2. i
Title Page
ASTRO®
Digital XTL™ 2500
Mobile Radio
M5 Control Head
Service Manual
M
Motorola, Inc.
1301 E. Algonquin Rd,
Schaumburg, IL 60196-1078 USA
August, 2007
Preliminary
4. iii
6871771L01-A August 6, 2007
Document History
The following major changes have been implemented in this manual since the previous edition:
Edition Description Date
6871771L01-A Initial Release Aug. 2007
6. Table of Contents v
6871771L01-A August 6, 2007
Table of Contents
Foreword.........................................................................................................ii
Product Safety and RF Exposure Compliance............................................................................................ii
Manual Revisions ........................................................................................................................................ii
Computer Software Copyrights ...................................................................................................................ii
Document Copyrights..................................................................................................................................ii
Disclaimer....................................................................................................................................................ii
Trademarks .................................................................................................................................................ii
Document History .........................................................................................iii
Commercial Warranty .................................................................................xiii
Limited Warranty ...................................................................................................................................... xiii
MOTOROLA COMMUNICATION PRODUCTS.............................................................................. xiii
I. What This Warranty Covers And For How Long ................................................................... xiii
II. General Provisions............................................................................................................... xiii
III. State Law Rights .................................................................................................................xiv
IV. How To Get Warranty Service ............................................................................................xiv
V. What This Warranty Does Not Cover...................................................................................xiv
VI. Patent And Software Provisions ..........................................................................................xv
VII. Governing Law....................................................................................................................xv
Chapter 1 Introduction ......................................................................... 1-1
1.1 Notations Used in This Manual...................................................................................................... 1-1
1.2 Control Head Features .................................................................................................................. 1-2
1.3 Control Head Descriptions............................................................................................................. 1-2
1.3.1 XTL 2500 Control Head. ................................................................................................... 1-2
1.3.2 XTL 2500 Controls............................................................................................................ 1-3
Chapter 2 Basic Maintenance.............................................................. 2-1
2.1 Introduction.................................................................................................................................... 2-1
2.2 Preventive Maintenance ................................................................................................................ 2-1
2.2.1 Inspection ......................................................................................................................... 2-1
2.2.2 Cleaning............................................................................................................................ 2-1
2.2.2.1 Cleaning External Plastic Surfaces.......................................................................... 2-1
2.2.2.2 Cleaning Internal Circuit Boards and Components.................................................. 2-1
2.2.3 General Radio Care and Handling Precautions................................................................ 2-2
2.3 Handling Precautions..................................................................................................................... 2-2
7. vi Table of Contents
August 6, 2007 6871771L01-A
Chapter 3 Theory of Operation............................................................ 3-1
3.1 System Overview...........................................................................................................................3-1
3.1.1 Dash Mount.......................................................................................................................3-1
3.1.2 Remote Mount ..................................................................................................................3-2
3.1.2.1 Remote Mount Data and Audio Communications....................................................3-2
3.1.2.2 CAN Bus and Auto-Termination...............................................................................3-3
3.1.3 System On / Off / Reset Communications ........................................................................3-4
3.2 M5 Control Head Main Board ........................................................................................................3-8
3.2.1 DC Power Distribution.......................................................................................................3-8
3.2.1.1 TPS65010 Power Management IC ..........................................................................3-8
3.2.1.2 2.8 Volt Regulator (Main Board) ............................................................................3-10
3.2.1.3 3.3 Volt Un-switched Regulator (Main Board)........................................................3-11
3.2.1.4 5 Volt Regulator (Main Board) ...............................................................................3-13
3.2.2 Mobile Microphone Port (MMP) ......................................................................................3-14
3.2.3 Microcontroller and Memory ...........................................................................................3-16
3.2.4 User interface..................................................................................................................3-16
3.2.5 AVR On, Off, Reset Control Circuit.................................................................................3-18
3.2.5.1 Power Button .........................................................................................................3-18
3.2.5.2 Ignition ...................................................................................................................3-19
3.2.5.3 MMP Power on Accessory.....................................................................................3-19
3.2.5.4 Emergency.............................................................................................................3-19
3.2.5.5 Remote Commands...............................................................................................3-20
3.2.5.6 Local Commands...................................................................................................3-20
3.2.5.7 5 Volt Transceiver Feedback .................................................................................3-21
3.2.6 AVR Outputs ...................................................................................................................3-21
3.3 Remote Back Housing Assembly.................................................................................................3-22
3.3.1 Control Head Interface Board (CHIB) .............................................................................3-22
3.3.1.1 DC Power Distribution............................................................................................3-22
3.3.1.1.1 1.5 Volt Regulator (CHIB) ...............................................................................3-23
3.3.1.1.2 1.8 Volt Regulator (CHIB) ...............................................................................3-23
3.3.1.1.3 2.85 Volt Regulator (CHIB) .............................................................................3-24
3.3.1.1.4 3.3 Volt Un-switched Regulator (CHIB) ..........................................................3-24
3.3.1.1.5 3.3 Volt Regulator (CHIB) ...............................................................................3-24
3.3.1.1.6 9.66 Volt Regulator (CHIB) .............................................................................3-25
3.3.1.1.7 11 Volt Regulator (CHIB) ................................................................................3-25
3.3.1.2 FPGA .....................................................................................................................3-25
3.3.1.3 Version ID ..............................................................................................................3-26
3.3.1.4 CAN Transceivers..................................................................................................3-26
3.3.1.5 CODEC SSI Bus....................................................................................................3-27
3.3.1.6 SPI Bus..................................................................................................................3-27
3.3.1.7 Main SSI Bus .........................................................................................................3-27
3.3.1.8 Control signals .......................................................................................................3-27
3.3.1.9 USB Connectivity...................................................................................................3-28
3.3.1.10 USB Device port ....................................................................................................3-28
3.3.1.11 USB Host port........................................................................................................3-29
3.3.1.12 Audio Section.........................................................................................................3-30
3.3.1.12.1TX Audio.........................................................................................................3-30
3.3.1.12.2Rx Radio.........................................................................................................3-31
3.3.2 Control Head Universal Connector (CHUC) ...................................................................3-32
3.3.2.1 DC Power Distribution............................................................................................3-32
3.3.2.2 J100 / J400 switching and VIP / DEK cable use....................................................3-33
3.3.2.3 Cable Detection at Power on .................................................................................3-33
3.3.2.4 ESD and RFI suppression .....................................................................................3-34
8. Table of Contents vii
6871771L01-A August 6, 2007
3.4 Transceiver Interface Board (TIB) ............................................................................................... 3-34
3.4.1 DC Power Distribution .................................................................................................... 3-35
3.4.1.1 1.5 Volt Regulator (TIB)......................................................................................... 3-35
3.4.1.2 2.85 Volt Regulator (TIB)....................................................................................... 3-36
3.4.1.3 3.3 Volt Un-switched Regulator (TIB) .................................................................... 3-36
3.4.1.4 3.3 Volt Regulator (TIB)......................................................................................... 3-37
3.4.1.5 5 Volt Regulator (TIB)............................................................................................ 3-37
3.4.1.6 A+ and SW_B+ (TIB)............................................................................................. 3-38
3.4.1.7 MMP Power ........................................................................................................... 3-38
3.4.2 AVR On, Off, Reset Control Circuit................................................................................. 3-38
3.4.2.1 Ignition at J2 (MAP) ............................................................................................... 3-38
3.4.2.2 Ignition at J600 ...................................................................................................... 3-39
3.4.2.3 AVR Outputs.......................................................................................................... 3-39
3.4.3 Emergency at J2 (MAP) and J600.................................................................................. 3-40
3.4.4 5 Volt input from Transceiver.......................................................................................... 3-40
3.4.5 Charge Pump.................................................................................................................. 3-40
3.4.6 CODEC........................................................................................................................... 3-41
3.4.7 FPGA .............................................................................................................................. 3-41
3.4.8 Version ID ....................................................................................................................... 3-42
3.4.9 CAN Transceivers........................................................................................................... 3-42
3.4.10 CODEC SSI Bus............................................................................................................. 3-43
3.4.11 SPI Bus........................................................................................................................... 3-43
3.4.12 Main SSI Bus .................................................................................................................. 3-43
3.4.13 Control Signals ............................................................................................................... 3-43
3.4.14 Mobile Microphone Port (MMP) ...................................................................................... 3-44
3.4.15 VIP-OUT operation (i.e. Vehicle Interface Port).............................................................. 3-44
3.4.16 VIP-IN operation (i.e. Vehicle Interface Port).................................................................. 3-44
3.4.17 Quick Disconnect............................................................................................................ 3-44
