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g520
Level III Service Manual
g520
CONTENTS
SECTION 1: GENERAL
1.1 1.2 1.3 Introduction Motorola service policy for g520 in warranty General Safety Information
Page Number 2 4
3
SECTION 2: g520 DESCRIPTION
2.1 2.2 2.3 2.4 Specifications g520 Overview Connector Pinout Talk time, Weight and Volume Matrix 7 6 8 8
SECTION 3: FEATURE LIST
3.1 List of Features available 10
3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
Menu Phone Book Call Related Features Messages Phone Set Up Network selection Call Meters Accessory set-up
10 10 11 12 13 14 14 15
SECTION 4: DISASSEMBLY & PARTS
4.1 4.2 4.3 4.4 4.5 4.6 Dissasembly Introduction Recommended Tools Disassembly Procedure Assembly procedure Exploded Parts diagram Replacement parts 17 17 17 17 21 22
SECTION 5: SIM CARDS AND SECURITY
5.1 5.2 5.3 5.4 5.5 Manual test mode Live Sim Card Personality Transfer GSM Test Commands Identity and Security 24 24 24 26 27
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g520
6.1 6.2 6.3 6.4 6.5 6.6
t
SECTION 6: REPAIR AND TEST PROCEDURES
Repair Introduction Mechanical repairs Basic modular troubleshooting Software Upgrade Testing on HP 8922 Testing on Go / NoGo Tester 29 29 29 32 33 34
SECTION 7: ACCESSORIES
7.1 Accessory Statement 36
SECTION 8: GLOSSARY OF TERMS
8.1 List of Abbreviations 38
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SECTION 1: GENERAL
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1.1 Introduction
This manual is intended for use by technicians familiar with similar types of equipment. It contains all service information required for the equipment described and is current as of the printing date. The scope of this document is to provide the reader with basic information relating to the g520 and also to provide procedures and processes for repairing the units up to and including Level 2 repair. Level I and II repairs involve the following activities to be carried out: · · · · · · · Unit swap out Repairing of mechanical faults Basic modular troubleshooting Testing and verification of unit functionality Upgrading software Flashing units Initiate warranty claims and send faulty modules to Level III or IV repair centers.
Computer Software Copyrights The Motorola products described in this instruction manual may include copyrighted Motorola computer programs stored in semi-conductor memories or other media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or reproduce in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the Motorola products described in this instruction manual may not be copied or reproduced in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for the normal non-exclusive, royalty free license to use that arises by operation of law in the sale of a product.
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1.2 Motorola Service Policy for g520 in warranty
1.2.1 Warranty: Product will be sold with the standard 12 months warranty terms and conditions. Accidental damage, misuse, and retailers extended warranties will not be supported under warranty. Non warranty repairs will be available at agreed fixed repair prices. Refer to the latest version of CSB 235 for details. Proof of purchase will be required to validate warranty claims. 1.2.2 Out of Box Failure Policy Refer to the latest version of CSB 270 for the definition of Out of Box Failures, and for specific instructions.
1.2.3 Product Support Customers original units will be repaired but not refurbished as standard. Level I shops may replace accessories and Level I parts; Level II shops may replace non-soldered parts; Level III shops may perform some board level repairs. The U.S. National Service Center makes all repairs. 1.2.4 Customer Support: Consumers should call 1 - 800 331 - 6456. Motorola Warranty Authorized Service Centers should call 1 - 877 777 - 7520 55# for access to Technical Support. 1.2.5 Replacement Parts Ordering Only shops authorized to carry out repairs will be able to purchase spare parts. Orders for spare parts should be placed with the Accessories and Aftermarket Division (AAD) of Motorola. Refer to the latest version of CSB 260 for details.
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1.3 General Safety Information
1.3.1 Portable Operation · DO NOT hold the radio so that the antenna is very close to, or touching, exposed parts of the body, especially the face or eyes whilst transmitting. The radio will perform best if it is held in the same manner as you would hold a ` land'telephone handset, with the antenna angled up and over your shoulder. · DO NOT operate the portable phone in an aircraft. Switch off your telephone. The use of a cellular telephone in an aircraft may be dangerous to the operation of the aircraft, disruption of the Cellular Network may occur, and is illegal. Failure to observe this instruction may lead to a suspension or denial of Cellular Telephone Service to the offender, or legal action, or both. 1.3.2 Mobile/Portable Operation - Telephone use in Vehicles: · All equipment must be properly grounded according to installation instructions for safe operation. · Users are advised to turn off their equipment when at a refueling point. · Safety is every driver' responsibility. Cellular telephones should only be used in situations in s which the driver considers it safe to do so. 1.3.3 General · DO NOT allow children to play with any radio equipment containing a transmitter. · DO NOT operate this equipment near electrical blasting caps or in an explosive atmosphere. Mobile Telephones are, under certain conditions, capable of interfering with blasting operations. When you are in the vicinity of such work, look out for and observe signs cautioning against mobile radio transmission. If transmission is prohibited, you must turn off your mobile telephone to prevent any transmission. In standby mode the mobile telephone will automatically transmit to acknowledge a call if it is not turned off. · Refer to the appropriate section of the product user manual for additional pertinent safety information · All equipment should be serviced only by a Motorola qualified technician.
