FlexRadio Systems FLEX-1500 Service Manual Download Page 2

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Revision 1.0

Contents

Introduction ..... 3

Theory of Operation ..

Alignment, Test and Calibration.... 11

Troubleshooting and Diagnostics ....... 14

Assembly and Disassembly....... 15

Fuse Replacement... 16

Appendix “A” Schematic, PTRX (Transceiver) Board

Appendix “B” Schematic, PPA05 (RFPA) Board

Appendix “C” Boards, Top View.

Appendix “D” Test Points and Bus Access.

Appendix “E” Test Fixtures.

Appendix “F” Parts List.

Summary of Contents for FLEX-1500

Page 1: ...Revision 1 0 1 Copyright FlexRadio Systems 2010 2011 FlexRadio Systems FLEX 1500 Software Defined Radio Service Manual Author Graham Haddock KE9H...

Page 2: ...ent Test and Calibration 11 Troubleshooting and Diagnostics 14 Assembly and Disassembly 15 Fuse Replacement 16 Appendix A Schematic PTRX Transceiver Board Appendix B Schematic PPA05 RFPA Board Appendi...

Page 3: ...ware defined radio including the sophisticated high performance filters panoramic spectrum displays and computer based graphic interface characteristic of a software defined radio This service manual...

Page 4: ...ex 1500 radio and the host computer is via a USB connection capable of USB 1 1 or higher level USB operation The protocol is USB Full Speed or 12 Megabits per second data transfer rate Power Systems a...

Page 5: ...Revision 1 0 5 Copyright FlexRadio Systems 2010 2011...

Page 6: ...Revision 1 0 6 Copyright FlexRadio Systems 2010 2011...

Page 7: ...xWire port audio amplifier as well as audio and baseband routing CODEC clock generation data conversion gain and level controls for the radio All of the above must be translated from local hardware an...

Page 8: ...MHz or 38 4 MHz reference input The 20 MHz signal comes from doubling the external 10 MHz input and the 38 4 MHz is generated by an onboard temperature compensated crystal oscillator The TPIC6B595 Rel...

Page 9: ...analog I and Q signals output from the CODEC are filtered in a 26 kHz low pass filter to remove wideband digital noise then sent to the QSE for up mixing Communications In the receive configuration d...

Page 10: ...ly in the Mono configuration In stereo each of the two amplifiers are carrying the appropriate left or right channel information and driving a low power amplifier suitable for headphones or high imped...

Page 11: ...es not have to be connected to the TRX board since it is all DC settings and you do not want any RF drive present With just the PA by itself on the workbench Plug in 13 8 Volts into the normal power c...

Page 12: ...nsmitter If not detected by the host computer the appropriate test button will be disabled and grayed out Required test equipment Host computer with PowerSDR version 2 0 or later with appropriate driv...

Page 13: ...he power connector on the RFPA Turn on the power switch on the PTRX board The Blue LED should light within two seconds Open PowerSDR 2 0 Press Start Note that the program is running and a moving Panad...

Page 14: ...hift P The blue light in the center of the power on switch is controlled by the CPU This light will only light if the CPU has downloaded valid firmware from the EEPROM and has completed initialization...

Page 15: ...slide both cards toward the rear panel the one with all the BNCs until the connected pair of cards are clear of the outer case The two cards may be separated Re assembly Reconnect the cards with the t...

Page 16: ...nternal short excessive power drain or application of power with reversed polarity to the radio Replace with LittleFuse 297003 or equivalent housing color purple 3 Ampere To replace the fuse follow th...

Page 17: ...Revision 1 0 Copyright FlexRadio Systems 2010 2011 Appendix A Schematic PTRX Transceiver Board...

Page 18: ...2C BUS Switch Control I2C EXPANDER A D D A 120 SPI BUS Key In Clocks TLV320AIC33 TAS1020B 74LVC74D SN65LVDS34D 2 ea PCA9555 CVT25 38 4 SN74LVC1G04 THS4520 0 88 1 6 MHz 0 49 0 88 MHz PTT In LED Version...

Page 19: ...TX COM FRONT END 2 Ground 1 SPI5 LOAD 3 SPI5 CLK 5 SPI5 DATA 4 12V 7 5 9 RF 10 Ground 8 5 Flat Cable Assignments 6 Ground R2 C4 C6 J1G 1 J2G 1 R1 D1 D2 3 2 1 6 4 T1 C1 R7 C16 X1 C13 C15 C7 C8 RFTP1 1...

Page 20: ...9 1 6 2 3 MHz Band 1 37 6 56 0 MHz Band 12 Bypass Band 6 5 2 7 7 MHz Band 10 0 88 1 6 MHz Band 3 17 0 25 3 MHz Band 7 3 5 5 2 MHz Band 11 0 49 0 88 MHz Copyright FlexRadio Systems 2009 2010 5 1 3 6 4...

