FLEX-1500 Service Manual - V 0.1

FlexRadio Systems
FLEX-1500
Software Defined Radio
Service Manual
PRELIMINARY
Author: Graham Haddock, KE9H
Revision 0.1
Copyright FlexRadio Systems, 2010
Contents
Introduction .....
Theory of Operation ..
Alignment, Test and Calibration.... 11

Troubleshooting and Diagnostics ..... 15
Assembly and Disassembly..... 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 Fixture.
Appendix F Bill of materials.
Revision 0.1
Introduction
The FLEX-1500 QRP Software Defined Radio is both 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 filters, panoramic
spectrum displays and computer based Graphic interface characteristic of a Software
defined Radio.
This service manual assumes that the reader / service technician is familiar with the
operation of the radio and powerSDR control software. If additional information is
required on those topics, please refer to the Product Manual and Quick Start Guide.
Front View - FLEX-1500
Revision 0.1
Theory of Operation
Refer to the Block Diagrams on the two following pages.
The Detailed Schematic is included in Appendix A.
The unit is powered by +13.8 Volts DC, supplied via the 2.5 mm x 5.5 mm coaxial power
connector on the rear of the unit. The unit has an internal 3.0 Ampere fuse, that will blow
if the unit draws excessive current, or if the polarity of the power connected to the unit is
reversed.
The FLEX-1500 CPU (TAS1020B Streaming USB Controller) will communicate via
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.
Communication between the Flex-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 and Distribution

The transceiver board requires a source of regulated +5 Volts at approximately 400 mA
to function. +3.3 Volts is supplied to the board in general by a linear +3.3Volt regulator
derived from the +5 Volt line. Additional +3.3 Volt and +1.8 Volts required to operate
some of the integrated circuits is provided by point-of-load regulators in the vicinity of
the IC.
Overall power for the unit is derived from the +13.8 Volt input on the RFPA board.
This 13.8 Volts directly supplies the relays and power amplifier transistors. It is also
feeds two regulators. A 6 Volt regulator is switched on when transmitting, and off when
receiving. This switched +6 Volt output is used to bias the RF power transistors. A
separate +5 Volt regulator supplies power for the SPI decoder and relay driver IC on the
RFPA board, as well as supplies all +5 Volt power to the transceiver board (PTRX) via
the board to board interconnect system.
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Revision 0.1
Revision 0.1
Control Busses
There are several control busses that interconnect the radio. A USB Full Speed bus
interconnects the host computer running PowerSDR with the on-board CPU, the
TAS1020B. Control from the TAS1020B CPU to the rest of the radio and external
control is via an I2C bus sysem, and two each SPI busses.
Firmware for the CPU is resident in a local (I2C) EEPROM on the transceiver board.
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
device.
The FLEX-1500 CPU will communicate via 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. All of the above
must be translated from local hardware and register controls to the Command and Data
structures chosen for USB transport and interface in the host to the PowerSDR software.
I2CBus
The I2C bus exists as three instances.
(1.) The computer bus (I2C-C), which contains the (master) CPU, the EEPROM
containing program memory and calibration parameters, and the Bus Mux.
(2.) The Internal I2C bus, (I2C-I) containing the two bus expanders and the
CODEC chip.
(3.) The External I2C bus (I2C-E) which is routed to the FlexWire DB-9
connector, and is only used in conjunction with an external FlexWire device.
The I2C Bus Mux selects whether the Computer I2C bus will be connected to the Internal
or External I2C bus extension at any given time, as well as passing any interrupt requests
upwards to the CPU. Since the EEPROM and the Bus Mux are on the computer bus, their
addresses will appear in all I2C bus spaces.
I2CBusStructure
The I2C bus address values are provided according to the TI convention, where the
address is an eight bit word, expressed as two hexadecimal characters. The least
Revision 0.1
significant bit is actually the ~read/write bit, but is always presented as a 0 when the
address is expressed. The TAS1020B is the I2C Bus Master and is always connected to
the I2C Multiplex Chip and the EEPROM.
When the Bus Multiplex is set to Outside, the I2C bus is routed to the appropriate pins
on the FlexWire connector. When set to Inside the I2C bus is routed to the CODEC,
and the two Bus Expanders, which convert I2C commands to many high/low outputs
used to control the individual switches that control signal routing in the radio.
The Audio Amplifier is controlled by general purpose outputs from the CODEC.
SPIBus
There is also a SPI bus, used to control the DDS and the RFPA. It appears as two
physical instances, a 3.3V version and a 5V version. The SPI is outbound control only,
for both the AD9951 DDS and RF PA board.
The AD9951 DDS is controlled via the 3.3 Volt SPI bus, directly from the CPU.
The DDS will operate with either a 20 MHz or 38.4 MHz reference input.
The TPIC6B595 Relay Driver is controlled by the 5 Volt SPI bus, and controls the
following relays according to the band of operation or transmit/receive status.
A High SPI control bit is the active state, which provides a LOW output from the relay
driver to turn the relays ON.
I.C. Name
Drain0
Drain1
Drain2
Drain3
Drain4
Drain5
Drain6
Drain7
Bit
0
1
2
3
4
5
6
7
Pin
4
5
6
7
14
15
16
17
Name
15M
160M
20M
6M
80M
10M
XMIT
40M
Function
Active = 17 or 15 Meter Band
Active = 160 Meter Band
HIGH = Transmit mode, LOW = Receive mode
Initial
0 = Inactive
0 = Inactive
0 = Inactive
0 = Inactive
0 = Inactive
0 = Inactive
0 = Receive
0 = Inactive
RF Signal Processing
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
20 dB pad to offset the gain of the preamp. The output of the preamp is fed to the QSD
down-mixer, with an output of I and Q baseband signals in the range of 0 to 24 kHz.
Revision 0.1
The QSD down-mixer is also supplied with a quadrature local oscillator signal which is
derived from the DDS. The DDS operates at twice the desired local oscillator signal,
passes though a 120 MHz low pass filter, into a Johnson Counter that both divides the
DDS frequency by two, as well as generates the two quadrature local oscillator signals.
In transmit, in a reverse manner, I-Q baseband signals from the CODEC in the baseband
range of 0 to 24 kHz are supplied to the QSE, along with the quadrature local oscillator
signals at the operating frequency, resulting in a direct QSE output on the final transmit
frequency, which is routed via the bandpass filters to either the transverter output
connector, or the input to the RFPA.
Baseband Processing
In the receive direction, output I and Q signals from the QSD are passed through a set of
OpAmps that have 18 dB of signal gain and 28 kHz low pass filters, then sent to the
CODEC for digitization and transmission to the host computer.
In transmit, 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, digitized I and Q signals from the 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. Processed and demodulated audio is returned via the USB protocol to the
controller, then transferred to the CODEC via I2S protocol for conversion into analog
audio signals.
In transmit, configuration, digitized microphone audio signals from the CODEC 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. Processed transmit
audio in a digital I and Q format is returned via the USB protocol to the controller, then
transferred to the CODEC via I2S protocol for conversion into analog baseband signals to
drive the QSE up-mixer.
In the BITE (Built In Test Equipment) configuration, digitized I and Q signals from the
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
sent via the USB protocol to the controller, then transferred to the CODEC via I2S
protocol for conversion into analog baseband signals to drive the QSE up-mixer.
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Audio Amplifier
An audio amplifier is present, capable of driving stereo headphones, or stereo powered
speakers, in the Stereo configuration, or a monophonic speaker directly, 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 impedance loads. In the Mono configuration, the two incoming stereo signals are
mixed together to form a single mono signal, then this is fed to one amplifier directly, and
inverted and fed to the other amplifier to form an 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.
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10
Alignment, Test and Calibration