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SECTION 2: g520 DESCRIPTION
g520
2.1 Specifications of g520 Specification
1850.2 - 1909.8 MHz Tx 1930.2 - 1989.8 MHz Rx General Function Frequency Range GSM PCS
Channel Spacing Channels Modulation Transmitter Phase Accuracy Duplex Spacing Frequency Stability Operating Voltage Transmit Current Stand-by Current Dimensions Size (Volume) Weight Temperature Range Transmitter Function RF Power Output Output Impedance Spurious Emissions
200 kHz 174 GSM/374 DCS carriers with 8 channels per carrier GMSK at BT = 0.3 5 Degrees RMS, 20 Degrees peak 45 MHz GSM 95Mhz DCS + 0.10 ppm of the downlink frequency (Rx) +4.0V dc to +6.0V dc (battery) +6.7V dc to +8.6V dc (external connector) Typically 250 ma avg, 1.0A peak Typically 7.0 ma (DRX2) 140mm X 50mm X 25mm 155 cc 168 g -10C to +55C
Specification 33 dBm + 2dB GSM/ 30 dBm + 2 dB DCS 50 ohms (nominal) -36 dBm from 0.1 to 1 Ghz -30 dBm from 1 to 4 Ghz
Receiver Function RF Level RX bit error rate (100 k bits) Channel Hop Time Time to Camp Speech Coding Function Speech Coding Type Bit Rate Frame Duration Block Length Classes Bit Rate with FEC Encoding
Specification -102 dBm < 2% 500 microseconds Approximately 5-10 seconds
Specification Regular Pulse Excitation / Linear Predictive Coding with Long Term Prediction. (RPE LPC with LTP). 13.0 k bps 20 ms 260 bits Class 1 bits = 182 bits. Class 2 bits = 78 bits 22.8 k bps
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2.2 g520 Overview
The g520 is marketed as a ` price beater'unit in its class. It is now designed with a new chip set to allow the unit to operate at a lower working voltage and therefore prolong battery life, in both Standby and Talk time. It is a single band PCS 1900 band product, using the same batteries and rear door as the D520. Display 2 X 12 character based LCD display
The g520 main features include: · Single Band · Longer Talk time / Standby time · Class II Sim tool kit · Internal headset socket · Potential to support Enhanced Full Rate mode of transmission (dependant on Network)
The g520 is mechanically very similar to the D520 (shown beloe); it does however contain the internal headset socket. All the circuitry is contained on 1 PCB including the Keypad. The Display is connected to the PCB via a ZIF connector. The charger is now placed on the bottom left hand side of the unit The Antenna is a fixed stub type antenna. Fig 2.1 Mechanical pictorial Overview Display Speaker
Keypad
Headset Jack Socket
Antenna SIM Contacts IMEI & MSN Label
Accessory Connector
Battery Contacts
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2.3 Connector Pinout
1
11
1- Ext B+ 2- Ground 3- Man Test 4- Uplink 5- Not Connected 6- Downlink 7- DSC_EN_B 8- UTXD 9- Ground 10- UTXD_IN 11- Ground
2.4
Talk Times, Weight and Volume Matrix
White holographic film on display Weight Battery Talk Time Standby time (grams) only (gr) (minutes) (hours) 203 218 196 167 170 98 113 91 62 65 165 - 240 250 - 365 60 - 85 125 - 180 160 - 230 80 - 120 110 - 180 105 - 140 60 - 90 80 - 120
X
Volume (cubic cm) 174 174 174 157 157
With Battery type:
720mAh NiCd AA 1100mAh NiMh AA Lithium AA 550mAh Std. NiMh 700mAh AAA Long NiMh
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SECTION 3: FEATURE LIST
g520
3.1 List of Features Available
Below are the list of Menu functions available at present.
Menu
1st Generation Menu 2 Generation Menu 3rd Generation Menu 4th Generation Menu 5th Generation Menu 6th Generation Menu Messages Phone Setup Only Available with Headset or Car Kit connected Call Related Features Call Meters
nd
Phone Book
Network Selection
Accessory Setup
PHONE BOOK
Find Entry by Name 1.Last Calls made 2.Last calls received 3.Erase all numbers
Personal Numbers
Enter Name
Last 10 Calls
1.Call Number 2.Modify Name or number 3.Erase name or number
Find Entry By Location
Enter Location
My phone number(s)
Add Entry Fixed dialing View fixed dial list Setup fixed Dialing Enter Pin2 1.On 2.Off 3.Edit Entry 4.Add Entry 5.Erase Entry Check Capacity Number of unused locations Enter Number
Prevent access
1.No memory restrictions 2.To SIM card memory
One-Touch Dial Setting
1.To SIM memory 2.To Fixed Dial list
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CALL RELATED FEATURES
Show battery meter Restrict my Phone number Call Diverting Talk and Fax Call waiting 1.On 2.Off 1.On 2.Off Bar outgoing calls 1.Int' Calls l 2.Int' Calls Except home l 3.All Calls 4.Off 1.When Roaming 2.All Calls 3.Off 1.Show ID on next call 2.Restrict ID on next call
Call Barring
Bar Incoming Calls
Change Bar password Cancel all barring 1.Default 2.On 3.Off 1.On 2.Off
Closed user Group
Set Group ID
Allow Outside Access
Divert Voice calls
Divert when unavailable
1.On 2.Off 1.On 2.Off
Divert Fax Calls Divert Data Calls
1.On 2.Off 1.On 2.Off
Divert all Voice calls
Cancel all diverting
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Messages
Call Voicemail
Received messages
Go to Next message Delete Message Return Call Edit Message Reply to message Delete all messages 1.Send Message 2.Store Message
Outgoing Messages
Go to next message Send message Edit message Delete message 1.Send message 2.Store message
Cell broadcast
1.On 2.Off 1.Voicemail Number 2.Service Centre 3.Expiry Period 4.Outgoing message type
Message Settings
Message Editor
Edit Message
Send message
Enter Number
Store Message
Stored to Outgoing
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PHONE SETUP
Adjust Ring volume Ringer On or Off Set Ringer Tone Set Ringer Tone 2 Phone Lock Automatic Lock Lock Now Change Unlock mode Change SIM PIN2 Code 1.On 2.Off 3.Change SIM pin Code 1.On 2.Off 1.On 2.Off
Standard Tone . . Music Tone
Require SIM card pin New security code Extended menus Change Greeting
1.On 2.Off
Language Selection
English . . Automatic 1.On 2.Off 1.Normal Tones 2.Single Tones 3.No Tones 1.Status review 2.Master reset 3.Master Clear
Battery saving mode
Select Keypad tones
Phone Status
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NETWORK SELECTION
Available Networks 1.Register Now 2.Make Preferred
Network Search
Registration Preferences
1.Automatic Search 2.Manual Search 1.Slow Search 2.Medium Search 3.Fast Search 4.Continuous Search 1.Choose From Available 2.Choose From Known 3.Add new Network Code
Frequency of Search
Preferred Networks
Add network to List
Find New Networks
1.Move to New Location 2.Delete Selection
CALL METERS
Show Call charges
1.Show last call 2.Total for all calls 3.Credit remaining 1.Show last call 2.Total for all calls 3.Reset all timers
Show call timers
Set audible Call Timers
Single Alert Timer Repetitive Timer
1.On 2.Off 1.On 2.Off
Set in call Display
1.Show time per call 2.Show Charge per call 3.Show total Call charges 4.No in call display Reset Call charges Set Total Charge Limit 1.On 2.Off 1.Units 2.Currency
Call charge settings
Lifetime Timer Set Charge Type
g520
ACCESSORY SETUP
Note: THIS MENU IS ONLY AVAILABLE WITH EITHER HEADSET PLUGGED IN OR WHEN INSTALLED IN A CAR KIT.