Chapter 4 Troubleshooting.................................................................. 4-1
4.1 Introduction.................................................................................................................................... 4-1
4.2 Handling Precautions..................................................................................................................... 4-1
4.2.1 Parts Replacement ........................................................................................................... 4-1
4.2.2 Rigid Circuit Boards .......................................................................................................... 4-2
4.2.3 Heat-Related Precautions................................................................................................. 4-2
4.3 Troubleshooting Charts ................................................................................................................. 4-2
4.3.1 Radio Does not power on Troubleshooting ...................................................................... 4-4
4.3.2 FL 01-90 Troubleshooting................................................................................................. 4-8
4.3.3 System “ON” pulse not sent by Control Head Troubleshooting........................................ 4-9
4.3.4 Remote SW_B+ not present Troubleshooting ................................................................ 4-10
4.3.5 Fail 05-93 Troubleshooting ............................................................................................. 4-13
4.3.6 Control Head SSI Troubleshooting ................................................................................ 4-17
4.3.7 CHIB Voltage Troubleshooting ....................................................................................... 4-20
4.3.8 CHIB USB Device Troubleshooting ................................................................................ 4-21
4.3.9 CHIB USB Host Troubleshooting.................................................................................... 4-22
4.3.10 CHIB CAN Verification Troubleshooting ......................................................................... 4-23
4.3.11 CHIB CODEC Troubleshooting ...................................................................................... 4-24
4.3.12 CHIB No Audio Troubleshooting..................................................................................... 4-25
4.3.13 CHIB No Transmit Troubleshooting................................................................................ 4-26
4.3.14 CHIB Transmit Path Troubleshooting ............................................................................. 4-27
4.3.15 CHIB Audio PA Troubleshooting .................................................................................... 4-28
4.3.16 CHIB Record Audio Troubleshooting.............................................................................. 4-29
9. viii Table of Contents
August 6, 2007 6871771L01-A
4.3.17 CHUC Fail J100 Troubleshooting ...................................................................................4-30
4.3.18 CHUC Emergency Activation Fail Troubleshooting ........................................................4-31
4.3.19 CHUC Remote Mount Operation Fail Troubleshooting...................................................4-32
4.3.20 CHUC DEK Fail Troubleshooting....................................................................................4-33
4.3.21 CHUC VIPOUT Fail Troubleshooting..............................................................................4-34
4.3.22 CHUC VIPIN Fail Troubleshooting..................................................................................4-35
4.3.23 No A+ Detected at CHIB Troubleshooting ......................................................................4-36
4.3.24 TIB Data Loss or Distorted Audio Troubleshooting.........................................................4-37
4.3.25 TIB Emergency Activation Fail Troubleshooting .............................................................4-38
4.3.26 Power on Failure at J600 with Emergency Accessory Troubleshooting .........................4-39
4.3.27 TIB SSI Troubleshooting.................................................................................................4-40
4.3.28 Radio does not Power on with Ignition Applied Troubleshooting....................................4-41
4.3.29 Radio does not work without Control Head or TIB attached Troubleshooting ................4-42
4.3.30 Radio will not Power Off Troubleshooting.......................................................................4-43
4.3.31 Multi-control head Turn On or Refresh Fail Troubleshooting..........................................4-44
4.3.32 Cable / Accessory at J700 Fail Troubleshooting.............................................................4-45
4.3.33 VIPS not working at J600 Troubleshooting.....................................................................4-46
4.3.34 J600 Fail Troubleshooting...............................................................................................4-47
4.4 TIB Board Verification..................................................................................................................4-48
4.5 Troubleshooting procedures ........................................................................................................4-49
Chapter 5 Schematics, Overlays, and Parts Lists ............................. 5-1
5.1 List of Schematics, Component Location Diagrams, and Parts Lists ............................................5-1
Appendix A Replacement Parts Ordering..............................................A-1
A.1 Basic Ordering Information ............................................................................................................A-1
A.2 Motorola Online..............................................................................................................................A-1
A.3 Mail Orders ....................................................................................................................................A-1
A.4 Telephone Orders..........................................................................................................................A-1
A.5 Fax Orders.....................................................................................................................................A-1
A.6 Parts Identification .........................................................................................................................A-2
A.7 Product Customer Service.............................................................................................................A-2
Appendix B Motorola Service Centers...................................................B-1
B.1 Servicing Information .....................................................................................................................B-1
B.2 Motorola Service Center ................................................................................................................B-1
B.3 Motorola Federal Technical Center................................................................................................B-1
B.4 Motorola Canadian Technical Logistics Center .............................................................................B-1
Glossary.........................................................................................Glossary-1
Index.....................................................................................................Index-1
10. List of Figures ix
6871771L01-A August 6, 2007
List of Figures
Figure 1-1. XTL 2500 Control Head ....................................................................................................... 1-2
Figure 3-1. Control Head to Transceiver Interface (Mid Power Only) .................................................... 3-1
Figure 3-2. Remote Control Head Interface (High Power) ..................................................................... 3-2
Figure 3-3. Remote Control Head Interface (Mid Power)....................................................................... 3-3
Figure 3-4. CAN BUS Auto-Termination................................................................................................. 3-3
Figure 3-5. System Level Block Diagram ............................................................................................... 3-5
Figure 3-6. Transceiver Interface Board (TIB) Block Diagram ............................................................... 3-5
Figure 3-7. Control Head Interface Board (CHIB) Block Diagram.......................................................... 3-6
Figure 3-8. Control Head Main Board Block Diagram ............................................................................ 3-7
Figure 3-9. Main Board DC Distribution.................................................................................................. 3-8
Figure 3-10. MMP Connector ................................................................................................................. 3-14
Figure 3-11. MMP Multiplex Block Diagram ........................................................................................... 3-15
Figure 3-12. M5 Control Head................................................................................................................ 3-16
Figure 3-13. LED Shutter Control Diagram ............................................................................................ 3-17
Figure 3-14. On / Off / Reset Control Circuit .......................................................................................... 3-21
Figure 3-15. Remote Back Housing Assembly (CHIB and CHUC) ........................................................ 3-22
Figure 3-16. CHIB power distribution ..................................................................................................... 3-23
Figure 3-17. FPGA and supporting circuits ............................................................................................ 3-26
Figure 3-18. USB device port connections............................................................................................. 3-28
Figure 3-19. USB D+ and D- during full speed transaction .................................................................... 3-29
Figure 3-20. Transmit Audio Path........................................................................................................... 3-30
Figure 3-21. RX Audio Path ................................................................................................................... 3-31
Figure 3-22. Control Head Universal Connector (CHUC)....................................................................... 3-32
Figure 3-23. Control Head Universal Connector (CHUC) Power distribution......................................... 3-32
Figure 3-24. CHUC Connectors ............................................................................................................. 3-33
Figure 3-25. Transceiver Interface Board (TIB)...................................................................................... 3-34
Figure 3-26. TIB Assembly Accessory Connectors................................................................................ 3-34
Figure 3-27. TIB Power Distribution Block Diagram............................................................................... 3-35
Figure 3-28. TIB AVR Block Diagram..................................................................................................... 3-40
Figure 3-29. PA mode and EXTERNAL RADIO mode audio routing ..................................................... 3-41
Figure 3-30. FPGA Block Diagram......................................................................................................... 3-42
Figure 4-1. Radio Does not power on Troubleshooting (Sheet 1 of 4) ................................................... 4-4
Figure 4-2. Radio Does not power on Troubleshooting (Sheet 2 of 4) ................................................... 4-5
Figure 4-3. Radio Does not power on Troubleshooting (Sheet 3 of 4) ................................................... 4-6
Figure 4-4. Radio Does not power on Troubleshooting (Sheet 4 of 4) ................................................... 4-7
Figure 4-5. FL 01-90 Troubleshooting.................................................................................................... 4-8
Figure 4-6. System “ON” pulse not sent by Control Head Troubleshooting ........................................... 4-9
Figure 4-7. Remote SW_B+ not present Troubleshooting (Sheet 1 of 3)............................................. 4-10
Figure 4-8. Remote SW_B+ not present Troubleshooting (Sheet 2 of 3)............................................. 4-11
Figure 4-9. Remote SW_B+ not present Troubleshooting (Sheet 3 of 3)............................................. 4-12
Figure 4-10. Fail 05-93 Troubleshooting (Sheet 1 of 4).......................................................................... 4-13
Figure 4-11. Fail 05-93 Troubleshooting (Sheet 2 of 4).......................................................................... 4-14
Figure 4-12. Fail 05-93 Troubleshooting (Sheet 3 of 4).......................................................................... 4-15
Figure 4-13. Fail 05-93 Troubleshooting (Sheet 4 of 4).......................................................................... 4-16
Figure 4-14. Control Head SSI Troubleshooting (Sheet 1 of 3).............................................................. 4-17
Figure 4-15. Control Head SSI Troubleshooting (Sheet 2 of 3).............................................................. 4-18
Figure 4-16. Control Head SSI Troubleshooting (Sheet 3 of 3).............................................................. 4-19
Figure 4-17. CHIB Voltage Troubleshooting........................................................................................... 4-20
Figure 4-18. CHIB USB Device Troubleshooting ................................................................................... 4-21
Figure 4-19. CHIB USB Host Troubleshooting ....................................................................................... 4-22
11. x List of Figures
August 6, 2007 6871771L01-A
Figure 4-20. CHIB CAN Verification Troubleshooting.............................................................................4-23
Figure 4-21. CHIB CODEC Troubleshooting..........................................................................................4-24
Figure 4-22. CHIB No Audio Troubleshooting ........................................................................................4-25
Figure 4-23. CHIB No Transmit Troubleshooting....................................................................................4-26
Figure 4-24. CHIB Transmit Path Troubleshooting.................................................................................4-27
Figure 4-25. CHIB Audio PA Troubleshooting ........................................................................................4-28