The only manual alignment required is setting the quiescent bias for the RF power
transistors on the RFPA (PPA05 PCB.)
All other alignment, test and calibration will occur 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 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.
==
The Bias settings are normally set with the PA board out of the radio. It does 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 connector.
To turn on the PA bias, ground the test point named "XMIT" at the lower right corner of
the board, between K8 and K15. This will also activate relay K15, so you will hear a
"click."
To measure current in the driver transistor, there is a one Ohm shunt resistor between test
points DM- and DM+. Put a voltmeter that will give good readings in the range of 50
milliVolts across these two test points and normally, you would adjust R8 for 50
milliVolts plus minus 5 milliVolts, corresponding to 50 milliAmps flowing through
driver transistor Q1.
(Hint: do not use long test probes that will go all the way through the PC board and touch
the plate below. This will short the +13 Volts to ground, or destroy the metering resistor
R2.)
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11
After adjusting bias on Q1, adjust bias on Q3. The procedure with a cold plate will be to
set total power drain to 530 mA, plus minus 25 ma, by adjusting R10.
You will see it drift some with temperature. With a hot base plate, it can rise as high a
580 mA.
Test and Calibration

FLEX-1500 Transceiver Final Assembly, Test and Calibration.
Required test equipment:
Host computer with PowerSDR version 2.0 or later and appropriate drivers for the
FLEX-1500 and PowerMaster RF Powermeter installed.
USB Signal Generator, FlexRadio Systems model FLEX-1599
PowerMaster RF Power Meter model ____ with serial interface to host computer.
Loop-back test cable per accompanying diagram.
Suitable power and RF BNC connection cables.
Power Supply capable of supplying at least 2.5 Amperes at 13.8 Volts with current limit
adjustable to 2.5 Amperes.
==
Power Supply Setup:
Adjust Power Supply to 13.8 Volts Output Voltage.
Adjust Power Supply 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.
==
Check for the presence of the latest version of the radio Firmware
from the FlexRadio Systems SVN.
If not a current version of the radio firmware, use Firmware Updater to install and
update the latest version of firmware
==
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12
If there is any question as to whether the quiescent bias currents are properly set on the
RFPA power transistors, they should be set prior to performing the PA calibration tests.
==
Plug the BNC-Coaxial cable from the PowerMaster watt meter into the BNC connector
on the RFPA.
Plug the USB cable from the computer into the USB connector on the front edge of the
PTRX board.
Plug the Powered speaker plug into the Speaker jack on the PTRX front edge.
Plug the loop-back test cable into the FlexWire DB-9 connector on the rear card edge,
and the Key and Mike connectors into the connectors on the front card edge.
(Until full automatic test software is available, the speaker plug on the loop back test
cable will be not be used.)
Plug in the +13.8 Volt power connector into the 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 noise floor appears.
Turn up the volume control to verify that noise comes out of the speakers, and the audio
amplifier is operating. Return the volume control to "0".
Bring up the production test screen by pressing Control-Shift-P.
Check that the appropriate Com Port for the PowerMaster RF Power Meter is indicated.
The fully automated sequence of tests may be started, or the individual tests run for
diagnostic purposes.
Press "Dot"
Press "DASH"
Press "PTT"
Press "Mike"
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13
Press "Balance"
Press "Attenuator"
Press "Filter"
Press "Level"
(Additional tests will be added as additonal test software
is completed.)
If all tests are passed, as indicated by all green buttons,
Press "PA" to perform full calibration of the
RFPA on all bands.
If this final test is passed, then radio level testing of the assembled radio is complete.
Close Production Test window, Stop PowerSDR, close PowerSDR,
turn off power Switch on PTRX, Remove cables from Radio Assembly.
==
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14
Troubleshooting and Diagnostics

For bench testing the complete unit or RFPA as a stand alone board, it is recommended
that a 13.8 Volt current limited bench supply is used, with the current limiter set to 2.5
Amperes.
If necessary to test a transceiver board as a stand alone board, a holding fixture with
number 4 corner pins can be used to hold the board. A source of regulated +5.0 Volts,
current limited at 600 mA may be applied in place of the power source jumper on Jxxx.
The results from the software tests built into PowerSDR should provide direction as to
any failures in the radio.
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
completed initialization.
If no blue light, check all voltages, including the output of the dedicated +3.3V regulator
feeding the CPU digital power pins, which is separate from the general 3.3V regulator.
If the blue light is present, but the unit will not enumerate on the USB host, check cables,
connectors, and proper voltage output from the dedicated +3.3V regulator feeding the
CPU digital power pins.
None of the band pass filters in the transceiver board should have an insertion loss greater
than 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.
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15
Assembly and Disassembly

Required tools
Number 1 Phillips and number 2 Phillips screwdrivers are needed, and a nut driver
to remove the DB-9 retention nuts.
Disassembly
Remove the two retention nuts on either side of the FlexWire DB-9 connector.
Remove the four corner screws on both the front and back covers using the number 2
Phillips screwdriver.
Observe the position of the upper PCB, it is in the fourth card slot. That is, three empty
slots are above it. Observe the position of the two screw clearance holes on the bottom of
the case. These holes are not equally spaced from the ends. The hole furtherest from the
edge is on the rear end (end with all BNCs.)
Remove the four bottom feet, using the number 1 Phillips screwdriver.
Gently slide both cards toward the rear panel, the one with all the BNC's 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 ten pin card to card connector.
Orient the case so that the rear of the case (end with screw clearance hole spaced furthest
from the edge) is upwards.
Lower the upper board into the fourth board slot from the top of the housing. Once the
upper board engages the side rails by an inch or two, then lower the lower board and heat
spreader plate into the box and engage the board to board to board connection. The lower
(PA board) should not engage any board slots, and will just roughly center in the bottom
of the case. Gently slide in the pair of cards, until fully inside the new case.
Check that the two transistor mounting screws in the heat spreader are visible / roughly
centered in the screw clearance relief holes in the bottom of the case.
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16
Install the four feet using the number 1 Phillips screwdriver.