Automatic answer
1.On 2.Off
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SECTION 4: DISASSEMBLY & PARTS
g520
4.1 Disassembly Introduction
The g520 is held together by 5 screws as other Modulus products; 1 of these screws is placed beneath the IMEI label. Care should be taken whilst removing the display flex cable as this can be torn or broken without too much stress being applied. Ensure that a properly grounded high impedance conductive wrist strap is used while performing any tasks during the disassembly and assembly of the unit. Avoid stressing the plastics in any way to avoid damage to either the plastics or internal components.
!! CAUTION !!
Many of the intergrated devices used in this equipment are vulnerable to damage from electro-static charges. Ensure that adequate static protection is in place when handling, shipping and servicing the internal components of this equipment.
4.2
Recommended Tools
The following tools are recommended for use during the assembly / disassembly of the g520. · Anti-static Mat Kit - 0180386A82, includes: Antistatic mat 66-80387A95 Ground Cord 66-80334B36 Wrist Band 42-80385A59 · Plastic Bladed Tool SLN7223A · T7 Torx Driver
4.3
Disassembly Procedure
The following set of diagrams will demonstrate the correct sequence and action required to disassemble the g520. The use of the exploded diagram on page 17 may be of some assistance for part recognition.
4.4
Assembly Procedure
Once the unit is disassembled and the repair is carried out, the unit must then be reassembled, this is carried out in the exact reverse order as the disassembly.
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1. Remove battery door by pressing down on clip while pulling towards you.
2. Remove battery by pushing and lifting at the same time.
3. Press down and pull SIM door to right and lift. Then pull SIM card to the left to remove.
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4. Unscrew antenna and remove.
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5. Unscrew all 5 screws, remembering the one beneath the label in the center.
6. Lift off back housing from PCB.
7. Pry the alert from the back housing.
8.Remove keypad PCB from board
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9. Remove the keypad from the front housing.
10. Fit a blade under the speaker and carefully lift it from the front housing.
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4.5 Exploded Parts Diagram SWF3076DA
1 2
3
4
5
6
7
8
10 9
11
12
14 13
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4.6 Replacement Parts
SWF3076DA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0103892K01 not available 3809378T02 5009150J04 6103893K02 0109482U02 5009005J09 8504892Z02 0309315B02 3203997K01 4009410U05 5009536H15 7204516Z02 SHN6842A
Xcvr Item Number Frnt Hsng Assy Lens tape Keypad Speaker Lens Rear Hsng Alert Stubby Antenna Screw Speaker Gasket Keypad Domes Microphone Display Batt Door
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SECTION 5: SIM CARDS AND SECURITY
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5.1 Manual Test Mode
The GSM Motorola g520 is equipped with a manual test mode capability. This capability allows service personnel to take control of the unit, and by entering certain keypad commands, make the unit performs desired functions. To enter the manual test command mode, a GSM / DCS test sim (Part No 8102430Z04) must be used. The test sim is inserted into the SIM slot beneath the battery (See figure 6.1), the battery should then be re-inserted and the unit powered on. The # button should then be pressed for approximatly 3 second until ` test'appears on the display, and the correct commands must then be followed.
SIM CARD
Figure 6.1 SIM Card insertion
5.2 Live Sim Card
A SIM (Subscriber Identity module) card will be required to access the existing local GSM / DCS cellular network, or remote networks when travelling. (If the roaming agreement has been made with the provider.) The SIM card contains all the data necessary to access GSM services, and also: · The ability to store user information such as phone numbers etc... · All information required by the network provider to provide use to the network
5.3 Personality Transfer
5.3.1 Introduction Personality Transfers are required when a phone is Express Exchanged or when the main board is replaced. The reason for personality transfers are to reproduce the customer' original personalized s details such as menu and stored memory such as phone books etc... or even just to program a unit with basic user information such as language selection. There are two possible methods of transferring this information from unit to unit, or with a master transfer, card to unit: ·Normal Transfer is used when the customer' original unit still powers up and as discussed above s the customers personalized menu selections etc... are required to be transferred to the replacement unit. ·Master Transfer is used when the faulty unit will not power up and the transfer is used to configure the replacement board to a set standard. Below is the procedure to set up a Master Transfer Card and to carry out each method of transfer correctly.
5.3.2 1. 2. 3.
Normal Transfer
Insert transfer card into ` Donor'Unit. Turn unit on till ` Clone'appears. Enter 021# to upload first block of data. ` Please wait'will be displayed.. Remove card.
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4. 5. 6. 7. 8. Insert card into replacement unit, or unit with new main RF / Logic PCB. Turn unit on wait till ` Clone'appears. Enter 03# ` Please wait'will be displayed while data is transferred. Repeat steps 1 6 but enter 022# at step 2 to transfer data on to Clone card. Repeat steps 1 6 but enter 025# at step 2 to transfer data on to Clone card. Master SIM Card Creation
5.3.3 1. 2.
3.
Insert transfer card into a unit with the desired setup Pwr on and wait till unit displays ` Clone' Enter 024# to copy unit ` personality'onto card. ` Please wait'will be displayed Master Transfer card is created. Master Transfer
5.3.4 1. 2. 3.
Insert Master Transfer Card (explained above) into replacement unit. Pwr on and wait till unit displays ` Clone' Enter 03# to download data into replacement unit. Please wait will be displayed. When ` Clone'reappears download is completed.
