FlexRadio Systems FLEX-1500 Service Manual
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FlexRadio Systems FLEX-1500 Service Manual

Software defined radio
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FlexRadio Systems
FLEX-1500
Software Defined Radio
Service Manual
Author: Graham Haddock, KE9H
1
Revision 1.0
Copyright FlexRadio Systems, 2010-2011

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  • Page 1 FlexRadio Systems FLEX-1500 Software Defined Radio Service Manual Author: Graham Haddock, KE9H Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 2 ... 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. Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 3 Introduction The FLEX-1500™ QRP Software Defined Radio is an entry level QRP radio and is also suited to be the ideal IF deck for VHF-Microwave operation. It provides all of the advantages of a software defined radio, including the sophisticated high performance filters, panoramic spectrum displays and computer based graphic interface characteristic of a software defined radio.

  • Page 4: Theory Of Operation

    USB for both control and streaming baseband data with the host CPU running the PowerSDR software. The CPU in the FLEX-1500 has control of all switching, signal routing, frequency generation via the DDS, FlexWire port, audio amplifier, as well as audio and baseband routing, CODEC clock generation, data conversion, gain and level controls for the radio.
  • Page 5 Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 6 Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 7 Upon power up, the CPU will look for the presence of a properly programmed EEPROM, load this code, begin execution, and register with the host computer as a FLEX-1500 device. In the absence of the EEPROM, or lack of correctly identified firmware, the CPU will execute from internal ROM, and identify itself to the host computer as a “TI DFU...
  • Page 8 The incoming RF signals may be received via the antenna connector on the RFPA board, the transverter receive connector, or the transverter common connector. These signals are routed via the appropriate bandpass filter, then either directly to the preamp, or through a Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 9 CODEC, representing the received pass band, are transferred using the I2S protocol to the Streaming USB controller. This controller then transfers this information via the USB protocol to the host computer. Transmit test signals in a digital I and Q format are Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 10 “H-Bridge” speaker amplifier. In this mode the speaker must be wired to bridge the amplifier output (connect to tip and ring on stereo speaker plug) with no connection to ground. Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 11 All other alignment, test and calibration will occur under computer control using production test software built into PowerSDR. Bias Adjustment FLEX-1500 RFPA (PPA05) Bias settings Power Supply Setup: Adjust Power Supply to 13.8 Volts Output Voltage. Adjust Power Supply maximum current limit to 2.5 Amperes. To do this, place a short across the output terminals of the power supply and adjust the Output Current knob to read 2.5 Amps on the current meter.
  • Page 12 “grayed out.” Required test equipment: Host computer with PowerSDR version 2.0 or later with appropriate drivers for the FLEX-1500, FLEX-1599 signal generator, and PowerMaster RF power meter installed. USB Signal Generator, FlexRadio Systems model FLEX-1599. PowerMaster RF Power Meter model PM003 with serial interface, or USB serial adaptor as appropriate to connect to the host computer.
  • Page 13 If all tests are passed, as indicated by all green buttons, then radio level testing of the assembled radio is complete. Close Production Test window, stop PowerSDR, close PowerSDR, turn off power switch on PTRX and remove cables from Radio Assembly. Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 14 6 dB inside the band pass, so signal tracing with an RF signal generator and level meter or spectrum analyzer is very practical. Excessive filter loss is usually associated with an incorrect inductance value, or shorted turns in one or more filter inductors. Revision 1.0 Copyright FlexRadio Systems, 2010-2011...

  • Page 15: Assembly And Disassembly

    Check that the two transistor mounting screws in the heat spreader are visible and roughly centered in the screw clearance relief holes in the bottom of the case. Install the four feet using the number 1 Phillips screwdriver. Revision 1.0 Copyright FlexRadio Systems, 2010-2011...

