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PRM.

4031

HFISSB Transmitter-Receiver

Tsehnlcal Manual

4>

1.77

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Racal- Tacticom Limited

P.o. Box 112, 472 Ba~ingstqkeRoad, Reading, Berks; RG200F TeL Reading (b734}8!5181 Telex: 8413bn Grams: TacticomReading Prepared by Group TechoicalHandbooks ()epartrnent.RacaIGroup $ervicesLiniited

............... -------------' · rm~[J

The Electronics Group

R.et WOH8106

Issue 3:5.81 • 135

(fE.eJD

rwoHs1061

HF Transmitter-Receiver PR.M4031

HANDBOOK AMENDMENTS

Amendments to this handbook (if any), which are on coloured paper for ease of indentification, will be found at the rear of the book. The action called for by the amendments should be carried out by hand as soon as possible.

GASEOUS TRITIUM - SAFETY PRECAUTIONS

INTRODUCTION

Gaseous tritium emits beta particles, and is used in 'beta lights' for front panel controls. Both button and strip form lights are used. The following safety precautions should be observed.

STORAGE OF SPARES ITEMS

Not more than twenty-four buttons or strips should be handled at anyone time. This is to ensure that in the unlikely case when all buttons being handled are broken sirnulataneously, the amount of escaped gas is kept to a safe level.

BREAKAGE.

If buttons or strips are broken the tritium gas will quickly disperse if the area is well ventilated. Should a large quantity, e.g. 24 be broken simultaneously the immediate area should be evacuated for twenty minutes.

BERYLLIUM OXIDE - SAFETY PRECAUTIONS

I~1'l'-ODUCTION

The following safety precautions are necessary when handling components WhLCh cuntain Beryllium Oxide. Most RF transistors contain this material althouQh Berylli'~ Oxide is not visibl~ externally. Certain heatsink washers are also manufactured from this material.

PRACTICAL PRECAUTIONS

Beryllium Oxide is dangerous only in dust form when it might be inhaled or p.nter

u C'Jt or irritation area. Reasonable care should be taken not to generate dus t by d~rasion of the bare material.

Power Transistors

There is normally no hazard with power transistors as the Beryllium Oxide is encapsulated within the devices. They are safe to handle for replacement purposes but care should be exercised in removing defective items to ensure that they do not becom~ physically damaged.

They MUST NOT:

(a) be carried loosely in a pocket, bag or container with other components where they may rub together or break and disintegrate i.nt;o dU5C,

!.DJ be heated excessively (normal soldering is quite safe) ,

((,., be broken open for inspection or in any way abraded by tools.

hedtsink W-'lshers

Heatsink washers manufactured from Beryllium Oxide should be handled wit~ gloves, clJth or tweezers when being removed from equipment. They are usually white or

t: Lue in colour although sometimes difficult to distinguish from other types. Examples of washers used are 917796, 917216 and 700716.

~U::;T Nar:

b~ stored loosely,

iL,

be filed, drilled or in any way tooled,

\ .. '

l "

be heated other than when clamped in heatsink applicat.ion.

DISPOSAL

[)(~f"ctive ,.nd broken components must not be disposed of in containers used for i,:'neral refuse. Defective components should be individually wrapped, clearly l.dE':ntified as "DEFECTIVE BERYLLIA COMPONENTS" and returned to the Equipment Manufacturer for subsequent disposal.

~roken components should be individually wrapped and identified as "BROKEN BERYLLIA COMPONENTS". They must not be sent through the post and should be returned by hand.

MEDICAL PRECAUTIONS

If Beryllia is believed to be on, or to have entered the skin through cuts or ~brasions, the area should be thoroughly washed and treated by normal first-aid methods followed by subsequent medical inspection.

Suspected inhalation should be treated as soon as possible by a Doctor - preferably a. t a hospital.

**********"'***

PART 1 PART 2 PART 3 PART 4 PART 5 PART 6

PRM.4031

CONTENTS

PRM.4031 B HF SSB TRANSMITTER-RECEIVER OVERALL DESCRIPTION 719197 TRANSCEIVER SUS-ASSEMBLY

719250 POWER AMPLIFIER AND FILTER SUB-ASSEMBLY 719073 ANTENNA TUNING UNIT (ATU)

719198 SYNT HES IZER SUB-ASSEMBLY

I LWSTRA TED MEC HANICAL PARTS LIST

PART 1

PRM.4031 HF SSB TRANSMITTER-RECEIVER

CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 CHAPTER 7 CHAPTER 8

CONTENTS

TECHNICAL SPECIFICATION GENERAL DESCRIPTION EQUIPMENT AND ACCESSORIES INSTALLATION AND OPERATION

INTERCONNECTION AND MECHANICAL DESCRIPTION TEST EQUIPMENT

PREVENTIVE AND CORRECTIVE MAINTENANCE FAULT FINDING AND PERFORMANCE CHECKS COMPONENTS LIST - CHASSrS

ILLUSTRATIONS (AT REAR OF PART)

(See individual Chapter Contents' pages for in-text illustrations)

Fig. No.

Mechani cal Construction

Mounting of Transceiver and Synthesizer Boards External connections to Audio Sockets Interconnection Diagram

PRM.403TI

1 2 3 4

Contents Part'

General

Frequency Range:

I .6 - 29. 9999M Hz .

Channels:

284,000 channels in 100Hz steps derived from a single high stability TCXO selected by 6 switches. Maximum synthesizer locking time, less than I second.

Operating Modes: USB (A3J)
USB CW (A2J) 1 k Hz keyed tone
LSB CW
lSB (A3J)
Compatible
AN\ (A3H) frequency Stabi I ity:

Better than + 1 ppm over the operating temperature range

- a

with respect to that at 25 C.

a Accuracy be tter than 0.3 ppm at 25 C.

Power Supply:

12 Volt nominal from 4Ah nickel-cadmium rechargeable battery type MA.4025A, or associated power supply unit.

Antennas:

2.4m (8 ft) whip long wire Dipole

Optional short hel ical battle antenna

Antenna Tun ing:

Single control tuning. lnbuilr ATU runes the above antennas for both transmit and receive.

Sealing:

Transmitter-receiver case sealed and fitted with desiccator. Battery case sealed and fitted with desiccator bag.

Weight:

Basic PRM.4031 only:

3.5kg (8.0 lb), Operational manpack with handset, nickelcadmium battery and haversack: Bkg (17.6Ib).

PRM.4031

Tech. Spec. (1)

Dimensions:

Env i ronmenta I

a)

Temperature

b)

Humidity:

T ronsm itter

Output power: Voice (SSB) CW

Harmonic Emissions:

Carrier Suppression: (SSB,

CW)

Intermodulation distortion:

Dynamic Range of Compressor Input:

Current Consumption:

Overall AF Response:

PRM.4031

Basic set (no battery) Width; 230mm (9. 1 in), Height: 75mm (3.0 in). Depth; 253mm (10.0 in).

Basic set with battery Width: 230mm (9. 1 in). Height: 80mm (3.2 in). Depth: 335mm (13.2 in).

Operational -100 to +550C

o 0

Storage: -40 to +70 C

The unit is enclosed in a sealed desiccated box.

High Power

10 watts pep + 1.5dB 1 0 watts + 1 • 5d B

All into ;- 50 Ohm load.

Low Power

Approx. 6dB reduction Approx. 6dB reduction

No harmonic wil! exceed -40dB relative to pep in 50 Ohm load.

Better than -45dB relative to pep in 50 Ohm load.

Not worse than -25dB relative to full pep output.

Greater than 30dB above compression threshold.

SSB ... two tones at the compression threshold: i .SA CW: 3.0A.

Better thon -6dB at 500 and 2500Hz.

Tech. Spec. (2)

Receiver

Sensitiv i ty:

Not less than 5mW AF output into 300 Ohm for I uV pd RF input at stated SIN ratio.

Signal/Noise Ratio:

SSB: not less than 15dB for 0 1 uV pd RF input. CW: not less than 22dB for a 1 uV pd RF input.

AM: not less than IOdS for a 3uV pd RF input with 30% rnodu lotion.

Selectivity:

SSB: 6dB bandwidth 2.0kHz minimum. AM: 40dB bandwidth 5.0kHz maximum.

CW: 3dB bandwidth 100Hz + 30Hz centred on 1kHz.

Current Consumption:

Maximum: 170mA. Typical: 150mA.

Image Rejection:

Be tter than 70d B .

IF Rejection:

Better than 70dB.

AF Output fbwer:

Phone not less than 20mW into 300 Ohm, Fixed not less than 45mW into 50 Ohms.

AGC

The AF output changes less than 6dB for RF input variation of 1 ODdS above 2uV pd.

Control and Facilities

a. Front Panel

Frequency Selection Controls: The six control switches ore used to select the required frequency,

Mode Switch:

The six position rotary switch is used to select the mode

of operation of the equipment. The positions of the switch are:-

AMI LSS-CW, lSB, USB, USB-CW and TUNE.

Power Switch:

The three position rotary switch is used to select a high or low power output condition and is also used to switch the unit off. The positions of the switch are:-

OFF, LP and HP.

PRM.4031

Tech. Spec. (3)

GAIN:

This potentiometer (which is concentric with the 100Hz frequency selection switch) controls the gain of the handset audio outputs.

TUNE:

This control tunes the antenna except when a remote ATU is used.

Meter:

The meter indicates the battery voltage (when the unit is in the receive condition and the Power Switch is in the HP position), the age voltage (when the unit is in the LP position) and antenna current (when the unit is in the transmit condition). The meter incorporates coarse tune indicating Le.d. 's ,

Audio 1 socket:

This socket has pins A to F connected in parallel with

Pins A to F on the Audio 2 socket and allows ancillary

equ ipment (such as a headset, morse key, ex.ternal power supply or battery charging equipment) to be connected to the transceiver. Pin G enables iniHote tune when a remote ATU is used with the equ ipment.

Audio 2 socket:

This socket provides the same facil ities as the Audio 1 socket except that Pin G has a fixed audio output for use with, example, a vehicle harness.

Whip Socket:

This socket allows a whip antenna to be connected to the set.

50n BNC 1.6-8MHz 500 BNC a-30M Hz

These sockets allow a dipole antenna to be connected to the set.

b. Rear Panel

W/B Socket:

This socket provides a connection to either an external filter, a remote ATU or on r.f , amplifier. The d.c. impedance presented to the socket automatically switches the output to the socket and determines whether the output is high or low power.

ATU Socket:

This socket provides a return to the set from the external filter 50 that the internal ATU may be used to match the antenna.

Ground Terminal:

The terminal allows a ground connection to be mode to the set.