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5.3 GSM Test Commands
This is a list of Level 1 and 2 Test commands available to g520 Table 6.1 Test commands Key Sequence #(hold down for 2 seconds) 01# 07x# 08# 09# 10# 15x# 16# 19# 20# 36# 37# 38# 39# 43x# 47x# 51# 52# 57# 58# 58xxxxxx# 59# 59xxx# 60# 980# / 981# 99# Enter manual test mode Exit manual test mode Mute RX audio path Unmute RX audio path Mute TX audio path Unmute TX audio path Generate tone Mute tone generator Display S/W version number of Call Processor Display S/W version number of Modem Initiate acoustic loopback Stop test Activate Mini SIM Deactivate Mini SIM Change audio path Set audio volume Enable sidetone Disable sidetone Initialize non-volatile memory Display security code Modify security code Display lock code Modify lock code Display IMEI DCS / GSM mode Display all display pixels 36XX# Full Rate Enhanced Full rate Half Rate
GSM Test Commands
Test Function/Name
0 or Omitted 1 2
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5.5 Identity and Security
Each Motorola GSM Cellular Telephone is labelled with various number configurations. The following information describes what these configurations mean. MSN The mechanical Serial Number (MSN) is an individual unit identity number and will remain with the unit throughout the life of the unit. The MSN can be used to log and track a unit on Motorola' EPPRS system. s The MSN is divided into 4 sections. MSN 10 Digits
3 digits APC 1 digit DC 2 digits DC 4 digits SNR
Account Product Code e.g., A60
Distribution Center e.g., Harvard, IL
Date Code: Year and Month of Shipment
Unit's individual serial number
Figure 5.2 MSN label breakdown IMEI The International Mobile station Equipment Identity (IMEI) number is an individual number unique to the PCB and is stored within the unit' memory. The following figure gives a description of the make s up of this number.
IMEI 16 Digits
6 digits TAC 2 digits FAC 6 digits SNR 2 digits IU
Type Approval code
Distribution Center factory code
Individual PCB Serial Number
Internal use spare digits
Figure 5.3 IMEI label breakdown Some other label number configurations that will be present will be: XCVR NUMBER: Identifies type of product; e.g., g520 (Usually SWF number) PACKAGE NUMBER: Determines type of equipment, mode in which it was shipped and language with which it was shipped.
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SECTION 6: REPAIR AND TEST PROCEDURES
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6.1 Repair Introduction
The g520 is divided into 3 main sections when it comes to part replacability: the housings which contain the alert, speaker, the main PCB which contains RF / Logic circuitry and the keypad; and finally the display which connects to the main PCB via a ZIF connector. If the RF / Logic board is faulty then the entire unit must be replaced since there is no replacement PCB available. Also, if the unit is replaced, it is necessary to perform an identify transfer.
6.2
Mechanical repairs
Assembly replacement level troubleshooting and repair of the g520 is limited to isolation and replacement of the main mechanical parts only (See Exploded parts diagram and associated parts list)
6.3
Basic Modular Troubleshooting
The troubleshooting information in Table 2 shows some typical malfunction symptoms, and for the corresponding verification and repair procedures refer to the disassembly instructions located in the disassembly section of this manual. (Section 5).
NOTE
Defective Logic/RF assemblies must be replaced with pre-tested, pre-phased assemblies
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Repair Chart
Table 2. GSM g520 Cellular Telephone: Troubleshooting and Repair Chart. (Assembly Replacement Level). SYMPTOM
Personal telephone will not turn on or stay on
PROBABLE CAUSE
a) Battery pack either discharged or defective
VERIFICATION AND REMEDY
Measure battery. If the battery voltage is <4.00 V dc, recharge the battery using the appropriate battery charger. If the battery will not recharge, replace the battery. If battery is not at fault, proceed to b. Visually inspect the battery connectors on both the battery assembly and the portable telephone. Re-align and, if necessary, replace either the Battery or the battery connector assembly. Removing the battery connector assembly has to be done with extreme care to avoid damaging the housings. If battery connectors are not at fault, proceed to c Remove the Logic/RF Assembly. Substitute a known good assembly and temporarily reassemble the unit. Depress the PWR button; if unit turns on and stays on, disconnect the dc power source and reassemble the telephone with the new Logic/RF Board assembly. Verify that the fault has been cleared. If the fault has not been cleared then proceed to d. Disassemble unit and remove LCD module and insert known good module. Insert Battery and depress PWR button. Ensure unit stays on, if OK reassemble unit in new housing assembly
b) Battery connectors open or misaligned.
c) Logic/RF Board Assembly Defective.
d) Display circuit failure
2. Personal telephone exhibits poor reception and/or erratic operation (such as calls frequently dropping, Weak and/or distorted audio, etc.).
a) Antenna is defective
Check to make sure that the antenna pin is properly connected to the Logic/ RF assembly. If OK, substitute a known good antenna. If the fault is still Present, proceed to b. Replace Logic/RF Assembly (refer to symptom 1c). Verify that the fault has been cleared and Re-assemble the unit with the new PCB. Remove rear housing from unit, check general condition of flex connector from display. If OK check that the Zif connector is fully pressed down and that the flex collars are flush with the plastic of the connector.If not check Zif to PCB connections, if faulty connector, replace RF / Logic PCB. If Ok proceed to b. Substitute a known good LCD module onto the suspect board and connect to DC Pwr supply depress PWR and ensure display is now correct,if Ok rebuild unit with new LCD module if LCD module is not at fault proceed to c. Replace Logic/RF Assembly (refer to symptom 1c). Verify that the fault has been cleared and Re-assemble the unit with the new PCB.
b) Logic/RF Board Assembly Defective.
3. Display is erratic, or provides Partial or no display.
a) Mating connections to / from LCD Module faulty.
b) LCD module is Defective.
c) Logic/RF Board Assembly Defective.