  • Page 16: Fuse Replacement

    DB-9 connector. Fuse Replacement The Flex-1500 contains a 3 Ampere, standard automotive type AutoFuse Mini fuse to protect the radio in the event of an internal 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.
  • Page 17 Appendix "A" Schematic, PTRX (Transceiver) Board Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 18 System Block Diagram To PA Band Pass Filter Bank FLEX-1500 TRX BOARD Bypass Version 2010 APR 05 XV-RX 0.49 - 0.88 MHz 0.88 - 1.6 MHz 4 to 1 PRE-AMP TLV320AIC33 3 to 1 Switch CODEC Mike In 1.6 - 2.3 MHz...
  • Page 19 9.) RF 10.) Ground SPI5-DATA/8 GBLC03C FRTENDA/11 FRTENDB/11 PE42641 RFTP1 10MW TX/COM J2G$1 BPFI/2 SD-73100 GBLC03C 3.32k 3.32k +3.3V BITE/5 10 MHz Input BAS70-00-V-GS08 74AHC1G04DBV 20MHZ/9 TC4-1T BAS70-00-V-GS08 +3.3V FRONT END Copyright FlexRadio Systems 2009, 2010 10 MHz Doubler IC2P...
  • Page 20 Band 8 - 2.3 - 3.5 MHz Band 2 - 25.3 - 37.6 MHz Band 5 - 7.7 - 11.4 MHz Copyright FlexRadio Systems 2009, 2010 Band 9 - 1.6 - 2.3 MHz Physical Position on PCB: Band 1 - 37.6 - 56.0 MHz Band 12 - Bypass Band 6 - 5.2 -...
  • Page 21 Band 8 - 2.3 - 3.5 MHz Band 2 - 25.3 - 37.6 MHz Band 5 - 7.7 - 11.4 MHz Copyright FlexRadio Systems 2009, 2010 Band 9 - 1.6 - 2.3 MHz Physical Position on PCB: Band 1 - 37.6 - 56.0 MHz Band 12 - Bypass Band 6 - 5.2 -...
  • Page 22 Band 8 - 2.3 - 3.5 MHz Band 2 - 25.3 - 37.6 MHz Band 5 - 7.7 - 11.4 MHz Copyright FlexRadio Systems 2009, 2010 Band 9 - 1.6 - 2.3 MHz Physical Position on PCB: Band 1 - 37.6 - 56.0 MHz Band 12 - Bypass Band 6 - 5.2 -...
  • Page 23 PE42641 C138 74CBT3253PW TXA/11 LO-I/10 +3.3V LO-Q/10 TXB/11 PE4259 QSE-QP/6 ATN/11 QSE-IM/6 RF2 GND CTRL QSE-QM/6 TC1-1T QSE-IP/6 +3.3V BITE/1 1.25 V ~QSE/11 74CBT3253PW GEN/11 C143 +3.3V C144 QSD / QSE C146 C147 Copyright FlexRadio Systems 2009, 2010 IC4G$2 IC5G$2...
  • Page 24 12.7 C173 C174 .15u .15u QSE-IP/5 HPLM/7 12.7 12.7 BASEBAND PROCESSING To QSE From AIC33 HP Out QSE-QM/5 HPRP/7 Copyright FlexRadio Systems 2009, 2010 12.7 12.7 C177 C178 .15u .15u QSE-QP/5 HPRM/7 12.7 12.7 28 kHz LPF 67 Hz HPF...
  • Page 25 330u SPEAKER ST/MO FILT HEADPHONES MICROPHONE C204 C205 I-SDA/11 I-SCL/11 FDV303 ~CRESET/8 R500 FWLO/12 FlexWire Line In/Out FWLI/12 J4-1 J4-2 J4-3 650W J4-4 J4-5 CODEC J4-6 J4-7 MPTT/8 J4-8 Copyright FlexRadio Systems 2009, 2010 C502 C207 C208 650W C209 C210...
  • Page 26 DVSS3 DVDD3 AVSS AVDD 7408PW 5V-USB/12 C219 C220 C221 C222 C297 1SS400 ~MRESET/12 C223 ~DOT/12 IC28 TPS79333-DBV ~DASH/12 1267W +3.3V C224 C225 FW-PTT-IN/11 MPTT/7 C~INT/11 +3.3V STREAMING USB CONTROLLER Copyright FlexRadio Systems 2009, 2010 IC13D C226 C227 IC13P IC14P 7408PW...
