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Reparacion de R2600
Reparacion de R2600
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So now I was the proud owner of a pretty useless Radio Test Set, since none of the RF functions worked. First
1 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
I set the unit aside and thinked about scrapping or reselling it. After a few days, I took the challenge and
decided to see if I would be able to repair this thing.
RF Ratsnest
Opening the box, I was pretty fast persuaded that I'd have to find a service manual before attempting to repair
anything:
In the meantime, the forum mentioned above disappeared. In case you're looking for these files, have a look at
KO4BBs manual collection: http://www.ko4bb.com (go to Manuals and search for R2600). As many of these
sites, it is run by a private person, making no profit. Please read his info page and consider supporting this
great site.
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Motorola R2600B http://www.wunderkis.de/r2600/index.html
As it is quite usual with such old equipment, the service manual contained full schematics and parts lists of
the box. For each board there is also a fine description of how it works. Having this comprehensive
information, it was easy for me to discover that I'm in the need of some RF instrument (preferably a spectrum
analyzer) to do the basic diagnostics. Your average scope simply won't show anything if you try to follow a
1.7GHz signal. Luckily I was able to borrow such an instrument (an Advantest R3131 9kHz ... 3GHz
spectrum analyzer) from work.
So I needed some point to start the basic diagnosis. Looking at the generate mode block diagram:
I found it easy to pull one SMB cable after another and compare the real signal (using the R3131) to the
expectation. Pretty fast I discovered that the high synthesizer module didn't output the 1st GEN LO signal.
There was some signal visible, but not at the expected frequenzy and at least 20dB lower level than expected.
Other signals, like the LO SYNTH RF from the low synthesizer module looked fine.
3 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
Pretty much shielding, the right two SMB connectors carry the 1st GEN LO. In the first place I soldered some
wires to the relevant power supply rails, re-seated the board into the card cage and checked the supply
volatages. They were OK.
Next I suspected the VCO module to malfunction, since this is the source of the bad signal.
I had to remove the VCOs shield to gain access to the signals around the VCO module.
4 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
The VCO is in its own shielded box inside the shielded box inside the shielded card cage. I didn't look inside
the the VCO box, maybe there's more shielding? Looking at the schematic page concerning this part of the
high synthesizer module, I started to check the supply and control voltages of the VCO module, using the
same technique of soldering wires and re-seating the board into its box again.
The supply voltage was OK, the control voltage was stuck at one end. At some frequency setting the range
selector input of the VCO (Pin 4) changed its level and the signal at J1 changed frequency. Carefully checking
not to destroy any driving circuit, I did override the control voltage input using an external volatage source,
and look here: The output frequency moved around proportional to the control voltage. Exactly what one
would expect of a perfectly working VCO. The VCO module was OK, phew!.
Not too many parts left to check: The MMIC gain blocks AR3 and AR5. I soldered wires to their bias
voltages (collector of Q5 and Q6) and found one of them not plausible (way to high). Logical conclusion after
checking the transitor: The MMIC must be defective. No MAR-8 lingering around in my workshop, but some
other RF gain block samples left over from past RF experiments, having similar gain and frequency specs, but
5 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
other case and bias requirements. I temporarily mounted this part and tested the R2600 functions again:
Everything worked as expected. I was able to generate plausible signals, receiving a local FM radio station
worked after discovering and replacing the blown fuse inside the ANT connector. So the fault was located and
the unit seemed to be alive again.
I decided to order some spare MAR-8 MMIC to have an original replacement for the broken amplifier.
Ordering this part turned out to be somewhat difficult, not beeing available at the usual suspects, finally I've
found the german Amateurfunker Magazine web shop having them in stock. When they arrived, I replaced the
part, soldered the shield, screwed the module into the card cage, did a short test: Yes everything was fine.
A short excursion
Having downloaded the firmware and EEPROM images for the CPU board, I started investigating the new
firmware and options. I had to burn four old style UV-erasable EPROMs and a 93C46 EEPROM, which
turned out not be as easy as believed, since my good old ALL-03 didn't work anymore. Just for the records: I
didn't repair that one, I found an colleague at work having an old EPROM burner that I could borrow. So I
replaced the EPROMs and the EEPROM just to discover that the R2600 didn't work anymore. There was
some kind of a heavily distorted signal at gen out and no useful receiving. I suspected either the new firmware
or the new EEPROM content to somehow change the way the software accessed the hardware (maybe another
hardware revisision has some bits in some register changed or whatever), and changed the EPROMS and
EEPROM back to their originals, which I kept just in case I'd need them. And yes: everything worked again.