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SYMPTOM 4. Incoming call alert transducer audio distorted or volume is too low. 5. Personal telephone transmit audio is weak, (usually indicated by called parties complaining of difficulty in hearing voice from personal phone). PROBABLE CAUSE a) Faulty alert Transducer / Main RF / Logic PCB defective VERIFICATION AND REMEDY Replace Logic/RF Board Assembly (refer to symptom 1c). Verify that the fault has been cleared and re-assemble the unit with the new PCB. Gain access to the Microphone as described in the DISASSEMBLY instructions in this manual. . Check connections. If connector is faulty proceed to c if the connector is OK, proceed to b. Gain access to microphone .Disconnect and substitute a known good Microphone. Place a call and verify as heard by called party. If good, reassemble portable with new Microphone. If Microphone is not at fault, re-install original Microphone and proceed to c. Replace Logic/RF Board Assembly (refer to symptom 1c). Verify that the fault has been cleared and re-assemble the unit with the new PCB. Gain access to Logic/RF board as described in the DISASSEMBLY instructions in this manual. Check pads on the Logic/RF circuit board. Clean pads if necessary. If pad is at fault proceed to d. If connection is not at fault, Proceed to b. Remove speaker from front housing and insert known good speaker. Place a call and verify improvement in earpiece audio. If better, reassemble the phone with the good speaker. If it was no better then proceed to c. Attempt a re-phasing of the unit and recheck the symptom. If symptom is the same but unit re-phases correctly, check to make sure the antenna connector is correctly soldered to the main board and that the antenna is fitted correctly. If ok, substitute a known good antenna assembly. If this does not cure the fault, re-install the original assembly then proceed to d. d) Replace Logic/RF Assembly (refer to symptom 1c). Verify that the fault has been cleared and Re-assemble the unit with the new PCB. Initially check that the contacts on the card are not dirty. Clean if necessary, and check if fault has been eliminated. If the contacts are clean, insert a Known good SIM card into the portable telephone. Power up the unit and confirm whether or not the card has been accepted. If the fault no longer Exists, the defective SIM card should be replaced. If the SIM card is not at fault, proceed to b. Replace Logic/RF Board Assembly (refer to symptom 1c). Verify that the fault has been cleared and re-assemble the unit with the new PCB.
a) Microphone connections to The main RF / Logic board are defective.
b) Microphone defective
c) Logic/RF Board Assembly defective. 6. Personal telephone receive audio is weak and/or distorted. (From speaker) a) Connections to/from speaker and Logic/RF Circuit board defective.
b) Earpiece Speaker defective.
c) Antenna assembly is defective.
d) Logic/RF Board Assembly Defective.
7. Personal telephone will not recognize/accept SIM card
a) SIM card defective
b) Logic/RF Board Assembly Defective.
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SYMPTOM PROBABLE CAUSE VERIFICATION AND REMEDY
9. Internal Charger not working
a) Faulty charger circuit on main Board.
10. No / Weak audio when using headset
a) Headset not fully pushed home b) Faulty Jack Socket / Defective PCB
Test a selection of batteries in the rear pocket of the desktop charger. Check LED display for the charging indications. If these are charging ok, then the internal charger is at fault. Replace Logic/RF Board Assembly (refer to symptom 1c). Verify that the Fault has been cleared and re-assembles the unit with the new PCB. Fully ensure the ` click'is felt on the jack socket. Replace Logic/RF Board Assembly (refer to symptom 1c). Verify that the fault has been cleared and re-assemble the unit with the new PCB.
6.4
Software Upgrade
For information on setting up and equipment required for the flashing of software, contact Technical Support at 1 - 877 777 - 7520 55#.
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6.5 Testing on HP8922
Power Supply
HP8922 GSM Test Set 83220E Down Converter RF Cable PSU Cable
g520 under Test