  • Page 27 C246 CRYSTAL_OUT IOSYNC SYNC_IN C247 C248 CLKMODESELCT C249 LOOP_FILTER PWRDWNCTL AGND AGND 20MHZ/1 SCLK AGND SDIO AGND AGND DGND AGND DRESET/8 DGND AGND DGND AGND DGND AGND DGND AGND AGND AD9951EP REF-SEL/11 SPI~CSDDS/8 SPI-CLK/8 Copyright FlexRadio Systems 2009, 2010 SPI-DATA/8...
  • Page 28 IC20 LO-I/5 C251 C252 C253 C254 24.9 100n 120n 100n DDS/9 C255 C256 C257 C258 74LVC74D IC19B TC4-1T LO-Q/5 24.9 120 MHz Low Pass Filter SN65LVDS34D 74LVC74D Johnson Counter +3.3V LO QUADRATURE GENERATOR C259 Copyright FlexRadio Systems 2009, 2010 IC19P...
  • Page 29 ~QSD/5 ~QSE/5 I/O0.1 I/O0.2 REF-SEL/9 I/O0.3 GEN/5 TXB/5 I/O0.4 I/O0.5 TXA/5 BAND07/3 I/O0.6 I/O0.7 BAND11/4 BAND10/4 I/O1.0 I/O1.1 FILTER AND SWITCH CONTROL BAND01/2 I/O1.2 I/O1.3 BAND12/4 BAND03/2 I/O1.4 Copyright FlexRadio Systems 2009, 2010 BAND09/4 I/O1.5 I/O1.6 BAND06/3 ATN/5 I/O1.7 PCA9555PW...
  • Page 30 J8-G GROUNDS POWER C271 C274 FW-PTT-IN/11 FWLO/7 GND1 GND2 +3.3V +3.3 GND3 GND4 +3.3V SPI BUS (3.3 V) I2C BUS I/O AND POWER I/O AND POWER SPI-CLK/9 C-SCL/11 C276 SPI-DATA/9 C-SDA/11 Copyright FlexRadio Systems 2009, 2010 SPI~CSDDS/9 IC24G$3 GND6 GND5...
  • Page 31 5.) EXPANDER 0 - 0100 0000 DATA GND 6.) EXPANDER 1 - 0100 0010 NOTE: Jumper SCA to GND to remove EEPROM from address space to force radio to enumerate as TI-DFU device. PORT AND CONNECTOR DEFINITIONS Copyright FlexRadio Systems 2009, 2010...
  • Page 32 Appendix "B" Schematic, PPA05 (RFPA) Board Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 33 Switch Bias Control Bias control, T/R control Filter Bank 13.8 V Input 13.8 V DC Power TPIC6B595 Filtering SPI Relay Driver FLEX-1500 Reg. 5 Watt Linear PA Version 2010 MAR 05 Reg. TO FLEX 1500 MAIN BOARD SPI BUS (5V)
  • Page 34 +12V +12V 1267W 160W C102 100u 470u XFMR_0.5BINOC 240p LPF-IN/2 RD00HHS1 RD16HHF1 Q3G$1 LPF-OUT/2 C100 ~ 2.6 V ~ 4.9 V J1G$1 SD-73100 +12V GBLC03C 2.00k 1267W XMIT/4 TX2SA-12V RF POWER AMPLIFIER RF-I/O/4 Copyright FlexRadio Systems 2009 XMIT/4 3.24k 10.0k...
  • Page 35 307n 307n TX2SA-12V TX2SA-12V 150p 220p 180p 20M/4 HIGH FREQUENCY LPF BANK All coils this page are Physical order on board is: 60/40 M Copyright FlexRadio Systems 2009 10 M CoilCraft MaxiSpring 80 M 17/15 M 160 M 30/20 M...
  • Page 36 8.2u TX2SA-12V TX2SA-12V 1.2n 2.2n 160M/4 LOW FREQUENCY LPF BANK All Coils this page are Physical order on board is: 60/40 M 10 M Copyright FlexRadio Systems 2009 CoilCraft 1812 CS Series 80 M 17/15 M 160 M 30/20 M...
