results of the
following parameters while transmitting:
5.7 Verify TX Performance - High Frequency

Configure the communications analyzer to monitor the high test frequency. Use PDLTEST to
select high test frequency and Random Data for the UUT. Observe and record the results of the
following parameters while transmitting:
5.8 CD Level
The Base will be in the high (factory test default) digi-squelch setting. Set the communications
analyzer to generate at the middle test frequency. Configure the modem to RX at the middle
frequency and verify that the RX LED comes on at the correct generator output level. Perform
CDLEV again if required. Indicate pass or fail on the report.

PDL HPB Final Test
D00564
Procedure
5.9 BER
Perform the BER test and print the results. Indicate pass or fail on the report.
5.10 Leak Test

Perform the leak test. Indicate pass or fail on the report. Attach the side mounting bracket to the
case after the leak test has passed.
5.11 PDLCONF
Run PDLCONF, install Default (or OEM Specific as appropriate) Settings and load any customer
requested frequencies if specified on the Sales Order. Program and print the configuration.
Indicate pass or fail on the report.
5.12 Package the modem

Turn off power to the UUT. Confirm that the serial number on the label matches the PDLCONF
printed value. Indicate pass or fail on the report. Attach all of the report sheets together for the
modem with the PDLCONF printout on the top and file by serial number.

Vacuum Test
D00603
Procedure
1. PURPOSE
The purpose of this procedure is to provide a standardized environmental test method for testing the EDL2, PDL
HPB, LPB and Rover,PDL450 and Sitecom.
2. HISTORY
March 3, 2001 – Rev 01 – initial release
October 18, 2001 – Rev 02 – revised for new equipment
October 17, 2003 – Rev. 03 – added GFU15
July 20, 2005 – Rev 04 – add EDL2,PDL450,Sitecom
T00090 – Vacuum Test System, PDL/LPB
T00091 – Stop Watch
Regulated Air Pressure
4. PROCEDURE
4.1 Visual Inspection
HPB Model:
Socket head cap screws all installed and tightened
Front panel overlay installed and uniformly applied
LEMO connector is tightened on the back panel (heat sink)
Front and back gaskets are properly installed
Toggle switch rubber boot is not torn
EDL, LPB and Rover Models:
Socket head cap screws all installed and tightened
Antenna connector on top cap has Teflon tape
Front overlay is properly installed
Gaskets are seated properly
Test Station:
Sealing the suction cup against a flat test surface (e.g. the counter) should “pass”
4.2 Testing the HPB Model

• Place transparent tape over the BNC connector and 2 of the 3 side mounting holes.
•
rd
Cover the 3 side hole of the UUT with the suction cup of the fixture.
4.3 Testing the LPB or Rover Model

• Cover the hole in the bottom end cap of the UUT with the suction cup of the fixture.

Vacuum Test
D00603
Procedure

4.4 Testing the GFU15 (SEE PHOTO BELOW)
• Cover the vent hole in the bottom end of the UUT with the suction cup of the fixture.
If UUT drops below 5 in/Hg during the 10-second time period then the UUT fails.
4.5 Testing the EDL2, PDL450, Sitecom

• Cover the hole in the bottom end cap of the UUT with the suction cup of the fixture.
4.6 Record the results

• Record the results of the vacuum test on the final test report.

BER TEST
D00590
PROCEDURE
1. PURPOSE
This procedure is defines how to perform Bit-Error-Rate (BER) testing on Pacific Crest
manufactured Radio Modems. The BER test system is used as a final test to verify radio data
modems can transmit and receive without errors.
2. HISTORY
Oct 3, 2000 – First Draft
May 22, 2001 – Update calibration section
Dec.17, 2001 – ECN X01634 Rev. 03
July 10, 2003 – ECN X01861, Rev. 04, add the LPB settings
Jan 28, 2005 – ECN X02042, Rev. 05 update procedure.
April 29, 2005 – ECN X02056, Rev 06
3. REFERENCES
D00832 PROC,BER,PC,CONFIGURATION
D00836 PROC,BER,MOD/DEMOD,ASSY
T00075.DDB All Document Database for BER Test System
T00075xx.doc TOOL,BER,MOD/DEMOD,SYSTEM
5. PROCEDURE
5.1 Automated (PDL) Test
Testing PDL modems is almost fully automated. The UUT must be configured in advance (using
PDLCONF) with “Factory Defaults”. This configures the modem to be in Transparent Mode with
EOT Timeout, Digi-Squelch set to HIGH, data SCRAMBLING and FEC both turned ON. The test
will be performed at the frequency that is programmed in channel 0 of the UUT
Place the UUT in the chamber and attach the RF cable and the serial power cable to the UUT.
Make sure the UUT has power appied to it and is turned on. Close the chamber. Make sure the
TX/Manual / RX/Auto switch is in Auto. Set the 25 KHz / 12.5KHz Bandwidth switch to the correct
transmit bandwidth of the UUT.
Double click on the “BERTEST” icon located on the desktop.
NOTE: if testing LPB or EDL with 10MHz bands, double click on the “10MHz BERTEST” icon.
When the screen opens, click on the “UUT Loaded” button to start the process. This button will use
a soft break to acquire the UUT configuration data. This data will be used by the system to
automatically configure the UUT and the BER test system (T00075).
Click on the “Test Sequence” button to perform the automated testing of the UUT. The results will
print automatically.

©2005, Pacific Crest Corporation 04/08/05
BER TEST
D00590
PROCEDURE
NOTE: if individual test sequences are required to be run (usually for diagnosic purposes) press
the “Single Test” button and then select any single sequence from the pull down menu. If a printout
of these results is desired, click on the “Print” button.
The BER test will “PASS” if 0 errors are detected in the first run. If a single error is detected in the
1rst run, and the UUT is tested again immediately and passes on the 2nd run, this is a “PASS”.
NOTE: the specification is 1 error allowed in 100k bits. Each run is approximately 50k bits.
6. SEQUENCE DEFINITIONS (REFERENCE)

MDMCMD BERCMD BERTEST
UUT and Silver Box
Seq 12.5k 25k 12.5k 25k
# Mod Link Link RS232 SW RF Freq Dev. Dev. Scenario
Type Rate Rate dBm Offset kHz kHz (filename)
0 GMSK 4800 9600 38400 RX -109 0 2 4 sc0.sco
1 GMSK 4800 9600 38400 TX +7 54.45 0 0 sc1.sco
2 4LFSK 9600 19200 38400 RX -105 0 2 4 sc0.sco
3 4LFSK 9600 19200 38400 TX +7 54.45 0 0 sc1.sco
4 GMSK 4800 9600 9600 RX -109 0 2 4 sc2.sco
5 GMSK 4800 9600 9600 TX +7 54.45 0 0 sc3.sco
6 GMSK 4800 9600 38400 RX -107 0 2 4 sc0.sco
7 GMSK 4800 9600 38400 TX +7 54.45 0 0 sc1.sco
8 4LFSK 9600 19200 38400 RX -103 0 2 4 sc0.sco
9 4LFSK 9600 19200 38400 TX +7 54.45 0 0 sc1.sco
10 GMSK 4800 9600 9600 RX -105 0 2 4 sc2.sco
7. TEST DEFINITIONS (REFERENCE)

Model: First Second Third Fourth
PDL HP BASE 3 2 1 0
PDL ROVER 2 0
PDL LP BASE (20MHZ) 9 8 7 6
RFM96W 4 5
PDL RXO 2 0
RFMRXO 10
EDL (20MHZ) 9 8 7 6
PDL LP BASE (10MHZ) 7 6

EDL (10MHZ) 7 6
8. CALIBRATION
A low amplitude RF signal is used to test the receiver. If this RF signal amplitude is too high,
receivers will easily pass the test but they may not perform well for our customers. If the RF signal
amplitude is too low, receivers will fail when they should have passed. This procedure is used to
measure the RF signal loss as it passes through the various connectors and switches in the “silver
box” and the loss through the RF attenuators that are inside the RF test chamber. This procedure

BER TEST
D00590
PROCEDURE
measures the loss in the RF signal path from the RF generator to the receiver under test. The loss
measurement is used as a variable in the test software. The software calculates the correct RF
signal amplitude to compensate for the “path loss”. The result is that an accurate RF amplitude
(signal level) is applied to the receiver under test
Monthly calibration of the test set is required to assure uniform results. Cables and connectors will
wear out with repeated usage and should be replaced accordingly. The BER test system should
also be calibrated when any part of the test set or cables are modified or changed.
A communications monitor (Motorola R2670 or equivalent) will be used to record the low power
levels produced by the BER test system. Before proceeding, confirm that an external standards
laboratory has calibrated the communications monitor within the last 12 months.
8.1 Attach Communications Monitor

Inside the Shielded Test Chamber is a coaxial cable that normally connects the output of the 50dB
fixed attenuator of the test system to the UUT as shown. For the purpose of calibration only,
disconnect this coaxial cable from the UUT and connect it instead to the ANTENNA input port on
the communications monitor.
8.2 Configure Communications Monitor

Configure the communications monitor (in the “RF Control” area of the display) for “MON” mode at
a frequency of 460.000 MHz. Select the “ANT” port for the monitor input. Set attenuation to 0 dB.
Select "Spectrum Analyzer" in the "Display" area.
8.3 Configure RF generator

Press "Local" on the HP8648A RF generator and set frequency to 460.000 MHz, amplitude to
0dBm, and modulation "off" via the appropriate front panel keys.
8.4 Configure BER test fixture

Run PDLCONF on the BER test computer and select serial port COM1. Load settings from the
BER test fixture "silver box" on COM1. On the "Serial Interface" tab within PDLCONF, select 9600
Baud and Packed Switched mode. Program these settings and exit PDLCONF.
Place the "silver box" in TX mode by running PDLTEST, selecting COM1, and selecting "Carrier"
and "START TX."
8.5 Make the Calibration Measurement

Observe that the signal is present in the spectrum analyzer display. A measured signal level of
between –53 and –57 dBm should be displayed on the numeric display of the communications
monitor. Variations will exist due to differences between communications monitors as well as all
the sum of the specific losses of the particular BER Test System being calibrated. Record the
calibration measurement reading to the nearest 0.1dBm. If this calibration measurement produces
a reading that is outside of this expected range then it is likely that the BER Test System, or a
coaxial connection, has become damaged and must be repaired before this system can be used.
This newly measured attenuation value is used to calculate how much power the HP8648A signal
generator must put out in order to achieve the net desired test power level at the UUT.

BER TEST
D00590
PROCEDURE
The equation to do this is as follows:
(Desired Test Level Power) + (Measured Attenuation) = (Commanded Power at HP8648A)
For example, assume the calibration procedure (step 5.3 above) produced a level of -55.6 dBm on
the communications monitor in response to a 0 dBm input signal from the HP8648A signal
generator. This means the BER system has 55.6 dB of total attenuation.
If a desired test level of –109 dBm is required to test GMSK, then an output power of –109 dBm +
55.6 dB = -53.4dBm must be commanded as the output level of the HP8648A when testing GMSK.
Similarly, if –105 dBm is required to test 4LFSK, then –105 dBm + 55.6 dB = -49.4 dBm must be
commanded as the output level for testing 4LFSK. The software must be updated accordingly.
8.6 Apply the Calibration Measurement

. After recording the newly measured attenuation value, the file "BEREXEC.INI" must be updated
accordingly so that the correct levels of RF power will be generated into the UUT.
To update the file, right-click on the icon for BEREXEC.EXE and select "Properties." In the
Properties window, select "Find Target" and an Explorer window will open into the folder where
BEREXEC is installed, with BEREXEC.EXE highlighted.
Scroll through this window to locate BEREXEC.INI. Right-click BEREXEC.INI and select "Open."
Locate the line "<station-cal>" and check the calibration number contained within this line. If this
number is the same as the attenuation value obtained in step 8.5, the calibration has not changed.
If the new attenuation value is different than that contained in the line "<station-cal>" then change
this number to the new value.
Note that discrepancies of more than 1 dB from a known good previous calibration may indicate
problems with the system, such as faulty cables, which should be repaired or replaced and the
calibration sequence repeated.
SEE THE SAMPLE BERECEC.INI FILE ON THE NEXT PAGE.