Install the front and rear panels, using the black #6 pan head screws, with a number # 6
flat washer under each screw head, with the number 2 Phillips screwdriver.
Install the two retention nuts on either side of the DB-9 connector.
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17
Appendix "A"
Schematic, PTRX (Transceiver) Board
Revision 0.1
10 MHz
SN74LVC1G04
Doubler
4 to 1
Switch
20 MHz
BITE
38.4 MHz
CVT25-38.4
+0 dBm TX Level
ANT/XV-TX
XV-RX
To PA
DDS
AD9951
3 to 1
Switch
120
MHz
LPF
0 - 120 MHz
37.6 - 54.0 MHz
25.3 - 37.6 MHz
17.0 - 25.3 MHz
11.4 - 17.0 MHz
7.7 - 11.4 MHz
5.2 - 7.7 MHz
3.5 - 5.2 MHz
2.3 - 3.5 MHz
1.6 - 2.3 MHz
0.88 - 1.6 MHz
0.49 - 0.88 MHz
Bypass
Band Pass Filter Bank
SPI BUS
SN65LVDS34D
-20
dB
PRE-AMP
74LVC74D
LO-Q
To PA
SPI
D->A
A->D
Level
Shift
Gate
I2S
BUS
SPI BUS
I2C BUS
Clocks
TLV320AIC33
CODEC
74HCT08
26 kHz
LPF
THS4520
0 - 60 MHz
LO-I
QSE
QSD
74CBT3253
Johnson
Div by 2
ADL5531
Version 2010 APR 05
FLEX-1500 TRX BOARD
System Block Diagram
I2C
MUX
I2C
BUS
CONTROL
USB /
TAS1020B
I2C EXPANDER
2 ea. PCA9555
Switch
Control
FlexWire
PTT Out
PTT/INT In
I2C BUS
Line In/Out
EEPROM
24C128
Spkr/Headset
Audio Out
LED
Key In
PTT In
USB
Mike In
5V-PA/12
C1
SSQ-105-01-F-D
1.) SPI5-LOAD
+12V
2.) Ground
C4
.1u
XVRX
4.) +12V
5.) SPI5-DATA
6.) Ground
P2
+3.3V
GND
D1
7.) +5
R3
619
R4
3.32k
R1
SD-73100
GND
5.1k
SPI5-LOAD/8
GBLC03C
16
RFTP1
V1
GND
GND
GND
GND
GND
GND
GND
V2
C7
1
5
7
9
10
12
14
R2
5.1k
0
R73
6 RF4
BPFI/2
PAD
.1u
C6
ANT 11
RFC
8 RF3
D2
SD-73100
GND
GBLC03C
10.) Ground
GND
NC
C3
VDD
R6
619
15 RF2
J2G$1
SPI5-DATA/8
FRTENDB/11
R5
619
PE42641
2
.1u
GND
13 RF1
ANT
10MW TX/COM
9.) RF
FRTENDA/11
IC1
GND
8.) +5
SPI5-CLK/8
GND
J1G$1
3.) SPI5-CLK
GND
GND
.1u
10
8
6
4
2
C275
9
7
5
3
1
Flat Cable Assignments
.1u
10n
R8
C8
3.32k
10n
R9
3.32k
GND
GND
GND
+3.3V
BITE/5
R7
10k
20MHZ/9
100
1M
R10
+3.3V
FRONT END
.1u
GND
GND
10 MHz Doubler
GND
IC2P
3
GND
.1u
BAS70-00-V-GS08
L1
TC4-1T
C15
D4
C16
1
2
3
IC2
74AHC1G04DBV
R72
VCC
1M
R87
Test 10 MHz Multiplier
GND
.1u
BAS70-00-V-GS08
D3
T1
C5
X1
C13
.1u
1267W
10 MHz Input
GND
Copyright FlexRadio Systems 2009, 2010
K1
L2
C21
C23
L5
C24
K2
307n
51p
91p
C25
307n
82p
GND
GND
130p
C26
307n
82p
RF2 GND CTRL
GND
GND
C33
BAND01/11
C37
L7
L8
C38
C39
L9
5 RFC
K4
1
491n
491n
75p
491n
110p
491n
110p
75p
GND
GND
200p
C41
C42
GND
150p
GND
GND
C48
BAND02/11
+3.3V
+3.3V
C49
L11
C51
L13
C52
PE4259
1
RF1
K6
CTRL GND RF2
C53
220p
C54
GND
GND
680n
180p
300p
680n
180p
C55
GND
110p
3
RF2 GND CTRL
220p
GND
680n
110p
680n
BPFO/3
VDD
RFC
L12
5 RFC
GND
BAND03/11
+3.3V
+3.3V
L14
C58
L15
C59
L16
C60
L17
PE4259
K8
1 RF1 VDD
RFC
1.2u_CS
1.2u_CS
150p
1.2u_CS
220p
1.2u_CS
220p
CTRL GND RF2
GND
C63
390p
GND
C64
300p
GND
3
RF2 GND CTRL
300p
C62
GND
BAND04/11
C66
GND
150p
5 RFC
C61
GND
RF1
10n
VDD
C65
K7
PE4259
Coilcraft CS1812
11.4 - 17.0 MHz
BAND 4
C57
10n
C50
GND
L10
10n
VDD
RF1
C56
K5
PE4259
Delevan
17.0 - 25.3 MHz
BAND 3
10n
150p
GND
RF2 GND CTRL
C40
CTRL GND RF2
GND
VDD
RFC
10n
PE4259
RF1
GND
C36
L6
10n
RF1
+3.3V
C46
K3
VDD
MaxiSpring
25.3 - 37.6 MHz
BAND 2
PE4259
GND
91p
C27
GND
51p
307n
+3.3V
BPFI/1
PE4259
1 RF1 VDD
CTRL GND RF2
L4
RFC
10n
C22
5 RFC
GND
L3
GND
RF1
10n
VDD
+3.3V
C31
PE4259
MaxiSpring
37.6 - 56 MHz
BAND 1
+3.3V
Physical Position on PCB:
Band 4 - 11.4 - 17.0 MHz

Band 8 - 2.3 - 3.5 MHz
Band 2 - 25.3 - 37.6 MHz
Band 5 - 7.7 - 11.4 MHz
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
BANDPASS FILTER BANK - HIGH

Copyright FlexRadio Systems 2009
+3.3V
+3.3V
C67
L19
C68
L20
C69
L21
C70
5 RFC
1.8u
3
1.8u
220p
1.8u
330p
PE4259
RFC
1.8u
330p
220p
430p
C72
GND
620p
C73
GND
430p
GND
GND
BAND05/11
+3.3V
+3.3V
C76
L23
C77
L24
C78
L25
C79
5 RFC
2.4u_FS
3
2.4u_FS
560p
360p
2.4u_FS
PE4259
RFC
2.4u_FS
560p
360p
680p
C81
GND
1n
680p
C82
GND
GND
GND
BAND06/11
+3.3V
+3.3V
C85
L27
C86
L28
C87
L29
C88
5 RFC
3.9u_FS
3
3.9u_FS
750p
470p
3.9u_FS
PE4259
RFC
3.9u_FS
750p
470p
C90
GND
C91
1.3n
GND
910p
GND
GND
L31
C95
L32
C96
L33
5 RFC
5.6u_FS
3
5.6u_FS
1.3n
750p
5.6u_FS
1.3n
PE4259
K16
1 RF1 VDD
RFC
5.6u_FS
750p
CTRL GND RF2
RF2 GND CTRL
C98
1.3n
GND
C99
2n
GND
C100
1.3n
GND
GND
BAND08/11
C102
GND
C97
GND
C94
C101
L30
10n
RF1
+3.3V
2.3 - 3.5 MHz
PE4259
Coilcraft FS
BAND 8
K15
BAND07/11
+3.3V
VDD
10n
10n
GND
C93
GND
RF2 GND CTRL
910p
CTRL GND RF2
C89
BPFO/4
K14
1 RF1 VDD
GND
L26
C92
RF1
Coilcraft FS
10n
PE4259
VDD
3.5 - 5.2 MHz
K13
BAND 7
10n
GND
C84
GND
RF2 GND CTRL
C80
CTRL GND RF2
GND
K12
1 RF1 VDD
GND
L22
C83
RF1
Coilcraft FS
10n
PE4259
VDD
5.2 - 7.7 MHz
K11
BAND 6
10n
GND
C75
GND
RF2 GND CTRL
C71
CTRL GND RF2
BPFI/2
K10
1 RF1 VDD
GND
L18
C74
RF1
10n
PE4259
VDD
Delevan 1812 Iron Core, Unshielded
K9
7.7 - 11.4 MHz
BAND 5
BANDPASS FILTER BANK - MIDDLE