Page 21: ...Band 9 1 6 2 3 MHz Band 1 37 6 56 0 MHz Band 12 Bypass Band 6 5 2 7 7 MHz Band 10 0 88 1 6 MHz Band 3 17 0 25 3 MHz Band 7 3 5 5 2 MHz Band 11 0 49 0 88 MHz Copyright FlexRadio Systems 2009 2010 5 1 3...

Page 22: ...MHz Band 1 37 6 56 0 MHz Band 12 Bypass Band 6 5 2 7 7 MHz Band 10 0 88 1 6 MHz Band 3 17 0 25 3 MHz Band 7 3 5 5 2 MHz Band 11 0 49 0 88 MHz 5 1 3 6 4 2 CTRL VDD RFC RF1 RF2 GND K17 PE4259 5 1 3 6 4...

Page 23: ...C4G 2 R11 C146 R13 R15 C138 1G 1 B 2 1C3 3 1C2 4 1C1 5 1C0 6 1Y 7 2Y 9 2C0 10 2C1 11 2C2 12 2C3 13 A 14 2G 15 IC5 8 16 GND VCC IC5G 2 5 1 3 6 4 2 CTRL VDD RFC RF1 RF2 GND K26 PE4259 C147 3 2 1 6 4 T3...

Page 24: ...exRadio Systems 2009 2010 C152 C164 C169 R31 R35 R29 R25 C157 C150 R32 R33 R26 R27 C162 C166 C154 C156 C151 C168 C163 C148 C158 C161 C171 C153 C165 C155 C167 L48 L50 L52 L53 VIN 2 VOUT 3 VIN 11 VOUT 1...

Page 25: ...9 HPROUT 23 HPRCOM 22 MONO_LOP 27 MONO_LOM 28 LEFT_LOP 29 LEFT_LOM 30 RIGHT_LOP 31 RIGHT_LOM 32 AVSS_ADC 15 MFP3 48 MFP2 47 MFP1 46 MFP0 45 SELECT 43 SDA 2 SCL 1 RESET 33 GPIO1 35 GPIO2 34 IO DVSS 42...

Page 26: ...1 8 P1 7 31 P1 6 30 P1 5 29 P1 4 27 P1 3 26 P1 2 25 P1 1 24 P1 0 23 CSCHNE 32 CRESET 34 CSYNC 35 CDATI 36 CDATO 38 CSCLK 37 MCLKO1 39 MCLKO2 40 RESET 41 VHEN 42 SDA 43 SCL 44 IC15 GND 4 D 3 D 2 VCC 1...

Page 27: ...TAL_OUT 10 IOUT 21 IOUT 20 DAC_RSET 24 SYNC_IN 44 OSK 46 PWRDWNCTL 35 RESET 36 CLKMODESELCT 11 LOOP_FILTER 12 DACBP 23 IOSYNC 37 SDO 38 CS 39 SCLK 40 SDIO 41 DVDD 2 DVDD 34 DGND 3 DGND 33 DGND 47 DGND...

Page 28: ...68p LO QUADRATURE GENERATOR 120 MHz Low Pass Filter Johnson Counter Copyright FlexRadio Systems 2009 2010 C250 CLR 1 D 2 CLK 3 PRE 4 Q 5 Q 6 IC19A CLR 13 D 12 CLK 11 PRE 10 Q 9 Q 8 IC19B 7 14 IC19P G...

Page 29: ...17 I O1 5 18 I O1 6 19 I O1 7 20 SCL 22 SDA 23 A0 21 A1 2 A2 3 INT 1 VSS 12 VDD 24 IC23 I O0 0 4 I O0 1 5 I O0 2 6 I O0 3 7 I O0 4 8 I O0 5 9 I O0 6 10 I O0 7 11 I O1 0 13 I O1 1 14 I O1 2 15 I O1 3...

Page 30: ...yright FlexRadio Systems 2009 2010 1 5 SW1 C267 C266 IN1 6 FB NC 15 EN 5 OUT1 13 PG 16 OUT2 14 IN2 7 GND 1 GND 2 GND 3 GND 20 GND 19 GND 12 GND 11 GND 10 PAD PAD GND 9 IC25 R65 J8 2 J8 3 J8 4 J8 5 J8...

Page 31: ...I2C SCL 7 I2C SDA 8 13 8 Volts Out 9 LINE OUT FlexWire Assignments SPI DDS BRIDGE ASSIGNMENTS 1 USB CPU I2C MASTER ONLY 2 CODEC 0011 0000 3 EEPROM 1010 0000 4 I2C MUX 1110 0000 5 EXPANDER 0 0100 0000...

