HYT TC-580 Service Manual

TC-580 Service Manual
Contents
Introduction...................................................................................................................... 1
Safety Information........................................................................................................... 1
Radio Overview................................................................................................................ 2
Software Specifications .................................................................................................. 5
Circuit Description ........................................................................................................ 13
CPU Pins ........................................................................................................................21
TC-580 Parts List 1 ........................................................................................................ 25
Adjustment Description ................................................................................................ 40
Troubleshooting Flow Chart......................................................................................... 50
Disassembly and Assembly for Repair........................................................................ 53
Exploded View ............................................................................................................... 56
TC-580 Parts List 2 ........................................................................................................ 57
Packing........................................................................................................................... 59
TC-580 PCB View........................................................................................................... 60
TC-580 Level Diagram................................................................................................... 62
TC-580 Block Diagram................................................................................................... 63
TC-580 Schematic Diagram .......................................................................................... 64
Specifications ................................................................................................................ 69

HYT TC-580 Specifications

General

Channel Capacity	256
Zone Capacity	16
Channel Spacing	12.5/25 kHz
Frequency Stability	±2.5 ppm
Antenna Impedance	50 Ω
Modulation	16K0F3E/11K0F3E
Spurious Emission	≤ -36 dBm
Audio Distortion	≤ 5%
Receiver Sensitivity	≤0.25μV (12dB SINAD)
Spurious Response	≥70dB
Audio Power Output	0.5 W
Water Resistance	IP54
Frequency Range	400-470MHz
Operating Voltage	7.4V
Battery Life (5-5-90 duty cycle)	14 hours
Operating Temperature	-20°C to +55°C
Adjacent Channel Power	≥60dB
Hum & Noise	≥40dB
Adjacent Channel Selectivity	≥60dB
Intermodulation	65 dB

Summary

Introduction

Manual Scope and Purpose

Defines the intended audience and scope of the service manual.

General Safety Precautions

Lists critical safety guidelines for radio operation, service, and repair.

Radio Overview

External Component Identification

Identifies key external components of the radio unit with numbered labels.

Keypad Operation Guide

Explains the functions of specific keys on the keypad for radio operation.

Keypad and Indicator Functions

Numeric Keypad Usage for Programming

Describes how to use the numeric keypad for radio programming and character input.

LED Indicator Status and Alerts

Details LED indications and alert tones for various radio operations and functions.

LED Indicator Status Details

Power, Battery, and Transmission Status Indicators

Explains LED indications for power-on, low battery, and transmission states.

Receiving, Scanning, and Data Transfer Indicators

Describes LED indicators for receiving, scanning, and data transfer operations.

Software Specifications

Radio Feature List

Lists the various features and capabilities of the radio's software.

Software Features and Operating Modes

Additional Software Features

Lists further software features like low battery alert, emergency alarm, and software update.

Description of Operating Modes

Details User Mode, PC Programming Mode, Reset Mode, and Channel Set Mode.

Channel Set Mode Configuration

Channel Set Mode Navigation Flowchart

Illustrates the flow and options within the Channel Set Mode for configuration.

Menu Structure for Channel Parameter Editing

Explains the menu hierarchy and descriptions for editing channel parameters.

Wired Clone Mode Operation

Channel Parameter Editing Details

Details how to edit specific channel parameters like frequency and CTCSS/CDCSS.

Wired Clone Mode Description and Process

Explains the purpose and process of wired cloning between radios.

Cloning and Tuning Modes

Wired Clone Process Steps and Indicators

Outlines the step-by-step process and LED indications for wired cloning.

Manual Tune Mode Entry and Usage

Describes how to enter and use the Manual Tune Mode for radio adjustments.

Manual Tune Mode Parameters

TX and RX Tuning Item Structure Diagram

Illustrates the structure of tuning items for TX and RX sections with detailed parameters.

Manual Tune Mode Operations

Navigating and Adjusting Tuning Items

Explains how to navigate, select, and adjust tuning items and values.

Saving Tune Settings and Special Items

Details how to save adjustments and measures for specific tuning items.

Circuit Description Overview

General Realization Method

Provides a high-level overview of the TX, RX, and Power Supply sections' circuitry.