+3.3V
+3.3V
C105
L36
L37
C106
PE4259
5 RFC
10u_FS
3
10u_FS
1.3n
910p
10u_FS
RFC
10u_FS
1.3n
2n
C108
GND
3n
C109
GND
2n
GND
GND
BAND09/11
+3.3V
+3.3V
C112
L39
C113
C114
L40
L41
C115
PE4259
5 RFC
10u_FS
3
10u_FS
5.6n
2.7n
10u_FS
RFC
10u_FS
5.6n
C117
GND
4.7n
C118
GND
3.3n
GND
GND
BAND10/11
C10
PE4259
VDD
RF1
L42
C121
L43
C122
L44
C123
L45
BPFO/5
C124
15u_FS
3
15u_FS
5.1n
15u_FS
12n
PE4259
RFC
15u_FS
12n
5.1n
GND
6.8n
GND
C126
9.1n
GND
C127
RF2 GND CTRL
C125
CTRL GND RF2
6.8n
GND
GND
BAND11/11
C129
10n
K22
1 RF1 VDD
5 RFC
+3.3V
CoilCraft FS
K21
0.49 - 0.88 MHz
GND
BAND 11
BPFI/3
NP
C128
+3.3V
NP
10n
C9
C120
10n
GND
3.3n
RF2 GND CTRL
C116
2.7n
CTRL GND RF2
GND
K20
1 RF1 VDD
GND
L38
C119
RF1
CoilCraft FS
10n
PE4259
VDD
0.88 - 1.6 MHz
K19
BAND 10
10n
GND
C111
GND
RF2 GND CTRL
C107
910p
CTRL GND RF2
GND
K18
1 RF1 VDD
GND
C104
L35
C110
C103
L34
RF1
CoilCraft FS
10n
PE4259
VDD
1.6 - 2.3 MHz
K17
BAND 9
+3.3V
+3.3V
1 RF1 VDD
K24
5 RFC
RFC
10n
RF2 GND CTRL
GND
GND
BAND12/11
C131
GND
CTRL GND RF2
GND
PE4259
C130
RF1
10n
PE4259
VDD
K23
BAND 12 (BYPASS)
BANDPASS FILTER BANK - LOW

Note: 5.1n = 1.8n +3.3n
RFTP2
+3.3V
R86 3.32k
R85 619
+5V
IC3
C135 1267W
.1u
L46
1
3
4
6
8
NC
NC
NC
NC
NC
6
4
GND
C137
R12
+3.3V
95.3
RFC
2Y
1C0
1C1
1C2
1C3
2C0
2C1
2C2
2C3
QSE
+3.3V
GND
R18
2.00k
R20
1.20k
BITE/1
1.25 V
C143
1Y
2Y
1C0
1C1
1C2
1C3
2C0
2C1
2C2
2C3
A
B
1G
2G
6
5
4
3
10
11
12
13
14
2
1
15
C144
GND
GND
GND
QSD / QSE
VCC
16
8
GND
VCC
16
QSE
IC5G$2
GND
.1u
QSD
IC4G$2
8
C146
C147
.1u
QSD-QM/6
QSD-IP/6
~QSD/11
LO-Q/10
10u
GND
QSD-IM/6
IC5
74CBT3253PW
GEN/11
10n
14
2
1
15
QSD-QP/6
LO-I/10
GND
GND
GND
10
11
12
13
10u
TC1-1T
GND
6
5
4
3
74CBT3253PW
1
2
3
RF2 GND CTRL
3.32k
R21
C138
10n
+5V
A
B
1G
2G
1.0 V
T3
C18
2.87k
R13
GND
1 RF1 VDD
ATN/11
1.20k
R15
K26
PE4259
619
3.32k
1Y
GND
+3.3V
+3.3V
95.3
TC4-1T
10n
619
R19
R84
R11
1
2
3
GND
PE42641
GND
SEQ: 0, 1, 3, 2
QSD
IC4
GND
T2
GND
R14
TXB/11
330u
3.30
CLIN
GND IC27
TXA/11
10n
PAD
20 dB
Attn
GND
GND
GND
GND
GND
GND
GND
RFOUT 7
14
12
10
9
7
5
1
PAD
RFIN
P$1
61.9
R81
RF4 6
V2
C11 R16
GND
RF2 GND CTRL
240
RF3 8
C132
RFC
RFC
R83
11 ANT
VDD
.1u
RF1
C134
RF1 13
RF2 15
K25
PE4259
R82
V1
+3.3V
GND
VDD
NC
ADL5531
.1u
16
C28
61.9
BPFO/4
R74 0
QSE-QP/6
QSE-IM/6
QSE-QM/6
QSE-IP/6
~QSE/11
34 kHz LPF
100
1.60k
915W
QSD-IM/5
9
CM
L1LP/7
C150
C151
2.7n
.1u
R26
PAD
16
15
14
13
CM
VOUT-
VIN+
PAD
VSVSVSVS-
120
C155
R27
12n
120
C157
C156
.1u GND
L49
C158
330u
GND
VOUT+
.1u
VIN-
10u
10u
/PD
.1u
C153 C154
NC
C35
4.7n
C32
VS+
VS+
VS+
VS+
1000W
IC6
C152
8
7
6
5
THS4520
L48
10
R25
11
R24
12
330u
QSD-IP/5
C148
2.4 Hz HPF
2.7n
R28
R29
L50
100
1.60k
915W
L1LM/7
L51
To TLV320 Line 1 In
100
1.60k
915W
NC
1
GND
9
CM
VOUT-
VIN+
L1RP/7
C162
C163
2.7n
.1u
R32
PAD
16
15
14
13
CM
.1u
PAD
VSVSVSVS-
10u
VOUT+
10u
VIN-
.1u
C165 C166
C43
IC7
4.7n
C34
VS+
VS+
VS+
VS+
/PD
C164
8
7
6
5
THS4520
L52
10
R31
11
R30
12
C161
330u
QSD-QP/5
1000W
+3.3V
From QSD
C167
R33
12n
120
C168
.1u GND
120
C169
QSE-QM/5
C177
.15u
QSE-QP/5
R37
12.7 C174
12.7
R38
.15u
12.7
R40
R41
12.7 C178
12.7
.15u
12.7
28 kHz LPF
L1RM/7
Remove GROUND under OpAmp