PRMA031

Tech. Spec. (4)

ROLE

DESCRIPTION COMPOSITION OF MANUAL

LIST OF ASSOCIATED PUBLICATIONS

CONTENTS

ILLUSTRATIONS (IN TEXT)

Block Diagram

PRM.4031

Chapter 1 Contents.

Para.

1 2 3 4

Fig. No.

1.1

1. ROLE

1 .1 The PRM .4031 is an HF transceiver operating in the SSB, AM and CW modes.

Although designed primarily as a manpack the equipment can be used as a ground station or vehicle radio.

2. DESCRIPTION

2.1 The transceiver is a fully waterproof, I ightweight portable transceiver which operates in the frequency range 1 .6 to 29. 9999MHz. The unit provides 284000 synthesizer-controlled channels separated by 100Hz steps, and has facilities for both voice and telegraphy, operating in SSB (upper or lower) AM or CW modes.

2.2 The design of the manpack allows it to be operated and carried by one operator, although provision is made to allow two operators to use the manpack simultaneously.

2.3 Power supplied to the manpack is obtained from a battery which is contained in a case attached to the base of the moin transceiver case. The power supply is a nickel-cadmium (NICAD) rechargeable battery MA.4025A, and is capable of continuous high power operation for 13 hours with 0 senq/receive time rorio of 1 :9. A non-rechargeable battery, using primary cells, is available as an alternative.

2.4 As a monpack radio with a whip antenna, the transceiver provides rei iable ground wave SSB communication for distances up to 25km, day or night, over roll ing terrain. As a ground station using a dipole antenna the sky wave range can be several thousand kilometres. Remote control, including intercommunication and call facil ities, is available with MA. 986B and MA.9856 control boxes.

2.5 Manual rebroadcast facilities can be obtained in conjunction with MA.4009 control unit or vehicle control harness.

2.6 The sub-assembl ies which comprise the transceiver are shown in the block diagram Fig.l.1.

1-1

PRM.4031

34-0 TO 141KHz OUT-OF-I.OCK

36·8 MHz SIGNAL

MHz

IPART 31 POWER AMPLIFIER [PAIA~D FILTER SUB-ASSE~BLY 719250

IPART 11 TRANSCEIVER SUB-ASSEMBLY "9191

__._ RECEIVE PATH

-~- TRANSMIT PATH

+ SYNTHESIZER OUTPUTS

I PART 51 SYNTHESIZER sue-ASSEMBLY 713198

Block Diagram: PRM.4031

Fig.'·1

3. COMPOSITION OF MANUAL

This manual is sectional ized into Parts as listed below:-

PART 1. PART 2. PART 3. PART 4. PART 5. PART 6.

PRM.4031 HF SSB TRANSMITTER-RECEIVER OVERALL DESCRIPTION 719197 TRANSCEIVER SUB-ASSEMBLY

719250 POWER AMPLIFIER AND FILTER SUB-ASSEMBLY 719073 ANTENNA TUNING UNIT (ATU)

719198 SYNT HES IZER SUB-ASSEMBLY

ILLUSTRATED MECHANICAL PARTS LIST

4. LIST OF ASSOCIATED PUBLICATIONS

User Handbook for Transmitter/Receiver Type PRM.4031 Technical Manual for Battery Charger MA. 945B Technical Manual for Local and Remote Control Unit

MA. 985p/ MA. 9868

PRM.4031

Ref. WOH 8106 Ref. WOH 1075 Ref. WO H 4030

1-2

T echn icc I Manual for the Loudspeaker Ampl ifier MA. 988 Technical Manual for the Test Set CA531 C

Technical Manual for the Vehicle Interface Box (H. F. and V. H. F.) MA. 41 06

Technical Manual for Hand Generator MA.4175

PRM.4031

Ref. WOH 3074 Ref. WOH 9148

Ref. WO H 8069 Ref. WOH 8425

1-3

CONTENTS

INTRODUCTION

RECHARGEABLE BATTERY MA.4025A (5T719004) PRIMARY BATTERY MA.4025B (719063) CARRYING FRAME (5T719063)

AUDIO EQUIPMENT

Telephone Handset (5T719215 or 5T711013)

Headset/Boom Microphone Assembly (5T719214 or 5T711024) Headset Assembly (ST711 015)

Headset Assembly (ST71 1 014)

Loudspeaker Amplifier Unit MA.988 (5T700860) MORSE KEY (5T700059)

SECTIONAL WHIP ANTENNA (5T719094) BATTERY CHARGER MA. 945B (5T719238)

LOCAL/REMOTE CONTROL BOXES MA.985B/MA.986B (5T701683/4) 3-30MHz DIPOLE ANTENNA (5T790008 or 5T711169)

END FED ANTENNA (ST790012)

5.4m MAST KIT MA.2231

VEHICLE INTERFACE BOX (VIB) MA.4106 HAND GENERATOR MA.4175A

ILLUSTRATIONS (IN TEXT)

Basic Equipment

Major Ancillary Items (1) Major Ancillary Items (2)

APPENDICES

Appendix 1

list of Equipment and Ancillaries.

PRM.4031

Para.

1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 1 5 16 17 18 19

Fig. No.

2.1 2.2 2.3

Chapter 2 Contents.

1. INTRODUCTION

1 .1 Listed below are brief details of the equipment and accessories commonly used with the transceiver in order to build up a complete transmitter-receiver station (see Figs. 2.1, 2.2 and 2.3). A complete list of accessories is given in Appendix 1 to this chapter.

2. RECHARGEABLE BATTERY MA.4025A (5T719004)

2.1 This 12V 4Ah nickel-cadmium battery screws directly to the base of the transceiver, nn arrangement that facil itates rapid battery changing. The battery may be charged either while attached to the monpock or when removed from it, by using charger type MA. 945B or Hand Generator type MA. 4175A.

2.2 The user can charge and discharge the battery many hundred of times before its copacity is seriously affected and, unlike many secondary batteries, nickel-cadmiums require no maintenance. The MA.4025A is fully sealed thus eliminating any

adverse effects due to the ingress of moisture.

3. PRIMARY BATTERY MA.4025B (719063)

3.1 This battery screws directly to the base of the transceiver, as does the MA.4025A.

It contains 10 'D' size cells which are easily replaced by removing two wing nuts, enabl ing the end cover to be detached.

4. CARRYING FRAME (ST719097)

4.1 This is a plastic coated metal frame, which can accomodate a transceiver complete with an MA. 4025A or MA .4025B battery.

5. AUDIO EQUIPMENT

6. Telephone Handset (ST719215 or 5T711013)

6.1 This is a lightweight nylon handset complete with plug and coiled lead extendable up to 1.8m.

7. Headset/Boom Microphone Assembly (ST719214 or 5T711024)

7.1 This is a twin earpiece and boom microphone assembly, complete with plug and 1.6m lead, which permits 'hands off' operation of the transceiver. A pressel switch (PTT) and securing clip is fitted into the lead.

2-1

PRM.4031

8. Headset Assembly (STlI1015)

8.1 This is a single earpiece assembly with a 1 .3m lead.

9. Headse~ Assembly (ST71 1014)

9.1 This is a twin earpiece headset assembly with a 1 .3m lead.

10. Loudspeaker Amplifier Unit MA.988 (ST700860)

10.1 This is a weatherproof monitoring loudspeaker amplifier with an output of 0.5W.

The power supply is derived from the transceiver.

11 . MORSE KEY (5T700059)

11.1 The morse key is complete with knee strap and lead.

12. SECTIONAL WHIP ANTENNA (5T719094)

12.1 This is a 2.4 metre whip antenna comprising eight sections with a stainless steel retaining cord and a flexible plug-in antenna mount which enables the whip antenna to be set to the required operational angle and protects both the whip and manpack from damage due to excessive shock or impact.

13. BATTERY CHARGER MA.945B (5T719238)

13.1 This battery charger enables the nickel-cadmium battery MA.4025A to be recharged from a supply of 12V d.c., 24V d.c., l10V a.c. or 230V o .c , (nominal).

14. LOCAl/REMOTE CONTROL BOXES MA.985P/MA.986B (5T701683/4)

14.1 The addition of these two boxes enables a transceiver to be operated at a distance of up to 3km using the D10 twin cable. Intercommunication between the local and remote positions is also provided.

15. 3-30MHz DIPOLE ANTENNA (5T790008 or 5T711169)

15.1 This antenna is complete with feeder, support I ines, throwing weight and spools.

If required, it can be supported by the 5.4m mast.

16. END FED ANTENNA (5T790012)

16.1 This antenna kit is complete with support I ines, throwing weight and spool. It is connected to the radio using adaptor ST 700074.

2-2

PRM.4031

17. 5.4m MAST KIT MA.2231

17.1 This kit comprises six glass fibre tubes, colour coded guys, I ight alloy pegs, mast head adaptor for 'F' rods and PVC coated down lead. Also included are two folding sand anchors which give the extra hold required when using an antenna in soft sand conditions. The golf bag type carrying case hos a reinforced cap which may be used as a base plate on soft ground.

18. VEHICLE INTERFACE BOX (VIS) MA.4106

18.1 The Vehicle Interface Box (VIS) is used wherever the transceiver is fitted in a vehicle. The VIB provides the following facilities:

(1) Allows the transceiver to be suppl ied directly from the vehicle electrical system. The VI B can accept an input of 24V to 32V d. c., or with an internal change 12V to 16V d.c., ond incorporates a regulator.

(Negatively earthed systems only). Supply filtering and transient suppression is provided.

(2) Provides transformer coupl ing of the audio input to el iminate earth loop problems.

(3) Provides an audio output to drive a loudspeaker (Type HOD).

19. HAND GENERATOR MA.4175A

19.1 This generator is for use with 12 volt rechargeable batteries and is used in conjunction with tree clamp 5T719348 or Unipod ST719347. The generator will supply on output in excess of lA with the handle turning at 70 r.p.m.

20. MAINS POWER SUm.. Y UNIT MA.4107

20.1 The MA.4107 operates from 110V or 230V c .c . mains and provides 12V at up to 4A for the radio. The unit also suppl ies 24V to power an AATAMU and includes an audio ampl ifier to give 3W into an external speaker.