Circuit Description: TX/RX Signal Paths

TX Section Circuitry Details

Details the audio signal path and modulation process in the transmitter.

RX Section Circuitry Details

Describes the RF signal path from antenna to audio output in the receiver.

Circuit Description: Core Modules

Power Supply Section Circuitry

Explains how the 7.4V battery voltage is converted and distributed to various ICs.

PLL Circuit Block Diagram

Illustrates the Phase-Locked Loop circuit responsible for RF carrier generation.

Circuit Description: RF Amplification

VCO and Unlock Detector Functions

Explains the role of Voltage-Controlled Oscillators and the unlock detector.

TX RF Circuit Block Diagram

Shows the RF power amplifier stages and control circuits for transmission.

Circuit Description: RX and IF Stages

RX RF Circuit Diagram

Details the RX RF circuit, including LNA and mixer stages.

IF Processing and Audio Demodulation

Illustrates the IF processing stages and audio demodulation path.

Circuit Description: Control and Processing

MCU Control Circuit Diagram

Shows the block diagram of the MCU control circuit and its functions.

Signal Processing Circuit Overview

Explains the baseband processing for TX and RX audio signals.

Circuit Description: Baseband Processing

TX and RX Baseband Processing

Describes the modulation signal path from MIC to VCO.

Audio Power Amplification Stage

Explains how the audio signal is amplified to drive the speaker.

Circuit Description: Power and Interface

Power Supply Processing Diagram

Illustrates the power supply circuit and voltage distribution.

Keypad and LCD Diagram

Shows the layout and connection of the keypad and LCD display.

Circuit Description: Display System

Display Circuit Block Diagram

Depicts the components and connections of the radio's display system.

CPU Pin Assignments

CPU Pin Details (1-22)

Lists pin numbers, names, I/O types, and functions for the first 22 CPU pins.

CPU Pin Assignments

CPU Pin Details (23-57)

Details pin assignments, including ports, names, I/O, and functions for pins 23-57.

CPU Pin Assignments

CPU Pin Details (58-93)

Lists pin assignments for pins 58-93, covering communication and input/output functions.

CPU Pin Assignments

CPU Pin Details (94-100)

Details the remaining CPU pin assignments, including control and interface functions.

TC-580 Parts List 1

Component List (1-43)

Lists part numbers, descriptions, quantities, and reference designators for components 1-43.

TC-580 Parts List 1

Component List (44-90)

Continues the component list, detailing capacitors and resistors from 44-90.

TC-580 Parts List 1

Component List (91-137)

Lists capacitors and resistors from part number 91 to 137.

TC-580 Parts List 1

Component List (138-184)

Details capacitors and resistors from part number 138 to 184.

TC-580 Parts List 1

Component List (185-230)

Lists capacitors, resistors, inductors, and transistors from part number 185 to 230.

TC-580 Parts List 1

Component List (231-277)

Lists capacitors, resistors, and inductors from part number 231 to 277.

TC-580 Parts List 1

Component List (278-324)

Details resistors, capacitors, inductors, and crystals from part number 278 to 324.

TC-580 Parts List 1

Component List (325-371)

Lists resistors, capacitors, inductors, and transistors from part number 325 to 371.

TC-580 Parts List 1

Component List (372-418)

Details resistors, capacitors, inductors, transistors, and MOSFETs from part number 372 to 418.

TC-580 Parts List 1

Component List (419-465)

Lists resistors, capacitors, and inductors from part number 419 to 465.

TC-580 Parts List 1

Component List (466-512)

Details capacitors, tantalum capacitors, and resistors from part number 466 to 512.

TC-580 Parts List 1

Component List (513-559)

Lists resistors, capacitors, and inductors from part number 513 to 559.

TC-580 Parts List 1

Component List (560-612)

Details beads, resistors, capacitors, inductors, and transistors from part number 560 to 612.

TC-580 Parts List 1

Component List (613-672)

Lists transistors, diodes, ICs, operational amplifiers, and PLL chips from part number 613 to 672.

TC-580 Parts List 2

Component List (1-45)

Lists major external and internal components with part numbers and quantities.