  • Page 37 10.) Ground DATA LOAD TPIC6B595 +12V/1 1SS400T1G Switched 6 Volts L78L06_D 15M/2 4.7k 160M/3 ~SRCLR 20M/2 Vout SRCK 6M/2 NTR1P02T1 SERIN 80M/3 10M/2 SEROUT 40M/3 XMIT/1 Test Points XMIT GND1 GND2 INTERCONNECT AND POWER GND3 GND4 Copyright FlexRadio Systems 2009...
  • Page 38 Appendix "C" PC Board Component View Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 40 1 2 3...
  • Page 41 Appendix "D" Test Points Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 42 TEST POINTS 3.3 Volts I2C Bus SPI Bus (3.3 V) I2S Bus 1.8 Volts 3.3 Volts (CPU Only) 5.0 Volts...
  • Page 43 +5Volts "XMIT" Test Point SPI Bus (5 Volt) +6 Volts +12 Volts (Keyed) Driver Bias Adjust Driver current PA Bias Adjust metering...
  • Page 44 Appendix "E" Test Fixture Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 45 White of Blue MIKE Orange MIKE PTT N.C. N.C. N.C. NOTES: FLEX-1500 TEST FIXTURE 1. FlexWire Line-Out drives Microphone In Audio And Switching Test Cable 2. Speaker/Phones drive FlexWire Line-In 3. PTT-OUT from FlexWire drives FW-PTT-IN, MPTT, DOT, & DASH...
  • Page 46 USB to Host Computer USB to Host Computer NOTES: 1. DDS SigGen drives 10 MHz input at 0 dBm FLEX-1500 TEST FIXTURE 2. DDS SigGen drives XVRX, XVTX/C at -70 dBm through splitter RF Connections 3. PowerMaster verifies RF power output...
  • Page 47 ALL FEMALE PINS ALL MALE PINS WHITE SPI5-DATA BLACK ORANGE +5 Volts CONNECTS TO BOTTOM CONNECTS TO TOP OF TRX BOARD ORANGE +5 Volts OF RFPA BOARD RF - 50 Ohm Coax FLEX-1500 TEST FIXTURE Board to Board Jumper Cable...
  • Page 48 Appendix "F" Bill of Materials Revision 1.0 Copyright FlexRadio Systems, 2010-2011...
  • Page 49 PTRX - FLEX1500 RECEIVER / EXCITER BOARD -- B-0050 ASSEMBLY Sch. FlexRadio Ref. Description Detail ---- -------------------------- -------- ------ C001 CAP CER .1UF 16V 10% X7R 0402 SMD C-0102 C002 CAP CER 1UF 25V X5R 0805 SMD C-0117 C003 CAP CER .1UF 16V 10% X7R 0402 SMD C-0102 C004...
  • Page 50 C050 CAP 180PF 50V CERM CHIP 0805 SMD C-0224 C051 CAP 180PF 50V CERM CHIP 0805 SMD C-0224 C052 CAP CER 110PF 100V 5% C0G 0805 SMD C-0344 C053 CAP 220PF 50V CERM CHIP 0805 SMD C-0231 C054 CAP CERM 300pF 50V 5% COG 0805 SMD C-0268 C055...
  • Page 51 C105 CAP CER 1300PF 50V 5% C0G 0805 SMD C-0348 C106 CAP CER 910PF 50V 5% C0G 0805 SMD C-0242 C107 CAP CER 2000PF 50V 5% C0G 0805 SMD C-0347 C108 CAP CER 3000PF 50V 5% C0G 0805 SMD C-0181 C109 CAP CER 2000PF 50V 5% C0G 0805 SMD...
  • Page 52 C160 CAP CER 47PF 50V 5% C0G 0402 SMD C-0158 C161 CAP TANT 330UF 6.3V 20% C-0160 C162 CAP CER 2700PF 50V 5% C0G 0805 SMD C-0229 C163 CAP CER .1UF 16V 10% X7R 0402 SMD C-0102 C164 CAP CER 4700PF 50V 5% C0G 0805 SMD C-0166 C165...