2-3

PRM.4031

e.flJliQ~~=l
k~~t=gJ=£~~b~~£=~l=~[;;-I=~=~tJ=C;LLJ=~~LE=S=
ITEM DESCRIPTION RACAL WEIGHT DIMENSION
REFERENCE kg. mm ,
1 P RM .4031 T ransce i ver 5T719197 3.5 230x75x253
2 N ickel-Cadm ium Rechargeable
Battery (4Ah 12V) Type MA4025A ST719OO4 2.4 230x80x90
3 Primary Battery Pack MA .4025B
(without cells) 5T719063 0.77 230x80x90
4 2.4m (8ft) Sectional Whip
Antenna complete with
flexible mount 5T719094 0.28 360x35 dia.
Comprising: (folded)
Flexible Plug-in Antenna Mount
MA.712/11
Whip Antenna MA.714!10
5 Battle antenna 5T719103 0.2 475x30 dio.
6 Telephone handset 5T711013 or 0.39 196x72x55
5T719215
7 Headset and Boom Microphone 5T71 I 024 or 0.63
5T719214
8 Headset, Single earpiece 5T711 015 0.14
9 Headset, Noise Excluding 5T711014 0.37
10 Morse Key with knee strop 5T700059 0.21
11 Ground Spike and Lead 5T719096 0.17 305x38 dio.
12 Accessory Bag 5T719462 or 0.22 230x365x66
5T719191
13 Carrying Frame 5T719097 1.45 385x323x175
14 3-30MHz Dipole Antenna
Complete with Feeder, Support
Lines, Throwing Weight and
Spools 5T790008 or 2.2
5T711169
15 5.4m Mast Kit MA.2231 3.5 11Ox160xl010
16 End Fed Anrennc, complete
with throwing weight, line
and spool 5T790012 1.0
17 F rod No.2 920196 0.13 126xl0 dia.
18 F rod No.3 920197 0.07 126x6 dia. PRM.4031

Chap. 2 App. 1-1

ITEM DESCRIPTION RACAL WEIGHT DIMENSION
REFERENCE kg. rnrn ,
19 Universal Battery Charger
Type MA. 945B, for Rechargeable
Batteries 5T719238 3.74 288x89x160
20 Vehicle Interface Box (VIB) 5T719027 2.5 150x75x260
MA.4106
21 Loudspeaker/ Ampl ifier Unit
Type MA.988 ST700860 0.77 83xl12x54
22 Local Control Unit tvIA.985B 5T701693 1.1 206x94x68
23 Remote Control Unit MA. 986B 5T701694 1 .0 206x94x68
24 Test Set Type CA.531 C 5T719318 9.8 460x250x 180
25 Terminal Adaptor (Whip/Terminel)
for separate Whip Antenna 5T719186 0,6 85x30 dio ,
26 Terminal Adaptor (BNC/Term inal)
for end-fed Antenna 5T700074 0.06 45x15 dlo .
27 Mounting Plate for transceiver 5T719092 0.75 248x267x8
28 Quick Release Base for transceiver
and MA.4106 5T719174 3.1 418x290x27
29 User Handbook WOH8106 0.07
30 Hand Generator MA. 4175A 5T719329 2.0 1 14x 1 71 xl 07
31 Tree clamp for above 5T719348 0.62 252x95x95
32 Un ipod for above ST719347 480x160x66
(dismantled)
33 Mains PSU MA.4107 5T719192 5 230x75x250 PRM.4031

Chap. 2 App. 1-2

MORSE KEY WITH KNEE STRAP

I~ ,An

: I U /1

I I I'

f I

\

I

\ '

I I , \

I, \

I '

'_,

~

\\ -- WHIP

~ ANTENNA--...

ld

TRANSCEIVER IN FRAME

Basic Equipment

Fig.2.1

DIPOLE ANTENNA REELS AND ADAPTOR ST79000B

ST 711169

SINGLE EARPIECE HEADSET 5T711015

BOOM MICROPHONE sT719214 ST711024

UNIVERSAL BATTERY CHARGER

MA 9458

GROUND SPIKE AND LEAD sr 719096

Major Anci llary I terns (1)

Fig.2.2

VEHICLE BOX INTERFACE 06 (VIS) MA."1

,i

1 i

I:

I

I

BAG ST 719462 ACCESSORY

"AST KIT 5'4m ..,

MA.2231

, illory Items(2)

Major Anc:

Fig 2.3

CONTENTS

MANPACK STATION

ASSEMBLY OF MANPACK STATION CARRYING OF MANPACK STATION OPERATING INFORMATION

SILENT TUNING

METER INDICATION

BATTERY CARE

Battery Fuse

Battery Pack Replacement

Charging of Rechargeable Battery MA. 4025A Cell Replacement for Primary Battery MA .40258 5.4m MAST AND ALTERNATIVE ANTENNAS 5.4m Mast MA.2231

Erection of 5 Am Mast

Ground Wave Vertical Antennas End Fed Antenna

Vertical Dipole

Sky Wave Dipole and Inverted V Antennas LOUDSPEAKER AMPUF IER

REMOTE OPERATION

Setting-Up for Remote Operation

Modes of Operation

WORKING WITH OTHER RADIOS VEHICLE OPERATION

Installation

Whip Antennas

Remote ATU

Use of External Filters

Use of RF Power Amplifier Use of VIB

PRM.4031

Para.

1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Chapter 3 Contents (i)

Voice Operation Front Panel Battery Charging

Primary Battery MA .40256 Erection of 5.4m Mast

End Fed Antenna

Vertical Dipole Antenna Antenna Securing Horizontal Dipole Antenna Inverted V Dipole Antenna Remote Operation

Rear Panel

1 DOW System

PRM.4031

ILLUSTRATIONS (IN TEXT)

Fig. No.

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13

Chapter 3 Contents (ij)

1. MANPACK STATION

1.1 The items of basic equipment which comprise the mcnpock station are shown in Chapter 2, Fig. 2.1 .

2. ASSEMBLY OF MANPACK STATION

(1) Fit transceiver into carrier as shown on Fig. 2.1. The transceiver locates on two protrusions on the frame which engage in recesses in the transceiver front panel. Engage and tighten the two retaining straps.

(2) Fit battery to transceiver and tighten the two wing screws, by hand.

(3) Erect whip antenna by grasping the small whip section and pull ing the centre cord. Check that all sections are fully in place.

(4) Insert whip antenna into whip socket and screw down retaining ring.

(5) Plug handset into either audio socket on the transceiver. Fit the handset into the retainer on the harness.

(6) Plug a morse key or hcmdset,lheodset into the other audio socket if required.

(7) Fit the accessory bag to the carrier if required.

3. CARRYING OF MANPACK STATION

3.1 The correct carrying position is shown in Fig. 3.1. This figure also shows the use of a headset as an alternative to the handset.

4. OPERATING INFORMATION

4.1 Set up and tune the transceiver with reference to Fig. 3.2.

Set frequency

Set the six frequency selection controls to the required positions. (Shown set to 25.3547MHz). There is a stop at zero position to enable frequency to be set by touch in the dcrk ,

3-1

PRM.4031

o

o

o

PRM.4031

Check Battery

Tune Antenna

Set Power

Select Mode

Commun i cate

Adiust Volume

.~-.~-

Voice Operation

Fig, 3,1

Set MODE switch to any position but TUNE. Se+ POWER switch to HP and check that meter reads threequarter scale deflection, or greater. Do not depress key or pressel for this check,

Reset transmitter power to LP (low power).

Set MODE to TUNE. Pullout and rotate the TUNE control in the direction indicated by the illuminated red lamp in the meter. When the lamp extinguishes continue adjustment to achieve greatest meter deflection. Push

in TUNE control.

Reset transmitter power as required HP (high power) or LP (low power).

Set MODE switch to USB, LSB or AM for speech or CW for morse.

To transmit, depress pressel and speak into microphone

in speech modes or operate morse key when in CW mode. Sidetone is heard in all modes. To receive, release pressel/rnorse key. (A delay of approximately 1 second will occur between releasing the morse key and the changeover to the receive condition).

Adjust AF GAIN control for required volume of received signal.

3-2

ME TER .).NQ TUl\lif'jG

,- -' ----..INOICATOR 1.IGHT5 WHIP ~NTE"'i'I~

SJCK E r

<HZ ~ 100 '<Hl lI' 10 ~HZ

AUDIO POWER

SOCKETS SWiTCH

_____l

,4 SET powfflJ

, "'OOE SWITCH

I

,

AF GAIN CJN TROL

TUNE CONTROL

eNC A,..TENNA SOOETS

Is SELECT ...ooE[

Front Panel

Fig.3·2

NOTE: In the man-carried role, the tuning should be finally adjusted (by a second man) when the set is in its frame and in the normal carrying position on a men's back.

When the set is used in the static role the earth spike should be used wherever possible. If the sp ike cannot be used (i. e. on concrete paths, etc) care should be taken not to hold metal parts of the set during tuning to

avoid mistuning due to ground plane effect.

5. SILENT TUNING

5.1 The following procedure may be used for silent tuning, i.e. tuning without a signal being emitted.

(1) Set frequency.

(2) Set POWER switch to LP.

(3) Select MODE of operation.

(4) Pullout and rotate the TUNE control to obtain maximum noise level in the receiver if the channel is clear. If the channel is occupied, tune for maximum deflection on the meter.

(5) When transmitter is to be used carry out the procedure given in para. 4.1 (3) to 4.1 (6).

3-3

PRM.4031

6. METER INDICATION

6. 1 The meter performs a number of functions dependent upon the setti ng of the POWER switch. The Tobie below explains its indication:

Power Switch
Low Power High Power
TX RF RF
ou~put level output level
RX Receive signal Battery
strength Voltage 7. BATTERY CARE

7.1 The tronsceiver may be operated with either an MA.4025A nickel-cadmium rechargeable battery or an MA.4025B primary bottery. The current available from most readily obtainable primary cells prohibits the use of the high power transmit mode when a primary battery is used.

8 . Battery Fuse

8.1 The MA.4025A and MA.4025B battery packs incorporate a fuse mounted in a holder, ond also additional spare fuses. The correct fuse is 20mm x 5mm size rated at 6.3A (Racal Part Number 922454).

9. Battery Pack Replacement

9.1 Either battery pack may be disconnected from the transceiver without removing the manpack from its frame. Unscrew the two retaining screws ot the bottom, remove battery and replace with fully charged unit.

] 0 . Charg i ng of Rechargeab I e Battery MA. 4025A

to.1 The MA.4025A battery may be recharged using either the MA.945B charger or the MA .4175A Hand Generator. Recharg i ng may take p I ace either:

(1) Via an AUDIO socket while the bottery is connected to the transceiver.

Charging may take place with the transceiver switched OFF or whilst it is operational.

(2) When the battery is removed from the tronsceiver.

3-4

PRM.4031

The procedure is as follows:

10.2 Using MA.945B Charger (Fig. 3.3)

(2)

(3)

(4)

(5)

NOTE:

PRM.4031

(1)

Set the MA.945B SUPPLY switch to OFF and the SUPPLY VOLTAGE switch to suit the voltage supply i.e. 12V or 24V d .c . or 110V or 230V a.c.

Connect the MA. 945B to the supply using appropriate cable.

Set the CHARGE RATE switch to position 2.