Narrow bandpass for QSE?
R39
12.7
R42
HPLP/7
C172
R36
47u
915W
47u
To QSE
1.60k
C175
QSE-IP/5
100
47u
.15u
L53
HPLM/7
From AIC33 HP Out
C176
C173
R35
HPRP/7
R43
12.7
47u
QSE-IM/5
R34
C179
330u
QSD-QM/5
C171
2.7n
67 Hz HPF
HPRM/7
BASEBAND PROCESSING
+3.3V
IC8
TPS79318
L54
.1u
10u
C182
GND
L55
1267W
L56
.1u
PAD
LEFT_LOP
LEFT_LOM
RIGHT_LOP
RIGHT_LOM
29
30
31
32
+5V
R17
C14
511
IC10
TPA0233
R69 511
10k
R45
10k
2
7
47n
+5V
R75
I-SCL/11
Q2
FDV303
.1u
C242
RIN
RO
LIN
LO
SD
ST/MO
BYP
FILT
GND
PAD
C206
.1u
GND
100
C207
C208
10n
10n
GND
GND
MPTT/8
L60
650W
C209
C210
10n
10n
GND
GND
L57 650W
C202
330u
4
1
C203
SPEAKER
10n HEADPHONES
C205
1u
GND
GND
GND
FWLO/12
FlexWire Line In/Out
CODEC
J3
2
1
C204
1u
GND
10n
L58 650W
10
+3.3V
R68
L59 650W
2.2k
100
R46
R67
1u
10k
C2
I-SDA/11
~CRESET/8
C197
VDD
R44
GND
C200
330u
47n
AUDIO AMP
GND
BASEBAND
10u
HPLM/6
HPRM/6
C12
GND
TO QSE
HPRP/6
27
28
PAD
AVSS_DAC
26
DRVSS
DRVSS
IO/DVSS
21
20
42
/RESET
GPIO1
GPIO2
33
35
34
MFP3
MFP2
MFP1
MFP0
SELECT
SDA
SCL
MONO_LOP
MONO_LOM
18
19
23
22
HPLP/6
FWLI/12
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
10u
10u
24
17
25
36
DRVDD
DRVDD
AVDD_DAC
IOVDD
DVDD
44
37
38
39
40
41
MCLK
BCLK
WCLK
DIN
DOUT
HPLOUT
HPLCOM
HPROUT
HPRCOM
GND
+5V
C184
GND
LINE_OUT
LINE_IN
MIC_IN
10u
GND
MICROPHONE
EN
GND
TLV320AIC33IRGZ
AVSS_ADC
MIC3L
MIC3R
MICBIAS
MICDET
.1u
3.3 V
16
LINE2LP
LINE2LM
LINE2RP
LINE2RM
15
11
14
13
12
LINE1LP
LINE1LM
LINE1RP
LINE1RM
NR
C185
C189 C190
1.8 V
48
47
46
45
43
2
1
.1u
7
8
9
10
C187 C188
.1u
AVDD_ADC
10u
.1u
10u
10u
C198
L1RM/6
10u
L1RP/6
3
4
5
6
10u
L1LM/6
C196 C194 C193 C192
L1LP/6
GND
IC9
C191 C186
1267W
FROM QSD
BASEBAND
IN
3.3 V
1u
MCLK/8
OUT
10u
3.3 V
1u
BCLK/8
C183
.1u
C201 C199
WCLK/8
C195
DIN/8
1.8 V
GND
C181
C180
P$1
1267W
DOUT/8
+3.3V
2
3
IO1
VCC
IO2
IO4
GND
IO3
C212
GND
.1u
C213
TPD4E0014DRLR
GND
C214
GND
SPI-CLK/9
SPI-DATA/9
C47
27p
C133
GND
MCLK/7
QG2
6 MHz
BCLK/7
GND
C-SCL/11
C-SDA/11
33p
GND
SPI~CSDDS/9
PTC/11
C136
27p
C139
DIN/7
IC13A
3
1.47k R51
90W
R52
120W
24.9
24.9
C217
47p
GND
5V-USB/12
GND
44
43
42
41
40
39
37
38
36
35
34
32
R50
C218
47p
GND
GND
SCL
SDA
/VHEN
/RESET
MCLKO2
MCLKO1
CSCLK
CDATO
CDATI
CSYNC
/CRESET
CSCHNE
XTALO
XTALI
PLLFILI
PLLFILO
MCLKI
PUR
DP
DM
DVSS1
DVSS2
DVSS3
AVSS
IC15
TAS1020B
P1.0
P1.1
P1.2
P1.3
P1.4
P1.5
P1.6
P1.7
DVDD1
DVDD2
DVDD3
AVDD
23
24
25
26
27
29
30
31
8
21
33
2
~MRESET/12
C223
IC13B
PTT-OUT/12
4
6
7408PW
IC13C
9
8
IC28
7408PW
5
C219 C220 C221 C222

.1u
.1u
.1u
MPTT/7
~DASH/12
C224
C225 1267W
FW-PTT-IN/11
.1u
10u
C~INT/11
+5V
OUT
IN
TPS79333-DBV
4
10u
L65
GND
~DOT/12
GND
SPI5-DATA/1
+5V
10
GND
.1u
SPI5-CLK/1
47p
46
47
48
1
3
5
6
7
4
16
28
45
~LED/12
C45
4 L62
Level Translator
74LVC1G04DBV
/MRESET
TEST
EXTEN
/RSTO
P3.0
P3.1
P3.2,/XINT
P3.3
P3.4
P3.5
NC1
NC2
4
3
2
1
9
10
11
12
13
14
15
17
18
19
20
22
C216 C215
1n 100p
GND
D+
DVCC
7408PW
IC14
~CRESET/7
3.09k
GND
L63
+3.3V
NR
EN
GND
C17
.1u
GND
GND
+3.3V
7408PW
.1u
VCC
VCC
IC13P
IC14P
3
11
13
GND
GND
GND
C226
GND
IC13D
12
14
STREAMING USB CONTROLLER
J5
SPI5-LOAD/1
WCLK/7
R49
GND
27p
DOUT/7
33p
27p
GND
8
7
6
5
IC12
VDD
PTC
SCL
SDA
Review USB Power chokes