BER TEST
D00590
PROCEDURE
8.7 Re-configure BER test fixture for normal operation
Within PDLTEST, select "STOP TX." Exit PDLTEST and run PDLCONF. Connect to the "silver
box" on COM1, select "Factory Defaults", program the "silver box", and select "Close" to
disconnect from the "silver box." While still in PDLCONF, select serial port COM2. Exit
PDLCONF.
8.8 Record calibration results
Use the form on the last page of this procedure to record the date, technician's initials,
communications monitor serial number, calibration measurement, and any comments.

BER TEST
D00590
PROCEDURE
9. BER SYSTEM CALIBRATION LOG

The following form should be used to record the results of the monthly calibration process. The
data should be stored, and made available, in accordance with Preventative Maintenance SOP
D00264.
Date Technician Com Mon SN Attenuation (dB) Notes:

Chapter 8
8 Assembly Drawings & Schematics
List of drawings
Drawings
This chapter provides the assembly and schematic drawings for the PDL HPB. The assembly
drawings show the top level (finished goods) assembly, and component locations for all sub-
assemblies. Each sub-assembly has its own assembly and schematic drawings.
For current assemblies, these are the current revision drawings as of publication of this manual.
Drawings for obsolete assemblies are the last released version. For prior revisions of drawings,
contact Pacific Crest.
The drawings have been scaled to fit the pages of this manual. Use the “zoom” function of your
PDF reader to see more detail, especially in schematic diagrams.
Some drawings originally contained bills of materials as additional pages. These BOM pages
have not been reproduced here, as the information is contained in the tables in Chapter 10.

Chapter 8
List of drawings
Drawing No. Document name Notes
A02393 ASSY,PDL,HPB,35W,450,25K,AUTO,PWR,ON Top level assembly
A01649 ASSY,HPB,AMPMOD,LDMOS,35W,450 AMPMOD assembly
A01611 ASSY,PCB,HPB,AMP,LDMOS,35W,450 AMPMOD PCB sub-

assembly
A01655 ASSY,HPB,PCB,RFMOD,100mW,450 RFMOD assembly
A02457 ASSY,HPB,PCB,RFMOD,100mW,GEN RFMOD “generic” PCB

sub-assembly
A02413 ASSY, PDL,BASE, FRONT, PANEL,W/AUTO,PWR ON Front panel assembly
A02388 ASSY,PDL,BASE,I/O BD,AUTO, PWR/ON I/O board assembly
A00933 ASSY,PDL,BASE,CONN,RS232 Internal data/power

cable assembly
A00936 ASSY,PDL,BASE,AMPMOD,35W,450 Obsolete AMPMOD

assembly
A00938 ASSY,PDL,BASE,PCB,RFMOD,450 Obsolete RFMOD

assembly
A01387 ASSY,PDL,BASE,PCB,RFMOD,GEN Obsolete “generic”

RFMOD PCB sub-
assembly
D00485 SCHM,PDL,BASE,RFMOD,450 RFMOD assembly

schematic
D00668 SCHM,HPB,AMP,LDMOS,35W,UHF AMPMOD schematic

(A01649)
D00483 SCHM,PDL,BASE I/0 INTERFACE BD I/O board schematic
D00476 SCHEM,PDL,BASE,AMP,35W,UHF Obsolete AMPMOD

schematic
(A00936/A00986)

PDL
Positioning
Data Link
DOCUMENT REFERENCES:
TEST REPORT D00563
TEST PROCDR. D00535
SCHEMATIC. D00668
By DCC - Pacific Crest Corp at 10:39 am, Jun 26, 2006
By DCC - Pacific Crest Corp at 10:39 am, Jun 26, 2006
By DCC - Pacific Crest Corp at 10:16 am, Jul 27, 2006
By DCC - Pacific Crest Corp at 3:33 pm, Aug 23, 2006
By DCC - Pacific Crest Corp at 3:34 pm, Aug 23, 2006
By DCC - Pacific Crest Corp at 11:11 am, Sep 01, 2006
By DCC - Pacific Crest Corp at 2:38 pm, Feb 27, 2007
1 2 3 4
THIS DRAWING AND ITS DESIGN ARE THE PROPERTY OF PACIFIC CREST CORPORATION.
THIS DRAWING IS LOANED TO YOU SUBJECT TO THE CONDITION THAT IT SHALL NOT BE 05 ECN X01228 12/8/99 KW
REPRODUCED, COPIED, LENT OR OTHERWISE DISPOSED OF, DIRECTLY OR INDIRECTLY. IT
SHALL NOT BE USED TO FURNISH ANY INFORMATION FOR THE MAKING OF DRAWINGS, 06 ECN X01262 2/2/00 KW
PRINTS, OR EQUIPMENT, OR PARTS THEREOF, EXCEPT WHERE OTHERWISE SPECIFICALLY
PROVIDED FOR BY CONTRACT WITH PACIFIC CREST CORPORATION.
07 ECN X01366 8.15.00 KW
08 ECN X01413 9.26.00 KW

D D
TO INTERFACE BD. 09 ECN X01439 10.23.00 XY
SCHM,PDL BASE, RFMOD
D0048522.SC2 10 X01448 01.15.01 PAW
J2
HILOSW PAW
11 DEVIATION 08.XX.01
1 GND
2 GND GND
TO AMPLIFIER BD. 12 ECN X01646 04.10.02 VH
3 +UNREG
SCHM,PDL BASE, RFMOD
4 +UNREG PAW
D0048522.SC3 J1 13 ECN X01713 01/22/03
5 GND
GND
6 PWRBUT GND 1
7 GND GND GND GND
GND
2 14 ECN X1881 09/30/03 XY
+UNREG
8 SPIDAT +UNREG 3
9 DISPCLK +UNREG +UNREG PCNTL
PCNTL
4
15 ECN X01955 05/06/04 XY
AMPWR
10 GND AMPWR 5
11 TXD1 +8V +8V +USW
+USW
6 16 ECN X02018 02/09/05 VH
TAMP
12 RXD1 TAMP 7
-ISENSE 17 ECN X02051 (new ftprint VC7) 03/15/05 KW
13 RTSD1 KEYAMP KEYAMP -ISENSE 8
C +ISENSE C
14 CTSD1 +ISENSE 9
KEYAMP 18 ECN X02143 12/09/05 VH
15 TXD2 RX_ENBL RX_ENBL KEYAMP 10
HI/LO
16 RXD2 HI/LO 11
GND 19 ECN X02156 03.03.06 VH
17 RTSD2 TXA TXA 12
HILOSW
18 CTSD2 13
19 TXD3 RXA RXA 20 ECN X02182(C197-2PF-410MHZ 06.26.06 VH
CON13
20 RXD3
21 TXD4 RSSI RSSI 21 ECN X02196 MATCH MAS200 07.24.06 VH
22 RXD4
RF IN THROUGH AMPLIFIER BD. 22 ECN X02202 R79 3.3k C96 15pF 08.14.06 VH
23 RXD0 SPIDAT SPIDAT
24 TXD0 J3
25 GND SPICLK SPICLK MCX
26 DCD RFIN
27 SYNLAT SYNLAT
28 CHNBUT
29 +8V SYNLCK SYNLCK GND
30 +8V
RF OUT TO AMPLIFIER BD.
PCNTL PCNTL
CONN30
B J4 B
TRADIO TRADIO MCX
RFOUT
TAMP TAMP
+ISENSE +ISENSE GND
-ISENSE -ISENSE
HI/LO HI/LO
+USW +USW
AMPWR AMPWR
A
FCC ID: KEAPDL4535 A
Title Pacific Crest Corporation
SCHM,PDL,BASE, RFMOD 990 Richard Ave
Suite 110
Santa Clara, CA 95050
Size: A Number: D00485 Revision: 22
USA
Date: 14-Aug-2006 Time: 09:50:36 Sheet 1 of 3
File: T:\TPCEcn\X02202\e0005007.ddb - Documents\D0048522.prj
1 2 3 4
1 2 3 4 5 6 7 8
THIS DRAWING AND ITS DESIGN ARE THE PROPERTY OF PACIFIC CREST
CORPORATION. THIS DRAWING IS LOANED TO YOU SUBJECT TO THE CONDITION
THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR OTHERWISE DISPOSED
OF, DIRECTLY OR INDIRECTLY. IT SHALL NOT BE USED TO FURNISH ANY
INFORMATION FOR THE MAKING OF DRAWINGS, PRINTS, OR EQUIPMENT, OR
PARTS THEREOF, EXCEPT WHERE OTHERWISE SPECIFICALLY PROVIDED FOR BY
+8V +5V
CONTRACT WITH PACIFIC CREST CORPORATION.
+8V
(C)opyright 1999, Pacific Crest Corporation
TP13 Q5
TP14 FMMT717
HI/LO
CONFIGURATION OPTIONS:
+8V
R111
U1 (PA3) U1 (PA5) U3 PIN 3 U3 PIN 4 U6 PIN 10 U6 PIN 9 10K
CLKDV1 CLKDV2 CLKDIVA CLKDIV2 MUX A MUX B BPS BW
MODE
U4 R1
1 8 330K C15
0 0 0 0 0 0 19.2K 25 4LFSK VOUT VIN
+ C62 2 7 .01uF + C53
0 1 0 1 0 1 9600 25 GMSK SENSE FDBCK
1 0 1 0 1 0 4800 25 GMSK
22uF,16V 3
SHTDWN 5V TAP
6 10uF,6.3V R113
D 4 5 470/.125W D
GND ERROR
R41
+5V
LP2951ACM
1K
R114
10
11
12
13
14
15
16
GND
Q13
9
1K 2N2222A
RP1
+5V 10Kx8
BD TP1
+5V R112
2.45760 MHz 10K
+UNREG R3
8
7
6
5
4
3
2
1
R45 10K
R60 9-16V 10K TP24
D0
D1
D2
D3
D4
D5
D6
D7
698K
C12
.1uF C18 C19
RESET U9
18pF 18pF
R59 Y1 R14 2.4576 MHz CLOCK 35 7
9.8304MHz X1 RX TXD1
17
R116 100
9.8304 MHz 36
TX
14
RXD1
249K 100
D[0..7]
X2
A RTS
CTS
CD
11
9
CTSD1
RTSD1
12
DTR DCD
R2 A[0..15] 10
11
DSR
37 8
U8A RAM FLASH MX919
TP15
1V P-P @ 2.5V 15
RESET
IRQ
RI
2 10M 32K x 8 1M BIT x 8 C178 29
1 2.5-0V U1 D0 11 D0 13 MODEM 82pF
RX
19
TXD2
3 37 33 D1 12
D0 U5 D1 14
D0 U10 D0 66
TX
22
RXD2
+5V
LMC6584AI +5V
36
XTAL
EXTAL
MODA
MODB
32 D2
D3
13
15
D1
D2
D3
D2
D3
15
17
D1
D2
D3
1
IRQ U27 R120 R119
D1
D2
67
68
D0
D1
D2
B RTS
CTS
CD
25
27
CTSD2
RTSD2
+5V 34 40 D0 D4 16 D4 18 17 23 D3 1 24
4
E D0 D4 D4 CKI RXAOUT D3 DTR