Connect the charger output lead either to the transceiver or directly to the battery •

Switch on the MA.945B and check that the charging indicator lamp illuminates.

A discharged battery will be completely recharged in 16 hours.

TO E"'RT~ TERMlPUlL

CONNECTIONS FOR CHAR()lNG BA TTERV WHEN REMOVED FROM THE M"NP~CK

Battery Charging

Fig.3.3

3-5

10.3 Us i n9 Hand Generator MA. 4175A

(1)

Fit the Hand Generator to a suitable tree or pole using the adjustable tree clamp or fit to the Unipod stand.

(2)

Connect the Generator output lead either to the transceiver or directly to the battery.

(3)

Turn the handle on the Generator at a speed suffi c ient to ill um inate the charging indicator lamp.

NOTE:

A discharged battery will be completely recharged in 5 hours.

11. Cell Replacement for Primary Battery MA.4025B

11.1 The MA.4025B accommodates ten IDI size primary cells. For best performance it is recommended that alkaline manganese MA.1300 cells are used. If the unit is

to be stored for any length of time all cells should be removed to minimise corrosion. The cells can only be replaced when the battery box has been removed from the transceiver.

The procedure is as follows: (see Fig. 3.4).

(1) Remove battery from transceiver.

(2) Unscrew the two wing nuts and remove end cover.

~

!t?~~

~

mH Primary Battery MA 40258 Fig.3.4

3-6

PRM.4031

(3) Remove spent cells.

(4) Fit new cells arranged as indicated on the outside of the battery pack.

Ten cells are required.

(5) Reassemble end cover ensuring that seal ing gasket is properly seated.

12. 5.4m MAST AND ALTERNATIVE ANTENNAS

12.1 The mcnpcck is normally operated with the standard 2.4m whip antenna. This antenna is generally satisfactory for ground wave propagation over distances of up to 25km. For improved ground wave and for sky wave communication alternative antennas are required. These antennas require to be elevated for good performance using convenient buildings, trees or a 5.4m lightweight mast.

13. S.4m Mast MA.2231

13.1 This kit comprises six glass fibre tubes, colour codes guys, I ight alloy pegs, mast head adaptor for 'F' rods and PV C cooted down lead. Also i ncl uded are two folding sand anchors which give the extra hold required when using an antenna in soft sand conditions.

13.2 The golf bag type carrying case has a reinforced cap that can be used as a base p late on soft ground.

13.3 While these masts are ideal for desert use they are equally suitable for general field use 05:-

(1) Support for sloping wire or in pairs to support a centre fed dipole (halyard provided) •

(2) A vertical radiator using the down lead.

(3) A vertical radiator using the IF' rods and the down lead.

14. Erection of 5.4m Mast

14.1 The mast is erected as follows:-

(1) Assemble the mast sections on the ground with the guy plates and halyard cleats fitted as shown on Fig. 3.5, with the middle guy plate between sections 2 and 3 from top.

(2) Assemble the mast head adaptor to the top of the mast if a vertical end-fed antenna is to be used.

(3) Fit the two 'F' rods if available (for vertical end-fed antenna).

3-7

PRM.4031

(4) Place the cap of the case in position (to act as the foot of the mast) and position the pegs (or sand anchors for soft ground) as shown.

(5) Erect the mast and adjust the guys.

(6) If required connect antenna adaptor to halyard and raise adaptor.

wIRE ANTENNA DIRECTION

SANO ANCHORS (IF' USED 1 POSITIONED HERE

TWO F RODS

! IF AVAILABLE)

FOR WHIP AN TfNNA

~

/

GROUND PLAN /

/

Erection of 5'4m Mast

Fig.3.S

15. GROUND WAVE ANTENNAS

15.1 For improved ground wave operation (in comparison with the whip antenna), the transceiver uses vertical antennas supported by the 5Am mast, or convenient buildings or trees.

16. End Fed Antenna

16.1 The 50 metre End Fed Antenna, illustrated in Fig. 3.6, must be operated with the earth spike or an antenna counterpoise.

3-8

PRMA031

(1) Unwind the throwing cord and sufficient antenna wire for the frequency of operation. Markers on the antenna wire are provided as a gu ide.

(2) Make a small loop in the wire at the measured point. Insert into slot in spool as shown in Figure 3.8.

(3) Erect one end of wire on mast or throw weight over convenient tree. The wire should be as close to the vertical as conditions allow.

(4) Connect the free end of i·he antenna wire to the terminal of the BNC adaptor and plug into the appropriate 50n socket on the transceiver.

(5) Drive the earth spike into the ground and connect its lead to the ground terminal on the transceiver.

DRIVE EARTH SPIKE INTO GROUND

CONNECT ADAPTOR INTO SOCKE T 10 SUIT FREQUENCY IN USE

END·FED AN:ENNA ERECTION

rrmm

IWOH 8106 I

End-fed Antenna

Fig. 3·6

3-9

PRM.4031

17. Vertical Dipole

17.1 The vertical dipole, illustrated in Fig. 3.7., should be erected as close to vertical as conditions allow. The dipole is a kit comprising two reels and a centre junction box. Each reel contains 25m of braided wire marked with rings according ro resonant frequency, and a throwing cord and weight. Proceed as fol lowsr-

(1) Unwind the throwing cords and enough antenna wire from each reel to the length indicated on the markers for the frequency in use.

(2) Make a small loop in the antenna wire at the measured point. Insert into slot in reel as shown in Fig. 3.8. Repeat for other half.

(3) Connect plug on antenna feeder to centre junction box and fasten the 'D' shackle to anchor ring. Connect other end of feeder to appropriate BNC socket on radio.

(4) Erect one end of wire 5.4m mast or throw weight over convenient tree.

(5) Ensure that the antenna feeder is wet! separated from the antenna braid.

(6) Drive earth spike in ground and connect lead to earth terminal of man pack .

18. Sky Wave Dipole and Inverted V Antennas

18.1 For sky wave operation the transceiver can use a horizontal dipole or its derivative the inverted V antenna. Both are based on the 3-30MHz braid dipole kit.

3-10

PRM.403J

ADAPTOR

THROWING WEIGHT AND CORD

REEL

KEEP WELL APART

CONNECT PLUG INTO APPROPRIATE ~:::;;;;;~::4h. BNC SOCKET

DRIVE EARTH SPIKE INTO GROUND

Vertical Dipole Antenna

Fig.3.7

3-11

PRM.4031

IoIEASURED LENGTH

/

.r

REto1AINDER OF ANTENNA WIRE LEF'T ON REEl

THROWING CORD

METHOD OF SECURING ANTENNA WIRE AT MEASURED LENGTH

Antenna Securing

Fig.3.8

PRM.4031

3-12

VIEW OF PRM 4031 AS BELOW

THROWING WEIGHT AND CORD

/

THROWING WEIGHT AND CORD

HORIZONTAL DIPOLE ANTENNA I USED WHEN TWO SUPPORTS ARE AVAILABLE)

MHENNA

ANTENNA

DRIVE EARTH SPIKE INTO GROUND

li1fJS(j,fJ

I WOH 8106 I

Horizontal Dipole Antenna

Fig.3.9

3-13

PRM.4031

5'4m MAST TYPE MA 2231 OR SIMILAR

THROWING W8GHT AND CORD

Inverted V Dipole Antenna

Fig.3.10

3-14

PRM.4031

18.2 For distances greater than 300km the antenna must be erected broadside to the direction of communication.

18.3 The procedure for erecting these antennas is similar to the vertical dipole (see para. 17 and Figs. 3.9 and 3.10).

18.4 The horizontal dipole should be used when the two supports are available and the inverted Y when only one is available. In both cases it is important to raise the centre point as high as possible.

19. LOUDSPEAKER AMPLIFIER

19.1 The loudspeaker/amplifier unit type MA.988 may be used with the transceiver.

The ampl ifier should be plugged into either of the AUDIO sockets and the level of output is then adjusted by using the GAIN control on the transceiver. The MA.988 has a maximum output of 0.5 watts.

20. REMOTE OPERATION

20.1 The transceiver can be operated remotely in speech or CW modes from a distance of up to 3km using MA.9858 and MA.9868 control boxes. The two control boxes are connected together using the necessary length of D.I0 cable as shown in Fig. 3.11. Call and intercom facil ities are also provided.

M.l.N PAC K

REMOTE CONTROL UNIT MA 9B6 B

lOCAL CONTROL UNIT MA 98S B

l11mDIJ Remote Operat ion

1 WOH 81051

Fig. 3.11

3-15

PRM.4031

21 . Setting-Up for Remote Operation

21.1 (1)

Set up transceiver for operation as detailed in preceeding paragraphs.

(2) Connect flying lead of local control unit MA.9858 to an AUDIO socket on the transceiver.

(3) Connect audio ancillaries to local control unit.

(4) Connect 0.10 twin cable to the LINE terminals on the local control unit.

(5) Run out cable to remote site and connect to liNE terminals 011 remote unit MA.986B, disregarding polarity.

(6) Connect audio ancillaries to remote control unit.

(7) Operate system in required mode QS outlined below.

22. Modes of Operation

22.1 l/COM (intercom)

Remote operator may speak to local operator one( v r ce-verso without radio transmission.

KEY

Remote or local operator may common i cote with other operator via a radio I ink using morse.

VOICE

Remote or local operator may commun icate with another operator via a radio link using speech.

CALL

At both local and remote control units, a warbl ing tone is produced in the headset when CALL hos been selected.

23. WORKING WITH OTHER RADIOS

23.1 The transceiver will work with another transceiver without any frequency channel limitation, and in any mode. The transceiver will operate with any ather type of HF SSB, AN.. or CW transceiver in the frequency range 1 .6-30MHz. With other Racal transceivers the channel spacings and modes are os given in the following table.

24. VEHICLE OPERATION

24.1 The following poragraphs give general information on the use of the transceiver in a vehicle installations is covered in the appropriate vehicle installation handbook.

3-16

PRM.4031

PRM.4031


PRM.4021 B


PRM.4021

TRA.931
SYNCAL

TRA.932
COMCAl30

TRA.1338B


TRA.921
SYNCAL
PRM.4031

TRA.922
COMCAL

TRA.906
SQUADCAL

TRA.6929
M1NICAL

RA.929
RECEIVER
ONLY WORKING TO OTHER RADIOS

PRM.4031

SSB CW AM

1 .6-29. 9999MHz 100Hz CHANNELS

SSB CW AM

1 .6-29. 9999MHz 100Hz CHANNELS

SSB CW AM 2-15.9999MHz 100Hz CHANNELS

SSB CW AM

1 .6-29. 999MHz

1 kHz CHANNELS

SSB CW AM

1 .6-29. 999M Hz

49 CHANNELS (AS CRYSTALS)

SSB CW 2-9MHz

10 CHANNELS (AS CRYSTALS)

SSB CW AM 2-7. 999MHz

1 kHz CHANNELS

SSB CW AM 2-8MHz

49 CHANNELS (AS CRYSTALS)

SSB CW AM 2-7MHz

29 CHANNELS (AS CRYSTALS)

SSB CW

2-7MHz or 2.6-9MHz 6 CHANNELS (AS CRYSTALS)

SSB CW AM 1.6-29.999MHz

1 kHz CHANNELS

3-17

25. Installation

25.1 The rronsce iver is mounted in Cl vehicle using a special mounting plate. The equipment can be connected directly to a headset or handset via an audio socket as in the manpack role or into the vehicle harness vic a Vehicle Interface Box (VIB) MA.4106.