DRESET/9
10.0k
+5V
A0
A1
A2
VSS
R89
1
2
3
4
.1u
C211
+3.3V
IC11
24C128

C227
.1u
GND
GND
RFC
1.00k 3
RF2 GND CTRL
R54
CVT25-38.4
R76
GND
GND
GND
1k
R55
OUT
GND
.1u 2
45
.1u
PE4259
1 RF1 VDD
C19
K27
GND
C244
VCC
C246
C247 .1u
.1u
10
11
12
.1u
20MHZ/1
C44
39
DRESET/8
38
40
41
3
33
47
42
48
EXP
GND
C170
DVDD_I/O
RESET
I/O_UPDATE
SYNC_CLK
REFCLK
DAC_RSET
DACBP
IOUT
REFCLK
CRYSTAL_OUT
IOUT
IOSYNC
SYNC_IN
CLKMODESELCT
OSK
LOOP_FILTER
PWRDWNCTL
CS
AGND
AGND
SDO
SCLK
AGND
AGND
SDIO
AGND
AGND
DGND
DGND
AGND
DGND
AGND
DGND
AGND
DGND
AGND
EXP
AGND
C241
.1u
.1u
GND
RFTP4
T4
TC1-1T
24
23
21
DDS/10
2
20
37
44
C248
46
1u
R77
6
C249
.1u
35
5
7
14
15
17
22
26
28
30
31
32
GND
GND
GND GND
AD9951EP
GND
GND
REF-SEL/11
SPI~CSDDS/8
SPI-CLK/8
SPI-DATA/8
C142
C240
.1u
C160
C239
47p
AVDD
AVDD
AVDD
AVDD
AVDD
AVDD
AVDD
AVDD
AVDD
68p
DVDD
DVDD
GND
RFTP3
NC/TS
1u
GND
4
6
13
16
18
19
25
27
29
C141
36
C237
EN
68p
+3.3V
QG1
4
C238
.1u
3.9k
1.20k
NR
IN
IC18
2
34
43
R53
.1u
GND
+3.3V
+3.3V
68p
10u
OUT
330p
.1u
.1u
.1u
R56
.1u
+3.3V
C234
C233
1u
C231 C232
68p
C235
C159
C236
+3.3V
10u
C145
DDS-1.8V-ANALOG
68p
C228
NR
C149
EN
DDS-1.8V-DIGITAL
OUT
68p
IN
GND
C230
IC17
TPS79318
IC16
TPS79318
C140
+3.3V
DDS
Changed T5 to TC4-1T
Changed IC20 to SN65LVDS34D
+3.3V
C30
68p
27p
27p
15p
C251
C252
100n
C253
120n
C254
100n
IC20
C255
C256
C257
C258
15p
27p
27p
15p
GND
GND
1
2
3
TC4-1T
GND
6
5
T5
1B
2A
2B
1Y
2Y
4
2
3
1
PRE
D
CLK
CLR
R90
24.9
LO-I/5
74LVC74D
3
IC19B
10
12
GND
11
13
120 MHz Low Pass Filter

SN65LVDS34D
PRE
D
CLK
CLR
R91
24.9
LO-Q/5
74LVC74D
Johnson Counter
GND
VCC
IC19P
7
.1u
GND
C259
14
+3.3V
C29
GND
R78 0
1A
GND
L68
200
L67
R79
L66
68p
DDS/9
IC19A
RFTP5
1
15p
.1u
GND
VDD
GND
GND
GND
C250
+3.3V
GND
GND
LO QUADRATURE GENERATOR
INTERNAL I2C BUS
A0
A1
A2
/INT0
SD0
SC0
VSS
VDD
SDA
SCL
/INT
SC1
SD1
/INT1
2.2k
2.2k
R62
2.2k
R61
R60
2.2k
C-SCL/12
23
22
21
2
3
VDD
SDA
SCL
I/O0.0
I/O0.1
I/O0.2
I/O0.3
I/O0.4
I/O0.5
I/O0.6
I/O0.7
A0
A1
A2
GND
I/O1.0
I/O1.1
I/O1.2
I/O1.3
I/O1.4
I/O1.5
I/O1.6
I/O1.7
2.2k
R70
2.2k
VSS
.1u
24
4
5
6
7
8
9
10
11
E-SDA/12
GND
INT
C261
IC22
1
CPU I2C BUS
C~INT/8
+3.3V
I-SCL/7
E~INT
EXTERNAL I2C BUS
FW-PTT-IN/12
(FlexWire)
BAND05/3
BAND08/3
BAND02/2
PTC/8
13
14
15
16
17
18
19
20
FRTENDB/1
FRTENDA/1
BAND04/2
12
PCA9555PW
GND
23
22
21
2
3
INT
VDD
SDA
SCL
I/O0.0
I/O0.1
I/O0.2
I/O0.3
I/O0.4
I/O0.5
I/O0.6
I/O0.7
A0
A1
A2
GND
I/O1.0
I/O1.1
I/O1.2
I/O1.3
I/O1.4
I/O1.5
I/O1.6
I/O1.7
VSS
24
4
5
6
7
8
9
10
11
GND
IC23
1
.1u
+3.3V
C262
+3.3V
2.2k
R59
C-SDA/12
E-SCL/12
GND
2.2k
R48
2.2k
R58
14
13
12
11
10
9
8
PCA9542A
I-SDA/7
R47
R57
IC21
1
2
3
4
5
6
7
+3.3V
GND
.1u
C260
+3.3V
~QSD/5
~QSE/5
REF-SEL/9
GEN/5
TXB/5
TXA/5
BAND07/3
BAND11/4
13
14
15
16
17
18
19
20
BAND10/4
BAND01/2
BAND12/4
BAND03/2
BAND09/4
BAND06/3
ATN/5
12
PCA9555PW
GND
FILTER AND SWITCH CONTROL

J6
3
2
1
5V-USB/8
Select
MA03-1
GND8
GND
+3.3V
5V-PA/1
R63
2.2k
R65
ON-OFF
C263
~MRESET/8
KEY
10n
1k
GND
R64
2.2k
L69 650W
~LED/8
+3.3V
SW1
IC25
1
2
3
9
10
GND
Q4
2N7002
GND
OUT1
OUT2
EN
PG
FB/NC
GND
GND
GND
GND
GND
GND
GND
GND
GND
PAD
13
14
GND
2
1
C264
GND
R71
16
15
10k
20
19
12
11
PAD
+3.3V
+3.3V
C267
IC26
10u
GND
TPS76833QPWP
GND
1
2
3
6
5
4
GND
+12V
GND
GND
GND
IO1 VCC
IO2
IO4
GND IO3
C229
1u
IN1
IN2
L70 650W
10n
R66
330u
3.90k
C266
R80
1.00k
R88
6
7
C20
~DASH/8
2.2k
+5V
J7
~DOT/8
.1u
Source
+3.3V
5 Volt
TPD4E0014DRLR
10n
10n
1n
C268
C269
C270
FLEXWIRE
DB-9
J8-1
J8-2
J8-3
J8-4
J8-5
J8-6
J8-7
J8-8
J8-9
FWLI/7
Q3
FDV303
PTT-OUT/8
TEST POINTS
GROUNDS
GND1
GND
GND2
GND
GND3
GND
GND4
+5V
+5
E-SDA/11
FW-PTT-IN/11
FWLO/7
C271
C274
10n
.1u
GND
+3.3V
TP3
GND5
TP4
GND6
C-SCL/11
C-SDA/11
GND
SPI~CSDDS/9
TP8
IC24G$3
2
TP2
GND
SPI-CLK/9
SPI-DATA/9
VCC
I2C BUS
TP7
J8-G
+3.3V
+3.3
SPI BUS (3.3 V)
GND
GND
POWER
GND
E-SCL/11
GND
I/O AND POWER