Figure 4-26. CHIB Record Audio Troubleshooting .................................................................................4-29
Figure 4-27. CHUC Fail J100 Fail Troubleshooting................................................................................4-30
Figure 4-28. CHUC Emergency Activation Fail Troubleshooting............................................................4-31
Figure 4-29. CHUC Remote Operation Fail Troubleshooting .................................................................4-32
Figure 4-30. CHUC DEK Fail Troubleshooting.......................................................................................4-33
Figure 4-31. CHUC VIPOUT Troubleshooting........................................................................................4-34
Figure 4-32. CHUC VIPIN Fail Troubleshooting.....................................................................................4-35
Figure 4-33. No A+ Detected at CHIB Troubleshooting..........................................................................4-36
Figure 4-34. TIB Data Loss or Distorted Audio Troubleshooting ............................................................4-37
Figure 4-35. TIB Emergency Activation Fail Troubleshooting ................................................................4-38
Figure 4-36. Power on Failure at J600 with Emergency Accessory Troubleshooting ............................4-39
Figure 4-37. TIB SSI Troubleshooting ....................................................................................................4-40
Figure 4-38. Radio does not Power On with Ignition Applied Troubleshooting ......................................4-41
Figure 4-39. Radio does not work without Control Head or TIB attached Troubleshooting....................4-42
Figure 4-40. Radio will not Power Off Troubleshooting ..........................................................................4-43
Figure 4-41. Multi-control head Turn On or Refresh Fail Troubleshooting .............................................4-44
Figure 4-42. Cable / Accessory at J700 Fail Troubleshooting................................................................4-45
Figure 4-43. VIPS not working at J600 Troubleshooting ........................................................................4-46
Figure 4-44. J600 Fail Troubleshooting..................................................................................................4-47
12. List of Tables xi
6871771L01-A August 6, 2007
List of Tables
Table 1-1. Control Head Basic Features............................................................................................... 1-2
Table 3-1. CAN3 Command Pulse Widths............................................................................................ 3-4
Table 3-2. VMAIN (3.3 volt) Step-down Converter Load List ................................................................ 3-8
Table 3-3. VCORE (1.5 volt) Step-down Converter Load List............................................................... 3-9
Table 3-4. VLDO2 (1.8 volt) Regulator Load List ................................................................................ 3-10
Table 3-5. 2.8 Volt Regulator Load List............................................................................................... 3-10
Table 3-6. 3.3 Volt Un-switched Regulator Load List .......................................................................... 3-11
Table 3-7. 5 Volt Regulator Load List................................................................................................. 3-13
Table 3-8. Local Command Pulse Widths........................................................................................... 3-20
Table 3-9. 1.8 Volt Regulator Load List.............................................................................................. 3-23
Table 3-10. 2.85 Volt Regulator Load List............................................................................................ 3-24
Table 3-11. Unswitched 3.3 Volt Regulator Load List .......................................................................... 3-24
Table 3-12. 3.3 Volt Regulator Load List.............................................................................................. 3-24
Table 3-13. 9.66 Volt Regulator Load List............................................................................................ 3-25
Table 3-14. 11 Volt Regulator Load List ............................................................................................... 3-25
Table 3-15. 1.5 Volt Regulator Load List.............................................................................................. 3-35
Table 3-16. 2.85 Volt Regulator Load List............................................................................................ 3-36
Table 3-17. Unswitched 3.3 Volt Regulator Load List .......................................................................... 3-36
Table 3-18. 3.3 Volt Regulator Load List.............................................................................................. 3-37
Table 3-19. 5 Volt Regulator Load List................................................................................................. 3-37
Table 3-20. A+ and SW_B+ Volt Regulator Load List .......................................................................... 3-38
Table 4-1. List of Troubleshooting Charts ............................................................................................. 4-2
Related Publications
ASTRO Digital XTL 2500 Mobile Radio User’s Guide .................................................................... HLN6942_
ASTRO Digital XTL 2500 Mobile Radio Installation Manual........................................................... HLN6923_
ASTRO Digital XTL 2500 VHF/UHF Range 1/700-800 MHz Mobile Radio
Detailed Service Manual...........................................................................................................6816533H01
CPS Programming Installation Guide..........................................................................................6881095C44
KVL 3000 User’s Manual............................................................................................................. 6881131E16
13. xii List of Tables
August 6, 2007 6871771L01-A
Notes
14. Commercial Warranty
Limited Warranty
MOTOROLA COMMUNICATION PRODUCTS
I. What This Warranty Covers And For How Long
MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured Communication
Products listed below (“Product”) against defects in material and workmanship under normal use and
service for a period of time from the date of purchase as scheduled below:
Motorola, at its option, will at no charge either repair the Product (with new or reconditioned parts),
replace it (with a new or reconditioned Product), or refund the purchase price of the Product during
the warranty period provided it is returned in accordance with the terms of this warranty. Replaced
parts or boards are warranted for the balance of the original applicable warranty period. All replaced
parts of Product shall become the property of MOTOROLA.
This express limited warranty is extended by MOTOROLA to the original end user purchaser only
and is not assignable or transferable to any other party. This is the complete warranty for the Product
manufactured by MOTOROLA. MOTOROLA assumes no obligations or liability for additions or
modifications to this warranty unless made in writing and signed by an officer of MOTOROLA.
Unless made in a separate agreement between MOTOROLA and the original end user purchaser,
MOTOROLA does not warrant the installation, maintenance or service of the Product.
MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished by
MOTOROLA which is attached to or used in connection with the Product, or for operation of the
Product with any ancillary equipment, and all such equipment is expressly excluded from this
warranty. Because each system which may use the Product is unique, MOTOROLA disclaims
liability for range, coverage, or operation of the system as a whole under this warranty.
II. General Provisions
This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the Product.
Repair, replacement or refund of the purchase price, at MOTOROLA's option, is the exclusive
remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE
DURATION OF THIS LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR
DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF
USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS
OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE
USE OR INABILITY TO USE SUCH PRODUCT, TO THE FULL EXTENT SUCH MAY BE
DISCLAIMED BY LAW.
ASTRO Digital XTL 2500 One (1) Year
Product Accessories One (1) Year
15. August 6, 2007 6871771L01-A
xiv CommercialWarranty
III. State Law Rights
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY.
This warranty gives specific legal rights, and there may be other rights which may vary from state to
state.
IV. How To Get Warranty Service
You must provide proof of purchase (bearing the date of purchase and Product item serial number)
in order to receive warranty service and, also, deliver or send the Product item, transportation and
insurance prepaid, to an authorized warranty service location. Warranty service will be provided by
Motorola through one of its authorized warranty service locations. If you first contact the company
which sold you the Product, it can facilitate your obtaining warranty service. You can also call
Motorola at 1-888-567-7347 US/Canada.
V. What This Warranty Does Not Cover
A. Defects or damage resulting from use of the Product in other than its normal and customary
manner.
B. Defects or damage from misuse, accident, water, or neglect.
C. Defects or damage from improper testing, operation, maintenance, installation, alteration,
modification, or adjustment.
D. Breakage or damage to antennas unless caused directly by defects in material workmanship.
E. A Product subjected to unauthorized Product modifications, disassemblies or repairs
(including, without limitation, the addition to the Product of non-Motorola supplied equipment)
which adversely affect performance of the Product or interfere with Motorola's normal
warranty inspection and testing of the Product to verify any warranty claim.
F. Product which has had the serial number removed or made illegible.
G. Rechargeable batteries if:
- any of the seals on the battery enclosure of cells are broken or show evidence of
tampering.
- the damage or defect is caused by charging or using the battery in equipment or service
other than the Product for which it is specified.
H. Freight costs to the repair depot.
I. A Product which, due to illegal or unauthorized alteration of the software/firmware in the
Product, does not function in accordance with MOTOROLA’s published specifications or the
FCC type acceptance labeling in effect for the Product at the time the Product was initially
distributed from MOTOROLA.
J. Scratches or other cosmetic damage to Product surfaces that does not affect the operation of
the Product.
K. Normal and customary wear and tear.
16. 6871771L01-A August 6, 2007
Commercial Warranty xv
VI. Patent And Software Provisions
MOTOROLA will defend, at its own expense, any suit brought against the end user purchaser to the
extent that it is based on a claim that the Product or parts infringe a United States patent, and
MOTOROLA will pay those costs and damages finally awarded against the end user purchaser in
any such suit which are attributable to any such claim, but such defense and payments are
conditioned on the following:
A. that MOTOROLA will be notified promptly in writing by such purchaser of any notice of such
claim;
B. that MOTOROLA will have sole control of the defense of such suit and all negotiations for its
settlement or compromise; and
C. should the Product or parts become, or in MOTOROLA's opinion be likely to become, the
subject of a claim of infringement of a United States patent, that such purchaser will permit
MOTOROLA, at its option and expense, either to procure for such purchaser the right to
continue using the Product or parts or to replace or modify the same so that it becomes
noninfringing or to grant such purchaser a credit for the Product or parts as depreciated and
accept its return. The depreciation will be an equal amount per year over the lifetime of the
Product or parts as established by MOTOROLA.
MOTOROLA will have no liability with respect to any claim of patent infringement which is based
upon the combination of the Product or parts furnished hereunder with software, apparatus or
devices not furnished by MOTOROLA, nor will MOTOROLA have any liability for the use of ancillary
equipment or software not furnished by MOTOROLA which is attached to or used in connection with
the Product. The foregoing states the entire liability of MOTOROLA with respect to infringement of
patents by the Product or any parts thereof.
Laws in the United States and other countries preserve for MOTOROLA certain exclusive rights for
copyrighted MOTOROLA software such as the exclusive rights to reproduce in copies and distribute
copies of such Motorola software. MOTOROLA software may be used in only the Product in which
the software was originally embodied and such software in such Product may not be replaced,
copied, distributed, modified in any way, or used to produce any derivative thereof. No other use
including, without limitation, alteration, modification, reproduction, distribution, or reverse
engineering of such MOTOROLA software or exercise of rights in such MOTOROLA software is
permitted. No license is granted by implication, estoppel or otherwise under MOTOROLA patent
rights or copyrights.
VII. Governing Law
This Warranty is governed by the laws of the State of Illinois, USA.
The circuitry found on the M5 control head and its associated interface
boards is designed to function "as-is". Any attempt at modifying or
altering the circuitry would void the warranty, and/or could result in radio
malfunction or hazardous conditions for the radio and its associated
vehicle.
!
W A R N I N G
!
17. August 6, 2007 6871771L01-A
Notes
xvi Commercial Warranty
18. Chapter 1 Introduction
This chapter describes the control head used with the XTL 2500 radio.
1.1 Notations Used in This Manual
Throughout the text in this publication, you will notice the use of note, caution, warning, and danger
notations. These notations are used to emphasize that safety hazards exist, and care must be taken
and observed.
NOTE: An operational procedure, practice, or condition that is essential to emphasize.
CAUTION indicates a potentially hazardous situation which, if
not avoided, might result in equipment damage.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or injury.
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death or
injury.
!
C a u t i o n
!
W A R N I N G
!
D A N G E R
!
19. August 6, 2007 6871771L01-A
1-2 Introduction: Control Head Features
1.2 Control Head Features
The table below outlines the basic features of the XTL 2500 control head.
1.3 Control Head Descriptions
The control head used with the XTL 2500 radio has microprocessor circuitry that operates the
standard and optional features built into the system.