The battery may be float-charged by an MA.9458 or the radio may obtain its supply from the VIB in 24V installations.

The radio may be connected via its antenna terminal to the vehicle whip antenna if the cable length is less than 0.6 metres.

26. Whip Antennas

26.1 A 2.4m (8ft) whip antenna mounted on a vehicle can give a similar range to the standard whip antenna mounted directly in the whip socket. A longer whip antenna gives increased range but the length should be restr ic+ed to 8.2m (27ft) over the frequency range 1.6 to 8MHz or 4.8m (16ft) over the range 1.6 to 16MHz or 2.4m (8ft) over the range 2.0 to 27MHz.

(1) Mount the whip antenna on the antenna base insulator.

(2) Using high insulation cable with copper conductor, connect the antenna base to the manpock. The length of this coble should be as short as possible and must not exceed O.6m (2 ft). It should be mounted clear of metal surfaces. Connect the free end of the cable to the terminal of the whip adaptor and plug it into the WHIP socket of the manpack.

NOTE: Where a tuning point cannot be obtained, connect the free end of the antenna base cable to the terminal of the BNC adaptor and plug it into the appropriate SOD socket of the manpack, instead of into the WH IP socket.

(3) Connect a short length of heavy duty cable between a suitable earthin9 point on the vehicle and the ground terminal on the monpcck ,

27. Remote ATU

27.1 In situations where the radio cannot be positioned close to the antenna 0 remote ATU wit! be required such as the BCC540. ln this cppl icoticn the RF connection to the radio is mode via the rear W!B socket (5) (see Fig. 3.12).

28. Use of External Fil ters

28.1 In multi-radio instcllcfions external bandpass Filters may be incorporated to reduce mutual interference. The filter is connected electrically between the two rear sockets 011 the transceiver (see Fig. 3.12).

3-18

PRM.4031

(1) Connect filter input W/B socket 5.

(2) Connect filter output to the ATU socket 6.

ALTERNATIVE "IlSITION FOIl EAII1H SCIIEW

SAIR£ FUSE HOlDER

Rear Panel

Fig.3.12

29. Use of RF Power Ampl ifier

29.1 The RF power output may be increased with the addition of an RF power amplifier, for example the lOOW TA.4OMB. In such applications the power output from the radio is taken from W/B socket 5 (see Fig. 3.12). A typical installation is shown diagrammatically in Fig. 3.13.

30. Use of VIB

30.1 The Vehicle Interface Box (VIB) is used wherever the transceiver is fitted in a vehicle. The VIB provides the following facilities:

(1) Allows the transceiver to be supplied directly from the vehicle electrical system. The VIB can accept an input of 24V to 32V d.c., or, with an internal change 12V to 16V d.c., and incorporates a regulator.

(Negatively earthed system only). Supply filtering and transient suppression is provided.

3-19

PRM.4031

(2) Provides a transformer coupl ing of the audio input to el iminate earth loop problems.

(3) Provides a 3W audio output to drive a loudspeaker (Type HOD).

MA "'0', Ixm.. I PR""031
, him,. 2 i------ ------------,

I TA 40" 8 I

I _ _j

FRONT CONNECTIONS

I 5 -~~~-:o~

'] ---_j

70066'

[" -----

104."061 .

5 ~

LOUOSf'EAKER

702746

RFfOATU

700664

TA'O"B

702747

2'V SUF'PlY

___________ _ ____.J

REAR CONNECTIONS

100W System

Fig.3.13

3-20

PRM.4031

CONTENTS

Para.

MECHANICAL DESCRIPTION INTERCONNECTIONS

COMPONENT AND PIN PREFIX CODING POWER SUPPLIES

COMMON EARTH POINT

EXTERNAL CONNECTIONS

FRONT PANEL MOUNTED COMPONENTS

1 2 3 4 5 6 7

ILLUSTRATIONS

Fig. No.

Connections to Common Earth Point Front Fbnel Mounted Components

4.1 4.2

PRM.4031

Chapter 4 Contents.

1 . MECHANICAL DESCRIPTION (Figs 1 and 2 at the end of this part)

1 .J The transceiver and synthesizer sub-assemblies and the antenna tuning unit are attached to the front panel of the set, which is bolted to one end of the plastic sleeve using metal spacers which cl ip to the sleeve. The power crnpl ifier and filter sub-assembly is contained in a casting which is bolted to the rear of the plastic sleeve.

1.2 The control, meter, audio and antenna sockets are mounted on the front panel.

The battery is attached to the reor of the set by two wing nuts and is removed when access to the rear-mounted spare fuses or W/B (widebcnd) and ATU sockets is required.

1.3 Figures I and 2 illustrate the construction of the set. A detailed mechanical breakdown is provided in the illustrated Mechanical Parts List (part 6 of the handbook) and detailed dismantl ing instructions are given in Chap. 7 of this part.

2. INTERCONNECTIONS

2.1 The interconnections between the various sub-cssernbl i eSt controls and sockets are shown in the interconnection diagram, Fig. 4.

3. COMPONENT AND PIN PREFIX CODING

3.1 The component and pin prefix coding for the sub-assemblies are tabulated below:

Sub Assembl~ Component Prefix Pin Prefix
Transceiver 719240 1 A
Synthesizer 719198 2 B
P . A. Board 704759 3 C
Meter Boord 703635 4 D
F i I ter Board 704760 5 E
Chassis 719197 6 F For example 1R45 is a resistor within the transceiver assy. and BTP7 is a test point pin within the synthesizer assy.

4-1

PRM.403J

4;1 lh~powerch·cvn(jllowslhe bCltt~ry to be cho~geQviq. E;itherovdlos-ocketwhenfhe mDdeswitchisOFF. . Charsrngt¥carriedout viadi~es lD400nd JD41 ~fig.4)i

. whh:hpteverif<;YfrerHbeThgdrownbyeqUipmehf eOhrle.cfed to fhesatketi-

5.1 . AH··sQb-q$$emb[i~$ ate eottht?!dtcfCf ·cofYunQl1poihfWhic.nisflfvSfrijfid ··l;jFf9.<4~t.

L9t9~cvrrel1ls flo,# .. froni the ·OdltefY. orexterno I supplies .to JhepowatarnpHfiel' stib-o,sembJ yond .. 1f .isessen Uol··.t<s provIde Jhe$horlestpothf ex.· thJs¢onnection,fo avoidinduct!dvol tagesbeingoppl iedtofhemlq<:>pHone:precimpl ifier,¢ou$ ing ·imfabirny •• · tot this·redsol1l.·theedttbcohnectot$~d.rty ittg· these lo .. ~ ·tiirientsdte mOde es shown in Fig. 4.1, ... 1fitifhecessoryiforrepqirplJrPQs;es orolhef'A'I5e, 10 removetheseconnectionstheymuslolwaY$ ··~·.reebnne(;tedexa(;HyQsshoWh •.

·MAIN· EARTH .'..__--') UNK

(.'~\ ..

~,-~)

.. ·~·-9RV-'fmr.=.···········~.;-fj' .. ·.·'~

. "\ i ,If,

6. IE.xferhotc;onhecli ot1soremodev}6pII.lQscohnec t~df()al1dj6so(;ke·tsSkl ah4l6f Sk2ontnefronl >pall~1 • Conoetlions are shown Hlrig;3 •

• 7..1· A. humber. of . components CfretnountedQri the . front ··pari~l. These •. ore· •• illo$trated·,and

idefltifiedin Fig. 4.2 ~ .

PRM.4031

'" n

<It

en n ...

>i
~
..
."
~
0
~
-
-0 ©
a
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"
.....
3:
0
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©


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N WOM 1106

4-3

CHAPTER 5

====~=====

CONTENTS

INTRODUCTION TEST EQUIPMENT

PRM.4031

Chapter 5 Contents.

Para.

1 2

l. INTRODUCTION

1.1 The test equipment I isted below is required to carry out fault location and main tenance procedures on the complete transrn itter/ rece iver.

2. TEST EQUIPMENT

(1) Digital Frequency Meter

Frequency:

10Hz to 100MHz with resolution to 1 Hz.

Sensitivity:

lOmV r.m.s.

Racal 9911 (Option 04A) is recommended.

(2) Osc i \I oscope

Bandwidth:

0-100MHz

Input Impedance: 50 ohm or high impedance.

Sensitivity:

5mV/cm to 20V/em.

Hewlett Packard Type H07-1715 is recommended.

(3) RF Power Meter (see note)

Bandwidth:

Up to 30MHz.

Range:

0-20W r.m.S.

Dymar 2081/30 is recommended.

(4) AF Signal Generator

Range:

30Hz - 10kHz, two-tone.

Output:

lmV - IV e.m.f.

Impedance:

600 ohms.

Racal 9083 is recommended.

5-1

PRM.4031

(5) AF Power Meter (see note)

Bandwidth:

Range:

30Hz to 10kHz. 0-10W r .m.s.

Dymar 2085 is recommended.

(6) RF Signal Generator

Range:

Output:

Impedance:

10kHz - 30MHz. luV to lV e.m.f. 50 ohms.

Marconi TF 144H is recommended.

(7) Mul timeter

Sensitivity:

500mV to SOV.

Racal 9077 A is recommended.

(8) RF Mill ivol tmeter

Bandwidth:

Range:

Impedance:

1 Ok Hz to 1 00 M Hz . 1 mV to 30V.

lOOk.

Racal 9301 is recommended.

(9) Power Supply (see note)

Vol toge range: 12V to 20V d. c.

Output:

Up to 4A.

Roband 33-10 is recommended.