R58 R57 R56 39 43 D1 D5 17 D5 19 16 100K 82K D4 2 26
4XOUT D1 D5 D5 CKO D4 DSR
R9 44 D2 D6 18 D6 20 D5 3 28
10K D2 D6 D6 D5 RI
50 45 D3 D7 19 D7 21 D6 4
RESET D3 D7 D7 D6
18.7K 100.0K 10 V_EXT 52 46 D4 A0 12 D0 9 22 TP16 D7 5 41
IRQ D4 A0 D0 RXAIN D7 RX TXD3
51 47 D5 A0 10 A1 11 D1 8 51
XIRQ D5 A0 A1 D1 TX RXD3
C13
C
48 D6 A1 9 A2 10 D2 7 RX EYE A0 34 48
D6 A1 A2 D2 A0 RTS AMPWR
.1uF TXCLK 77 49 D7 A2 8 A3 9 D3 6 A1 33 45 10K
PA0 D7 A2 A3 D3 A1 CTS R157
RXCLK 76 A3 7 A4 8 D4 5 20 A2 32 43
PA1 A3 A4 D4 TXOUT A2 CD
+5V RXDAT 75 17 A0 A4 6 A5 7 D5 4 A3 20 46
PA2 A0 A4 A5 D5 A3 DTR
74 16 A1 +5V A5 5 A6 6 D6 3 A4 50 44
PA3 A1 A5 A6 D6 A4 DSR
TXDAT 73 15 A2 A6 4 A7 5 D7 2 42
PA4 A2 A6 A7 D7 RI
R137 72
PA5 A3
14 A3 A7 3
A7
A8 27
A8 Vbias
21
14
10K 71 13 A4 A8 25 A9 26 A0 14 63
PA6 A4 A8 A9 A0 RX TXD4
C 70 12 A5 U2A A9 24 A10 23 A1 15 18 53 C
RP2 PA7 A5 A9 A10 A1 R/W TX RXD4
D
11 A6 1 A10 21 A11 25 19 56
A6 A10 A11 DOC1 RTS R156
+5V
R122 R138
GND
1 16 63 10 A7 3 A11 23 A12 4 11 16 59
TXD0 PD0/RXD A7 A11 A12 WR 100K 100K CS CTS HILOSW
2 15 64 9 A8 2 A12 2 A13 28 10 61 1K
RXD0 PD1/TXD A8 A12 A13 RD CD
MISO 3 14 65 8 A9 A13 26 A14 29 13 18 31 58
SYNLCK PD2/MISO A9 74LS00 A13 A14 CS DOC2 16/68 DTR
MOSI 4 13 66 7 A10 A14 1 A15 3 60
SPIDAT PD3/MOSI A10 A14 A15 C181 C182 C171 DSR
7
5 12 67 6 A11 2 MX919BDS C180 C179 C32 62

SPICLK PD4/SCK A11 A16 RI
6 11 68 5 A12 22 24
SYNLAT PD5/SS A12 OE OE 82pF 150pF
7 10 4 A13 27 31 4700pF .1uF 68pF ST16C454IJ68
10
11
12
13
14
15
16
10
11
12
13
14
15
16
16
15
14
13
12
11
10
16
15
14
13
12
11
10
TRADIO A13 WE WE 4700pF
9
8 9 18 3 A14 20 22 NOTE: PIN 31 GROUNDED FOR MOTOROLA "68" MODE
TAMP PE0 A14 CS CS
1k 23 78 A15 U2D +5V
R155 PE1 A15
100x8 25
PE2
12 HY62256ALJ-120 AM29F010A-120JI RP3 RP4 RP5 RP6
(VBATT) 27 35 11 10Kx8 10Kx8 10Kx8 10Kx8
PE3 R/W
U2B U2C 19 13
PE4
R136 5 10 24
PE5 PG0
62
DACLAT
6 8 C167 C35 26 59 74LS00
DISPCLK PE6 PG1
4 9 28 58
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
100 DISPLAT .1uF .1uF PE7 PG2 DISPLAT
57
74LS00 74LS00 PG3
30 56
VRH PG4/CSIO2
29 55
VRL PG5/CSIO1
54
PG6/CSGEN
53 R121
R44 PG7/CSPRG
10K NL
MC68HC11F1CPU5 19.2Kbps
PWRBUT
+5V 9.6Kbps
CHNBUT R4 R36 Sallen-Key 2-Pole Filter
R51 C172 C173 R200 +5V R34 Bessel configuration
10K 10K
R5 100K R18 15K 100K
68pF 68pF R8 4800bps C5 C24
10K 10K C25 C61
100K Scale, Offset, LPF
R37 470pF .1uF NL NL
R71
16
11
5 TP6
RSSI 10K U7B U7A
7 U6 R33
10K
C55 R10 R42 R22 R23 U7C
6 + R39 12 13 5 2
Vin
U8B 1uF,25V 10K 9600bps 14
X0 X
7 1 10
RSSI BUFFER & FILTER LMC6584AI
10K
15
X1
X2 Y
3 6 82K 3 8
TXA
47K C20 11 51K 51K 9
GAIN = 1.33 +5V CMX589 +5V 470pF
X3
LMC6584AI C10 LMC6584AI
C168 R40 1 +5V LMC6584AI
-3dB @ 33KHz MODEM
4
Y0
10K 5
Y1
470pF BT=.5=+5V 2 .1uF R35 C59
24
Y2
4
Y3
CLKDIV1 6
INH 10 NL
CLKDIV2 2 16 10 8
C1
VCC
CLKIN TXA A GND C48

R38 TP2 1
CLKOUT R32 9
B GND
7
100K 15 +5V
BT .1uF
11 TP3 74HC4052 68pF
RXA
19 R21 82K TP4
22
TXDAT
TXCLK
U3 C60 100K R28
B 18
TXPSAV
18K 2v - 3v B
Q1 +8V 17
TXENBL RXFB
10 22pF 1V P-P @ 2.5V
FMMT717 20 R27
RXDAT
TP5 21
KEYAMP RXCLK
8 9 51K
RXPSAV VBIAS
R16 5 R29
RXHLD
R6 23
RXSN
11K Sallen-Key 2-Pole Filter (inverting)
10K Bessel configuration
5.6K 3 14 -3dB @ 15kHz
CLKDV1 DOC1
4
C2 CLKDV2
R19 C51 C56 R26 51K
(WIRE OR w/RXPSAV) .1uF R15 6 3M + C58
GND
5.6K 7
RXACQ
13 .015uF RXA @ 1.40V
RX_ENBL PLLACQ DOC2 U7D
R11 1uF,25V
100pF R25 R24
470/.125W CMX589E2 C50 C57 13
RXA
14
12
.015uF 220pF 12 51K 51K

Q2 2N2222A +5V
R12 C49 R17 C22
LMC6584AI
U13 C9 390pF 5.6K 68pF
1K 7 8 .1uF C11
REF VDD
5 6 +5V
SPICLK SCLK OUT2 .1uF
4 2
R7 SPIDAT
3
DIN OUT1
1 R30 R31
DACLAT CS GND
10K
31.6K 20.0K
MAX549AEUA
8 BIT DAC
TP21
+USW
U8D
R13 R55 12
+USW
C14 14 C71 C67 .01uF
100 10K
C72 R46 C75
13
120 C26
100pF .01uF LMC6584AI .1uF C70 15uF,35V
R61 R50
68pF
R49
7
47K 4.7K
TP22 U11 10K .033uF
9 R62 L1 1 8 3
GND
R20 +ISENSE +RS V+
IXMIT 8 2 7 6
10
47K 1uH
3
-RS PG
6 R48 2
2.2K U8C L2 4
NC OUT
5 U14 R43
-ISENSE NC GND 10K PCNTL
LM7301IM 51
A LMC6584AI C37 1uH MAX4172 A
4
1
5
-4 C64 C65 C68 C66
+5V VIXMIT = 2.5 - ( 1 X 10 ) ( I RFAMP) (2200) C36 +5V
68pF
.01uF .01uF 1000pF .01uF
IRFAMP = TRANSMITTER CURRENT IN AMPS 68pF U12
TLE2425
2200 = VALUE OF R47 IN OHMS R47 1 8
C177 C169 C17 C74 C3 C8 C7 C16 C4 C52 C54 C6 C69 2
OUT NC
7
2.2K GND NC
+ + 2.5 = OFFSET REFERENCE VOLTAGE FROM U12 3 6
+V NC
.1uF .1uF 4 5
.1uF .1uF .1uF .1uF .1uF .01uF .1uF .1uF .01uF NC NC
10uF,6.3V 10uF,6.3V
P:\PDLBASE\EE\D00485\02\D0048502B.SC2
U9 U9 U9 U10 U5 U2 U1 U1 U1 U3 U3
D00485 = SCHEMATIC Title
FCC ID: KEAPDL4535 PACIFIC CREST CORP.
E00050 = PCB SCHEM,PDL,BASE,RFMOD 990 Richard ave
A00938 = ASSY Suite 110
Size: D Number: D00485 Revision: 22 USA
File: T:\TPCEcn\X02202\e0005007.ddb - Documents\D0048522.SC2
1 2 3 4 5 6 7 8
1 2 3 4
OF, DIRECTLY OR INDIRECTLY. IT SHALL NOT BE USED TO FURNISH ANY R64
INFORMATION FOR THE MAKING OF DRAWINGS, PRINTS, OR EQUIPMENT, OR 100
PARTS THEREOF, EXCEPT WHERE OTHERWISE SPECIFICALLY PROVIDED FOR BY TP9
C124 +5VRX 17mA
CONTRACT WITH PACIFIC CREST CORPORATION. +5VRX
1000pF 5mA C176 R118
BP OUT + C164 TP11
C125 R52 R84 .01uF 51
-2dB 54.45MHz 1000pF 1uF,25V
TP7 10K 1K C106
R69 U15 54MHz
BPF1 .01uF
+5VTX 10 16 1
SEE TAB C94 L11 CF1 CF2 C93 MXI XIN
-2dB C86 C148
R139 C126
100pF 56pF 54.450MHz 54.450MHz 18pF 15 2
TP8
1000pF 150nH 18pF Q7 GND XOUT
BPF2 1 7 3 1 1 3
330 CF3
C143 SEE TAB NE85633
1
C40 3 9 14 3 450KHz
100pF MUTE MXO
2
L23 68pF U18 R81 VC1 3 C23
R80 VC4 VC5
D 1 7 1 6 13 4 BW 20KHz D
+
51
2
R83
21
RFIN IN VCC 51 MD VCC
15nH 3 9 4
11
10
RF
IF
D1 2 5 2-6pF L16 3-10pF 5-20pF L17 6.8K 12 5
GND GND C90 R92 SQ LI 1uF,25V
C194 C195 470nH 470nH C104
12
100pF L10 470 C99
5.6pF 3 4 -7dB C95 .01uF R72 11 6
11
10
5.6pF GND OUT U16 150nH 0.01uF FO DEC1
3
LO
56pF 56K R73
G
UPC3215TB TUF1 10
FI DEC2
7 CF4 +5VRX
MMBV3401L G=20.5dB 4 220
NF=2.3 9 8 450KHz
3
C105 RA QC C98
14mA
2
7dBm MC3371 C110 .1uF 0.01uF
.01uF
STRIPLINE
TP12
50 OHM
C89 C111 .1uF
L8 L9
L6
FILTER TO KEEP TX OUT OF RX 22nH 22nH 100pF U19 +5VTX TP20
4 3 RXA 680uH
OUT GND Q3
5 2 R109 2N2222A RSSI 3 1 C97 C170
C138 C135 C139 GND GND
L15 10 10pF
5pF 10pF 5pF 220nH 6 1 0.01uF
VCC IN R105
UPC2710TB R104 TXA +5V_ +5V_
3.3K R74
G=33dB 27K
NF=3.2 C33 C108 R65 +5VRX L3
C88 27K
R68 C161 C127 Psat=13.5dBm 0.15uF .01uF R103 82nH
100pF 10
.1uF 1000pF Ic=22mA 10K
10
+ R70
C166 C30 1.2k
+5VRX R107 R102 R54 1uF,25V
+
R150
820
33K
68 50K POT 1uF,25V
KEYAMP -16dBm C163 R142 C162
C129 1000pF R144 .1uF C117
+ C142
.01uF R132 +5V_ 450-470MHz 10K 15k C146 L5
43 0dBm L25 MOD 1uF,25V 82nH
R149 .1uF R96
R82 220nH L19 C184 C118 82pF
C121 R93 15K 6.8pF
2
390 VC7 C209 .01uF

+
1000pF 68 Q12 C201 SEE TAB L26 22K 470nH

C29 R99 C204 1.5-3.0 pF
1uF,25V C158 C206
68 NL C140
C L4 R134 .1uF C
FE BEAD 10 C159 100pF 220nH NE85633 Q8 C141
1000pF 5.0pF D4 82pF
R126 L21 R90 C198 C203 10pF
15nH R153
150mA 270 R124 R130 62 NE85633 L30 Q9 C191
1
C122 6.8K 3.3K TAB TAB 5.45nH C190

SMV1236-11
C214 L24 390 150pF 15pF NE85633
1000pF R125 R115 R86
L20 220nH C212 R85 R79
270 15nH 10K -6dBm C197 330
C87 .01uF C199 15K R94 3.3k C112
470 .01uF
4
C152 R128 R148 TAB TAB 100pF