The following illustration shows a typical XTL 2500 control head
1.3.1 XTL 2500 Control Head.
Figure 1-1. XTL 2500 Control Head
Table 1-1. Control Head Basic Features
Feature XTL 2500
Display 2 lines/14 character of text, 1 menu line,
bit map Liquid-Crystal Display (LCD)
Control Type Rotary Mode and Volume Control, Push
Button On/Off
Numeric Keypad Available with Keypad Microphone
Channel Capability 512
Remote Mount Available
Dash Mount Available
Dual Control Head Available
Motorcycle Not Available
INDICATORS
HOME
MODE
KNOB
EMERGENCY
VOLUME
KNOB
DIM
BUTTON
SOFT MENU
KEYS
NAVIGATION
KEYS
POWER
ON/OFF
MMP
CONNECTOR
XTL 2500
20. 6871771L01-A August 6, 2007
Introduction: Control Head Descriptions 1-3
1.3.2 XTL 2500 Controls
• VOLUME KNOB – Changes the audio volume.
• MMP CONNECTOR – Used to connect accessories, such as the microphone, to the control
head.
• DIM BUTTON – Dims the backlight through three levels of brightness including backlight off.
• HOME – Used to exit all menu functions. The long press behavior of the HOME button is programmable.
• POWER ON/OFF – Turns the radio on and off.
• SOFT MENU KEYS – Field-programmable buttons.
• INDICATORS – Red, Yellow and Green LED’s that indicate transmit, busy and private call respectively.
• MODE KNOB – Used to change channels.
• NAVIGATION KEY – Used to scroll through menu items and selections.
• EMERGENCY – Field-programmable button usually used for the emergency feature.
21. August 6, 2007 6871771L01-A
1-4 Introduction: Control Head Descriptions
Notes
22. Chapter 2 Basic Maintenance
2.1 Introduction
This section of the manual describes handling precautions, and some basic repair procedures and
techniques. Each of these topics provides information vital to the successful operation and
maintenance of your control head.
2.2 Preventive Maintenance
2.2.1 Inspection
Check that the external surfaces of the radio are clean, and that all external controls and switches
are functional. A detailed inspection of the interior electronic circuitry is not needed.
NOTE: Verify that all dust covers are in place.
2.2.2 Cleaning
The following procedures describe the recommended cleaning agents and the methods to be used
when cleaning the external and internal surfaces of the radio. External surfaces include the control
head and radio chassis. These surfaces should be cleaned whenever a periodic visual inspection
reveals the presence of smudges, grease, and/or grime. Internal surfaces should be cleaned only
when the radio is disassembled for servicing or repair.
The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of a mild
dishwashing detergent in water. The only factory recommended liquid for cleaning the printed circuit
boards and their components is isopropyl alcohol (70% by volume).
2.2.2.1 Cleaning External Plastic Surfaces
The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-bristled
brush to work all loose dirt away from the control head. A soft, absorbent, lint-free cloth or tissue
should be used to remove the solution and dry the control head. Make sure that no water remains
entrapped near the connectors, cracks, or crevices.
2.2.2.2 Cleaning Internal Circuit Boards and Components
After removing PCB from plastic housing, isopropyl alcohol may be applied with a stiff, non-metallic,
short-bristled brush to dislodge embedded or caked materials located in hard-to-reach areas.
The effects of certain chemicals and their vapors can have harmful results on certain
plastics. Aerosol sprays, tuner cleaners, circuit board cleaners, alcohols, and other
chemicals should not make contact with plastic or metal radio housings. Extreme etching
or disintegration to the plastic can result.
Any cleaning to the printed circuit board requires the complete removal of the circuit
board from any plastic or metal housings, to prevent the chemical from making contact
with the plastic housing. After the printed circuit board has been cleaned and the
chemical has evaporated, the circuit board can be returned to the plastic or metal radio
housing.
!
C a u t i o n
23. August 6, 2007 6871771L01-A
2-2 Basic Maintenance: Handling Precautions
Alcohol is a high-wetting liquid and can carry contamination into unwanted places if an excessive
quantity is used. Make sure that controls or tunable components are not soaked with the liquid. Do
not use high-pressure air to hasten the drying process, since this could cause the liquid to puddle
and collect in unwanted places.
Upon completion of the cleaning process, use a soft, absorbent, lint-free brush to dry the area.
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by
dissolved material (from previous usage).
2.2.3 General Radio Care and Handling Precautions
• Avoid physical abuse: do not pound, drop, or throw the radio. Exposed parts, such as controls
and connectors, might be damaged.
• Operating the radio without an antenna cable attached may lead to radio failure and may void
the warranty.
2.3 Handling Precautions
Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology devices,
are used in this family of radios. While the attributes of these devices are many, their characteristics
make them susceptible to damage by electrostatic discharge (ESD) or high-voltage charges.
Damage can be latent, resulting in failures occurring weeks or months later. Therefore, special
precautions must be taken to prevent device damage during disassembly, troubleshooting, and
repair. Handling precautions are mandatory for this radio, and are especially important in low-
humidity conditions. DO NOT attempt to disassemble the radio without observing the following
handling precautions:
• Eliminate static generators (plastics, styrofoam, etc.) in the work area.
• Remove nylon or double-knit polyester jackets, roll up long sleeves, and remove or tie back
loose-hanging neckties.
• Store and transport all static-sensitive devices in ESD-protective containers.
• Disconnect all power from the unit before ESD-sensitive components are removed or inserted
unless otherwise noted.
• Use a static-safeguarded workstation through the use of an anti-static kit (Motorola part number
01-80386A82). This kit includes a wrist strap, two ground cords, a static-control table mat and a
static-control floor mat.
NOTE:Be sure that the table and floor mats are properly grounded.
When these items are not readily available, observing the following techniques will minimize the
chance of damage:
- If a static-sensitive device is to be temporarily set down, use a conductive surface for
placement of the device.
- Make skin contact with a conductive work surface first and maintain this contact when the
device is set down or picked up.
- Always wear a conductive wrist strap when servicing this equipment. The Motorola part
number for a replacement wrist strap that connects to the table mat is 42-80385A59
24. Chapter 3 Theory of Operation
3.1 System Overview
The M5 control head provides the user interface for the XTL2500 radio system. The control head
provides this interface with a 320 x 83 pixel display, five programmable menu buttons, one
programmable button that defaults to emergency operation, volume knob, mode knob, dim button,
home button, power button, and navigation pad. The mobile microphone port (MMP) is also located
on the control head and allows attachment of accessories such as the microphone and programming
cables.
The M5 control head communicates with the radio transceiver using a Synchronous Serial Interface
(SSI). This interface consists of a frame synchronization clock, a data clock, transmit data line, and a
receive data line. The frame sync clock frequency is 8 kHz. The data clock frequency is determined
by the number of 16-bit words that are transferred within each frame sync period. The M5 system
uses 12 words resulting in a data clock frequency of 1.536 MHz.
The M5 control head supports two installation configurations, dash mount and remote mount. In the
dash mount configuration, the control head is connected directly to the transceiver. In remote mount,
the control head is attached to a Control Head Interface Board (CHIB). A Transceiver Interface
Board (TIB) is attached to the transceiver. Cabling is then used to connect the control head / CHIB
assembly to the transceiver via the TIB.
3.1.1 Dash Mount
In dash mount, the SSI from the control head is connected directly to the SSI in the transceiver. All
audio functions are handled by the transceiver. Audio from the microphone is routed from the MMP
through the control head to the transceiver for processing. Receive audio is amplified by an audio
power amplifier (PA) inside the transceiver.
Figure 3-1. Control Head to Transceiver Interface (Mid Power Only)
M5 Control Head
Headbridge
XTL2500 Transceiver
Control Head Flex
25. August 6, 2007 6871771L01-A
3-2 Theory of Operation: System Overview
3.1.2 Remote Mount
In remote mount, the control head is attached to a Remote Rear Assembly consisting of a Control
Head Interface Board (CHIB) and Control Head Universal Connector (CHUC). The control head with
rear assembly is then connected, via a cable, to the Transceiver Interface Board (TIB). The TIB is
attached to the transceiver.
3.1.2.1 Remote Mount Data and Audio Communications
The TIB and CHIB are used to convert SSI signals into a robust signally protocol that can travel over
several meters of cable. A Controller Area Network (CAN) is used for this purpose. The CAN bus is a
differential bus operating at approximately 1MHz. An FPGA on the CHIB converts the SSI signals
from the control head into the CAN protocol. These signals are sent to the TIB where an identical
FPGA converts the CAN signals back to SSI and routes the SSI signals to the transceiver. This is a
bidirectional bus allowing the transceiver to send messages back to the control head using the same
CAN bus. Two CAN buses are used to transfer data and audio between the TIB and CHIB. These
are labeled CAN1 and CAN2, where CAN1 carries audio and CAN2 carries data. A third CAN bus is
used for system on/off/reset commands. All three CAN bus twisted wire pairs are contained in a
single cable that connects the control head assembly to the transceiver.
The CAN1 bus is used for all audio exchange between the control head and transceiver. The CHIB
converts microphone signals received on the MMP to SSI using a CODEC. In addition, received
audio from the transceiver is sent to the CHIB on this CAN bus. The FPGA on the CHIB converts the
CAN data back to SSI and routes the signal to a CODEC. The CODEC converts the audio back to an
analog signal and routes the signal to an audio PA on the CHIB. A speaker can then be connected to
the control head / CHIB assembly at the control head location.
Figure 3-2. Remote Control Head Interface (High Power)
26. 6871771L01-A August 6, 2007
Theory of Operation: System Overview 3-3
.
Figure 3-3. Remote Control Head Interface (Mid Power)
3.1.2.2 CAN Bus and Auto-Termination
The CAN bus has many benefits for long-distance and robust communication of digital signals.
However, in order to function correctly in a multi-node system, cable termination must exist only at
the end nodes. Any termination in the middle can greatly distort the CAN signals, reducing the
effectiveness of the CAN bus. When only one cable is inserted into either CAN connector, the
termination circuit defaults to shorting a 120Ω load across the CAN_HIGH and CAN_LOW signals,
for each CAN bus. When both CAN connectors are used, meaning that the device is in the middle of
the CAN bus, the auto-termination circuit removes the termination from that device.