PRM.4031

5-2

(10) RF Adaptor Lead

Racel T J289.
(11) Adaptor Box (see note)
Racal T J290.
(12) Tool Kit
Racal ST71 9254
( 13) Sniffer Box (see note)
Racel T J333.
(14) Field Test Set
Racel CA531 C.
NOTE: If the Field Test Set CA531 C is used, items 3, 5, 9, 11 and
13 are not required.
(15) Cable Assy (for testing only)

Racel ST790033. 5-3

PRM.4031

CONTENTS

INTRODUCTION FAILURE TO OPERATE FUNCTIONAL CHECKS

BATTERY AND INDICATOR CHECK

POWER SUPPLY AND INDICATORS CHECK OPERATIONAL CHECKS

TRANSMITTER CHECK - LSB

TRANSMITTER CHEC K - USB

TRANSMITTER CHECK - AM

TRANSMITTER CHECK - LSB CW TRANSMITTER CHECK - USB CW

RECEIVER CHEC K - LSB

RECEIVER CHECK - USB

RECEIVER CHECK - AM

RECEIVER CHECK - LSB CW

RECEIVER CHECK - USB CW

Chapter 6

PRM.4031

Contents.

Para.

1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16

1. INTRODUCTION

1.1 No equipment ccn be expected to work properly unless it is kept in first class condition by requlor maintenance conscientiously curried out. This is the responsibil ity of the NCO or man who is in direct charge of the equipment and NOT of the workshop repair stoff.

1.2 The tasks in the case of the transceiver are simple and few in number as detailed below. They are performed daily when the set is in use and weekly when in store. The transceiver is a fully sealed radio and is NOT to be opened by the operator.

ROUTINE CHECK LIST

I tems to be checked

Procedure

1.

Compl eteness

Check that the equipment is complete with accessories.

2.

Exterior surfaces

Remove dust, dirt and moisture from equ ipment surfaces.

3.

Controls

Check that controls work smooth] y, ore tight on their shafts, and do not bind.

4.

Sockets

Check that sockets are tightly secured to the front panel.

5.

Desiccator

Check that the crystals are bl ue.

6.

Handset

I nspect for cuts in cable and secure connection to plug.

7.

BaHery MA. 4025N B

Inspect for corrosion of terminals, check fuse and establ ish when the battery was c harged/ or ce II s changed.

8.

Wh ip Antenna

Inspect for damage, loose fit and state of inner cord.

6-1

PRM.4031

I terns to be checked

Procedure

9.

Frame

Inspect for damage, particularly to strops.

10.

T ransm i tter-rece iver

Perform steps in operof ionql checkl ist in para. 3 and subsequent.

2. FAILURE TO OPERATE

2.1 Should the equ ipment fail to operate correctly f turn the mode switch to OFF and check the following:-

(a) Switches for correct setting.

(b) Handset and antenna for loose connection.

(c) Insufficient charge in battery to operate radio, check by substitution.

If the above checks do not locate the foul t,. proceed to the functional checks.

3. FUNCTIONAL CHECKS

3.1 When carrying out the following checks, ensure that the equipment has been correctly set up and is being operated in accordance with the operating information given in Chapter 3. If a foul t is apparent after the functional checks have been carried out refer to Chapter 7.

4. BATTERY AND INDICATOR CHECKS

4.1 Check the state of the battery and fuses as follows:

6-2

PRM.4031

5. POWER SUPPLY AND INDICATORS CHECK

5.1 Connect battery and whip antenno, and proceed as follows:

Set MODE switch to LSB

Set POWER switch to HIGH

YES

Does Meter indicate more than i FSD

OK

Replace or charge battery

YES

NO

Set MODE swi tch to TUNE

--REPlACE

Direction I ndi eator lights or Meter Indicates

NO Check Manpack Fuse

YES

Pull out ATU knob and tune for peak meter reading

0-----.

OK ,...----------

YES

Proceed to remainder of check ~ables

6-3

PRM.4031

6. OPERATIONAL CHECKS

6.1 Check the transceiver for correct operation as gi",~, in the following paragraphs.

When checking reception in each mode, another ~ceiver can be used as a transmission source by transmitting on the same ~nc:y.

6-4

PRM.4031

7. TRANSMITTER CHECK - LSB

7.1 Set MODE switch to LSB, the AF GAIN control to a suitable level, depress the pressel switch and speak into microphone. Carry out the checks in routes 1 and 2.

YES
NO
Out of lock tone heard
In handset
NO NO
i Check Antenna length 15 frequency of
rYES correct and antenna 'I .6-30MHz selected?
raised above ground NO
NO
Select correct frequency
-YES Does out-of-Jock tone

NO disappear?