100pF C193 C92 18 R146 D3 C103
RFOUT 100pF 5.0pF C91 100pF 18 18 .01uF
INPUT
OUTPUT GND
GND
GND
100-130 mW L7 100pF C189

R141
43nH U24 6.8pF MMBV3102L
R160 C134 UPC1678GV C157 Q14 R127 C210 10K
TAB L14 100pF Gain=23dB 100pF 0dBm NE85633 18 -6dBm
GND
GND
VCC
SEE TAB C133 R129

C147 Psat=17.5dBm Q15 R147
470pF 68
Ic=49mA 18 TAB
18dBm NE85633 R133 R91 R89 R123 R131 R154
100pF R97 24 43 220 12K L27 D5
18 C200 C211 L29
5
R87 R135 C160 C174

VC2 NL 220nH TAB 3.85nH SMV1236-11
R158 R159 270 C31 R117 33 5.6pF 100pF 390 Q16
NL 504-524MHz NL C96
SEE TAB SEE TAB 1uF,25V 100 C175 0dBm C202
+
C130 C131 NE85633 C137

SEE TAB L13 100pF + C34 15pF
Q10 8nH 15pF L12 R106 1uF,25V C109 C207 C205
R88 3.3K .01uF 100pF NL TAB L28
MRF5812 220nH 6.8pF R145 220nH
120 C132 VC6
50mA R110 R152 15K
6.8pF R143 0.6-2.0pF C208
C120 +5VRX 68 C196
1000pF 10 Q4 L18
KEYAMP R140 10K
2N2222A
R151 100pF
43, 1/4W 5% 68 1000pF 150nH
C213 C185
L22 .01uF
68nH
TO MODEM: C192 0.01uF
VCO CNTRL VOLT

TP19 3.0pF C102 R78 C145
+8V +5VTX 2.7K C114
B .01uF 0.15uF .1uF B
8 1
+8V VIN VOUT
C39 C107
+ C153 7 2 + C155 SPICLK 11 10 R108
C116 VIN VOUT CLOCK FIN
C156 4.7uF,10V 68pF .01uF R100 C186 4.7uF,10V 12 9
NC NC 10K
1000pF .1uF 10K 6 3 .01uF SPIDAT 13 8 SYNLCK
NC NC DATA LD
14 7 R53 C42
LE GND TP10
5 4 SYNLAT 15 6
ENABLE GND FC D0 10K NL
16 5 C123 +5V_
BISW VCC
U23 +5V_ 17 4 .01uF
F/OUT VP
MIC5200-5BM 18 3 REFERENCE OSCILLATOR
OP OSC/OUT C144
19 2 VALUE CHANGED TO STOP FALSE RSSI LED ON
Q6 PWDN NC
C81 C79 C82 C41 20 1
OR OSC/IN
2N2222A 68pF X2
68pF 68pF 68pF 10pF 7 8 C100
C28 C101 R67
R101 U17 A7 A8 .01uF
C84 C80 C78 C83 22K .01uF FREQUENCY TAB CHART 10
+
TP18 LMX2315 R98

+5VRX R66
68pF 68pF 68pF 1uF,25V 10
68pF TXA A1 A14
8 1 REFERENCE 410-430 430-450 450-470 1 14
R95 100K
TO MODEM: VIN VOUT
+5V_
DESIGNATOR MHz MHz MHz
C183
C115 7 2 + C154 R63 15P 12P 12P TCVCXO
VIN VOUT C187 4.7uF,10V 220 C198 C38
RX_ENBL + C27 C00837 C00836 C00836 1000pF
RX_ENBL .01uF C113 1K 68pF
TXA 6 3 15P 15P 12P
TXA .1uF NC NC .1uF C199 C00837
RXA 1uF,25V C00837 C00836
RXA
RSSI 5 4 12P 10P 8.2P
RSSI ENABLE GND C200
SPIDAT
SPIDAT C00836 C02434 C01300 TEMPERATURE SENSOR
SPICLK U22 12P 10P 10P
SPICLK
SYNLAT C47 MIC5200-5BM C202 C00836 C02434 C02434 FREQUENCY TAB CHART
SYNLAT 68pF U20
SYNLCK 1P 5P +5V_ TP23
SYNLCK C203 C00828 C02328 NL LM50C
PCNTL
PCNTL REFERENCE 25 KHz 12.5 KHz
TRADIO C209 12P 10P 10P
TRADIO C00836 C02434
AMPWR TP17 C02434 DESIGNATOR 1 2 TRADIO
AMPWR +Vs Vo
TO RF AMPLIFIER
GND
HI/LO +5V_ 15P 12P 8.2P CF1
HI/LO C210 C01300
TAMP C00837 C00836 C01728 C01729
TAMP C128
+ISENSE 8 1 GND BPF1 20/420 20/440 20/460 CF2
+ISENSE VIN VOUT GND BPF2 1000pF
-ISENSE GND C00754 C00770 C00606
-ISENSE GND CF3
3
KEYAMP 7 2 + C165 +UNREG NOT USED NOT USED 3.3pF C01406 C01535
KEYAMP VIN VOUT C188 4.7uF,10V +UNREG C130 NL CF4
+USW PCNTL NL C01713
+USW .01uF PCNTL R158 430
C150 6 3 AMPWR 560 470
C45 C44 C63 C85 NC NC AMPWR R159 C02329 C00615 C02330
A .1uF +USW A
+USW
5 4 TAMP 33nH 27nH 27nH
68pF 68pF ENABLE GND TAMP L14 C01878 C01877
68pF 68pF +ISENSE C01877
+ISENSE
U21 -ISENSE C197 2P 2P 1P
-ISENSE
C77 C46 C43 C76 C73 MIC5200-5BM KEYAMP C00830 C00830 C00828
KEYAMP
HI/LO R160 22 33 22
68pF 68pF 68pF 68pF HI/LO C00516 C02001
68pF C02001
Title
FCC ID: KEAPDL4535 PACIFIC CREST CORP.
SCHM,PDL,BASE,RFMOD 990 Richard Ave
Suite 110
Size: C Number: D00485 Revision: 22
USA
File: T:\TPCEcn\X02202\e0005007.ddb - Documents\D0048522.SC3
1 2 3 4
1 2 3 4 5 6 7 8
ECN # X01753
01 RELEASE TO PRODUCTION PAW
CORPORATION. THIS DRAWING IS LOANED TO YOU SUBJECT TO THE
CONDITION THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR
ECN # X01753
OTHERWISE DISPOSED OF, DIRECTLY OR INDIRECTLY. IT SHALL NOT BE USED
02 Change R34 and C37 PAW
TO FURNISH ANY INFORMATION FOR THE MAKING OF DRAWINGS, PRINTS, OR
EQUIPMENT, OR PARTS THEREOF, EXECPT WHERE OTHERWISE SPECIFICALLY
PROVIDED FOR BY CONTRACT WITH PACIFIC CREST CORPORATION.
03 410-430 & 430-450 BETA RELEASE PAW
04 ECN X01780 410-470 wideband beta release PAW
D D
3
R1
C14 C6
GND
2.2K
68pF 68pF
2 1
OUT V+
JP1
C70 U1
1 2200pF LM50C R2
2 TEMPERATURE SENSOR 1K
3
4
C1 PCTNTL
5 2200pF
6
7
8
C2 AMPWR
9 2200pF
10
11
C3 +USW
CONN_11PIN 2200pF
C4 TAMP
2200pF
C5 ISENSE-
2200pF
C7 ISENSE+
2200pF
C8 KEYAMP
2200pF
C71 HI/LOW
C 2200pF C
C11 C12
68pF 68pF
P2
9-16VDC
1
RTN
2
CON2
1
K1
2 I+ I-
3 L1 C10
4 D9 + R5 100pF
R16 2.2uH,9.5A
C26 + C25 C23 C22 10K C17 C16 C15 0.01, 2 WATT C21 C20 C19 + C18
RELAY SPST 0.1uF 68uF, 20V 0.1uF 68uF,20V 0.1uF 1000pF 1.0uF 0.1uF 100pF 68uF,20V C13
1000pF BZX84C12
D1 100pF
DL-35
R17
R8 470 R4
C36
10K 39 1/2W
D2
2
100pF C61 C55
DL-35 0.1uF 1000pF
B2 Q3 B3
ILHB-1206 2N2222 ILHB_1812 R3
2 1 39 1/2W
R33 R13
1
4.7K 10K
R6
C9 39 1/2W
100pF VR2 R7
TP2
10K POT 39 1/2W
C29
C54 C60 C28 100pF
1000pF 0.1uF 100pF C67 C44
VR1 TP1 R10 C73 100pF 1000pF C76 C24
D10 C53 R9 100pF
2K POT
390 1/4W
1000pF C66 1000pF
LM336-2.5V 1000pF C34 10K 1000pF
1000pF L3 L5
0.12uH
L26 0.12uH
R12 C27 C72 84NH
10K 1000pF 1000pF
L6 L11 R34
0.12uH 470 L20 C42 D3 C32 L4 L7 L10 D4 C33
84nH
3.5nH 300pF MA4P1250 300pF 24nH 24nH SHORT MA4P1250 300pF J2
C52 MRF1535 1
330pF Q2 BNC_ANT
1000pF L13 C43 C41
B R11 3.85nH 10pF C69 300pF C35 C45 C46 B
100
L18
C31 6.8pF NL C47
L12
2
C58 12pF
C40 L9 5.45nH C64 C65 C50 C51 8.2pF 3.3pF
J3 330pF 2.55nH Q1 D5 62pF 62pF 5.6pF 18pF 6.8pF 84nH
1 MRF1513 18pF L14 C49 C48 CHASSIS
MCX_TX MA4P1250
C68 18.5nH 10pF 5.1pF C63 C62
C75 56pF 56pF L19
L8
C39 L17 17.5nH
12pF C38
2
18nH 17.5nH
27pF
6.8
L16 C30
3.3pF
17.5nH MA4P1250 C57
D8 330pF
1 J4
C74 C37 MCX_RX
36pF
C59
2
6.8pF
3.3pF
D6 L23
D7 MA4P1250
C56 0.12uH
330pF
MA4P1250 Microstrip Line: W=0.0537" T=0.030" Er=4.6
A A
Title PACIFIC CREST CORP.