Figure 3-4. CAN BUS Auto-Termination
Transceiver
Control Head 1 Control Head 2
Default is
Enabled
Default is
Enabled
cable cable
High since
Pull-up to
VCC on
PCB
Low
via
Cable’s
loop
Low
via
Cable’s
loop
Low
via
Cable’s
loop
High since
Pull-up to
VCC on
PCB
Low
via
Cable’s
loop
120Ω Termination
resistor
120Ω Termination
resistor
120Ω Termination
resistor
disabled
27. August 6, 2007 6871771L01-A
3-4 Theory of Operation: System Overview
NOTE: The CAN cables must always be attached at both ends to a device. The cable detection
architecture presumes all cables attached have a device at both ends. The signal integrity of
the CAN data stream can be degraded if the system is not installed in this manner.
Figure 3-4 shows a typical system connection for multi-control head. Control Head 1 and the
transceiver have the termination resistors enabled since these devices are the end nodes of the
system. Control Head 2 has the termination resistor disabled since this device is in the middle of the
CAN bus. The termination resistors are enabled or disabled using an analog switch. The switch is
controlled by a NOR gate. The NOR gate inputs are pulled high by default and grounded when a
CAN cable is plugged into the CAN connector via a short in the cable between termination and
ground pins. When the termination and ground pins on both CAN connectors are grounded, the
termination resistor is removed from the circuit.
3.1.3 System On / Off / Reset Communications
System On / Off / Reset functionality is accomplished by manipulating the SW_B+ signal going into
the transceiver. In dash mount systems this is handled by a circuit in the control head. In remote
mount, SW_B+ is controlled by the TIB.
In order to turn the system on or off, or to reset the system, commands must be sent between the
devices in the system. In dash mount, the transceiver sends commands to the control head via the
signal BUS_PWR_OUT. The control head uses SW_B+ to control the transceiver as mentioned
earlier. In remote, all of the remote devices send system on/off/reset commands to each other via a
dedicated CAN bus named CAN3. At the transceiver, the TIB controls SW_B+ based on commands
received on the CAN3 bus. The TIB also provides the interface from the transceiver
BUS_PWR_OUT signal to the CAN3 bus.
The ON, OFF, and reset commands are encoded into pulse widths. The widths were chosen such
that several devices, in a multi-node remote configuration, could send commands at the same time
and the commands would be received correctly. For instance, the "ON" command is a pulse with a
duration of 0.5 ms. If ten devices send back-to-back "ON" commands, then a pulse with a duration of
5 ms is decoded by all the devices on the CAN3 bus. Therefore, a pulse width between 0.3 ms and
6.6 ms is decoded as an "ON" command, allowing for 20% variation in the receivers and guard band.
The next command, "RESET" has pulse width of 15 ms. The window that is decoded as a RESET is
10.8 ms to 198 ms. The "OFF" command is unique in that a pulse width greater than 358.8 ms is
decoded as off. So holding the CAN3 bus low is decoded as an "OFF" command. In dash mount,
these commands are sent directly from the transceiver to the control head using BUS_PWR_OUT.
On the control head main board and the TIB, an ATMEL AVR microcontroller is used to detect
commands sent over CAN3. In addition, the AVR's turn the system on due to various inputs, such as
ignition, or in the case of the control head, the power button.
Table 3-1. CAN3 Command Pulse Widths
Remote Command Pulse Width Receiver Specifications
COMMAND -20% Nominal 20% +20% x 10
nodes
ON 0.3 ms 0.5 ms 0.6 ms 6.6 ms
RESET 10.8 ms 15 ms 18 ms 198 ms
OFF 358.8 ms 500 ms N/A ms N/A ms
28. 6871771L01-A August 6, 2007
Theory of Operation: System Overview 3-5
NOTE: It is not recommended to supply power directly to SW_B+ at J2 or J100 in order to force the
radio on. This will defeat the system on/off control and the reset control. The ignition pins at
either the J2 or J600 connectors can be used for this purpose instead of SW_B+.
Figure 3-5. System Level Block Diagram
Figure 3-6. Transceiver Interface Board (TIB) Block Diagram
OMAP
Control Head (Remote Mount)
FPGA
CAN
FPGA
CAN
TO Transceiver
Control Head
Connector
Transceiver Interface Board (TIB)
CAN
Cable
OMAP
Control Head (Dash Mount)
See Figure 3.8 for details See Figure 3.8 for details
See Figure 3.6 for details
Control Head Interface Board (CHIB)
A+ (RED)
Ignition (YELLOW )
SPEAKER
DEK/VIP IN/OUT
MICROPHONE
See Figure 3.7 for details
Altera FPGA
IC
ON/OFF
Controller
& DC
Regulators
CODEC
IC
16MHz
OSC
80-pin rear connector J80
CODEC
SSI
SPI
To Transceiver
SSI
CAN Transceivers
& Auto -Termination
Charge
Pump
CAN 1 & CAN2
CAN3
Jumpered
Pathways
VIP
OUT
VIP
IN
SW_B+
1.5V
2.85V
5V
UNSW 3.3V
3.3V
TUC Conn
Parallel
CAN
Connectors
MMP
programming
Accessory Port for
Emergency / Audio /
Remote Ignition /
VIPS / RS232 /
SB9600
J700
J800L J800R J600
.
29. August 6, 2007 6871771L01-A
3-6 Theory of Operation: System Overview
Figure 3-7. Control Head Interface Board (CHIB) Block Diagram
Parallel
CAN
Connectors
Power
/
Ignition
/
Spe
ake
r
/
Record
Ou
t
VIP
/
DE
K
/
EMERGENCY
/
USB
DEVICE
/
A
UDIO
VIP
/
DE
K
USB
HO
ST
80-pin rear connector J 10
SW_B+ V SPI
USB Control
signals PG1
and PG2
SSI
From Control Head
Altera FPGA
IC
ON/OFF
control and
DC
Regulators
CODEC IC
16MHz
OSC
MI
C_HI
/
Aux
Mic
5
SSI
A+
Analog
Output
V
IP
S
/
DEK
IN
AND
O
UT
Earjack
Record
Out
CAN
Transceivers
Audio
PA
USB
Transceivers
CHUC Connector
Speaker
Output CAN1 and CAN 2
USB Device
and Host
J100
J200
J300L
J300R
J400
J500
30. 6871771L01-A August 6, 2007
Theory of Operation: System Overview 3-7
Figure 3-8. Control Head Main Board Block Diagram
ON/OFF
control and
DC
Regulators
MMP
connectivity
80-pin rear connector J 11
MMP 10-pin
connector
3.3V
2.8V
1.8V
1.5V
SW_B+
5V
To Transceiver in Dash.
To CHIB in Remote.
SDRAM
FLASH
LCD Module
32kHz OSC
User Input - Knobs ,
buttons , and LED’s
MMP Accessory,
e.g. Microphone
MIC_HI
KeyFail
OMAP
Microprocessor
12MHz
OSC
31. August 6, 2007 6871771L01-A
3-8 Theory of Operation: M5 Control Head Main Board
3.2 M5 Control Head Main Board
3.2.1 DC Power Distribution
Battery voltage, called A+, enters the control head from either the CHIB in remote mount, or the
transceiver in dash mount. Over-voltage protection is provided by the CHIB or transceiver. Figure 3-
9 shows the DC distribution on the control head main board. A+ feeds three devices, the main 5-volt
switching regulator, a small 50mA 3.3-volt un-switched linear regulator used to power the on/off
circuitry, and a MOSFET switch used to provide SW_B+. The 5-volt regulator feeds the TI TPS65010
power management IC, which provides power to the rest of the board
Figure 3-9. Main Board DC Distribution
3.2.1.1 TPS65010 Power Management IC
The Texas Instruments TPS65010 power management IC, U302 provides several voltages used by
the OMAP microcontroller and peripheral devices. It also provides the proper power-on sequence of
these voltages. The TPS65010 is supplied by the 5 volt switching regulator. It contains two step-
down converters and two low drop-out regulators. VMAIN is a step-down converter with a 1A
maximum output current. In addition to supplying 3.3 volts to some of the main board peripherals,
VMAIN also supplies the internal VLDO2 regulator and an external 2.8 volt regulator. VCORE is a
step-down converter with a 400mA maximum output current. VCORE is used to provide the 1.5 volt
OMAP core voltage. VLDO1, the first low drop-out regulator is not used. VLDO2 has a 200mA
maximum output current. VLDO2 provides 1.8 volts that is used mainly by the FLASH and SDRAM
memories. Table 3-2, Table 3-3, and Table 3-4 list the loads for each output.
Table 3-2. VMAIN (3.3 volt) Step-down Converter Load List
Reference Designator Device Usage
U302 TPS65010 VINLDO1 and VINLDO2
U314 TPS73201 2.8 volt regulator
Q300 Transistor that applied USB voltage to OMAP
U210, U211, U212, U213 MMP bi-directional level translators
R243, R244, R246, R250, R252, R262 Pull-up resistors on the MMP lines and MMP level translators
J11
CHIB
CHUC
29, 31, 33
J10
U305
A+
3.3 volt
regulator
5 volt
regulator
VCC_5
SW_B+
AVR
U300
U301
Q309
UNSW_VCC
Control Head Main Board
U302
TPS65010 Power
Management IC
VINMAIN
VINLDO2
VMAIN
VLDO2
VINCORE
VCORE
3.3 volts
1.8 volts
1.5 volts
2.8 volt
regulator
VCC_1.5
VCC_1.8
VCC_3.3 VCC_2.8
U314
32. 6871771L01-A August 6, 2007
Theory of Operation: M5 Control Head Main Board 3-9
* DSP not used in the M5 control head
U215 UART level translator
U214 I/O expander used to control MMP level translators
R256, R257, R258 I2C address select for U214
R218 Pull-up resistor on the UART1_RX line
Table 3-3. VCORE (1.5 volt) Step-down Converter Load List
OMAP Pin Signal Device Usage
W12 VDD_RTC Real Time Clock supply voltage
A15 VDD_1 OMAP core logic supply
Y20 VDD_2 OMAP core logic supply
Y9 VDD_3 OMAP core logic supply
M2 VDD_4 OMAP core logic supply
AA3 VDD1_1 OMAP core logic supply
A9 VDD2 OMAP MPU subsystem logic and memory supply
A3 VDD2_1 OMAP MPU subsystem logic and memory supply
E2 VDD2_2 OMAP MPU subsystem logic and memory supply
B13 VDD3_1 OMAP DSP subsystem logic and memory supply*
B20 VDD3_2 OMAP DSP subsystem logic and memory supply*
J21 VDD3_3 OMAP DSP subsystem logic and memory supply*
R20 VDD3_4 OMAP DSP subsystem logic and memory supply*
V13 OSC32K_IN Connected through 0Ω jumper R431. Pulled high for
external 32kHz oscillator
A11 VDD_DLL Connected through 10Ω filter resistor R467. Core
supply
Y21 VDDA Connected through 10Ω filter resistor R466. Analog
phase-locked loop supply voltage. Used to generate
48MHz clock.