Note: To test the PCB on its own without a housing or SIM card the unit must first be put into test mode and then into Tx or Rx mode using the applicable manual test commands. Ensure that a battery is installed during this, since the battery acts as a SIM card presence detect for the unit. The PCB can then be taken out of the housing for any analysis.
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6.6 Testing on Go / NoGo tester
The set up for the GO / NOGO tester must be set up as shown above. The tester must be set up following GSM specifications. Note, the D520 is shown in the illustration. The test incorporates the basic live call, during which many of the RF parameters are checked. This test can be run in ` Autotest'mode, where the radio is classified at the end of the test as a Pass or Fail. This can be used to indicate whether or not a unit is performing to spec through the accessory connector only.
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SECTION 7: ACCESSORIES
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7.1 Introduction
Most of the accessories are compatible with the previous models.
Accessories available with compatibility to C / D160
Part Number SYN 7167A SHN 6936A SYN 7158A SHN 6841A SYN 7168A SHN 6937A SYN 7158A SHN 6842A SYN 0003A SNN 4803A SNN 5363A SNN 4934A SPN 4366C SYN 4657 SPN 4434A S 8267A* S 8266A* SYN 7151A SYN 5383B Name AA Door With Belt Clip AA Battery Door W/ Stud for Belt Clip Belt Clip AA Battery Door AAA Door With Belt Clip AAA Battery Door with Stud for Belt Clip Belt Clip AAA battery door Deluxe Belt Clip 1100 mAh NiMh AA 700 mAh NiMh AAA Long Battery Spare 1100 mAh NiMh AA Universal Rapid Travel Charger US Plug Std. Charger, US Plug 900/1900 Simplified DHFA 900/1900 DHFA Hang-up Cup Cigarette Lighter Adapter
-
Under Investigation
Same as C160 Available Same as Populus Same as C160/New HUC Same as C160
36
European Customer Services
g520 - RF SCHEMATICS
MIX_275 GSM_LNA275
FL459
TEXT
RX SIGNAL PATH TX SIGNAL PATH MAIN VCO SIGNAL PATH TUNING VOLTAGES 13 MHz REFERENCE CLOCK DATA BUS ADDRESS BUS REFERENCE SIGNALS
TXVCO_EN
VCO_275
Q501
Q502
DCS_SEL GSM_SEL
FL400 Q410
GSM_LNA275 TX_EN MIX_275
TX_GSM_*DCS
RX_DCS_*GSM
FL457 Q408 Q453
MIX_275 400MHz
Q453
Q480
FILTERED_-10V
-10V
Q504
MIX_275 DCS_LNA275 RF_V2 RX_EN
VCO_275
Q506
FL458
1960MHz
SF_OUT
GP04
FL401
1960MHz
DCS_LNA275
DCS_SEL MIX_275 GSM_SEL
GSM_LNA275
Q430
Q503
DCS_LNA275 TXVCO_EN
TX_EN
Q505
RX VCO MID CHANNELS PCS: CH 661 -- 1560MHz RX VCO FRQ. RANGE PCS: 1530 - 1590MHz
SF_OUT
Q431
RX MID CHANNELS PCS: CH 661 -- 1960MHz
GSM_LNA275
TX_EN
RF_V2 VCO_275
Q262 CR259
RF_V2 RX_ACQ
Q421
BCLKR BFSR BDR
A100
CR230
SW_V1 RF_V1 GP04 GP05 SW_V1 RF_V1
SF_OUT RF_V1
U102
RF_V2
U201 MAGIC2_IC
BCLKX CLK_SELECT
MAGIC_13MHz
VCO_275 DCS_SEL RF_V1 A
B SW_RF
Q202
TX_KEY DM_CS MQSPI_CS1 MQSPI_CLK1 DX1 BDX
RF_V1
U104
RF_V2
Q201
RF_V2 RF_V2
Q240
Vref 1800MHz
Q242
ALRT_VCC
FL100
FILTERED_-10V SW_V1 MIX_275 TX_EN
VR201
CR201
RX_DCS_*GSM
Y230
TX FRQ. RANGE PCS:1850-1910MHz TXVCO_EN B+ B+ TXVCO_EN B+ GSM_SEL GSM_SEL TX_GSM_*DCS DCS_SEL
U301
DCS_SEL
Q333
SF_OUT
TXVCO_EN
Q302
SF_OUT
CR397
TX_GSM_*DCS
CR374 Q378 CR330 Q384 Q389
TX_GSM_*DCS
Q318 Q311
Q306
TX_GSM_*DCS
CR387 CR383
CR378
PAC_EN PAC_EN TX_GSM_*DCS V1
VR309 Q507
CR381 U350
TX_EN
VR308
TX_EN
Q360
DM_CS
SAT_DETECT DETECT_SW TX_KEY_OUT TX_EN DM_CS
V1_LF
PAC_EN
Q290 Q291 U290 Q291
g520 - AL SCHEMATICS
RX SIGNAL PATH TX SIGNAL PATH MAIN VCO SIGNAL PATH TUNING VOLTAGES 13 MHz REFERENCE CLOCK DATA BUS ADDRESS BUS REFERENCE SIGNALS V3 V2 V2 V2 V3 V2 V2 PWR_SW LBTO V2 TEXT KBR2 V2 URXD (WAS SCI_TX) TDO EMU1 TCK SIMPD0 DATA0_RX (WAS SCI_RX) TRST* SVEN0 CLK0 TDI TMS EMU0 RST0 UTXD
JTAG TEST POINT
TMS TRST* TDI TDO TCK EMU0 EMU1
KBR1 PD
KBR0 KBC3 KBC2 KBC1 KBC0 IRQ_0 CE1 CE0 CE2 CE3 CE4 CE5
BDX BFSR BDR BCLKR BCLKX
J810 10 PIN EXT CONN
EXT_B+ DIG_AUD(3:0) V2 V3 V3 V3 CE6 CE7 CE8 CE9 INT_CS ADDRESS(20:0)
R_W
VR830
V2 V2 UCTS_PA4 URST_PA5 CLK_SELECT TIMING8 TIMING7 TX_EN TX_KEY DATA0_TX UTXD URXD_IN STBY_PC5 DSC_TXD CCLOCK RCLOCK DSC_RXD KBR4 KBR3 KBR2 KBR1 KBR0 V2 OWDAT V3 CLKIN V2 DM_CS RX_EN RX_ACQ
MAN_TEST_AD
V2
V1
V2
V2
VR822
V1
V2
U700 RAM3_WHITE_CAP
U908 EPROM U703
V2
DOWNLINK
U912
U911 RAM
V2
CR810
V1 DOWNLINK_AD V1