990 Richard Ave.
SCHM, HPB, AMP, LDMOS, 35W, UHF Suite # 110
Size: D Number: D00668 Revision: 04 USA
File: C:\Documents and Settings\kwharton.PACCRST\Desktop\ldmos\wideband\D0066804.DDB
Date: 19-Dec-2002 Time: 15:13:44 Sheet 1 of 1 - Documents\D0066804.sch
1 2 3 4 5 6 7 8
1 2 3 4
04 ECN X01222 11.30.99 KW
3. 990805 CONNECT TRACE FROM Q1 PIN 8 TO J1 PIN 27 TO SUPPLY +USW TO RF MOD
2. 990805 ADD R1 AND C2 TO CLEAR SHIFT REGISTERS @ POWER ON
OF, DIRECTLY OR INDIRECTLY. IT SHALL NOT BE USED TO FURNISH ANY
1. 990805 CHANGE D3 FROM BAS16 TO BAV74 TO ENABLE PWR SW SENSE
INFORMATION FOR THE MAKING OF DRAWINGS, PRINTS, OR EQUIPMENT, OR
PARTS THEREOF, EXECPT WHERE OTHERWISE SPECIFICALLY PROVIDED FOR BY
+8V
CONTRACT WITH PACIFIC CREST CORPORATION.
+5V
D1 LM2940T-8.0
5819 U1
+UNREG Q1
1 8 1 3 8 1
VI VO VIN VOUT
GND
+ 2 7 7 2
C1 VIN VOUT
+ + C7
D 3 6 C3 C6 C18 6 3 10uF,6.3V D
15uF,35V D2 NC NC
NL .1uF
2
26V 4 5 220uF, 10V 5 ENABLE GND 4
R29 D4
SMBJ24ADICT 6.8K SI4435DY C4 U2
12V MIC5200-5BM
BZX84C12 .1uF
R17
3.3K
F4
C5 F-LINK
.01uF +5V
DISP1
3
7
+5V Q2 8 A
2N7002
POWER SW R39 F B
SW1 470 R19 9 6
SW-PB D3 R22
10K G
10K 10
CHANNEL BUTTON Q3
+5V VP0610L E C
SW2 +5V 1
EPON DP
SW-PB BAV74 D 5
R38 4
470 2
R1
R7 51K
470
RP1 LTS-546AWC
CHNBUT R21 1 3 1 16
A Q0
C 10K 2 4 2 15 C
R14 B Q1 5 3 14
Q2
10K 6 4 13
U3 Q3
Q4
10 5 12
8 11 6 11
CLK Q5
12 7 10
Q6
9 MR Q7 13 8 9
74HC164 8X1K
1 3 PWRLED
A Q0
2 4 RXLED
B Q1
5 TXLED
Q2
+5V 6 AMPLED
U4
DO NOT
Q3
Q4 10
8 11
R12 CLK Q5
10 12
INSTALL
Q6
9 13 R8 R9 R10 R11
MR Q7 EPON
J1 1K 1K 1K 1K
GND J2 74HC164
1
2
GND C10 U5 C8 CTS1
1
C2
+UNREG 10 9 RTS1 .1uF
3 C1+ VCC 2 D5 D6 D7 D8
+UNREG SGND1
4 .1uF .1uF C12 3 LED LED LED LED
GND 12 11 .1uF TX1
5 C1- V+ 4
PWRBUT I C11 C9 RX1
6 5
7 GND 13 C2+ V- 15 DCD1 6 HI/LOW TXLED RXLED PWRLED
SPIDAT O
8 .1uF .1uF CON6
DISPCLK O 14 8
9 C2- GND
GND
10
TXD1 I TX 6 7 RV5 RV4 RV1
11
12
RXD1 O RX VARISTOR VARISTOR VARISTOR F1
RTSD1 I RTS 5 2 POLYFUSE +5V
13
CTSD1 O CTS RV3 RV2
14
TXD2 I 4 3 VARISTOR VARISTOR
15
RXD2 O
16
RTSD2 I 18 1
17
CTSD2 O
18
B TXD3 I 22 23 C19 C20 B
19
RXD3 O .1uF .1uF
20
TXD4 I 19 24 J3
21
RXD4 O CTS2
22 1
RXD0 O 17 16 RTS2
23 TXD0 I SGND2 2
24 3
GND 21 20 TX2
25 4
DCD O RX2
26 5
+USW O ADM208EAR DCD2
27 6
CHNBUT O
28 CON6
+8V +5V
29 R13
+8V
30
C15 U6 10 C13 RV10 RV9 RV6
CON30 10 9 VARISTOR VARISTOR F2
C1+ VCC VARISTOR POLYFUSE
.1uF 12 11 .1uF C17
C1- V+ RV8 RV7
C16 C14 VARISTOR VARISTOR
13 15 .1uF
C2+ V-
.1uF 14 8 .1uF
C2- GND
J4
5 4 TX3 1
RX3
2
7 2 GND
3
TX4
4
22 23 RX4
5
GND
6 3 6
+8V 7
8
18 1
+5V 9
10
17 16
11
19 24 CON11
21 20 DCD
J5
ADM207EAR +UNREG 1
2
SGND3
3
A TX5 A
4
RX5
5
6
CON6
F3
POLYFUSE
RV11 RV12
VARISTOR VARISTOR

SCHM,PDL,BASE,I/O INTERFACE BD. 990 RICHARD AVE.
SUITE 110
Size: C Number: D00483 Revision: 04 Santa Clara, CA 95050
USA
File: O:\DOC\Schematics\D0048304.sch Date: 16-Feb-2001 Time: 13:04:11 Sheet 1 of 1
1 2 3 4
1 2 3 4 5 6 7 8
LAST MODIFIED 11/03/1999 PAW

P:\PDLBASE\EE\D00476\D0047607.SCH
CORPORATION. THIS DRAWING IS LOANED TO YOU SUBJECT TO THE CHANGES 06/04/1999 09 ECN X01220 11.24.99 KW
CONDITION THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT OR
OTHERWISE DISPOSED OF, DIRECTLY OR INDIRECTLY. IT SHALL NOT BE USED DES. WAS IS
10 ECN X01263 (ADD TAB CHART) 2.2.00 KW
TO FURNISH ANY INFORMATION FOR THE MAKING OF DRAWINGS, PRINTS, OR
EQUIPMENT, OR PARTS THEREOF, EXECPT WHERE OTHERWISE SPECIFICALLY C53 NL 10pF
11 ECN X01276 (ADD MISC NOTES) 3.8.00 KW
PROVIDED FOR BY CONTRACT WITH PACIFIC CREST CORPORATION. C69 100pF 10pF
C54 24pF 30pF
12 ECN X01439 10.20.00 XY
C55 24pF 30pF
C52 8.2pF 15pFX2
13 ECN?????? 02/05/01 PAW
C40 8.2pF 4.3pF
C41 3.3pF 4.3pF 14 ECN X01548 08.30.01 V.H.
C44 10pF 8.2pF
C45 10pF 8.2pF 15 ECN X01651 04.20.02 V.H.
C46 2pF 3.3Pf
C73 47pF 27pF 16 ECN X01652 06.20.02 VH
CHANGES 12/8/99 MM
C35 18pF 24pF

C50 43pF 27pF
C51 43pF 27pF
D D
CHANGES 10/20/2000
DES. WAS IS
C53 10pF 4pF

C69 10pF 15pF
C66 15pF 33pF
C73 27pF TAB
C49 NL 47pF
C60 NL 47pF
R18 NL 51
R19 NL 100
VC3 5-20pF NL
CHANGES 02/05/2001
ADDED C53 TO FREQUENCY TAB

JP1 CHART
C70
1 1500pF CHANGES 06/26/02
2 Q1 NEW DESCRIPTION IN MAS200
3 C1 C54 TAB
PCTNTL
4 C55 TAB
5 1500pF
6
7 C2
8 AMPWR
9 1500pF
10
11 C3 R1
+USW
CON11
1500pF U1LM50C
1K
C4 TAMP 2
OUT V+
1 FREQUENCY TAB CHART
1500pF
GND
C14 C6 R2 REFERENCE 410-430 430-450 450-470
C5 ISENSE- DESIGNATOR MHz MHz MHz
100pF 100pF 2.2K
1500pF C35 30pF 27P 24P
3
1210 C01381 C01281 C01280
C7 ISENSE+ 33pF
C36 33P 27P
1500pF 1210 C01507 C01507 C01281
TEMPERATURE SENSOR
C8 C37 62pF 51P 43P
KEYAMP
1210 C01510 C01612 C01289
1500pF C11 C12 62pF
C C38 51P 43P C
C71 HI/LOW C10 1210 C01510 C01612 C01289
100pF 100pF 15pF
1500pF 100pF C39 10P 8.2P
1210 C01278 C01509 C01295
R4 C40 15pF 6.8P 4.3P

1210 C01278 C01293 C01288
39 1/2W
C41 9.1pF 6.8P 4.3P
1210 C01787 C01293 C01288
J1 C42 11pF 6.8P 4.3P
C13
R6 1210 C01616 C01293 C01288
K1 100pF R3 10pF
1 39 1/2W C43 6.8P 3.3P
1 L1 R5 39 1/2W
2 B1 1210 C01509 C01293 C01284
2 I+ I-
3 1 2 11pF
C44 10P 8.2P
2
4
HEADER 2 D9 bead 4uH,10A 0.01 2 WATT 1210 C01616 C01509 C01295
D1 RELAY SPST R14 R16 B2
C15 C16 C17 C45 10pF 10P 8.2P
51 10K bead C21 C22 C23 C18
C19 C20 + R7 1210 C01509 C01509 C01295
BZX84C12
DL4001 L2
1
Q5 POWER 1000pF 0.1uF 33pF 100pF 0.1uF 1.0uF 39 1/2W C46 6.8pF 6.8P 3.3P
1000pF 0.1uF 33uF,50V
C74 D2 CONTROL Q6 0.1uH, 2.8A 1210 C01293 C01293 C01284
MJF122 AMPLIFIER R17 C9
100pF R15 470 C50 39pF 33P 43pF
DL4001
C72 SUD45P03-10 1210 C01722 C01507 C01289
0.1uF 10K R8 45A SWITCH 100pF 39pF
C51 33P 43pF
C62 C61 10K C25 C26 C27 C28 1210 C01722 C01507 C01289
L20
CHASSIS 0.22uH + C29 24pF
0.01uF 1000pF Q3 L3 C52 20P 15P
0.1uF 1000pF 100pF
R10 L5 C01280
2
33uF,50V 100pF SOLDER C76 TO END OF L5 1210 C01584 C01278

2N2222 C76 4.3pF
B3 R9 390 1/4W L4 0.22uH 0.22uH C24 C53 4.3P 4P
L6 100pF 0805 C01288 C01288 C00651
bead 100pF
10K 2-1/2T GRN 22nH 11pF
4T 33nH C69 15P 12P
1
0805 C01616 C01384 C00569

R19 24pF
L7 L8 L9 L10 C75 20P 15P
100 C31 D3 D4 C33 1210 C01280 C01584 C01278
C34 10.7nH C32 1-1/2T RED 22nH 1-1/2T GRN 25nH 1-1/2T RED 22nH
39pF 36pF
C63 L21 MRF650 1 J2 C73 33P
+
C64 C65 L11 R18 C36 0805 C00477 C01585 C00271
5T 47nH 100pF Q2 C37 C41 C42 91pF 91pF MA4P1250 91pF BNC_ANT
C54 33pF 30pF 30pF
1000pF 0.22uH 51 Q1 C38 C39 MA4P1250
10uF,50V 100pF
2
TAB * * C40 C43 C44 C45 C46 1210 C01507 C01381 C01381
B C48 D5 SD1429 C75 C52 TAB TAB TAB TAB TAB TAB C47 L12 C55 33pF 30pF 30pF B
C35 * * C50 TAB TAB TAB TAB
TAB TAB L13 * C51 6.8pF 6-1/2T 1210 C01507 C01381 C01381
* C30
Q4 C54 C55 4T 33nH TAB TAB
L14 33pF MA4P1250 SEE TAB
C66 MRF652S * * 6.8pF
J3 12.7nH SEE TAB SEE TAB L17 CHASSIS
1 C53 L15
5T 47nH R11 2-1/2T21.4nH
MCX_TX L19
2
SEE TAB
33pF C68 L16 10 C58
2
VC1 L22 B4 2-1/2T 21.4nH

C49 C60 15.3nH
47pF 47pF R12 bead 6.8pF
2
5-20pF 33pF 5T 47nH C57

1
10 B5 1 J4
D6 MCX_RX
bead
D8 C59 100pF
1
2
D7 MA4P1250
6.8pF
R13 C56
2
MA4P1250
B6 MA4P1250 100pF
10
bead
1
L23
W1 C73 0.22uH
C69 W2 COAX COAX
2W STAGE TAB
1 2 2 1
TAB
3
3
C67
6.8pF
A A
* CAPACITORS ADDED AFTER MOUNTING RF TRANSISTORS

990 Richard Ave.
SCHM,PDLBASE,AMP,35W,UHF Suite # 110
Size: D Number: D00476 Revision: 15
USA
File: U:\COMPLETED ECNS\X01652\D0047616.sch
Date: 2-Jul-2002 Time: 08:30:13 Sheet 1 of 1
1 2 3 4 5 6 7 8
Chapter 9
9 Service Software
List of service software
PDLCONF factory version
PDLTEST
CDLEV
BERTEST
This chapter describes the proprietary software used for testing and adjusting the PDL HPB.