-YES

NO ROUTE 1

Meter reads normal YES-E---t antenna current - only while speaking

Replace radio

ROUTE 2

!---~NO

t-~YES

I----3i'YES

~~~~~~~~~~-~ LSB transmission satisfactory ~-~------__.

8. TRANSMITTER CHECK - USB

8.1 Repeat tests given in para. 6 with the mode switch set to USB.

PRM.4031

6-5

9. TRANSMITTER CHECK - AM

9.1 Set MODE switch to AM, the AF GAIN control to a suitable level, depress the pressel swi tch and speak into microphone. Carry out the checks in routes 1 and 2.

ROUTE 1

ROUTE 2

Meter reads antenna current - falls while speaking

YES~----I

YES

Sidetone heard in handset

NO

NO

Out of lock tone heard handset

NO

YES

NO

NO

Check Antenna length correct and antenna raised above ground

I s frequency of

1 .6-30MHz selected?

YES~--I

NO

NO

Check antenna components

Select correct frequency Does out-of-lock tone disappear?

YES~--I

YES

NO

NO

NO

'--------------4 AM trqnsm issi on satisfactory 1-- -..1

6-6

PRM.4031

10. TRANSMITTER CHECK - LSB CW

10.1 Set the MODE switch to LSB (W, the AF GAIN control to a suitable level and depress the Morse Key. Carry ou t the checks in routes 1 and 2.

ROUTE 1

YES~----I

Meter reads normal antenna current

Check Antenna length and antenna raised above ground

YES~---1

ROUTE 2

5 ide tone heard in handset

f---~YES

NO

L-- ~ CW Transmission satisfactory ~---------___,

11 . TRANSMITTER CHECK - USB CW

11.1 Repeat the checks given in para. 10 with the mode switch set to USB CWo

PRM.4031

6-7

12. RECEIVER CHECK - LSB

12.1 Set the MODE switch to LSB and the AF GAIN control to a suitable level. Carry out the following checks. Arrange another transceiver to transmit on the same frequency and in ~he same mode.

Voice signals heard in handset

NO

Check setting of MODE switch

yES,.;---------l

13. RECE IVER CHECK - USB

Check AF GAIN control

NO

Check antenna connections

LSB Reception satisfactory

13.1 Repeat tests given in pcrc . 12 with the MODE switch set to USB.

PRM.4031

6-8

14. RECEIVER CHECK - AM

14.1 Repeat tests carried out in para. 12 with the MODE switch set to AM.

15. RECEIVER CHECK LSB CW

15. I Set the MODE switch to lSB CW and the AF GA!N control to a suitable level.

Arrange another transceiver to transmit CW on same frequency.

CW Heard in headset I----~YES---.

~~------~----------~

NO

Check MODE switch setting NO

~-------~YES---~

Check AF GAIN control

I---___;~;y ES ~--~

~--------~----------~

NO

Check Antenna connectors

I----~y ES--~

L- ~------ __ ~

CW Reception satisfactory

16. RECE IVER CHEC K USB CW

16. 1 Repeat tests carried out in para. 15 with the MODE switch set to USB CW.

PRM.4031

6-9

CONTENTS

Pora.

INTRODUCTION

CHANGING AND RE-ACTlVATING THE DESICCATOR CHECKING THE FUSE

TESTING SEALING OF CASE

DISMANTLING PROCEDURE

Power Ampl ifier and Fil ter Sub-Assembly Case Sleeve

Antenna Tuning Unit

Synthesizer and Transceiver Sub-Assembl ies RE-ASSEMBL Y

FAULT LOCATION

PERFORMANCE CHECKS

General

Equ ipmen t Requ ired

Prel iminory Procedure

CW Performance Check

AM Performance Check Overall Transmitter Check Power Supply Protection Check AF Bandwidth Check

CW Filter Check

Overall Rece iver Check

1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 18 19 20 21 22

TABLES

Table No.

F':1ult Finding and Rectification Procedure Fault Area Identification Flowchart

1 2

ILLUSTRA TIONS

Location of Fuses and Desiccator

Power Amplifier and Filter Boa-ds Securing Screws AM Envelope

Fig. No. 7.1

7.2

7.3

PRM.4031

Chapter 7 Contents.

1 . INTRODUCTION

1 .1 This chapter deals with some aspects of maintenance and repair of the transceiver which are classified as second-l ine servicing. Covered in this chapter are:-

(1) Changing and reactivating the desiccator.

(2) Che ck i ng the fuse.

(3) Testing the sealing of the case.

(4) Dismantling procedures sufficient to enable performance checks and faultfinding to be carried out.

(5) Re-assembly.

(6) Performance Checks.

(7) Fault location by means of a flow chart, to indicate the area in which a fault is probably to be found.

2. CHANGING AND RE-ACTIVATING THE DESICCATOR

2.1 If routine checks on a unit in service reveal thot the desiccator crystals are not blue, the desiccator should be changed after testing the equipment seal ing as detailed in para. 4.

(1) The desiccator is located in the costing at the rear of the set (see Fig. 7.1).

(2) Unscrew the des j ccotor to remove.

(3) Fit a new (or reactivated) desiccator taking care not to damage the rubber sealing ring,

A desiccator may be reccrivered by placing in an oven or a similar source of 'clecn' dry hect, at a temperature of 120 - 1500C for approximately two hours.

Allow the desiccator to cool before refitting.

7-1

PRM.4031

3. CHECKING THE FUSE

(1) The fuse is located in the casting at the rear of the set (see Fig. 7.1).

(2) Check the fuse and replace if necessary.

(3) Spare fuses are located at the rear of the casting and are accessible when the battery is removed (see Fig. 7.1). The correct fuse is 20mm x 5mm size rated at 6.3A (Rocol Part Number 922454).

i I

1 'OB'. I

ntiiRJU

Location of

Fuses and Dessicator

Fig.7.1

4. TESTING SEALING OF CASE

4.1 The following equipment is required:

(1) Schroder air valve, Racal Part No. 715105.

(2) Pressure gauge and air line.

7-2

PRM.4031

Proceed as follows:

( 1 )

(2)

(3)

(4)

(5)

(6)

Remove the desiccator and in its place insert the Schroder air valve. Take care not to lose or damage the rubber sea ling ring from its des i ccator .

2 Connect the cir-] ine to the valve and pressurise the ccse to 17kN/ m

(2 Ib/in2), keeping the oir-Line connected.

Totally immerse the unit in o water tank for at least 20 seconds and inspect for any air leaks. Remove the unit.

Should any leaks occur check that the seal ing ring around the offending component or case section is correctly seated and that the component or case is tightly screwed up. The correct torque setting for the ccse screws is 1.7Nm (151b in).

Remove any surplus water with the air-line.

Remove the Schroder air valve and fit a blue (dry) desiccator unit.

5. DISMANTLING PROCEDURE

5.1 The following procedures detail the amount of dismontl ing required to gain access to each sub-assembly.

In general the steps should be following in the order given until the required access is obtained. After servicing the unit should be re-assembled in accordance with paragraph 10. Reference to Part 6, III ustrateq/ Mechan icc! Parts List, may prove helpful.

6. Power Ampl jfier and Fil ter Sub-Assembly

(1) Remove four socket head screws from the four reer corners of the set.

(2) Place ~he set on its side and carefully pull the back away. Check that the seal ing ring remains seated.

(3) Limited access to the power amplifier board and filter board is now possible.

If better access is required, note the position of, then remove, the 12 way connector, the individual spade connectors and the individual snap-on coaxial connectors. The power amplifier and filter sub-assembly may be removed completely from the set.

(4) If it proves necessary to remove either the filter board or power ampl ifier board this mey be achieved by removal of the screws identified in Fig. 7.2. Both boards should be removed together as there are several interconnections between them.

PRM.4031

7-3

7. Case S:eeve

(1) To gain access to the rest of the set the plastic sleeve must be removed.

(2) Unscrew the four socket head screws from the four front corners of the set.

(3) 51 ide off the sleeve towards the rear of the set. Check that the seal ing ring remains seated.

NOTE:

The following procedures to remove the antenna tuning and synthesizer and transceiver sub-assembl ies are independent and one need not be performed in order to facil itate the other.

8. Antenna Tuning Unit (ATU)

(1) Remove the two circlips securing the ATU to the front panel.

(2) Move the ATU to one side, remove the four-way and five-way sockets,

BNC earth and whip socket connections by pull ing them from the connectors.

(3) The ATU may now be removed, taking care not to lose the washers and universal coupl ing, which is loose.

(4) The front panel meter is now accessible.

(5) The meter board may be removed by removing the interconnections and the securing screws, then sl iding out of the ATU.

(6) Instructions for dismantling the ATU for mechanical repair are given in Part 4 of the handbook.

P A PC B

REMOVE ONl Y THE SCREWS IDENTIFIED BY ARROWS

(JJ(J&liJlJ

I WDH Bl06 I

Power Amplifier and Filter Board Securing Screws

Fig 7-2

7-4

PRM.4031

9. Syn thes izer and T ransce iver Sub-Assembl ies

(1) To gain access to the synthesizer or transceiver board, remove the appropriate screened cover whi ch is secured by seven or five cross-head screws,

r espect ivel y , The cover for the transceiver board is identified by the offset centre screw.

(2) To remove the synthesizer board first remove two ten-way and one 12 way connector, anf four coaxial connectors. Then remove seven pillars and two screws.

(3) To remove the transceiver board first remove one twenty-way connector and five coaxial connectors. Then remove five pillars and three screws.

The synthesizer and transceiver sub-cssernbl ies may be removed as one unit as follows:

(4)

CAUTION

(5)

(6)

(7)

Unscrew the front panel knobs, allowing the front panel cover to be removed.

BEFORE PROCEEDING WITH NEXT OPERATION REFER TO THE TRITIUM WARNING PAGE AT THE FRONT OF THE MANUAL.

Pull the mylar discs from the frequency selection switch spindles and carefully remove the tritium beta lights to a safe place.

Remove the nuts and washer from the front panel synthesizers and transceiver controls noting the order in which they are fitted. Next remove ~he crosshead screw securing the earth connector to the front panel (access via transceiver sub-assembly). The synthesizer and transceiver sub-assembl ies may now be withdrawn as one unit.

If it is necessary to replace a switch, unscrew the plastic ring which secures it to the sub-ossembl y .

10. RE-ASSEMBL Y

10. 1 In general, re-assembly is the reverse of the procedures as descr ibed in para. 5 but the following points should be noted.

(1) If a switch seal is removed it must be renewed. It is a push-on fit.

(2) Ensure that the RF screening clips ore in position when replacing the transceiver or synthesizer screening covers.

(3) Ensure that all seals are correctly in place.

PRM.4031

7-5

(4) Take care not to overtighten the socket head screws that secure the front and rear panels to the case sleeve (torque setting l.7Nm (151b in.).

(5) IMPORTANT Ensure thot the leads to the common earth connection, if they have been disconnected, are replaced correctly (see Chop. 4 para. 4 and Fig. 4-1).

11 . FAULT LOCATrON

11.1 This information provided in this section is intended to make it possible to pin-point

o foul t to 0 specific sub-assembly. Table I at ~he end of this section indicates the steps involved. Separate fault-finding procedures for each sub-assembly are provided in the appropriate Part (2, 3, 4 or 5) of the handbook. Should the equipment foil

to operate correctly, the procedure given in Chapter 6, para. 4 (Operational

Checkl ist) should be followed. From this it should be possible to isolate the fault

to one of the following conditions.

(i) Transmitter and receiver fault.

(ii) Tronsmirter only fault.

(iii) Receiver only fault.

The following procedure should then be carried out:

(I) Remove the rear panel and main case as detailed in para. 5.

(2) Carry out a visuol check of the components and wiring for signs of breakage, loose connection or cverheoting ,

(3) Follow the procedure given in Table 2 at the end of this section the Faultarea Identification Flowchort, which should isolate the fault to a particular sub-assembly.

(4) Refer to the appropriate Part of the manual for the faul t-finding procedure for the suspected sub-assembly.

(5) Replace the faulty componen+ls}.

(6) Re-al ign any circuits where components have been replaced.

(7) Follow the procedures given in para. 12 to check the performance of the equ ipmenr .

Table 1 summarises the fault-finding and rectification procedure.

7-6

PRM.4031

12. PERFORMANCE CHECKS

13. General

The instructions in these paragraphs provide a series of checks on the performance of the PRM.4031 for use subsequent to an overhaul or in the event of adverse reports on the performance. The tests should be carried out in the order given and a satisfactory result must be obtained from each test before proceeding to the next.