Table 3-2. VMAIN (3.3 volt) Step-down Converter Load List (Continued)
Reference Designator Device Usage
33. August 6, 2007 6871771L01-A
3-10 Theory of Operation: M5 Control Head Main Board
3.2.1.2 2.8 Volt Regulator (Main Board)
U314 is a Texas Instruments TPS73201 low drop-out adjustable regulator with an output current of
250mA. The voltage is set to within 2% of 2.8 volts. The tight tolerance is needed by the display
module. In addition to the display module, this regulator supplies voltage to most of the OMAP I/O
pins and external peripherals on the main board. Table 3-5 lists the loads connected to this regulator.
Table 3-4. VLDO2 (1.8 volt) Regulator Load List
Reference Designator Device Usage
U213 MMP pin 8 bi-directional level translator
R513, R514 Mode knob MODE_2 and MODE_3 pull-up resistors
U400 OMAP FLASH and SDRAM memory supply voltage
U414 OR gate used to control GPIO expansion latch on FLASH
BUS
U415 Latch used for GPIO expansion on FLASH BUS
R474, R476, R478, R480,
R482, R484, R487
Board ID pull-up resistors
U412 SDRAM memory
U413 FLASH memory
Table 3-5. 2.8 Volt Regulator Load List
Reference Designator Device Usage
U656, U657, U658 NAND Gates used to drive the RED, GREEN, and YELLOW
indicators.
R308, R309, R310, R311,
R323, R324, R325, R326,
R327, R328
Pull-up resistors on various power management IC U302
pins
Q302 Used in the OMAP internal USB transceiver enable circuit
U210, U211, U212 MMP bi-directional level shifters
R238, R239 One-wire be-direction level translator pull-up resistors
U206 MMP audio amplifier
R231 MMP audio amplifier bias resistor
U201 AND gate controlling MMP USB/RS232 mux U200
U202, U203 UART, VIP, CHIB VBUS, and MMP VBUS level translators
R205, R219 MUX U200 configuration pull-up resistors
U502 XOR Gate used to control the display indicator shutters
34. 6871771L01-A August 6, 2007
Theory of Operation: M5 Control Head Main Board 3-11
3.2.1.3 3.3 Volt Un-switched Regulator (Main Board)
U301 is a Texas Instruments TPS71533 low drop-out regulator with a 50mA maximum output
current. This regulator draws a quiescent current of 3.2 μA and is used to power the ON/OFF
circuitry. This regulator is active whenever battery voltage is applied to the radio. Resistor R302 and
zener diode VR300 protect the TPS71533 from battery voltages that exceed 18 volts. The regulator
can withstand 24 volts on its input. The output is 3.3 volts. Table 3-6 lists the load devices attached to
this regulator.
U500 Multiplexer used to select input for A/D converter U501
U501 A/D converter used to capture volume knob settings a
temperature readings
R508 Volume knob pull-up resistor
R511, R512 Mode knob MODE_1 and MODE_4 pull-up resistors
R500, R501, R502, R503,
R504
Keypad matrix pull-up resistors. The keypad matrix is used
to receive input from all the front panel buttons
R367 Pull-up resistor on power button latch circuit
Q306 Buffer transistor between OMAP and CAN3 transceiver
U309 Buffer between AVR ignition out signal and OMAP
R427, R418 OMAP configuration pull-up resistors
R434, R436 OMAP I/O pull-up resistors
U404, U405, U406 OMAP input buffers
U402 Inverter used to generate 32kHz clock
U403 Schmitt trigger used in the 32kHz clock circuit
U400 OMAP pins V12, A19, E21, Y7, AA11, Y16, L21, U21
Table 3-6. 3.3 Volt Un-switched Regulator Load List
Reference Designator Device Usage
U303 Voltage supervisor IC used to monitor A+. Shuts down the
system if A+ drops below 6.5 volts.
U304 Voltage supervisor IC used to monitor the ignition input
R343 Pull-up resistor on U304’s output
S1 Power button
Q304 Transistor used as part of the ON/OFF feedback from the
transceiver
J4 Power for AVR In-System Programming (ISP)
Table 3-5. 2.8 Volt Regulator Load List (Continued)
Reference Designator Device Usage
35. August 6, 2007 6871771L01-A
3-12 Theory of Operation: M5 Control Head Main Board
U305 ATMEL AVR microcontroller used to turn on and off the
main board regulators
U315 Buffer on the MMP_ON input to the AVR
U306, U307, U308 Multiplexers used to change the function of AVR pins during
ISP
R348 Pull-up resistor for multiplexers U306, U307, and U308
Q305 Part of “wired-OR” circuit used to drive the CAN3
transceiver input
R354 Pull-up resistor for Q305
U310 AND gate used as part of OR circuit that drives the CAN3
transceiver
U311 NOR gate used to enable or disable the CAN3 transceiver
transmit section. Needed for under voltage protection
provided by U303
Q311 Transistor used to buffer the AVR from the 5-volt regulator,
U300, enable pin
U407, U408, U409, U410 Multiplexers that switch open the SSI bus when the system
is off
R247 Pull-up resistor on the MMP GPIO_0 pin. Used as part of
the accessory turn-on scheme
U205 Inverter between OMAP VBUS mode select output and
U204 enable pin. Needed on un-switched regulator to
ensure Vbus is not asserted during power-on
U312 D-Latch that is part of power button latch circuit. Not used
on final product but U312 is placed.
U313 OR gate that is part of power button latch circuit. Not used
on final product but U313 is placed.
R366 Pull-up resistor used as part of power button latch circuit.
Not used on final product but R366 is placed.
Table 3-6. 3.3 Volt Un-switched Regulator Load List (Continued)
Reference Designator Device Usage
36. 6871771L01-A August 6, 2007
Theory of Operation: M5 Control Head Main Board 3-13
3.2.1.4 5 Volt Regulator (Main Board)
U300 is a switching regulator. It supplies all the power for the main board and the CHIB with the
exception of the ON/OFF circuits. The 5 volt regulator input is driven by the battery voltage (A+). The
regulator output is controlled by the ATMEL AVR, U305 using an enable pin on the regulator. When
the enable pin is driven low, the regulator enters standby mode with a quiescent current of 50 μA.
Table 3-7 lists all of the devices attached to the 5 volt line.
Table 3-7. 5 Volt Regulator Load List
Reference Designator Device Usage
U208 One-wire mux
R236 One-wire pullup resistor
U209 HUB/KEYFAIL mux
U216 MMP pin 8 mux
R253, R254 Pullup resistors
U207 MMP Speaker mux
U200 MMP mux
U204 USB Vbus switch
U503, U504 Display level shifter
D500 – D513 Backlight LED’s (excluding the display)
U302 TPS65010 power management IC
J11 Interconnect to CHIB
37. August 6, 2007 6871771L01-A
3-14 Theory of Operation: M5 Control Head Main Board
3.2.2 Mobile Microphone Port (MMP)
The Mobile Microphone Port (MMP) on the control head is an accessory port designed to support
IMPRESTM
accessories, and the standard microphone.
Figure 3-11 is a block diagram showing the MMP signal routing and multiplexing. All the signals that
interface to OMAP must be level translated to 2.8 volts (1.8 volts for OMAP pin P3). In addition,
output lines must be tri-stated when not in use.
Figure 3-10. MMP Connector
1 2
4
6
8
10
9
5
3
7
38. 6871771L01-A August 6, 2007
Theory of Operation: M5 Control Head Main Board 3-15
Figure 3-11. MMP Multiplex Block Diagram
1
2
3
4
5
6
7
8
9
10
ONE_WIRE
PTT
SPKR
USB_D-
/
RXD
GND
VBus
MIC_HI
GPIO_1
/
USB_D+
/
TXD
HUB
/
KEYFAIL
GPIO_0
/
PWR_ON
J1
Mobile
Microphone
Port
(MMP)
EN
SEL
0
1
U200
A
EN
SEL
0
1
U200
C
EN
SEL
0
1
U200
B
U207
SEL
1
0
SEL
0
1
U216
U215
3.3
volts
U213
1.8
volts
3.3
volts
2.8
volts
DIR
Bi-Directional
Level
Translator
OMAP
M15
OMAP
L15
OMAP
P9
OMAP
Y14
OMAP
P3
OMAP
Y1
J11-55
OMAP
R18
OMAP
P20
I
2
C
I/O
P1
I
2
C
I/O
P3
I
2
C
I/O
P0
I
2
C
I/O
P4
OMAP
M14
OMAP
H20
OMAP
N21
J11-19
OMAP
R8
OMAP
V14
J11-54
OMAP
V8
OMAP
N20
J11-20
I
2
C
I/O
P2
OMAP
G20
Power
Management
IC
I/O
KEYFAIL
OUT
USB
Data
+
UART1
TX
GPIO1
/
UART1
TX
Select
USB
VBUS
Detect
USB
Data
-
UART1
RX
USB
VBUS
Host
/
Device
mode
select
USB
/
RS232
SELECT
USB
/
RS232
ENABLE
Front
/
Rear
ONE_WIRE
select
HUB
/
KEYFAIL
Select
USB
VBUS
Overcurrent
Detect
ONE_WIRE
Rear
ONE_WIRE
Input
PTT
RX_FILT_AUDIO
In
Audio
enable
MIC_HI
GPIO
1
HUB
GPIO
0
DIR
DIR
2.8
volts
3.3
volts
2.8
volts
3.3
volts
U212
U210
Bi-Directional
Level
Translator
Bi-Directional
Level
Translator
SEL
1
0
U209
U203
U202
2.8
volts
U206
3.3
volts
2.8
volts
3.3
volts
U205
-8dB
U211
2.8
volts
3.3
volts
DIR
Bi-Directional
Level
Translator
Q205
D202
2.8
volts
5.0
volts
Bi-Directional
Level
Translator
Over
current
Detect
OUT
IN
EN
VCC_5V
U204
VBus
overcurrent
protection
U208
SEL
1
0
39. August 6, 2007 6871771L01-A
3-16 Theory of Operation: M5 Control Head Main Board
3.2.3 Microcontroller and Memory
The control head contains a Texas Instruments OMAP microcontroller, reference designator U400.