Chapter 9
List of service software
PDLCONF factory version

PDLCONF is the configuration utility for all PDL family products. Information regarding its
use may be found in the PDLCONF User’s Manual, PCC document no. M00741. There are 3
versions of PDLCONF with increasing levels of functionality:
• User - This version is supplied on CD-ROM with each PDL HPB purchased. It provides
the basic functionality required by end users including selecting from pre-programmed
frequencies, as well as link rate, modulation type, transmission protocol, and serial port
settings. It also has a hidden “memory map” function which may be useful in remote
troubleshooting.
• Dealer - This version is provided to dealers and other qualified personnel. In addition to
the user functions, this version allows the entry of new frequencies into the user’s channel
table, as well as direct access to the memory map.
• Factory - This version is used by PCC Manufacturing and by Authorized Service Centers.
Additional functions appearing on the “Factory” tab include the ability to set product type,
frequency range, serial number, and other functions not available in the User or Dealer
versions. These functions are not described in the PDLCONF User’s Manual, and will be
listed below.
PDLTEST
PDLTEST provides service providers with utilities to start and stop transmission, select
modulation types, activate test signals, and adjust frequency error. Its operation is described in
Chapter 5 of this manual, under “Perform initial RF tests.”
CDLEV
CDLEV is used to set the RF signal amplitudes for the appropriate carrier detection levels for
the 3 digisquelch settings. Its operation is described in the factory test procedure D00535
provided in chapter 7.
BERTEST
BERTEST is the Bit Error Rate test software used by the BER test station. Its operation is
described in the BER Test Procedure, PCC document no. D00590.

Chapter 10
10 Replacement Parts List
Top level assembly (A02393 family)
Model-specific subassemblies
AMPMOD
Final assembly (A01649)
Subassembly (A01611)
RFMOD
Model specific components
Generic RFMOD (A02457)
Front panel assembly
I/O board
This section contains the bills of materials for the HPB and all sub-assemblies.

Chapter 10
Top level assembly (A02393 family)
Item Part no. Description Qty. U/M
no.
1 A01649 ASSY,HPB,AMPMOD,LDMOS,35W,450 1 Each
2 F00471 BUMPER,PDL BASE,BLK 2 Each
3 (See tab) ASSY,PDL,BASE,RFMOD,100mW 1 Each
4 F00501 MOUNT,PDL,BASE,RFMOD,MOLD 4 Each
5 C01395 HDWR,SCREW,SHC,SS,BLK,4-40,5/8 16 Each
6 (See tab) ENCL,PDL,BASE,PAINT 1 Each
7 A02413 ASSY, PDL,BASE, FRONT, PANEL,W/AUTO,PWR ON 1 Each
8 C01396 HDWR,SCREW,PH,PAN,SS,BLK,8-32, 2 Each
9 F00489 BRACKET,CASE,PDL,BASE,ANOD 1 Each
10 C01397 HDWR,WASHER,SEAL,.168ID 2 Each
11 (See tab) LBL,PDL,BASE,FRT 1 Each
12 P00035 LBL,WEBER,FSTPRNT,4.00X0.875 1 Each
13 C01466 HDWR,VENT,10.2MM,ADH,GORE 1 Each
14 C01552 TAPE,COPPER FOIL,1"x.0026x18Y 0.17 Inches
15 F00503 SHIELD,PDL,VCO,TOP 1 Each
16 F00505 SHIELD,PDL,XTAL,TOP 1 Each
Model-specific subassemblies
FINAL ASSY FREQ OEM BW RFMOD ENCL LABEL
(ITEM 3) (ITEM 6) (ITEM 11)
A02389 410-430 PCC 25 A01657 F00466 F00462
A02390 410-430 PCC 12.5 A01670 F00466 F00462
A02391 430-450 PCC 25 A01656 F00466 F00462
A02392 430-450 PCC 12.5 A01669 F00466 F00462
A02393 450-470 PCC 25 A01655 F00466 F00462
A02394 450-470 PCC 12.5 A01663 F00466 F00462
A02395 410-430 SOKKIA 25 A01657 F00466 F00531
A02396 430-450 SOKKIA 25 A01656 F00466 F00531
A02397 450-470 SOKKIA 25 A01655 F00466 F00531
A02398 410-430 JAVAD 25 A01657 F00545 F00531
A02399 430-450 JAVAD 25 A01656 F00545 F00543
A02400 450-470 JAVAD 25 A01655 F00545 F00543
A02401 410-430 ASHTECH 25 A01657 F00466 F00547
A02402 430-450 ASHTECH 25 A01656 F00466 F00547
A02403 450-470 ASHTECH 25 A01655 F00466 F00547
A02404 410-430 TOPCON 25 A01657 F00593 F00595
A02405 430-450 TOPCON 25 A01656 F00593 F00595
A02406 450-470 TOPCON 25 A01655 F00593 F00595
A02407 410-430 TNL 25 A01657 F00809 F00808
A02408 410-430 TNL 12.5 A01670 F00809 F00808
A02409 430-450 TNL 25 A01656 F00809 F00808
A02410 430-450 TNL 12.5 A01669 F00809 F00808
A02411 450-470 TNL 25 A01655 F00809 F00808
A02412 450-470 TNL 12.5 A01663 F00809 F00808

Chapter 10
AMPMOD
Final assembly (A01649)

Part no. Description Qty. U/M
F00645 PANEL,PDL,HPB,LDMOS,BCK 1 Each
A00933 ASSY,PDL,BASE,CONN,RS232 1 Each
F00653 SHIELD,PDL,LDMOS AMP,TOP 1 Each
C02084 TRANS,TO-272,RF,50W, MRF1550T1 1 Each
C00054 SWITCH SEAL,TGL,BLACK,B-1048 1 Each
C00198 CONN,BNC,FEM,BLKHD,SEALED 1 Each
C00377 GREASE,THERMAL,SILICON 0.01 Oz.
A01648 ASSY,CBL,HPB,RF,LDMOS 2 Each
A01611 ASSY,PCB,HPB,AMP,LDMOS,35W,450 1 Each
C01388 HDWR,SCREW,SHC,SS,4-40,5/16" 9 Each
C02076 ADH,VIBRA-TITE 3,30CC 0.01 Oz.
C00413 HDWR,SCREW,SHC,SS,4-40,1/4 1 Each
Subassembly (A01611)
ITEM# PCC Part Qty Designators Description Value Footprint
no.
1 A00956 1 JP1 ASSY,CBL,PDL,BASE,AMP,DATA N/A N/A
2 C00092 1" R5 WIRE,HOOK-UP,SLD,24AWG,GRN 24 AWG WIRE
3 C00159 10 C73 C72 C66 CAP,0805,MONO,X7R,50V,N001.00 1000pF 0805
C55 C44 C34
C27 C24 C23
C15
4 C00268 1 C43 CAP,0805,RF+/-.25P,P010.00 10pF 0805
5 C00475 1 C68 CAP,0805,MONO,COG,50V,P020.00 20pF 0805
6 C00318 1 Q3 TRANS,SOT-23,NPN,MMBT2222A-7 2N2222 SOT-23
7 C00338 6 D8 D7 D6 D5 DIODE,SMT,PIN,MA4P1250 MA4P1250 1072
D4 D3
8 C00352 3 L19 L17 L16 IND,B06T,5%,N017.50 17.5nH B06T
9 C00365 1 C51 CAP,1210,MONO,GRM,100V,P018.0 18pF 1210
0
10 C00367 1 VR1 POT,SMT,CERMET,K002.00 2K POT 3MMSMPOT
11 C00467 1 C39 CAP,0805,RF,+/-.25P,P012.00 12pF 0805
12 C00476 1 C38 CAP,0805,MONO,COG,50V,P027.00 27pF 0805
13 C00480 9 C9 C10 C13 CAP,0805,MONO,COG,50V,P100.00 100pF 0805
C19 C28 C29
C36 C67 C76
14 C00484 4 C61 C26 C22 CAP,0805,MONO,X7R,50V,U000.10 0.1uF 0805
C20
15 C00485 1 C21 CAP,1206,MONO,X7R,25V,U001.00 1.0uF 1206
16 C00615 1 R34 RES,0805,5%,1/10W,D470.00 470 0805
17 C00569 1 C35 CAP,1210,MONO,GRH,500V,P012.0 12pF 1210
0
18 C00610 3 C58 C74 C75 CAP,0805,RF,+/.25P,P006.80 6.8pF 0805
19 C00626 4 C56 C40 C57 CAP,0805,,COG,5%,50V,P330.00 330pF 0805
C69
20 C00642 1 L14 IND,A05T,5%,18.5NH 18.5nH A05T
21 C00678 1 VR2 POT,SMT,CERMET,K010.00 10K POT 3MMSMPOT
22 C00738 1 L13 IND,0906,10%,N003.85 3.85nH 0906-4J
23 C00814 1 U1 IC,SOT-23,TEMP SENSOR,LM50C LM50C SOT-23
24 C00841 4 C14 C12 C11 CAP,0603,MONO,NPO,25V,P068.00 68pF 0603
C6
25 C00844 3 C52 C53 C54 CAP,0603,MONO,X7R,25V,N001.00 1000pF 0603
26 C00849 1 R17 RES,0603,5%,1/16W,D470.00 470 0603
27 C00850 1 R2 RES,0603,5%,1/16W,K001.00 1K 0603
28 C00853 1 R33 RES,0603,5%,1/16W,K004.70 4.7K 0603
29 C00856 5 R8 R12 R13 RES,0603,5%,1/16W,K010.00 10K 0603
R16 R9
30 C00888 1 D9 DIODE,SOT-23,ZENER,12V BZX84C12 SOT-23

Chapter 10
31 C00892 2 C16 C60 CAP,0603,MONO,Y5V,25V,U000.10 0.1uF 603
32 C00895 1 R11 RES,0603,5%,1/16W,D100.00 100 0603
33 C01090 1 K1 RELAY,SPST,NO,8A,12V,OMRON 12V OMRON
34 C01108 2 D2 D1 DIODE,DL-35,SCHOTTKY,40V DL-35 MELF1
35 C01249 9 C71 C70 C8 CAP,1206-3,EMI FILTER,N002.20 2200pF CAP_FEEDTH
C7 C5 C4 C3 RU2
C2 C1
36 C01254 1 L18 IND,0906,5%,N005.45 5.45nH 0906
37 C01284 2 C47 C49 CAP,1210,RF,COG,100V,P003.30 3.3pF 1210
38 C01286 4 R7 R6 R4 R3 RES,2010,5%,.5W,D039.00 39 1/2W 2010
39 C01287 1 R10 RES,1210,5%,.25W,D390.00 390 1/4W 1210
40 C01293 1 C45 CAP,1210,RF,COG,100V,P006.80 6.8pF 1210
41 C01295 1 C31 CAP,1210,RF,COG,100V,P008.20 8.2pF 1210
42 C01310 1 R1 RES,0603,5%,1/16W,K002.20 2.2K 0603
43 C01493 1 L9 IND,0906,10%,N002.55 2.55nH 0906
44 C01508 1 C50 CAP,1210,RF,COG,100V,P005.60 5.6pF 1210
45 C02098 2 C65 C64 CAP,1210,RF,500V,P068.00 68pF 1210
46 C01533 1 Q1 TRANS,466- MRF1513 MRF1513
02,3W,520MHZ,MRF1513T1
47 C01590 2 J3 J4 CONN,MCX,PCB,SMT,STRAIGHT MCX_SMT CONN_COAX
RECPT
48 C01714 2 C30 C59 CAP,0805,MONO,COG,50V,P003.30 3.3pF 0805
49 C01784 3 C18 C17 C25 CAP,7243,LOW ESR,20V,U068.00 68uF,20V 7243S
50 C01897 4 C42 C41 C33 CAP,1210,RF,100V,P300.00 300pF 1210
C32
51 C01898 2 C62 C63 CAP,1210,RF,100V,P56.00 56pF 1210
52 C01899 4 L23 L11 L5 IND,1008,10%,N120.00 0.12uH 1008
L3
53 C01900 1 L8 IND,1008,10%,N018.00 18nH 1008
54 C01904 3 L26 L6 L12 IND,168,5%,N084 84NH 16807
55 C01906 1 B3 FE BEAD,1812,SMT,120,25%,6AMP ILHB_1812_12 1812
0+/-25%
56 C01908 1 L1 FE BEAD,SMB3528,9.5A,U002.20 2.2uH,9.5A SMB3528
57 C01978 2 L7 L4 IND,168,5%,N024.00 24nH 16803
58 C01979 1 L20 IND,168,5%,N003.5 3.5nH 16601
59 C01981 1 B2 FE BEAD,1206,120 OHM,6A ILHB_1206_12 1206
0+/-25%
60 C02002 1 D10 DIODE,TO92,VREF,2.5V,LM336BZ LM336 2.5V TO-92
61 C01283 1 C48 CAP,1210,RF,COG,100V,P002.0 2.0pF 1210
62 E00084 1 PCB,HPB,A PCB,HPB,AMP,LDMOS,35W,UHF
MP,LDMOS,
35W,UHF
63 F00493 1 SHIELD,PDL, SHIELD,PDL,AMP,WALLS
AMP,WALLS
64 NO LOAD 5 C46 L10 P2 NL
Q6 Q2
65 D00668 N/A SCHEMATIC SCHM,HPB,AMP,LDMOS,35W,UHF N/A N/A
66 C01585 1 C37 CAP,0805,COG,5%,50V,P036.00 36pF 0805
67 C02417 1" SEE DWG WIRE,BARE,SLD,20 AWG 20 AWG WIRE
PG 2
68 C00399 0.01 D10 GLUE ADH,RTV,CLEAR 2.8OZ TUBE N/A ADHESIVE
TO C17 (SEE
DWG)