C276
.1u
GND
Mike Connector Assignments

1.) SPI5-LOAD
2.) Ground
3.) SPI5-CLK
4.) +12V
5.) SPI5-DATA
6.) Ground
7.) +5
8.) +5
FlexWire Assignments
1.) N.C.
1.) Ground
2.) N.C.
2.) LINE INPUT
3.) Mike Bias (+5V)
3.) PTT OUT (New, was GND)
4.) Mike Ground
4.) PTT IN (New, was interrupt)
5.) Mike In
5.) Ground
6.) Mike PTT In
6.) I2C-SCL
7.) Ground
7.) I2C-SDA
8.) N.C.
8.) +5 Volts Out (New, was +13V)
9.) RF
9.) LINE OUT
10.) Ground
SPI (DDS) BRIDGE ASSIGNMENTS
CODEC BRIDGE ASSIGNMENTS
Individual holes for 0.025 in. square pins
Individual holes for 0.025 in. square pins
1 x 4 pattern on 0.1 in. grid

TP7
TP3
TP2
GND
BCLK
TP9
CLK
CS
DATA
MCLK
TP11
GND
DIN
TP10
WCLK
TP12
I2C ADDRESS 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

6.) EXPANDER 1 - 0100 0010
DOUT
TP13
GND
I2C (INTERNAL COMPUTER) BRIDGE ASSIGNMENTS

SCL
TP8
SCA
TP4
GND
GND
NOTE: Jumper SCA to GND to remove EEPROM from address space
PORT AND CONNECTOR DEFINITIONS

Appendix "B"
Schematic, PPA05 (RFPA) Board
Revision 0.1
Adj
Bias
Adj
Bias
RD16HHF1
SPI BUS (5V)
Version 2010 MAR 05
FLEX-1500
5 Watt Linear PA
Bias control, T/R control

Filter Bank
6V
Switch
Bias Control
TPIC6B595
SPI Relay Driver
TO FLEX 1500 MAIN BOARD
Switch
RD00HVF1
6V
5V
13.8 V
6M
12/10 M
17/15 M
30/20 M
60/40 M
80 M
160 M
Reg.
Relay Switched
Low Pass Filter Bank
Reg.
DC Power
Filtering
Relay
13.8 V Input
ANT
BAS70
D3
GND
1u
1.8k
3.24k
R13
R14
GND
PE4259
K16
RF-I/O/4
C60
5 RFC
VDD RF1
GND
.1u
C47
GND
10.0k
3.24k
GND
C51
R15
.1u
R4
CTRL GND RF2
R5
XMIT/4
GND
R8
2k
~ 2.6 V
C50 49.9
10
2.00k
R6
1267W
L16
GND
R1
C52
C95
1u
.1u
10n
GND
.1u
C48
GND
DM+
DM2k
.1u
10n
+6V
R10
GND
C97
GND
GND
D1
GBLC03C
~ 4.9 V
1u
C98
T1
4
100u
.1u
GND GND
C63 1267W
C21
C61
GND
R3
470u
GND
GND
.1u
C53
+12V
1u
C100
12
GND
GND
10n
SD-73100
J1G$1
LPF-OUT/2
XMIT/4
ANT
LPF-IN/2
GND
.1u
C102
+12V +12V
GND
R17
R9
NP
GND
C64
GND
K15
TX2SA-12V
10
NP
RD16HHF1
Q3G$1
J3
GND
160W
L17
T3 XFMR_0.5BINOC
GND
RF POWER AMPLIFIER
.1u
10n
GND
C99
C20
240p
C56
.1u
1u
GND
C55
C101
C62
C54
C96
L20
R7
10n
10u
+12V/1
49.9
R11
+5V
3
1
R20
Q1
RD00HHS1
3
1
R19
10.0k
R2
1k
10.0k
20M/4
15M/4
LPF-IN-A/3
10M/4
6M/4
K1
TX2SA-12V
GND
GND
K3
TX2SA-12V
GND
GND
K5
TX2SA-12V
GND
GND
K7
TX2SA-12V
GND
LPF-IN-A
+12V
+12V
+12V
CoilCraft MaxiSpring
All coils this page are
GND
LPF-IN/1
.1u
10n
.1u
10n
.1u
10n
12
12
12
12
.1u
10n
C79
C69
C80
C70
C81
C71
C82
C72
9
4
4
4
10
3
3
8
5
5
5
6 Meters
12/10 Meters
17/15 Meters
220p
GND
C29
C37
GND
36p
L14
307n
C45
C39
GND
82p
180p
L15
307n
C40
GND
C27
56p
+12V
+12V
+12V
+12V
K2
TX2SA-12V
K4
TX2SA-12V
K6
TX2SA-12V
K8
TX2SA-12V
LPF-OUT-A/3
LPF-OUT/1
HIGH FREQUENCY LPF BANK
82p
GND
C31
150p
GND
C49 24p
3.6p
75p
GND
C24
39p
GND
C30
200p
220p
L12
307n
Physical order on board is: 60/40 M

10 M
80 M
17/15 M
160 M
30/20 M
6M
GND
39p
L13
538n
150p
120p
C26
22p
L10
246n
C35
L21
169n
C19
68p
GND
C3
15p
180p
GND
C23
12p
GND
L11
380n
C36
GND
C25
C38
82p
L8
169n
C33
68p
L9
307n
C34
GND
C22
18p
C2
12p
L7
130n
C32
GND
C1
C28
30/20 Meters
9
9
8
8
8
3
10
10
10
10
10
10
10
8
8
8
8
9
9
9
3
3
3
3
4
4
4
.1u
10n
1
12
1
12
1
12
1
12
5
5
5
C83
C65
C84
C66
C85
.1u
10n
.1u
10n
.1u
10n
C67
C86
C68
GND
GND
GND
GND
GND
GND
GND
GND
+12V
LPF-OUT-A
K13
TX2SA-12V
CoilCraft 1812 CS Series
All Coils this page are
160M/4
80M/4
LPF-IN-A/2
K11
TX2SA-12V
GND
GND
GND
GND
40M/4
GND
GND
TX2SA-12V
K9
.1u
10n
.1u
10n
10n
+12V
+12V
GND
GND
GND
80 Meters
GND
160 Meters
GND
GND
2.2n
GND
C17
1.8u
L23
8.2u
8.2u
C15
L6
910p
L4
C10
Physical order on board is: 60/40 M