Two clocks are supplied to the microcontroller, a 32 kHz clock and 12 MHz clock. A buffered version
of the 32 kHz clock is visible on pin 44 of 80-pin connector J11 briefly on startup. This pin is later
reconfigured by software as a reset pin used by the CHIB. The microcontroller contains an integrated
synchronous serial interface (SSI), serial peripheral interface (SPI), LCD controller, keypad
controller, UART, and USB controllers. SSI is used to communicate with the transceiver. SPI is used
to transfer data to and from devices such as the A/D converter used to read the volume knob.
Switches are used to disconnect the OMAP SSI bus from the rest of the system. These switches are
U407, U408, U409, and U410. In addition, filters FL400 and FL401 are used to filter noise from the
SSI clock and frame sync lines. Finally, U416 is a Schmitt trigger used to square up the clock and
frame sync lines before these signals reach OMAP.
A NOR Flash memory device, U413, is used to store control head host code and non-volatile system
variables. An SDR SDRAM memory device, U412, is used for volatile code and variables. Neither of
these memory devices is field-repairable.
Pull-up and pull-down resistors are used to provide software with a board revision ID. These
resistors are located below the microcontroller shield SH400.
3.2.4 User interface
The user interface consists of 12 PC board pad buttons, a volume knob, mode knob, and a tactile
switch button. In addition, user feedback is provided using a 320 x 83 pixel LCD and three LED's.
One of the PC board pad buttons is used for the power button. This goes directly to an AVR input.
Four of the PC board pad buttons are grouped together and used for the Nav key. The Nav key,
remaining PC board pad buttons and the tact switch button provide inputs to the keypad controller
inside the microcontroller.
Figure 3-12. M5 Control Head
The volume knob is a 20 kΩ potentiometer. There is a 100Ω resistor on each end of the
potentiometer to set the maximum and minimum values. The potentiometer sweep arm is connected
to an Analog-to-Digital (A/D) converter. The A/D converter is connected to the SPI bus and the
microcontroller queries the A/D for volume knob position information. The mode knob is a 4-bit
encoder. Four microcontroller GPIO's are used to read the mode knob.
INDICATORS
HOME
MODE
KNOB
EMERGENCY
VOLUME
KNOB
DIM
BUTTON
SOFT MENU
KEYS
NAVIGATION
KEYS
POWER
ON/OFF
MAP
CONNECTOR
XTL 2500
40. 6871771L01-A August 6, 2007
Theory of Operation: M5 Control Head Main Board 3-17
The LCD module plugs into connector J7 on the main board. The LCD module is controlled by the
LCD controller contained in the OMAP microcontroller. The LCD interface consists of three clock
lines; YD_FR, LP, and XSCL; eight data lines, D0 through D7; and two control lines DOFF# and
STANDBY. XSCL is the pixel clock and it toggles for each bit of data. LP is the line pulse and toggles
after 320 bits have been sent to the display. Finally, YD_FR toggles after all the data has been sent
to the display. STANDBY is not used in the design and is always low. DOFF# toggles on power-on
and power-down. During operation this line should be high.
The LCD module also contains the three indicator LED's. These LED's are covered with shutters so
that sunlight will not reflect off of the LED and give the user the impression that the LED is on. These
shutters are controlled with a common line, ICON_COM, and three individual lines, ICON_SEG1
through ICON_SEG3, for each shutter. A 70Hz clock is output on these lines by the microcontroller
using a PWM. When an individual signal, such as ICON_SEG1, and the ICON_COM line are in
phase, the shutter is closed. When the signals are 180 degrees out of phase, the shutter is opened.
Figure 3-13 shows a diagram of the shutter control circuit. Exclusive OR gate U502 changes the
phase of the ICON_SEG signals based on input from the microcontroller. The microcontroller
provides this input by sending an I2C command to U302 telling U302 to toggle the appropriate GPIO.
When this input to the XOR gate is high, then the output of the XOR is a 70Hz clock that is 180
degrees out of phase with the clock input to the XOR gate. NAND gates U656 through U658 are
used as inverters. They are needed to ensure the LED's do not turn on and the shutters do not open
when the unit is first turned on. GPIO_1 through GPIO_3 on U302 are open drain outputs so pull-up
resistors are needed. The LCD shutter circuit runs at 5 volts so level translation is provided by U503.
Figure 3-13. LED Shutter Control Diagram
U400
OMAP Microcontroller
I2C
PWM0
1 = Open
0 = Closed
R567 0 Ω
M18 R564 0 Ω
C553
Not Placed
70 Hz
RED
YELLOW
GREEN
R565 0 Ω
R566 0 Ω
NAND Gates
used as
inverters
U502
U656
U657
U658
10 kΩ
10 kΩ
10 kΩ
RED LED CNTRL
YELLOW LED CNTRL
GREEN LED CNTRL
GPIO_1
GPIO_2
GPIO_3
U302
TPS65010 Power
Management IC
I2C
2.8V
2.8V
2.8V
ICON_COM
ICON_SEG[1:3]
Closed
ICON_SEG[1:3
Open
U503
Level
Translators
2.8 V 5 V
ICON_SEG1
ICON_SEG2
ICON_SEG3
ICON_COM
]
41. August 6, 2007 6871771L01-A
3-18 Theory of Operation: M5 Control Head Main Board
3.2.5 AVR On, Off, Reset Control Circuit
Refer to Figure 3-14 for a block diagram of the control head On/Off/Reset circuit. An ATMEL AVR
micro controller (U305) is used to turn on the control head based on any one of five input sources.
These sources are: power button; ignition; power-on capable accessory connected to the MMP port;
emergency; or a remote command received on the CAN3 bus. The AVR also enters the "ON" state
when power is initially connected to the radio (i.e. A+ is applied). After the system is powered on, the
AVR also provides the turn on reason to the OMAP system processor. The AVR is in direct control of
the 5 volt regulator U300 and the SW_B+ switching FET Q309. The system is turned on and off by
asserting and de-asserting the 5 volt regulator enable line and turning the SW_B+ switching FET on
and off. To reset the system, these signals are de-asserted for 500ms then reasserted.
3.2.5.1 Power Button
The power button pad is connected to U305 pin 10. Closing the power button pulls this pin to
UNSW_VCC. A low to high transition causes the AVR to move into the "ON" state and assert the
FIVE_V_EN and SW_BPlus_EN outputs. The AVR sends an "ON" pulse on the CAN_PULSE_OUT
pin to power on the rest of the system. Output pin 15, ON_OFF_SENSE, is set high to signify that the
AVR entered the "ON" state due to a power button press. Once the system is powered on and
communications have been established with the transceiver, the codeplug in the transceiver is
checked to determine if the power button is a valid turn on reason. An example of the power button
as an invalid turn on reason is if the ignition required feature is enabled in the code plug but ignition
is not present. In this case, the transceiver will send an “OFF” command via CAN3 to turn the system
off.
In addition to the above actions, when the AVR is in the "OFF" state and the power button is pressed,
an eight second counter is started. If this counter is allowed to expire, the AVR turns the system back
off. This feature turns the system off in case the host code stored in flash becomes corrupted or
OMAP becomes unresponsive for any reason. Without this feature, the control head would appear
dead but would continue to draw current, possibly draining the vehicle battery. After OMAP checks
for the turn on reason, it sends a "CANCEL" command to the AVR on the AVR_CMD line (AVR pin
5), which stops the eight second counter. The "CANCEL" command also unlatches the
ON_OFF_SENSE signal so that it reflects the current state of the power button. This allows OMAP to
know when the user presses and holds the power button down.
If the AVR is in the "ON" state and the power button is pressed, a 250ms timer is started. If this timer
expires, the AVR shuts down the system. This function provides the same protection from a
corrupted system as the eight second timer. OMAP can respond to the power button in three ways.
1. It can let the 250ms timer expire, the AVR will then power down the control head regulators,
remove SW_B+, and send an "OFF" command on CAN3.
2. A "TICKLE" command can be sent to the AVR on the AVR_CMD line, pin 5. This will reset the
250ms timer to its start value, giving another 250ms before system shutdown. The "TICKLE"
command is not used in the M5 architecture.
3. A "CANCEL" command can be sent, stopping the 250ms timer and leaving the AVR in the
"ON" state.
42. 6871771L01-A August 6, 2007
Theory of Operation: M5 Control Head Main Board 3-19
3.2.5.2 Ignition
In the remote mount configuration, the vehicle ignition signal is routed through the CHUC and CHIB
to the control head. In dash mount, the ignition signal passes through the transceiver's J2 rear
connector, and into the control head. The ignition signal then passes through a voltage divider, R341
and R342, which sets the ignition threshold to roughly 9.6 volts. The divided signal is applied to a
voltage supervisor IC, U304. The voltage supervisor, along with resistors R341 and R342, is used to
control the ignition threshold voltage. In addition a 300 ms debounce delay is added by the voltage
supervisor. Ignition must be held high for 300 ms before the voltage supervisor output will toggle.
The voltage supervisor output is an open-drain configuration. Pull-up resistor R343 is used to pull the
output high. This output is applied to the AVR ignition input on pin 10.