Chapter 10
RFMOD
Model specific components
Generic RFMOD (A02457)

no.
1 C00215 1 U5 IC,SO- HY62256ALJ- SOL-28
28W,SRAM,70N,32KX8,62256- 120
2 C00262 1 U2 IC,SO-14,MC74HC00AD 74LS00 SO-14
3 C00280 12 C146 C30 CAP,3216,TANT,25V,U001.00 1uF,25V 3216
C23 C164
C27 C28
C166 C55
C56 C29 C31
C34
4 C00281 4 C153 C165 CAP,3216,TANT,10V,U004.70 4.7uF,10V 3216
C155 C154
5 C00283 3 C52 C53 C54 CAP,3216,TANT,6.3V,U010.00 10uF,6.3V 3216
6 C00289 1 U4 IC,SMT,REG,LP2951ACM LP2951ACM SO-8
7 C00300 1 R2 RES,0805,5%,1/10W,M010.00 10M 805
8 C00309 2 R113 R11 RES,1206,5%,1/8W,D470.00 470/.125W 1206
9 C00318 5 Q13 Q2 Q3 TRANS,SOT-23,NPN,MMBT2222A-7 2N2222A SOT-23
Q6 Q4
10 C00368 1 R34 POT,SMT,CERMET,K100.00 100K POT 3MMSMPOT
11 C00371 1 R19 RES,0805,5%,1/10W,M003.00 3M 805
12 C00484 2 C114 C162 CAP,0805,MONO,X7R,50V,U000.10 .1uF 805
13 C00490 1 D1 DIODE,SOT-23,PIN,MMBV3401L MMBV3401L SOT-23
14 C00491 1 U15 IC,SO-16,FM IF, MC3371 MC3371 SOJ-16
15 C00493 1 L13 IND,1008,10%,N008.00 8nH 1008
16 C00494 2 L20 L21 IND,1008,10%,N015.00 15nH 1008
17 C00496 1 L22 IND,1008,10%,N068.00 68nH 1008
18 C00497 2 L2 L1 IND,1008,10%,U001.00 1uH 1008
19 C00500 1 L6 IND,CAN,6MM,U680.00 680uH CANSQ24
20 C00501 1 U16 MIXER,THRU-HOLE,TUF-1 TUF1 CAN4922
21 C00502 7 Q7 Q14 Q16 TRANS,SOT-23,RF,NPN,NE85633 NE85633 SOT-23
Q12 Q15 Q8

Chapter 10
Q9
22 C00505 1 L4 FE BEAD,AXI,5.3LX3.0D FE BEAD FE_BEAD
23 C00510 1 VC1 CAP,1804,ADJ,P010.00 3-10pF TZC03
25 C00513 1 D3 DIODE,SOT- MMBV3102L SOT-23
23,VARACT,MMBV3102
26 C00534 2 J4 J3 CONN,MCX,PCB,.2X.2,THRU MCX- MCX_ANT
STRAIGHT
27 C00546 7 L28 L15 L25 IND,1008,10%,N220.00 220nH 1008
L26 L24 L12
L27
28 C00563 1 L7 IND,B10T,5%,N043.00 43nH SMT_AC04/B
29 C00601 2 L8 L9 IND,1008,10%,N022.00 22nH 1008
30 C00603 3 L10 L11 L18 IND,1008,10%,N150.00 150nH 1008
32 C00638 1 C33 CAP,1206,MONO,X7R,25V,U000.15 0.15uF 1206
33 C00640 1 U17 IC,TSSOP-20,SYNTH,LMX2315TM LMX2315 MTC-20
34 C00647 2 D5 D4 DIODE,SOD-323,VAR,SMV1236-011 SMV1236-11 SOD-323
35 C02326 1 Q10 TRANS,SO-8,RF,ADV MRF5812 SO-8
PWR,MRF5812
36 C00657 1 L19 IND,1008,10%,N470.00 470nH 1008
37 C00679 1 U6 IC,SO-16,ANLG SW,74HC4052 74HC4052 SO-16
38 C00791 1 Y1 XTAL,SMT,CSM- 9.8304MHz CSM-7
7,PARL,9.8304MHZ
39 C00806 5 RP3 RP4 RES,PK,5%,ISO,16P,K010.00 10Kx8 RESPACK16
RP5 RP1
RP6
40 C00814 1 U20 IC,SOT-23,TEMP SENSOR,LM50C LM50C SOT-23
41 C00831 1 C192 CAP,0603,RF,+/-.1P,P003.00 3.0pF 603
42 C00833 4 C138 C139 CAP,0603,MONO,NPO,25V,P005.00 5.0pF 603
C193 C201
43 C00837 3 C190 C131 CAP,0603,RF,+/-2%,P015.00 15pF 603
C96
44 C00838 1 C60 CAP,0603,MONO,NPO,25V,P022.00 22pF 603
C84 C80 C81
C41 C171
C172 C173
C78 C82 C79
C83 C43 C77
C46 C45 C44
C73 C63 C85
C36 C37 C26
C22 C48 C47
C40
C87 C88 C89
C90 C91 C92
C134 C143
C147 C152
C157 C174
C175 C206
C207 C208
C212
47 C00843 1 C57 CAP,0603,MONO,NPO,25V,P220.00 220pF 603
48 C00844 14 C128 C156 CAP,0603,MONO,X7R,25V,N001.00 1000pF 603
C125 C196
C127 C159
C68 C163
C122 C120
C121 C124
C126 C183
49 C00846 32 C112 C100 CAP,0603,MONO,X7R,25V,N010.00 .01uF 603
C103 C184
C107 C188
C105 C106
C104 C123
C101 C102
C213 C16
C64 C66 C69

Chapter 10
C67 C72 C65
C15 C108
C186 C129
C187 C109
C98 C97 C99
C185 C214
C176
50 C00847 2 R46 R88 RES,0603,5%,1/16W,D120.00 120 603
51 C00848 3 R73 R123 RES,0603,5%,1/16W,D220.00 220 603
R95
52 C00849 2 R94 R92 RES,0603,5%,1/16W,D470.00 470 603
53 C00850 7 R63 R41 RES,0603,5%,1/16W,K001.00 1K 603
R114 R12
R84 R155
R156
54 C00851 1 R78 RES,0603,5%,1/16W,K002.70 2.7K 603
55 C00853 1 R50 RES,0603,5%,1/16W,K004.70 4.7K 603
56 C00854 3 R15 R16 R17 RES,0603,5%,1/16W,K005.60 5.6K 603
57 C00855 2 R83 R124 RES,0603,5%,1/16W,K006.80 6.8K 603
58 C00856 31 R52 R53 RES,0603,5%,1/16W,K010.00 10K 603
R108 R115
R141 R103
R5 R4 R42
R37 R9 R45
R8 R10 R3
R44 R137
R51 R112
R111 R6 R48
R49 R40 R71
R7 R143 R55
R142 R100
R157
59 C00857 1 R102 RES,0603,5%,1/16W,K033.00 33K 603
60 C00859 3 R62 R61 R39 RES,0603,5%,1/16W,K047.00 47K 603
61 C00860 1 R72 RES,0603,5%,1/16W,K056.00 56K 603
62 C00862 8 R66 R138 RES,0603,5%,1/16W,K100.00 100K 603
R122 R120
R21 R38 R18
R200
63 C00870 1 L29 IND,CERAMIC,3.85NH 3.85nH COAXR_SM
64 C00872 6 R146 R147 RES,0603,5%,1/16W,D018.00 18 603
R148 R127
R128 R89
65 C00877 1 C62 CAP,6032,TANT,16V,U022.00 22uF,16V 6032
66 C00878 1 R107 POT,SMT,CERMET,K050.00 50K POT 3MMSMPOT
67 C00892 30 C117 C150 CAP,0603,MONO,Y5V,25V,U000.10 .1uF 603
C110 C111
C158 C113
C161 C182
C177 C74 C7
C4 C35 C2
C8 C167
C169 C3 C17
C13 C12 C71
C11 C6 C9
C10 C1 C5
C115 C116
68 C00894 10 R67 R65 R98 RES,0603,5%,1/16W,D010.00 10 603
R68 R56 R35
R109 R69
R110 R134
69 C00895 6 R14 R13 RES,0603,5%,1/16W,D100.00 100 603
R136 R116
R117 R64
70 C00896 5 R96 R85 RES,0603,5%,1/16W,K015.00 15K 603
R145 R36
R144
71 C00898 2 R93 R101 RES,0603,5%,1/16W,K022.00 22K 603
72 C00899 2 R104 R74 RES,0603,5%,1/16W,K027.00 27K 603
73 C00900 4 R105 R130 RES,0603,5%,1/16W,K003.30 3.3K 603

Chapter 10
R106 R79
74 C00901 1 R135 RES,0603,5%,1/16W,D033.00 33 603
75 C00902 2 R86 R139 RES,0603,5%,1/16W,D330.00 330 603
76 C00903 4 R81 R80 R43 RES,0603,5%,1/16W,D051.00 51 603
R118
77 C00905 4 C179 C178 CAP,0603,MONO,NPO,25V,P082.00 82pF 603
C141 C142
78 C00917 2 C95 C94 CAP,0603,MONO,NPO,25V,P056.00 56pF 603
79 C00935 1 R59 RES,0603,1%,1/10W,K249.00 249K 603
C148
81 C00947 3 C160 C194 CAP,0603,RF,+/-.25P,200V,P005.60 5.6pF 603
C195
82 C01049 3 R125 R126 RES,0603,5%,1/16W,D270.00 270 603
R87
83 C01050 6 R23 R22 R25 RES,0603,5%,1/16W,K051.00 51K 603
R26 R24 R27
84 C01053 2 U8 U7 IC,SO-14,QUAD OP LMC6584AI SO-14
AMP,LMC6484AIM
85 C01054 4 C168 C25 CAP,0603,COG,25V,P470.00 470pF 603
C20 C133
86 C01058 1 R1 RES,0603,5%,1/16W,K330.00 330k 603
87 C01092 1 U13 IC,SMT,DAC,8 BIT,MAX549AEUA MAX549AEUA SO-8MAX
88 C01105 1 C75 CAP,7243D,LOW-ESR,35V,U015.00 15uF,35V 7243H
89 C01126 1 R31 RES,0603,1%,K020.00 20.0K 603
90 C01132 3 R32 R33 RES,0603,5%,1/16W,K082.00 82K 603
R119
91 C01148 3 U21 U23 U22 IC,SO-8,REG,MIC5200-5.0BM MIC5200-5BM SO-8
92 C01151 2 C51 C50 CAP,0603,MONO,X7R,25V,N015.00 .015uF 603
93 C01158 1 R30 RES,0603,1%,1/16W,K031.60 31.6K 603
94 C01233 1 RP2 RES PK,5%,ISO,16P,D100.00 100x8 RESPACK16
95 C01239 2 L5 L3 IND,1008,10%,N082.00 82nH 1008
96 C01240 1 U10 IC,PLCC32,FLASH,AM29F010A AM29F010A- PLCC32
120JI
97 C01241 1 J2 CONN,SMT,FFC,1MM,30 PIN CONN30 CONN_1MM30
FLEX
98 C01242 1 U14 IC,SO-8,OP AMP,LM7301M LM7301 SO-8
99 C01243 1 U11 IC,UMAX,ISNS,MAX4172 MAX4172 SO-8MAX
100 C01245 1 U9 IC,PLCC-68,QUART,ST16C454IJ68 ST16C454IJ68 PLCC68
101 C01246 1 U12 IC,SO-8,VGND,2.5V,TLE2425 TLE2425 SO-8
102 C01247 2 C191 C32 CAP,0603,MONO,COG,50V,P150.00 150pF 603
103 C01251 1 R133 RES,0603,5%,1/16W,D024.00 24 603
104 C01252 3 R154 R153 RES,0603,5%,1/16W,D390.00 390 603
R82
105 C01254 1 L30 IND,0906,5%,N005.45 5.45nH SMT_AC_0906
106 C01255 4 C118 C189 CAP,0603,RF,+/-.25P,P006.80 6.8pF 603
C132 C137
107 C01256 6 R99 R149 RES,0603,5%,1/16W,D068.00 68 603
R150 R129
R151 R152
108 C01304 1 J1 CONN,HDR,MOLEX,2MM,RA,13P CON13 CONN_13PIN
109 C01310 2 R47 R20 RES,0603,5%,1/16W,K002.20 2.2K 603
110 C01311 1 C145 CAP,0805,X7R,16V,U000.15 0.15uF 805
111 C01312 1 R57 RES,0603,1%,K100.00 100.0K 603
112 C01313 1 R131 RES,0603,5%,1/16W,K012.00 12K 603
113 C01314 1 R58 RES,0603,1%,K018.70 18.7K 603
114 C01315 2 R91 R132 RES,0603,5%,1/16W,D043.00 43 603
115 C01316 2 C180 C181 CAP,0603,X7R,50,N004.70 4700pF 603
116 C01317 1 R60 RES,0603,1%,K698.00 698k 603
117 C01318 1 U3 IC,TSSOP-24,CMX589AE2 CMX589AE2 TSSOP24
118 C01319 1 U1 IC,uP,MC68HC11F1CPU4 MC68HC11F1 QFP80
CPU4
119 C01320 1 U27 IC,SSOP-24,MX919BDS MX919BDS SSOP24
120 C01341 2 L16 L17 IND,0805,10%,N470.00 470nH 805
121 C01453 1 C49 CAP,0603,COG,5%,50V,P390.00 390pF 603
122 C01474 1 L23 IND,0603,5%,N015.00 15nH 603
123 C01475 2 Q5 Q1 TRANS,SOT- FMMT717 SOT-23
23,PNP,2.5A,FMMT717
124 C01480 1 C70 CAP,0603,X7R,10%,25V,N033.00 .033uF 603