But I was wrong with my suspect, as I discovered later.
A few days later, I turned on the unit and after a few ten seconds it turned off by itself. What's wrong now?
Retrying changed the behaviour from turning off after a some ten seconds to a few seconds to immediately. At
least I managed to check the internal supply voltages, and found many of them exceeding their nomimal
voltages. The 12V rails was OK, all other voltages were too high. After reading the manual, now the power
supply part, I was clear of the cause of the rapid turn-off: There's an overvoltage protection circuit that shuts
down the power supply in case the 5V supply rises. This is pretty useful, otherwise the electronics would have
been literally cooked by the excessive supply levels. So this little protection circuit saves the life of e.g. the
CPU board.
I did some checking to confirm my suspect: Powering the electronics from a bunch of lab power supplies
revealed that everything was fine with my R2600, now I'd just have to repair the power supply.
Next excursion
Beeing quickend by this, I re-tested the new firmware EPROMs and option EEPROM, and tadaa: the R2600
powered by the lab power supplies worked like a charm, providing me two new functions: tracking generator
and extended spectrum analyzer. So I suspected the former malfunction of the new firmware caused by the
power supply, which later turned out to be wrong.
6 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
Checking the output voltages in idle and lightly loaded state showed nothing suspicious. Each of the 5 output
voltages was perfectly in its specified range. Increasing the load on the +12V rails caused the supply to shut
down at some point, caused by a rising voltage on the 5V rail. First I suspected the electrolytic capacitors of
beeing old and lost ESR. I did replace them with not so nicely fitting ones (see them on the photo) and
checked the old ones for capacity and ESR. Since the behavior of the power supply board didn't change with
the replacement caps, and the old ones still looked very fine in terms of their electrical properties, I decided to
put the old ones in agail, just because it looks better.
Looking at the schematics, one can see that all of the output voltages were derived from a single transformer
using an isolated forward converter scheme with coupled filter inductors.
So basically any voltage in the output circuit is coupled to any other voltage. You just cannot easily use your
scope to find partially defective parts. Each particular waveform on any output voltage looks very like any
other voltage, just other amplitude. So I started removing rectifier diodes until the problem disappeared. Yes,
at some point (all rectifiers but the +12V rail removed) the problem disappeared :-). Didn't know much more
than before. It turned out that replacing all of them (except the 40V rails, since I didn't have suitable dioded)
solved the issue for now.
7 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
Don't know which one, but one of these must be bad in a bad way. Looking at them using the diode test of
your favourite multimeter doesn't show out the bad one.
So I started to think about what action was in common to the occurence of the failure: De- and re-assembly of
the power supply or CPU board and opening several ribbon cable connections. Beeing known as prone to
failures, I checked all of the ribbon cables and their connectors: No failures found, not even a hint of a slightly
bad contact.
Both actions include the task of removing the rear panel. For some reason, possibly simply because there
wasn't sufficient free space left anywhere else, the people who built this thing decided to put the reference
oscillator on the back panel. It is connected by a small ribbon cable and a SMB RF cable to the main unit.
And finally I discovered the reason for the misbehaviour exactly there:
That little beast went slightly loose while disassembling the rear panel and sometime got contact again while I
assembled it back and sometimes it did not contact proper. There's no real need to open this connector when
disassembling the rear panel, so I didn't and never noticed that it wasn't plugged in proper. Pushing this
connector a little bit solved the issue in a fraction of a second.
8 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
Replacing the memory backup battery with a fresh one takes care of the lengthy self calibration after power
on. Luckily enough, someone had removed the old and flat battery right before it could spill its corrosive
contents over the CPU board.
The generator out level was set to 0dBm, the -1.2dBm reading at 450MHz looks plausible for the used RG174
cable.
9 de 10 2/10/2017 22:39
Motorola R2600B http://www.wunderkis.de/r2600/index.html
To be continued ...
A fews days later, I discovered this: After some time, the unit starts to "turn the dial by a ghosts hand" (e.g. set
the cursor to a digit of the monitor frequency setting, and the set frequency increases magically). Another
noticed symptoms were an unexpected restart and a sudden shut off (remember the power supply issue?) of
the unit. I suspect, there's something left to do on the power supply board ...
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