The AVR also debounces the ignition input. When ignition is stable, the AVR transitions to the "ON"
state, asserting FIVE_V_EN and SW_BPlus_EN. The eight second timer described in the On/Off
button section is started and AVR_IGNITION_OUT is asserted to signify that the turn on reason was
due to ignition. The AVR only enters the "ON" state due to ignition. Turning the radio off is handled by
the system software.
Once the system is powered on and communications have been established with the transceiver, the
codeplug in the transceiver is checked to determine if ignition is a valid turn on reason. This includes
checking the last state of the radio in the case of ignition required. If the radio was previously turned
off due to ignition, then it will turn back on when ignition is reapplied.
After OMAP checks the power on reason, it sends a "CANCEL" command to the AVR. The
"CANCEL" command stops the eight second timer and unlatches the AVR_IGNITION_OUT signal.
The AVR_IGNITION_OUT signal then reflects the state of the ignition input.
3.2.5.3 MMP Power on Accessory
A power-on capable accessory can turn the radio on by toggling the GPIO_0 pin on the MMP port.
The AVR monitors this input for a low to high transition. When this transition occurs, the AVR enters
the "ON" state, asserting FIVE_V_EN and SW_BPlus_EN. The eight second timer is started and
output pins DAT_0 and DAT_1 are set to a logic low and high respectively. DAT_0 and DAT_1 set
this way signify that the turn on reason was due to an MMP Accessory. The AVR only enters the
"ON" state due to MMP Power-on. Turning off is handled by system software. If OMAP becomes
unresponsive, the control head power button must be used to power down the system.
After OMAP checks the power on reason, it sends a "CANCEL" command to the AVR to stop the
eight second timer. Once the system is powered on and communications have been established with
the transceiver, the codeplug in the transceiver is checked to determine if the MMP power-on feature
is enabled. If the feature is not enabled, then the transceiver shuts the system down with an "OFF"
command on the CAN3 bus.
3.2.5.4 Emergency
The AVR Emergency power-on function is only used in remote. In dash, the transceiver handles
emergency functionality. The emergency signal is not routed from the transceiver to the AVR input
and the AVR input is pulled low by resistor R350. In remote, the emergency signal is routed from the
external connector through the CHUC and CHIB to the AVR emergency input. Voltage translation is
accomplished by transistor Q101 on the CHIB.
The emergency input is debounced for 50ms by the AVR. When a low to high transition occurs on
this pin, the AVR enters the "ON" state, asserting FIVE_V_EN and SW_BPlus_EN. The eight second
timer is started and the EMER_SENSE output is asserted to signify that the turn on reason was
emergency. EMERGENCY will only place the AVR in the "ON" state. The system software turns the
system off.
43. August 6, 2007 6871771L01-A
3-20 Theory of Operation: M5 Control Head Main Board
NOTE: If you press and hold emergency button for longer than 2 seconds, and your radio was
programmed with a secure key, a display message will appear: “KEY ERASE”. If you don’t
want to erase key, press HOME button. If you do want to erase, press emergency.
After OMAP checks the power on reason, it sends a "CANCEL" command to the AVR to stop the
eight second timer and unlatch the EMER_SENSE output. EMER_SENSE will then reflect the state
of the EMERGENCY pin. Once the system is powered on and communications have been
established with the transceiver, the codeplug in the transceiver is checked to determine if the
emergency power-on feature is enabled. If emergency power-on is not enabled, the transceiver will
shut down the system with an "OFF" command on the CAN3 bus.
NOTE: Emergency power on is not supported using the control head programmable emergency
button.
3.2.5.5 Remote Commands
Remote turn on, turn off, or reset commands are received from other devices in the system, such as
the transceiver or another control head in the dual control head configuration. These commands are
received via the CAN3 bus and are received on the AVR BUS_CMD (pin 14) input.
When the AVR receives an "ON" command, it enters the "ON" state, starting the eight second timer
and asserting FIVE_V_EN and SW_BPlus_EN. When an "OFF" command is received, the AVR
immediately enters the "OFF" state, de-asserting FIVE_V_EN and SW_BPlus_EN. The 250 ms timer
is not set. When a reset command is received, the AVR de-asserts FIVE_V_EN and SW_BPlus_EN
then waits for the 5V_Brick feedback pin to go low to ensure that the transceiver is powered down.
Once 5V_Brick feedback is low, the AVR waits for 500 ms then re-asserts FIVE_V_EN and
SW_BPlus_EN. In addition, DAT_0 and DAT_1 are set to logic low and high respectively to signify
the turn on reason was RESET. This is needed because OMAP views RESET as a turn off then turn
on event. OMAP doesn't know that a RESET command was just received.
3.2.5.6 Local Commands
The "CANCEL" and "TICKLE" commands are sent directly from OMAP to the AVR via the AVR_CMD
input. These commands use the same protocol, described in the section 3.1.3, as the remote
commands received over the CAN3 bus.
Table 3-8. Local Command Pulse Widths
Remote Command Pulse Width Receiver Specifications
COMMAND -20% Nominal 20% +Guard Band
CANCEL 0.3 ms 0.5 ms 0.6 ms 2 ms
ON 5 ms 6 ms 7.2 ms 8 ms
RESET 10.8 ms 15 ms 18 ms 50 ms
OFF 358.8 ms 500 ms N/A ms N/A ms
44. 6871771L01-A August 6, 2007
Theory of Operation: M5 Control Head Main Board 3-21
3.2.5.7 5 Volt Transceiver Feedback
The five volt feedback input to the AVR, labeled as “5V Brick Feedback”, is used in the dash mount
configuration to ensure that the transceiver powers down completely during reset and fast on/off
cycles. This signal is derived from the transceiver regulators. When the AVR de-asserts SW_B+, the
transceiver begins its shutdown procedures, which includes cleanup tasks such as de-affiliating from
trunked systems. This results in an indeterminate power down time, hence the need for feedback to
the AVR. In the remote mount configuration, the control head 5 volt regulator output is routed to the
CHIB. The CHIB loops this signal back to the control head to satisfy the AVR “5V Brick Feedback”
requirement in the remote mount configuration.
3.2.6 AVR Outputs
The AVR has eight outputs (refer to Figure 3-14). Two control the power state of the control head,
one is used to send remote commands, and the last five are used to communicate power on reason
to OMAP. FIVE_V_EN and SW_BPlus_EN control the five volt regulator and SW_B+ respectively.
ON_OFF_SENSE, EMER_SENSE, and AVR_IGNTION_OUT are connected to OMAP GPIO's
through level translators. DAT_0 and DAT_1 are used together to encode two power on reasons,
MMP power on and RESET. CAN_PULSE_OUT is used to send commands to remote devices
connected to the CAN3 bus. Every time the AVR enters the "ON" state, an "ON" command is sent on
the CAN_PULSE_OUT pin. If the AVR enters the "OFF" state due to either the eight second timer
expiring or the 250ms timer expiring, then an "OFF" pulse is sent on CAN_PULSE_OUT.
Figure 3-14. On / Off / Reset Control Circuit
Voltage Supervisor
Circuit
Threshold set to 7.3
volts.
Power Button
UNSW_VCC
Ignition Conditioning
Threshold set to
roughly 9.6 volts.
100 volt tolerant .
Roughly 300ms
debounce time .
Level Translation
100 kΩ pullup to
UNSW_VCC
Emergency
conditioning on
CHIB.
Not connected in
dash.
CAN3 transceiver
in REMOTE.
Transceiver
microprocessor in
DASH.
Five volts from the
transceiver in
DASH.
Five volt loopback
from the CHIB in
REMOTE.
U305
ATMEL AVR
19
12
10
13
11
14
5
6
7
16
3
2
20
1
9
15
17
4
RESET
ON_OFF_B
IGNITION
MMP_GPIO_0
EMERGENCY
BUS_CMD
5V Brick Feedback
AVR_CMD
Rear Ignition
Board ID
Not Used
DAT_0
DAT_1
CAN_PULSE_OUT
ON_OFF_SENSE
EMER_SENSE
AVR_IGNTION OUT
FIVE_V_EN
SW_BPlus_EN
U309
U405
U404
A+
U214
I2C I/O
Expander
17
19
P5
P6
I2C
GPIO_9
ARMIO_5
ARMIO_12
GPIO_8
U400
OMAP
Microcontroller
V5 W8
T20
L19
Y8
I2C
To CAN3
transceiver
input
To 5V
regulator
enable pin
SW_B+
Level Translation
Buffer
SW_B+ Switch and
buffer circuit
45. August 6, 2007 6871771L01-A
3-22 Theory of Operation: Remote Back Housing Assembly
3.3 Remote Back Housing Assembly
The remote back housing assembly consists of the Control Head Interface Board (CHIB) and Control
Head Universal Connector (CHUC). These two boards are connected together via an onboard
connector. The CHIB contains the audio circuitry, a USB type "A" (HOST) connector interface, and
CAN auto-termination circuitry. The CHUC contains VIP/DEK circuitry, reverse voltage protection,
ESD suppression circuitry, and the physical connectors J100-J400.
Figure 3-15. Remote Back Housing Assembly (CHIB and CHUC)
3.3.1 Control Head Interface Board (CHIB)
The Control Head Interface Board (CHIB) is used to provide functionality and connectivity between
the CHUC, the transceiver, and the Control Head.
The CHIB will be explained in six different sections: FPGA, USB connectivity, Power, Audio, CAN
termination and Power ON/OFF - Emergency.
3.3.1.1 DC Power Distribution
The main power source to the control head is the battery voltage or raw A+, which is protected by
transorb U910 and 7 Amp Fuse F400. A+ is then switched at the control head by a FET Q309. Extra
protection is added and the voltage is routed back to the CHIB as SW_B+ (see control head section
for more detailed information).
A+ is also the input for the 5V regulator at the control head which is routed to the CHIB as VCC_5.
VCC_5 is used to generate 1.5V, 1.8V, 2.85V and 3.3V. The enable pin REG_EN is controlled by
OMAP in the control head.
VCC_9 and GREG_11V are supplied by SW_B+. The UNSW3.3V regulator is supplied by A+. These
regulators do not have an enable pin and are enabled when the input voltage reaches the minimum
threshold. Figure 3-16 is a block diagram of the CHIB power distribution.