PB8
KBC4 KBC3 KBC2 KBC1 KBC0 PB10 BKLITE_CNTL
V3
EEPROM
Q701 Q701
V1
J905 DISPLAY INTERFACE
MAGIC_13MHz V2
V2 INTR_OUT1 CHG PB5 PB4 PB3 PB2 PB1 PB0
V2
DSP_CLK_OUT
IRQ_3 IRQ_2
IRQ_0
VR621 J804 BATTERY CONTACTS
BATT+ SW_V2 BATT_THERM V1
V2 MQSPI_CS2 BOOM_EN RST_CNTL PB12
V3 EXT_B+_EN PB11
V3 DBGACK IRQ FIQ TSIZE TSTROBE* TSTATE0 TSTATE1 TSTATE2 MCLK
V3
V2
DATA(15:0) SW_V2 MAGIC_QSPI(3:0) MAGIC_QSPI(3:0) V2
GCLK GCAP_MQSPI(3:0)
IRQ_1
V1
GCAP_MQSPI(3:0)
Q905
DR1 DX1 MQSPI_CLK1 MQSPI_CS1 PB12
DP_ON_OFF
RESET
V_BOOST1
SW_V2 GCAP_CLK DIG_AUD(3:0)
DR2 DX2 MQSPI_CLK2 MQSPI_CS0
V3 V_TEMP
VSIM1
32,768KHz
Y633
B+
U906
-5V -10V CE6
V2
U905
DP_EN
CHG-
MAN_TEST_AD
STBY
V_BOOST1
CR638
EXT_B+
B+
TRST*
VCLK VDR VDX VFSRX
DOWNLINK_AD
U601 G_CAP2 JEKYLL
DSC_EN_AD BATT_THEERM EXT_B+_AD
PWR_SW
RESET V2 WDOG
A0
Q640
LBTO
V1 -5V
U907 CR812
-10V
R_W
Q640
CHGEXT_B+
VAG
MICVAG_FLTRD
Q685 CR813 U602 G_CAP2 CR681 Q683
J802 MIC CONN
J690
BATT+ B+
MICBOOM_EN MIC_BIAS V2
B+ BATT+
STBY
STBY VREF
RF_V2
Q680
EXT_B+_EN
Q681
Q980
Q681 VR681
HYDE
B+ ALRT_VCC
Q970
STBY_PC5 V2
Q690 CR814 U951
Q945
BOOM_PWR VAG VAG_FLTRD VREF B+
MIC_BIAS
STBY CHG B+ V_TEMP
Q683
V2
STBY
Q979
EXT_B+ SW_V2 SW_V1
U946
DNP
STBY V_TEMP V2
J901 CON_POWERJACK_B
Q978
V1
U950
Q971
B+ V_TEMP
J940 HEADSET CONN
V2 VSIM1
U603 Q671 J665 SIM CONN
SIM_PD CLK RESET VSIM1 BATT+ SW_V2 EXT_B+
V_BOOST1
Q956
Q671
EXT_B+ EXT_B+_AD BKLITE_CNTL
V2
SIM_I/O
Q901 Q903
Q902
J501 SPEAKER VR501
IRQ_2
VR661
VR662
VR670
VR671
VR672
CR671
CHG-
VR502
AL661 AL660
g520 - BLOCK DIAGRAM - PAGE 1/2
KBR0, KBR1, KBR2 to Keyboard KBC0, KBC1, KBC2 BKLITE_CNTL to Display CE5 PB12 H2, H1, H3 C4, C14, F10,H4, K5, K13, P13 J5, J3, J2 KEYPAD A9, A10, C5, G12, K6, K10, M8, M11 K3 B10 L6 DISPLAY INTERFACE V2 V3
WHITE_CAP
SPI INTERFACE
MAGIC SPI ADDRESS BUS DATA BUS
RESET
to MAGIC
SIM_PD LS1_IN LS2_IN LS3_TX LS3_RX HEADSET_INT CLK_SELCT TX_EN DM_CS TX_KEY RX_EN RX_ACQ RESET ( SDTX ) BDX ( TX_CLK ) BCLKX from / to MAGIC ( SCLK_OUT ) BCLKR ( SDFS ) BFSR ( SDRX ) BDR DSC_EN_B+ URXD_IN UTXD ( for RS232 )
A4 SIM 29 31 INTER 38 FACE 39 A1 C1 E2 CTM E1 E3 MODULE E4 P2 B6 B3 B4 D4 A3 K2 SERIAL INTER FACE DSP
U700
M E M O R Y I N T E R F A C E CTM D9 B9 C9 E10 C10 B10 F1 CE0 ( Flash ROM CS ) CE1 ( Flash ROM OE )
DISPLAY
CPU
26 12
28 FLASH
U908 ROM
14 37 V2 47 CE2 ( RAM Byte Control 1 ) CE3 ( RAM Byte Control LB+)
40 39
U911 SRAM
33 11
V2
7
U703 EEPROM
CE4 ( EEPROM OE ) CE5 ( EEPROM CS) 1 27
V2 RESET GND 2 4 DP_EN CE5 U905 from WhiteCap DP_ON_OFF PB12 Q905 / U906
1 6 3, 17, 18 4 5
( -5V )
J 810 7 10 8
DSC
EXT_B+_EN CHARGE L7 CHG A / D L1 SPI INTERFACE TIMER B7 H10 P4 13MHz CR813
V1 V2 STBY_PC5 VREF
DEEP SLEEP CIRCUIT
2 SW_V1 SW_V2 V1
U907
4
1
KBR0, KBR1, KBR2 to WhiteCap KBC0, KBC1, KBC2
KEYPAD
A5 UART A6 INTERF.
PWR_SW to Hyde
BATTERY
1 4 2 5, 6 Q681 3, 7 TRICKLE CHARGING R691 32.768 KHz CR681 J801 J906 GND CHGto Jekyll CHARGING / DISCHARGING J804 BATT+ J803 THERM
AUDIO SPI
GCAP SPI
MAGIC_13MHz
1
EXT_B+
EXT_B+
Parts of Backhousing Assembly
V_BOOST1 from Hyde BKLITE_CNTL from WhiteCap B
BACK LIGHT
C Q901 / 902 E
GCAP_CLK
J901
C901
2 9 11 5 3
CON_POWERJACK_B GND GND NC ( Ext Accessory Sense) DSC_EN_AD DOWNLINL_AD BATT_THERM EXT_B+_AD 59 58 SENSE 57 56 CNTL. 55 SPI INTERFACE
GCLK 32.768 KHz 67 SPI INTERFACE
Y633
VR830 GND
GCLK
B+ 1 71 SENSE CNTL 51 64 56 CLK BATT+ PWR_SW EXT_B+ RESET SIM_I/O 6 4 5 LS1_IN LS2_IN LS3_TX LS3_RX PWR_SW STBY_PC5 43 80 21 75 76 74, 77 VREF 2.775V,for MAGIC V3 1,8V, for WhiteCap V2 2.775V, for WhiteCap logic outputs, RAM, FLASH, EEPROM V1 5.0V, for DSC Bus, Negative Voltage Regulator CHGto Battery J665 SIM Con. 1 29 31 38 39 64 2, 3 from WhiteCap SIM_PD 3 5 Q671 4 VSIM1 6 Q685 TRICKLE CHARGING ENABLE 2 BATT+ EXT_B+
70
REAL TIME CLOCK
MAN_TEST_AD
50 - 29
1 - 20
U602 HYDE G_CAP2
LEVEL SHIFTER
2 Q671 6 1
4 6 10 PIN EXT CONN.
UPLINK DOWNLINK 13MHz GCAP_CLK VAG_FILTRD 3 1 U946 4
JEKYLL U601 G_CAP2
12 Audio Codec 19 24 21
Inter Connections
47 4 Logic Control RESET
62
VREF REG. V3 REG. V2 REG.
RX SIGNAL PATH TX SIGNAL PATH MAIN VCO SIGNAL PATH TUNING VOLTAGES REFERENCE CLOCK
MIC PA_DRV Audio Codec 27 28 34 SPRR940 IRQ_2 SPR+ ALRTOUT
V1 REG. VSIM REG.
VSIM1 3.0 or 5.0V, for SIM Card Circuit
V_TEMP
3 4 2 1 C955
41
52
79, 22
VBOOST1 REG.