Page 32: ...Revision 1 0 Copyright FlexRadio Systems 2010 2011 Appendix B Schematic PPA05 RFPA Board...

Page 33: ...r PA Bias control T R control FLEX 1500 SPI BUS 5V ANT TO FLEX 1500 MAIN BOARD 13 8 V Input Filtering Bias Bias Switch Filter Bank RD16HHF1 RD00HVF1 Relay Switched Version 2010 MAR 05 Bias Control TPI...

Page 34: ...3 24k GND 2 00k 1u 10n 10u 1u 1u 1u 1u 1u 1u GND 0 NP NP NP GND Copyright FlexRadio Systems 2009 ANT RF POWER AMPLIFIER J1G 1 D S G Q1 D S G Q3G 1 12 1 K15 3 5 4 10 8 9 1 2 3 5 4 T1 R1 R3 C20 R2 R5 R...

Page 35: ...GND GND GND GND GND GND GND GND 1u GND 1u GND 1u GND 1u GND 1u GND 1u GND 1u GND 1u GND 169n 3 6p 24p GND Copyright FlexRadio Systems 2009 HIGH FREQUENCY LPF BANK 12 1 K1 3 5 4 10 8 9 12 1 K2 3 5 4 10...

Page 36: ...ND GND GND GND GND 12V 12V 12V 12V 12V 12V 300p GND 10n 10n 10n 10n 10n 10n GND GND GND GND GND GND 1u GND 1u GND 1u GND 1u GND 1u GND 1u GND 10u 8 2u Copyright FlexRadio Systems 2009 LOW FREQUENCY LP...

Page 37: ...ts IC1 2 Ground 1 SPI5 LOAD 3 SPI5 CLK 5 SPI5 DATA 4 12V 7 5 9 RF 10 Ground 8 5 Flat Cable Assignments 6 Ground D0 4 D1 5 D2 6 D3 7 D4 14 D5 15 D6 16 D7 17 G 9 RCK 12 SRCLR 8 SRCK 13 SERIN 3 SEROUT 18...

Page 38: ...Revision 1 0 Copyright FlexRadio Systems 2010 2011 Appendix C PC Board Component View...

Page 39: ......

Page 40: ...1 2 3 1 2 3 FlexRadio Systems Copr 2010...

Page 41: ...Revision 1 0 Copyright FlexRadio Systems 2010 2011 Appendix D Test Points...

Page 42: ...FlexRadio Systems Copr 2010 1...

Page 43: ...1 2 3 1 2 3 FlexRadio Systems Copr 2010...

Page 44: ...Revision 1 0 Copyright FlexRadio Systems 2010 2011 Appendix E Test Fixture...

Page 45: ...R2 R3 PTT OUT PTT IN GND GND AUDIO LINE IN AUDIO LINE OUT I2C SCL I2C SDA 12 VOLTS 1 2 3 4 5 6 7 8 9 N C N C N C FLEXWIRE DB 9 CONNECTOR TIP TIP RING RING SLEEVE SLEEVE PHONES MICROPHONE RJ45 KEY N C...

Page 46: ...RX XVTX C at 70 dBm through splitter 3 PowerMaster verifies RF power output USB CONTROLLED SIGNAL GENERATOR 10 MHz XVRX XVTX C ANT 10 MHz RF Connections FLEX 1500 UNDER TEST XVTX C XVRX BNC to BNC Cab...

Page 47: ...1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 SPI5 LOAD GND GND GND SPI5 CLK SPI5 DATA 12 Volts RF 50 Ohm Coax 5 Volts 5 Volts GND BLACK BLACK RED GREEN BLUE WHITE ORANGE ORANGE ALL FEMALE PINS ALL MALE...

Page 48: ...Revision 1 0 Copyright FlexRadio Systems 2010 2011 Appendix F Bill of Materials...

Page 49: ...05 SMD C 0167 C023 CAP CER 82PF 50V NP0 0805 SMD C 0167 C024 CAP CER 51PF 50V 5 C0G 0805 SMD C 0352 C025 CAP CER 91PF 100V 5 C0G 0805 SMD C 0243 C026 CAP CER 130PF 100V 5 C0G 0805 SMD C 0221 C027 CAP...

Page 50: ...10 16V X7R 0402 SMD C 0109 C076 CAP CER 360pF 50V 5 COG 0805 SMD C 0269 C077 CAP 560PF 50V CERM CHIP COG 0805 SMD C 0178 C078 CAP 560PF 50V CERM CHIP COG 0805 SMD C 0178 C079 CAP CER 360pF 50V 5 COG...