13.1 Do not attempt to improve the performance of the PRM.4031 by adjusting any preset trimmer or core, etc .; other than in an approved al ignment procedure (Part 2, Chapter 3; Part 3, Chapter 3; Part 5, Chapter 3).

14. Equipment Required (See Chap. 5 for more detailed information).

(1) * RF power meter.
(2) * Two-tone a.f. signa! generator.
(3) AF power meter.
(4) RF signal generator.
(5) Multimeter.
(6) * RF adaptor lead T 1289.
(7) * Power supply.
(8) ,.. Adaptor box T J290.
(9) Tool kit.
(10) Digital frequency meter.
(11) Osc ill os cope .
(12) CA. 531 C Field Test Set. In I ieu of items marked * .
15. Prel iminory Procedure (J) at") CA.531C Test Set, set switches to following positions:-

AC ON

SET DC VOLTS

to

OFF 12V

to

7-7

PRM.4031

DC SUPPLY RANGE to 50 VOLTS
AF POWER RANGE to F 50mW
rX/RX to RX
MODULATION TONE to OFF
METER RANGE to DC
RF POWER RANGE to 30W (2) Connect SUPPLY lead on CA.531C to AUDIO socket 2 on the transceiver.

Connect SIGNAL lead on CA. 531 C to AUDIO socket 1 on the transceiver.

(3) On the transceiver,

select a frequency of 1 .6000MHz. set the MODE switch to LSB

connect the W/S socket (5) on rhe rear of the transceiver

to the RF IN socket on the (A.531 C via the adaptor (T J289).

(4) Set the AeON switch on the test set to ON. Check that green indicator illuminates. Check that meter on the test set reods 12V.

(5) Set the POWER switch on the transceiver to HP. Check that meter on the transceiver indicates approximately i FSD.

(6) Record results on performance check I ist at end of this chapter.

16. T ransm i tter Checks

(1) Set CA.531 C MODULATION TONE to a frequency of 1 kHz and a level of 6mV.

(2) Connect an oscilloscope (set to 50D input) to the RF MONITOR socket on the test set.

(3) Switch the T))/RX swi rch to TX and check that the output power is between 7.1Wand 18W.

(4) Set the POWER switch on the transceiver to LP, increase the audio level to 20mV and check that the power output is greater than 1 .8W and the supply current is less than 1. SA.

7-8

PRM.4031

(5) Turn OFF the MODULATION TONE and check that the resultant carrier leek, with the oscilloscope (SOn input) connected directly to the W/B socket is less than D.SV p.p. Connect the W/B socket on the transceiver to the RF IN socket on the test set via adaptor T J289. Connect oscilloscope to the RF MONITOR socket. Set the MODE switch to USB and the POWER switch to HP. Set the MODULATION TONE to 6mV.

at 1 kHz.

(6) Repeat sub-clause (3).

(7) Repeat sub-clause (4).

(8) Set Synthesizer switches to 29. 9999MHz. Connect a frequency counter

to the RF MONITOR socket and switch the MODE switch to TUNE. Check the indicated frequency which should be between 29.999909 and

29.999891 MHz.

(9) Switch the CA. 531 C to RX and set the MODE switch to USB CWo Set the synthesizer switches to 1 .6000MHz.

(10) Depress the KEY switch on the CA. 531 C and check the power output is greater than 1 .8W consistent with the supply current being less than 1. 5A.

(11) Set the POWER switch to HIGH, depress the KEY switch and check the power output which should be between 7.1W and laW.

(12) Release KEY switch and switch to TX on the CA. 531 C.

(13) Set the MODULATION TONE output to OFF and set the MODE switch to AM.

(14) Note the Power output reading.

(15) Set the MODULAT ION TONE to 15mV output and check that the output is a good compatible AM waveform and that the power has reduced.

(See Figure 7.3).

(16) Set the MODE switch to LSB.

(17) Set the MODULATION TONE to TWO TONE at a leve! of 6mV.

(18) Check that the transmitted waveform is undistarted.

(19) Increase the MODULATION TONE output level to 50mV.

(20) Check that the waveform is cI ipped symetricoll y.

7-9

PRM.4031

(21) Set the POWER switch to OFf and disconnect the test i ig (T J289) from the RF IN socket, connect the co-axial cable directly to the RF IN socket.

(22) Set the MODE switch to TUNE and the POWER switch to HP.

(23) Check thct the output power is greater than 1 .8W and the supply current is less than 1.5A.

(24) Set tre POWER switch to OFF and connect the co-axial coble to the front panel socket, 1.6 - 8MHz.

(25) Set the POWER switch to HIGH and check thot an LED indicates the direction of tune; tune the ATU un+il the meter starts to indicate and the LED extingu ishes.

(26) Tune the ATU for a peak on the meter and check that this coincides with maximum power reading on the CA.531 C.

(27) Set the MODE switch to USB and switch the T>yIRX switch to RX on CA.531 C.

(28) Set the POWER switch to L. P. and check that the meter indicates zero.

(29) Set the frequency selection switches to 29. 999MHz. Disconnect cable from 1 .6 - 8MHz BNC socket and connect to 8 - 30MHz BNC socket.

(30) Set the POWER switch to HP and MODE switch to TUNE.

(31) Tune the ATU for a peak on the meter.

(32) Check the RF output power whi ch should be greater than 7.1 W consistent with a supply current less than 3.3A.

(33) Connect the W/B socket to the RF IN socket on the Test Set CA. 53] C switch to TUNE on the rronce lver . Connect the frequency counter to the RF MON ITOR socket on the CA. 531 C.

(34) Rotate the frequency selection switches, step by step, noting that the frequency changes in lOMHz, ]MHz, 100kHz, 10kHz, 1kHz and 100Hz steps.

(35) Switch the POWER switch to OFF and disconnect test equipment.

17. Receiver Checks

(1) Conned the UC signal lead of CA.531C to UC audio socket 2 on the transceiver and the UC supply lead to UC audio socket 1. Set AF POWER

7-]0

PRM.4031

RANGE to G EXTERNAL and connect AF OUT to AF POWER METER, set to 300 ohms, 30mW.

(2) Set the MODE switch to USB.

(3) Switch the TX/RX switch to RX on CA.531 C.

(4) Set the POWER switch to LP.

(5) Connect a RF signal generator to the front panel socket marked 1 .6 - 8MHz and set the synthesizer controls to 1 .6000MHz.

(6) Set the RF generator to a frequency of 1.601 MHz and a level of 2uV emf.

(7) Adjust the ATU and the signal generator frequency for maximum output On the AF power meter.

(8) IncreQse the RF signal generator output by aOdB and check that the output changes by 2 to 6dB. Reduce the output from the signal generator to 2uVemf.

(9) Note the AF power meter reading.

(10) Interrupt the output of the RF generator and check that the change of reading of the AF power meter is greater than ISd B.

(11) Increase the output of the RF generator by 6dB.

(12) Connect a digital frequency counter across the AF power meter.

(13) Decrease the frequency of the RF signal generator until the same power level as (9) is achieved. Check the audio frequency is between 0 - 500Hz.

(14) Increase the freqvency of the RF signal generator until the same power level as (9) is achieved. Check the audio frequency is between 2650 - 3000Hz.

(15) Reduce the RF generator level to 2uV emf.

(16) Observe the meter and increase the RF input level in steps of IOdB. Check that the meter gives a relative indication of signal strength.

(17) Set the level of the generator to 2uV emf and a frequency of 1 .601 MHz.

(18) Set the MO DE swi tch to USB CW.

7-11

PRM.4031

(19) Adjust the generator frequency to give maximum audio output power.

(20) Decrease the generator frequency until the audio output level drops by 3dS.

Note the audio Frequency,

(21) Increase the generator frequency until the audio level passes the peak and again falls by 3dB. Note the audio frequency. Check this 3dB bandwidth is between 70 - 130Hz.

(22) Set the synthesizer controls to 29. 990MHz and the MODE switch to USB.

Disconnect cable from 1.6 - 8MHz BNC socket and connect to 8 - 30MHz BNC socket.

(23) Set the RF signal generator to 29.991 MHz and a level of 2uV.

(24) Repeat (7).

(25) Repeat (9).

(26) Repeat (10).

(27) Set AF POWER RANGE switch on CA.531C to F 50mW.

(28) Set RF signal generator to 2mV emf ou tput.

(29) Rotate the AF GAIN control on the transceiver from the fully anticlockwise position to the fully clockwise position, noting that the AF power output rises from a minimum to a maximum of 20mW to 40mW.

(30) Set the AF POWER RANGE to G 250mW and check that the fixed level AF output is at least 45mW.

(31) Switch transceiver POWER switch to OFF and disconnect all test equipment.

7-12

PRM.4031

PERFORMANCE CHECK LIST - PRM.4031
DATE: Serial No:
Paragraph Test and Conditions Spec ifi cat ion Resu It

16 (3) TX HIGH Power W/B J .6MHz
LSB 7.1 - 18W
(4) TX LOW POWER W/B 1 .6MHz
LSB :> i.sw
(4) TX LOW POWER current, W/B
1 .6MHz, LSB < 1.5A
(5) Carrier Leak < D.S\! p.p
(6) TX HIGH POWER W/B 1.6MHz
USB 7.1 - laW
(7) TX LOW Power W/B 1.6MHz
USB :> 1.8W
(7) TX LOW Power Current W/ B
1.6MHz, USB < 1.5A
(8) Frequency check at 30M Hz + 9Hz
-
(10) c . W. ou tpu t L. P. 1 . 6M Hz :> 1.8W
(10) C. W. current l. P. '.6MHz < J.5A
(11) C . W. Power ou tput H. P.
1.6MHz 7.1 - 18W
(23) W/B La/Hi Auto select switch
Tune J .6MHz power output :> 1.8W
(23) W/B La/Hi Auto Select switch
current tune 1 .6MHz < 1.5A
(32) RF output power via ATU
30MHz Tune 7. J - 13W
(32) Tune current via ATU 30MHz < 3.3A
17 (8) AGC Range 1.6MHz 2 - 6dB
(9) AF output power, 2uV emf
RF input 1.6MHz :> 5mW
(10) (S-tN)/ N 2uV emf RF input
1.6MHz :> I5dB 7-13

PRM.4D31

Paragraph T est and Conditions Specification Resul t
( 13) AF bandwidth 1.6MHz, lower
6dB point o - 500Hz
(14) AF bondwidth 1 .6MHz upper
6dB point 2650 - 3000Hz
(21 ) CW fil ter bandwidth 70 - 130Hz
(25) AF output power 2uV emf
RF input 30MHz :> 5mW
(26) (S-+N)/N, 2uV emf RF input
30MHz > 15dB
(29) AF output power, 2mV emf
input 30MHz 20 - 40mW
(30) Fixed AF output into
50Q load. 2mV RF input
30MHz :> 45mW PRM.4031

7-14

TABLE NO.1

FAULT·FINDING AND RECTIFICATION PROCEDURE

OPERATIONAL CHECKLIST PART 1 Chap. 6

INITIAL DIAGNOSIS PART 1

Chap. 7

Para. 7.7

REMOVE CASE PART 1 Chap. 7 Para. 7.5

VISUAL CHECK

POWER AMPLIFIER FAUL T·FINDING PART 3 Chap. J

TRANSCEIVER FAUL T-FINDING PART 2 Chap. 4

CHANGE COMPONENT OR RECTIFY FAULT

RE-ALIGN TRANSCEIVER CIRCUITS PART 2 Chap. 3

REPlACE CASE AND PRESSURE TEST PART 1 Chap, 7 Paras. 7.4 & 7.5

OVERALL

PE R FO R MANCE CHECK

PART 1 Chap. 7

Para. 7.8

RETURN TO USE

ANTENNA TUNING UNIT FAUL T·FINDING PART 4 Chap. 2

SYNTHESIZE R FAUL T-FINDING PART 5 Chap. 4

CHANGE COMPONENT OR RECTIFY FAUlT

RE-ALIGN SYNTHESIZER CIRCUITS PART 5 Chap. 3

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<{ W 0: <{

I...J ::J <{ lL

SATISFACTORY

SATISFACTORY

UNSATISFACTORY

AM Envelope

(=ig.7·3

eet. Value Description Rat. Tol Racal Part Number
Ref. %
Resistors W
1 R170 68k Carbon Film ~ 5 927802/EQ
, R17l 10 Corbon Film 1/8 5 925564
or 932806
lR172 10 Corbon Film 1/8 5 or 925564
932806
1 R173 22 Carbon Film 1/8 5 926971
or 930125
lR174 39 Corbon Film 1/8 5 931953
or 935026
1 R175 220 Corbon Film 1/8 5 925498
or 932805
lR176 lk2 Carbon Film 1/8 5 931954
or 932329
lRln 1 k5 Carbon Film 1/8 5 925502
or 931458
1R178 lk2 Carbon Film 1/8 5 931954
or 932329
1R179 470 Carbon Film 1/8 5 925499
or 932810
lRl80 100 Carbon Film 1/8 5 925497
or 928013 Capacitors V

1 C121 0.01 IJF Cerami c Plate 100 20 927395/EQ
1C122 0.01 IJF Ceramic Plate 100 20 927395/EQ
1C123 0.01 IJF Ceramic Plate 100 20 927395/EQ
lC124 0.01 IJF Ceramic plate 100 20 927395/EQ
1C125 0.01 IJF Ceramic Plate 100 20 927395/EQ 8-1

PRM 4031

Cct. Value Description Rat. Tol Racal Part Number
Ref. %
Capacitors (continued) V
lC126 0.01 ._,F Ceramic Pla~e 100 20 927395/EQ
1C127 0.01 ... F Cerami c Plate 100 20 927395jEQ
1Cl28 0.01 IJF Ceramic Plate 100 20 927395jEQ
6C4 100 pF Ceramic 4k 10 921968
6C5 66 pF Cerami c Disc 4k 10 923614
Diodes
6D40 IN4002 911460/EQ
6D41 iN4002 911460jEQ
Switches
Power 711855
Mode 711856
Dual concentric 711857 Connectors

6SK1 6SK2

Audio Audio

928128 928128

PRM 4031

8-2

TRANSCEIVER SUB -ASSEMBLY (UNDERSIDE)

719197

POWER AMPLIFI ER AND FILTER SUB -ASSEMBLY 719250

SLEEVE

MET AL SPACE R

ANTENNA TUNING UNIT 719073

FRONT PANel

msaJ [VIJ5tW@

Mechanical Construction

Fig.1

~ItOHT .. ANfL

LOCATION OF ANTENNA TUNING UNIT

SYNTHESIZER ~IIINTED CIIICUI1 80N1D I A I

181 IAI
@ e e e e
-
® ®
@ ®
e ® ®
0
@ @ @ e e
o SCREWS
® PIllARS •••

IWOH8106J

Mounting of Transceiver and Synthesizer Boards

Fig. 2

u"""" I WOH 81061

r-------------------- VARIABLE GAIN AUDIO OUTPUT

SKI

+VE }

'-- -_V'-'E;____ EXTERNAL 12V SUPPLY

KEY

,..-------------------- VARIABLE GAIN AUDIO OUTPUT

SK2

+VE

L- -_Ve,:E'--_} E~TERNAL 12V SUPPLY

'--------------------KEy

External Connections to Audio Sockets

Fig.3

,"

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