10 M
80 M
17/15 M
160 M
30/20 M
6M
GND
1.2n
10u
300p
1n
GND
C18
470p
330p
GND
C13
300p
GND
C6
120p
270p
1.2u
C8
L2
C46
GND
GND
C12
150p
2.2u
L22
10u
L5
C14
330p
GND
C16
C11
L3
91p
300p
GND
C5
39p
1.5u
C9
L1
C7
330p
GND
C4
60/40 Meters
10
+12V
12
12
12
.1u
C87
C76
C88
C77
C89
C78
5
8
8
3
10
10
4
9
9
8
5
5
9
4
4
GND
GND
GND
GND
GND
+12V
+12V
+12V
K10
TX2SA-12V
K12
TX2SA-12V
K14
TX2SA-12V
LPF-OUT-A/2
LOW FREQUENCY LPF BANK
GND
3
3
4
4
4
10
10
10
5
5
9
9
9
1
12
1
12
1
12
8
8
C90
C73
C91
.1u
10n
.1u
10n
.1u
10n
C74
C92
C75
GND
GND
GND
GND
GND
GND
SPI5-LOAD
Test Points
GND
GND4
GND3
GND2
GND1
GND
CLK
LOAD
DATA
Test Points
18
9
12
8
13
3
SPI5-DATA
NC
GND
GND
GND
GND
SEROUT
D0
D1
D2
D3
D4
D5
D6
D7
VCC
~G
RCK
~SRCLR
SRCK
SERIN
GND
.1u
C94
GND
4
5
6
7
14
15
16
17
80M/3
20M/2
40M/3
10M/2
6M/2
160M/3

1.) SPI5-LOAD
2.) Ground
3.) SPI5-CLK
4.) +12V
5.) SPI5-DATA
6.) Ground
7.) +5
8.) +5
9.) RF
10.) Ground
15M/2
.1u
C93
+5V +12V
U1
TPIC6B595
NC
+5V
M05X2JTAG
GND
2
4
6
8
10
1
11
1
3
5
7
9
2
19
RF-I/O/1
SPI5-CLK
GND
P1
20
10
XMIT
L18
Add DIODE
GND
1u
VO
GND
4 NC
GND
NC
Vout
GND
U2 L78L06_D
GND
8 Vin
VI
MC78T05
C44
IC1
GND
S1A
GND
.1u
J2
+5V
+6V
Switched 6 Volts
C42
+6V
GND
.1u
C41
1
3
2
KLDX-0202
.1u
GND
C57
GND
+5V
MINI ATO
FUSE
F1
+13.6 Volts
INPUT
INTERCONNECT AND POWER
XMIT/1
10
R16
GND
1u
C43
+12V
.1u
160W
C58
D4
GND
+12V/1
1SS400T1G
D2
GND
.1u
Q4
NTR1P02T1
4.7k
R12
L19
160W
C59
+12V
2
2
3
6
7
Appendix "C"
PC Board Component View
Revision 0.1
FlexRadio Systems Copr. 2010
+
+
3 2 1
1 2 3
Appendix "D"
Test Points
Revision 0.1
TEST POINTS
3.3 Volts
I2C Bus
SPI Bus (3.3 V)
I2S Bus
3.3 Volts
(CPU Only)
1.8 Volts
5.0 Volts
1 2 3
+5Volts
SPI Bus
(5 Volt)
"XMIT" Test
Point
+6 Volts
(Keyed)
+12 Volts
3 2 1
Driver
Bias
Adjust
Driver current
metering
PA Bias Adjust
Appendix "E"
Test Fixture
Revision 0.1
N.C.
N.C.
N.C.
White of Blue
R2 1k
R1 1k
White
Red
Shield
Shield
White
Red
Orange
3. PTT-OUT from FlexWire drives FW-PTT-IN, MPTT, DOT, & DASH
2. Speaker/Phones drive FlexWire Line-In
1. FlexWire Line-Out drives Microphone In
NOTES:
AUDIO LINE-OUT
+12 VOLTS
I2C-SDA
I2C-SCL
GND
PTT-IN
PTT-OUT
AUDIO LINE-IN
GND
DB-9 CONNECTOR
FLEXWIRE
SLEEVE
TIP
RING
SLEEVE
TIP
RING
N.C.
N.C.
N.C.
N.C.
N.C.
N.C.
FLEX-1500 TEST FIXTURE

Audio And Switching Test Cable
N.C.
GND
MIKE PTT
MIKE
GND
+5V
N.C.
N.C.
MICROPHONE -- RJ45
KEY
PHONES
ANT
XVTX/C
BNC to BNC Cable
BNC to BNC Cable
3. PowerMaster verifies RF power output
XVTX/C
BNC to BNC Cable
XVRX
BNC to BNC Cable
2. DDS SigGen drives XVRX, XVTX/C at -70 dBm through splitter
1. DDS SigGen drives 10 MHz input at 0 dBm
NOTES:
TEST
UNDER
FLEX-1500
XVRX
10 MHz
10 MHz
POWER
MASTER
DUMMY
LOAD
SIGNAL GENERATOR
CONTROLLED
USB

RF Connections
USB to Host Computer
OF RFPA BOARD
CONNECTS TO TOP
ALL FEMALE PINS
RFPA End
10
GND
ORANGE
ORANGE
BLACK
RED
WHITE
GREEN
GND
BLACK
RF - 50 Ohm Coax
+5 Volts
+5 Volts
GND
SPI5-DATA
+12 Volts
SPI5-CLK
SPI5-LOAD
BLUE
GND
10
OF TRX BOARD
CONNECTS TO BOTTOM
ALL MALE PINS

Board to Board Jumper Cable
TRX End
Appendix "F"
Bill of Materials
Revision 0.1

FLEX-1500 Service Manual - V 0.1

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FlexRadio Systems

Author: Graham Haddock, KE9H

Copyright FlexRadio Systems, 2010

Alignment, Test and Calibration.... 11

Appendix A Schematic, PTRX (Transceiver) Board

Copyright FlexRadio Systems, 2010

Front View - FLEX-1500

Copyright FlexRadio Systems, 2010

Power Systems and Distribution

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Alignment, Test and Calibration

Copyright FlexRadio Systems, 2010

Test and Calibration

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

Troubleshooting and Diagnostics

Copyright FlexRadio Systems, 2010

Assembly and Disassembly

Copyright FlexRadio Systems, 2010

Install the four feet using the number 1 Phillips screwdriver.

Copyright FlexRadio Systems, 2010

Copyright FlexRadio Systems, 2010

37.6 - 54.0 MHz

25.3 - 37.6 MHz

17.0 - 25.3 MHz

11.4 - 17.0 MHz

7.7 - 11.4 MHz

5.2 - 7.7 MHz

3.5 - 5.2 MHz

2.3 - 3.5 MHz

1.6 - 2.3 MHz

0.88 - 1.6 MHz

0.49 - 0.88 MHz

Band Pass Filter Bank

Version 2010 APR 05

FLEX-1500 TRX BOARD

System Block Diagram

Flat Cable Assignments

Test 10 MHz Multiplier

Copyright FlexRadio Systems 2009, 2010

RF2 GND CTRL

CTRL GND RF2

CTRL GND RF2

11.4 - 17.0 MHz

17.0 - 25.3 MHz

RF2 GND CTRL

CTRL GND RF2

25.3 - 37.6 MHz

CTRL GND RF2

Physical Position on PCB:

Band 4 - 11.4 - 17.0 MHz

BANDPASS FILTER BANK - HIGH

CTRL GND RF2

RF2 GND CTRL

2.3 - 3.5 MHz

RF2 GND CTRL

CTRL GND RF2