Page 51: ...0402 SMD C 0109 C130 CAP CER 10000PF 10 16V X7R 0402 SMD C 0109 C131 CAP CER 10000PF 10 16V X7R 0402 SMD C 0109 C132 CAP CER 10000PF 10 16V X7R 0402 SMD C 0109 C133 CAP CER 27PF 50V 5 C0G 0402 SMD C 0...

Page 52: ...C 0192 C185 CAP CER 1UF 16V 10 X7R 0402 SMD C 0102 C186 CAP CER 10UF 25V X5R 1206 SMD C 0192 C187 CAP CER 1UF 16V 10 X7R 0402 SMD C 0102 C188 CAP CER 10UF 25V X5R 1206 SMD C 0192 C189 CAP CER 1UF 16V...

Page 53: ...0 CAP CER 1UF 16V 10 X7R 0402 SMD C 0102 C241 CAP CER 1UF 16V 10 X7R 0402 SMD C 0102 C242 CAP CER 1UF 16V 10 X7R 0402 SMD C 0102 C244 CAP CER 1UF 16V 10 X7R 0402 SMD C 0102 C246 CAP CER 1UF 16V 10 X7R...

Page 54: ...LINEAR REG TPS79318DBVR U 0052 IC18 IC DDS DAC 14BIT 1 8V AD9951YSVZ U 0197 IC19 IC DUAL D TYPE FLIP FLOP 74LVC74AD 118 U 0210 IC20 IC DIFF RECEIVER DUAL HS SN65LVDS34D U 0211 IC21 IC I2C MUX 2CH PCA...

Page 55: ...0 COIL 68UH UNSHIELDED 1812 SMD L 0231 L11 COIL 68UH UNSHIELDED 1812 SMD L 0231 L12 COIL 68UH UNSHIELDED 1812 SMD L 0231 L13 COIL 68UH UNSHIELDED 1812 SMD L 0231 L14 INDUCTOR FIXED 1 2uH 5 1812 SMD L...

Page 56: ...IP 1267OHMS 100MA 0805 SMD FB 0013 L66 IND FIXED 100nH 5 0603 SMD L 0242 L67 IND FIXED 120nH 5 0603 SMD L 0241 L68 IND FIXED 100nH 5 0603 SMD L 0242 L69 FERRITE 200MA 1000 OHM 0603 SMD FB 0009 L70 FER...

Page 57: ...06 R47 RES 2 2K OHM 1 10W 5 0603 SMD R 0106 R48 RES 2 2K OHM 1 10W 5 0603 SMD R 0106 R49 RES 3 09K OHM 1 10W 1 0603 SMD R 0279 R50 RES 1 47K OHM 1 10W 1 0603 SMD R 0247 R51 RES 24 9 OHM 1 10W 1 0603 S...

Page 58: ...ER FILTER BOARD B 0051 ASSEMBLY Sch FlexRadio Ref Description Detail P N C001 CAP CER 18PF 50V NP0 0805 SMD C 0225 C002 CAP 68PF 50V CERM CHIP COG 0805 SMD C 0171 C003 CAP 68PF 50V CERM CHIP COG 0805...

Page 59: ...MD C 0117 C051 CAP CER 1UF 16V 10 X7R 0402 SMD C 0102 C052 CAP 1UF 50V CERAMIC X7R 0805 SMD C 0408 C053 CAP 1UF 50V CERAMIC X7R 0805 SMD C 0408 C054 CAP CER 10000PF 100V X7R 20 0805 SMD C 0402 C055 CA...

Page 60: ...A 100V 1SS400T1G D 0023 D3 DIODE SCHOTTKY 100MA 70V BAS70 00 V GS08 D 0024 D4 DIODE GEN PURPOSE 50V 1A S1A D 0025 F1 FUSE AUTO 3A 32VDC MINI BLADE TERMINAL F 0016 F1 FUSEHOLDER MINI AUTO 025 TH H 0119...

Page 61: ...ET PWR P CHAN 1A 20V NTR1P02T1G Q 0015 R01 RES 10 0 OHM 1 10W 1 0603 SMD R 0113 R02 RES 1 00 OHM 1 10W 1 0603 SMD R 0272 R03 RES 1 00 OHM 1 10W 1 0603 SMD R 0272 R04 RES 3 24K OHM 1 10W 1 0603 SMD R 0...

Page 62: ...06 CASE H 0296 PANEL FLEX 1500 FRONT FRONT PANEL H 0297 PANEL FLEX 1500 REAR REAR PANEL H 0298 HEAT SPREADER HEAT SPREADER H 0301 STANDOFF 1 4 X 3 16 X 4 40 AL H 0305 SCREW 4 40 x 3 16 SS PAN HEAD PH...

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