Orderable Part Non - Orderable Part
66 61
(to WHITE_CAP)
SPKR
5.0V
CONN HEADSET J940
U950 Q682 L638
ALRT ALRT_VCC B+
V_BOOST1 5.6V - 7,6V for Backlight
g520 - BLOCK DIAGRAM - PAGE 2/2
A100
RF_V2 RX LOCAL OSCILLATOR 64
Osc. discrete circuty
Q262 CR259 SW_V1
800MHz 58
PLL
RX MID CHANNELS PCS: CH 661 -- 1960MHz 1930-1990MHz 7 U102 EXT ANT SW_RF from J100 4 V1 6 V2 2 3 DCS_LNA275 5 FL401 B
PCS LNA
MIX_275 1930-1990MHz Q430 B C FL458 C Q453 E
3 U504 2
4
RX_EN
1
U201 MAGIC
54 ( SCLK_OUT ) BCLKR ( SDFS ) BFSR ( SDRX ) BDR to WhiteCap
MIX_275 FL457 400 MHz
B Q480 C
C
4 STEP ATT. SWITCH 2
RXI DEMODULATION RXQ
RX SPI
53 52
SW_VCC
5, 24 ,27, 57 RF_V2 ALRT_VCC RF_V1 C C Q242 E E Q240 B B 33 32 28
2 3 V1 V2 U104 U401 SWITCH 8 CONTROL 1 RF_V2 TX_EN 4 MIX_275 5 FILTERED_-10V 6
30
PHASE DET Divider 200KHz
VRef
13MHz VCO
REG.
49, 50 CR230
47
VCO_VCC from MAGIC GP04 FILTER 1850-1910MHz 4 FL100 RX VCO MID CHANNELS PCS: CH 661 -- 1560MHz RX VCO FRQ. RANGE PCS: 1530 - 1590MHz B+ VCO_VCC U506 2 RX VCO RX_DCS_*GSM 17 19 CR201 VR201 Q421 Q201 Q202 C201 SW_V1 48 GP04 C Q333 B C Q318 B DCS_SEL 56 15 PHASE DET
Divider
13MHz SWITCH
14, 34 46, 61
SUPER FILTER
MUX Startup Ref. 1 /2
Prog. Divider 200KHz REF. REF. OSC. 26 MHz
46 MAGIC_13MHz CLK_SELCT
to WhiteCap from WhiteCap
3
SF_OUT
21
TX FRQ. RANGE PCS:1850-1910MHz
25 Y230 26 26MHz
PLL
AFC
( CE ) MQSPI_CS1 SPI 38 ( SPI_CLK ) MOSPI_CLK1 ( SPI_DATA ) DX1 36 from WhiteCap INTER 37 FACE
CR330 C Q378 GSM: 880-915Mhz DCS: 1710-1785MHz EXC 7 PCS C 1, 3 TX VCO B VR309
TX LOOP FILTER
LOGIC CONTROL
B C
Q384
B C
Q389
B
U350 PAC
RF_IN 2 TX_EN from U700 Q507 4, 14 10 12 8 PAC_EN
C Q311
DET SAT.
11
( SDTX ) BDX
TXI MODULATION TXQ
TX SPI
35 ( TX_CLK ) BCLKX 44
*TX_DCS_VCO
DETECT_SW AOC_DRIVE SAT_DETECT TX_KEY_OUT
DETECT_SW AOC_DRIVE SAT_DETECT TX_KEY_OUT
9 51 7 13 8 PA CONTROL LOGIC 39 CONTROL 40
RX_ACQ DM_CS TX_KEY from WhiteCap
GSM_LNA275 DCS_LNA275 RX_DCS_*GSM *TX_GSM_VCO *TX_DCS_VCO FILTERED_-10V
RX SIGNAL PATH
REFERENCE CLOCK Orderable Part Non - Orderable Part
GSM / DCS SELECT CIRCUIT
TX SIGNAL PATH MAIN VCO SIGNAL PATH TUNING VOLTAGES
g520 - BOARD LAYOUT
g520 - SIGNAL FLOW
MIX_275 VCO_275 SW_VCC RF_V2 RF_V1 RF_V2 EEPROM CS RAM Byte Control LB+ RAM Byte Control 1 EEPROM 0E
SH202
V3
13MHz_CLK
25
1 64 2 4 58 49 48 45 H10 17 12
MIC_CON
WHITECAP
16
1 64
V2
Y201
26
U201
MAGIC 45 MAGIC_13MHz
21 24 B7
JEKYLL
BATT+
MAGIC SH700
22 1 3 28 27 15 1 32
H10
U700 V1
J665 1 2 3 4
SIM_CONN
MIX_275
1617 19 21
26
SH481
33 32
SH201
33
49 48
WHITE_CAP B7 GCAP_CLK 12
SIM_CONN SRAM EEPROM
20 21
SH600
80
GND VSIM 1 VSIM 1 RESET SIM_I/O CLK
BATT_ THERM
1
HYDE
VREF
27 28 4 6
5 6
U601
JEKYLL
4 5
2 7
1
23 1
44
1 14 48
D
C
34 36 40 41 61
CHG-
TX_EN
8
EPROM
60
GND
SH381
SH301
39 40
A B
PA DETECT LINE EXITER, DRIVER, FINAL TUNING VOLTAGE RX SPEAKER LINE + RX SPESKER LINE -
V_BOOST1
C D
24
28 26 25
A
B
B+
SF_OUT
Flash ROM CS
Flash ROM 0E
TXVCO_EN
RF_V2
FILTERED_-10V
MIX_275
VCO_275
TXVCO_EN
B+
B
A
18 8 1
GSM_SEL
J701 1
14
DISPLAY CONN.
DISPLAY CONN.
6 5
7
2
16
1 4 8
PAC
V2 A0 GND DP_EN DP_ON_OFF RESET R_W NC D4 D5 D6 D7 D0 D1 D2 D3 GND GND
17
2 3 4 5 6 7
1
5
4 1 7 8
J810 1 2 3 4
11
EXT CONN EXT_B+ GND MAN_TEST_AD UPLINK NC DOWNLINK DSC_EN_B+ UTXD GND URXD_IN GND
TP
TP 809 TP810 TP811 TP812 TP813 TP814 TP815 TP816 TP817 TCK V2 TD0 GND EMU0 EMU1 TMS TRST+ TD1
MIX_275
8 9 10 11 12 13 14 15 16 17 18
1
5 6 7 8 9
10
RX_EN
10 11
TP810
TP817
TP815
TP809
C
D
TP816 TP811
TP813 TP812
RF_V2
DCS_LNA275
GSM_LNA275
VCO_275
GP04
TX_EN
V1
PAC_EN
TP814