Packing Contents

Standard Package Contents Diagram

Illustrates the items included in the product packaging.

Exploded View

Radio Component Breakdown Diagram

Shows an exploded view of the radio's internal and external components.

Adjustment Description

Required Test Instruments and Preparation

Lists necessary test equipment and preparation steps for board testing.

Adjustment Procedures

PCB and Radio Tuning Procedures

Details procedures for PCB tuning, manual radio tuning, and automatic tuning.

Wired Clone Procedure Steps

Explains the steps for performing a wired clone between two radios.

Tuning Items: TX Section

TX Parameters: Power and Tolerance

Lists and categorizes TX section parameters that can be tuned, including power and tolerance.

Tuning Items: TX Section

TX Parameters: CDCSS and CTCSS Deviation

Details tuning procedures for CDCSS and CTCSS deviation across different frequencies.

Tuning Items: TX Section

TX Parameters: DTMF, VOX, and Voltage

Explains tuning steps for DTMF deviation, TX Max Deviation, and VOX Gain levels.

Tuning Items: RX Section

RX Parameters: Sensitivity and Squelch

Details tuning for RX sensitivity, bandpass filter, and squelch open levels.

Tuning Items: RX Section

RX Parameters: Volume and Threshold

Explains tuning for squelch close levels, RX low voltage, and RX volume.

Appendix 1: Reference Values

TX/RX Tuning Value References

Provides reference tuning values for TX and RX items across wide and narrow bands.

Troubleshooting Flow Chart: TX Section

TX Power and Transmission Issues Diagnosis

Guides through troubleshooting low TX power, no sound, and no transmission.

Troubleshooting Flow Chart: RX Section

RX Signal and Speaker Issues Diagnosis

Guides through troubleshooting no signal, LED, speaker, and demodulator problems.

Troubleshooting Flow Chart: MCU Section

MCU and Display Issues Diagnosis

Guides troubleshooting for power-on alerts, LCD display, keys, and MCU operation.

Disassembly and Assembly for Repair

Chassis Disassembly Steps

Provides step-by-step instructions for disassembling the radio's chassis.

Disassembly and Assembly for Repair

PCB Disassembly Steps

Details the process for removing the main PCB and keypad PCB.

Assembly Procedures: PCB

Main and Keypad PCB Assembly

Explains how to reassemble the main PCB and keypad PCB onto the chassis.

Assembly Procedures: Chassis

Chassis Reassembly Steps

Guides through reassembling the chassis components, rear cover, and connectors.

Exploded View

Radio Component Breakdown Diagram

Shows an exploded view of the radio's internal and external components.

TC-580 Parts List 2

Component List (1-45)

Lists major external and internal components with part numbers and quantities.

Packing Contents

Standard Package Contents Diagram

Illustrates the items included in the product packaging.

PCB Layout - Top View

Component Placement Diagram (Top)

Shows the layout of components on the top side of the main PCB.

PCB Layout - Bottom View

Component Placement Diagram (Bottom)

Shows the layout of components on the bottom side of the main PCB.

Level Diagram

RX and TX Signal Level Diagrams

Illustrates signal levels at various stages in the RX and TX sections.

Block Diagram

Overall System Block Diagram

Presents a comprehensive block diagram of the radio's internal architecture.

Schematic Diagram - Part 1

Audio and Signal Processing Circuits

Shows schematic details for audio processing, keypad, and signal input/output circuits.

Schematic Diagram - Part 2

LED, Keypad, and Display Circuits

Illustrates the schematic for LED indicators, keypad interface, and LCD connections.

Schematic Diagram - Part 3

MCU and Power Supply Circuits

Details the MCU connections, power supply distribution, and key component interfaces.

Schematic Diagram - Part 4

RF and VCO Circuits

Shows schematic details for the RF amplifier, VCO, and related tuning circuits.

Schematic Diagram - Part 5

PLL and Power Supply Circuits

Illustrates the PLL system, power supply regulators, and voltage distribution.

Specifications

General Specifications

Lists general radio specifications like frequency range, capacity, and operating conditions.

Receiver and Transmitter Performance

Details specific performance metrics for the receiver and transmitter sections.