  • Page 53 C215 CAP CER 100PF 50V NP0 0603 SMD C-0398 C216 CAP CER 1000PF 50V NPO 0603 SMD C-0399 C217 CAP CER 47PF 50V NP0 0805 SMD C-0031 C218 CAP CER 47PF 50V NP0 0805 SMD C-0031 C219 CAP CER .1UF 16V 10% X7R 0402 SMD C-0102 C220...
  • Page 54 C275 CAP .1UF 50V CERAMIC X7R 0805 SMD C-0408 C276 CAP CER .1UF 16V 10% X7R 0402 SMD C-0102 C500 CAP CER 270PF 50V 5% COG 0603 SMD C-0432 C501 CAP CERM .1UF 16V 0603 SMD C-0135 DIODE 3.3V TVS ARRAY GBLC03C D-0020 DIODE 3.3V TVS ARRAY...
  • Page 55 SPDT RF SWITCH MOSFET PE4259 SMD K-0007 SPDT RF SWITCH MOSFET PE4259 SMD K-0007 SPDT RF SWITCH MOSFET PE4259 SMD K-0007 SPDT RF SWITCH MOSFET PE4259 SMD K-0007 SPDT RF SWITCH MOSFET PE4259 SMD K-0007 SPDT RF SWITCH MOSFET PE4259 SMD K-0007 SPDT RF SWITCH MOSFET PE4259 SMD...
  • Page 56 FERRITE 200MA 1000 OHM 0603 SMD FB-0009 FERRITE 200MA 1000 OHM 0603 SMD FB-0009 CONN SOCKET STRIP 10POS J-0171 PCB FLEX-1500 PTRX BOARD PC-0048 TRANSISTOR MOSFET N-CH 25V FDV303N Q-0008 TRANSISTOR MOSFET N-CH 25V FDV303N Q-0008 MOSFET N-CH 60V 200MA...
  • Page 57 RES 1.20K OHM 1/10W 1% 0603 SMD R-0111 RES 3.32K OHM 1/10W 1% 0603 SMD R-0109 RES 100 OHM 1/10W 1% 0603 SMD R-0186 RES 1.60K OHM 1/10W 1% 0603 SMD R-0295 RES 120 OHM 1/10W 1% 0603 SMD R-0284 RES 120 OHM 1/10W 1% 0603 SMD R-0284...
  • Page 58 RES 0.0 OHM 1/10W 5% 0603 SMD R-0128 RES 0.0 OHM 1/10W 5% 0603 SMD R-0128 RES 200 OHM 1/10W 1% 0603 SMD R-0235 RES 3.90K OHM 1/10W 1% 0603 SMD R-0208 RES 61.9 OHM 1/10W 1% 0603 SMD R-0244 RES 61.9 OHM 1/10W 1% 0603 SMD R-0244...
  • Page 59 C025 CAP 120PF 50V C0G CERM CHIP 0805 SMD C-0219 C026 CAP 220PF 50V CERM CHIP 0805 SMD C-0231 C027 CAP CER 82PF 50V NP0 0805 SMD C-0167 C028 CAP CER 150PF 100V 5% C0G 0805 SMD C-0218 C029 CAP 220PF 50V CERM CHIP 0805 SMD C-0231 C030...
  • Page 60 C080 CAP .1UF 50V CERAMIC X7R 0805 SMD C-0408 C081 CAP .1UF 50V CERAMIC X7R 0805 SMD C-0408 C082 CAP .1UF 50V CERAMIC X7R 0805 SMD C-0408 C083 CAP .1UF 50V CERAMIC X7R 0805 SMD C-0408 C084 CAP .1UF 50V CERAMIC X7R 0805 SMD C-0408 C085...
  • Page 61 1812 SMD L-0148 INDUCTOR FIXED 8.2uH 5% 1812 SMD L-0219 CONN .025" SQUARE POST HEADER J-0168 PCB FLEX-1500 PPA05 BOARD PC-0049 TRANSISTOR RF POWER MOSFET 0.5W RD00HVS1 Q-0019 TRANSISTOR RF POWER MOSFET 16W RD16HHF1 Q-0014 MOSFET PWR P-CHAN 1A 20V...
  • Page 62 FLEX-1500 TOP LEVEL ASSEMBLY ITEMS Sch. FlexRadio Ref. Description Detail ---- ------------------------------ -------- ------ WASHER FLAT #4 SS H-0036 WASHER LOCK #4 INTERNAL TOOTH 18-8 SS H-0095 JACK SCREW W/HDWR 3/16" CHROME H-0141 FOOT RUBBER #4 SCREW HOLE FEET H-0238 SCREW 6-32 X 3/16"...

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