Chapter 10
125 C01481 1 R140 RES,1210,1/4W,5%,D043.00 43, 1/4W 1210
126 C01490 1 U24 IC,MS08,AMP,UPC1678GV UPC1678GV SO-8
127 C01527 1 R90 RES,0603,5%,1/16W,D062.00 62 603
128 C01532 1 R70 RES,0603,5%,1/16W,K001.20 1.2K 603
129 C02325 1 VC7 CAP,2MM,ADJ,P001.50 1.5-3.0pF MURATA
TZY2
130 C01735 1 VC6 CAP,A4M3,ADJ,P000.60 0.6-2.0pF A4M3
131 C01736 1 U19 IC,SO-6UPC,AMP,UPC2710TB UPC2710TB SO-6UPC
132 C02001 1 R160 RES,0805,1%,D0022.00 22 805
133 C02127 1 R54 RES,0603,5%,1/16W,D820.00 820 603
134 C02181 1 U18 IC,SOT-363,AMP,UPC3215TB UPC3215TB SOT-363
135 C02305 1 R29 RES,0603,5%,K011.00 11K 603
136 C02306 1 R28 RES,0603,5%,K018.00 18K 603
137 C00835 4 C140 C144 CAP,0603,RF,+/-,.25P,P010.00 10pF 603
C135 C170
139 E00050 1 PCB PCB,PDL BASE,RADIO MODEM,
REV 7
140 F00502 1 SHIELD SHIELD,PDL,VCO,WALL N/A N/A
WALL
141 F00504 1 SHIELD SHIELD,PDL,XTAL,WALL N/A N/A
WALL
142 no load 8 C205 C204 SEE NOTE 6 ON PAGE 1
C59 C24 C61
C42 R97
C130
143 no load 17 R121 R158 SEE NOTE 6 ON PAGE 1 NL N/A
R159 C197
C198 C199
C200 C202
C203 C209
C210 BPF1
BPF2 VC2
C211 L14 X2
144 no load 1PAI CF1 CF2 NL
R
145 no load 2 CF3 CF4 NL
Front panel assembly

Part no. Description Qty. U/M
A02388 ASSY,PDL,BASE,I/O BD,AUTO, PWR/ON 1 Each
F00419 BUTTON,PDL,TACT,BLK 2 Each
F00461 PANEL,PDL,BASE,FRT,ANOD 1 Each
C01393 HDWR,SCREW,PH,FL,SS,4-40,5/8 5 Each
C01461 HDWR,STOFF,HX,ALU,#4,297L 5 Each
C00217 HDWR,WASHER,SS,SPR LCK,#4 5 Each
C00263 HDWR,STOFF,HX,ALU,#4,3/16L 4 Each
C01228 CBL,FLEX,1MM,30C,7" 1 Each
C01451 HDWR,SPCR,NYL,.14ID,.250OD,.25 2 Each
C00377 GREASE,THERMAL,SILICON 0.01 Oz.
C00441 ADH,LOCTITE 242 0.01 Oz.

Chapter 10
I/O board
no.
1 C00105 1 GROUND CAP,RAD,TANT,25V,U010.00 25V,10uF N/A
AND C5
2 C00214 4 D7 D5 D6 LED,T-1,HI-EFF,RED LED SIP2
D8*
3 C00283 1 C7 CAP,3216,TANT,6.3V,U010.00 10uF,6.3V 3216
4 C00362 1 U1* IC,TO-220,REG,FXD,LM2940T-8.0 LM2940T-8.0 TO-220
5 C00399 0.01 C00105 ADH,SILICONE,RTV,CLEAR
Oz.
6 C00484 1 C19 CAP,0805,MONO,X7R,50V,U000.10 .1uF 805
7 C00846 1 C5 CAP,0603,MONO,X7R,25V,N010.00 .01uF 603
8 C00849 3 R39 R38 R7 RES,0603,5%,1/16W,D470.00 470 603
9 C00850 4 R8 R9 R10 RES,0603,5%,1/16W,K001.00 1K 603
R11
10 C00855 1 R29 RES,0603,5%,1/16W,K006.80 6.8K 603
11 C00856 4 R19 R22 R21 RES,0603,5%,1/16W,K010.00 10K 603
R14
12 C00884 2 RV12 RV11 VARISTOR,0805,TVS,18V VARISTOR 805
13 C00888 1 D4* DIODE,SOT-23,ZENER,12 BZX84C12 SOT-23
14 C00892 10 C20 C18 C13 CAP,0603,MONO,Y5V,25V,U000.10 .1uF 603
C17 C4 C14
C15 C16 C2
C6
15 C00894 1 R13 RES,0603,5%,1/16W,D010.00 10 603
16 C00900 1 R17 RES,0603,5%,1/16W,3.3K 3.3K 603
17 C00981 1 D1* DIODE,MELF,RECT,1N5819M 5819 MELF1
18 C01050 1 R1 RES,0603,5%,1/16W,51K 51K 603
19 C01101 1 J5 CONN,HDR,MOLEX,2MM,STRT,6P CON6 CONN_6PIN
20 C01105 1 C1 CAP,7243D,TANT,LOW- 15uF, 35V 7243D
ESR,15uF,35V
21 C01106 1 C3 CAP,7243D,TANT,LOW- 220uF, 10V 7243D
ESR,220uF,10V
22 C01107 1 D2* DIODE,SMBJ,TVS,26V SMBJ24A SMBJ
23 C01148 1 U2* IC,SMT,REG,MIC5200-5.0 MIC5200-5BM SO-8
24 C01152 1 F3 FUSE,1804.PTC,.5A POLYFUSE 1804
25 C01174 1 RP1 RES PK,5%,ISO,16P,K001.00 8X1K RESPACK16
26 C01191 2 SW1 SW2 SW,SMT,PCB,SPST,NO SW-PB SW_TACT6X6
27 C01197 2 U4 U3* IC,SO-14,SER SHIFT REG,HC164 74HC164 SO-14
28 C01241 1 J1 CONN,SMT,FFC,1MM,30 PIN CON30 CONN_1MM30
FLEX
29 C01305 1 Q2* TRANS,SOT-23,.2N7002 2N7002 SOT-23
30 C01306 1 DISP1* DISP,LDS-A5206RI 7 SEG LED DISPLAY_.5
DISP
31 C01307 1 U6* IC,SOL-24,ADM207EAR ADM207EAR SOL-24
32 C01309 1 Q1* TRANS,SO-8,PFET,Si4435D SI4435DY SO-8
33 C02502 1 Q3*TRANS, TP0610K SOT-23
SOT-23,
PFET,
TP0610K
34 C01416 1 D3* DIODE,SOT-23,BAS74 BAV74 SOT-23
35 E00052 1 PCB PCB,PDL,BASE,INTERFACE BD N/A N/A

PDL HPB Service Manual
Manual Change Log

Manual version
Version Date Changes
0.9 01-10-07 Initial draft for review
1.0 03-2-07 Initial release

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PDL HPB

PDL HPB Service Manual P/N M00746, Revision 1

Chapter 1 - General Information and Safety ............................................................ 1

Chapter 2 - Product History and Specifications ..................................................... 8

Chapter 3 - Theory of Operation ............................................................................. 11

PDL HPB Service Manual i P/N M00746 revision 1

Chapter 4 - Interfaces .............................................................................................. 21

Chapter 5 - Troubleshooting ................................................................................... 23

PDL HPB Service Manual ii P/N M00746 revision 1

Program test settings ................................................................................................................ 24

Chapter 6 - Maintenance and Repair ...................................................................... 26

Chapter 7 - Adjustments and Verification .............................................................. 43

PDL HPB Service Manual iii P/N M00746 revision 1

Chapter 8 - Assembly Drawings & Schematics ..................................................... 72

Chapter 9 - Service Software ................................................................................ 108

Chapter 10 - Replacement Parts List .................................................................... 110

PDL HPB Service Manual iv P/N M00746 revision 1

Model-specific subassemblies................................................................................................. 111

Manual Change Log................................................................................................ 121

PDL HPB Service Manual v P/N M00746 revision 1

PDL HPB Service Manual 1 P/N M00746, Revision 1

Updating this manual

Deciding what is serviceable

PDL HPB Service Manual 2 P/N M00746, Revision 1

Removing and replacing parts

Warnings and Cautions

Electrostatic Discharge (ESD)

PDL HPB Service Manual 3 P/N M00746, Revision 1

ESD Prevention Requirements

PDL HPB Service Manual 4 P/N M00746, Revision 1

Protective flooring requirements

Protective clothing requirements

Packaging and shipping requirements

Personal grounding straps requirements

Grounded workbench requirements

PDL HPB Service Manual 5 P/N M00746, Revision 1

Test equipment requirements

Setting up an ESD workstation

PDL HPB Service Manual 6 P/N M00746, Revision 1

PDL HPB Service Manual 7 P/N M00746, Revision 1

PDL HPB Service Manual 8 P/N M00746, Revision 1

PDL HPB Service Manual 9 P/N M00746, Revision 1

PDL HPB Service Manual 10 P/N M00746, Revision 1

PDL HPB Service Manual 11 P/N M00746, Revision 1

Radio Modem Board (RFMOD)

Table 1 – RFMOD pin-out descriptions Connector J1 – Amp Interface

Pin # Name Description Direction

PDL HPB Service Manual 12 P/N M00746, Revision 1

Pin# Name Description Direction

PDL HPB Service Manual 13 P/N M00746, Revision 1

Synthesizer and Dual Voltage Controlled Oscillators (VCO)

A01655 family RFMOD

A00938 family RFMOD (Pre-2003)

PDL HPB Service Manual 14 P/N M00746, Revision 1

A01655 family RFMOD

A00938 family RFMOD (pre-2003)

PDL HPB Service Manual 15 P/N M00746, Revision 1

Table 3 – AMPMOD pin-out descriptions, connector JP1 – RFMOD Interface