FlexRadio Systems

FLEX-1500

Software Defined Radio

Service Manual

PRELIMINARY

Author: Graham Haddock, KE9H

Revision 0.1 1 Copyright FlexRadio Systems, 2010

 Contents

Introduction …………………………………………...….. 3

Theory of Operation …………………………………….. 4

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 2 Copyright FlexRadio Systems, 2010

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 3 Copyright FlexRadio Systems, 2010

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.

Revision 0.1 4 Copyright FlexRadio Systems, 2010

Revision 0.1 5 Copyright FlexRadio Systems, 2010
Revision 0.1 6 Copyright FlexRadio Systems, 2010
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.

I2C Bus

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.

I2C Bus Structure

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 7 Copyright FlexRadio Systems, 2010

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.

SPI Bus

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 Bit Pin Name Function Initial

Drain0 0 4 15M Active = 17 or 15 Meter Band 0 = Inactive
Drain1 1 5 160M Active = 160 Meter Band 0 = Inactive
Drain2 2 6 20M Active = 30 or 20 Meter Band 0 = Inactive
Drain3 3 7 6M Active = 6 Meter Band 0 = Inactive
Drain4 4 14 80M Active = 80 Meter Band 0 = Inactive
Drain5 5 15 10M Active = 12 or 10 Meter Band 0 = Inactive
Drain6 6 16 XMIT HIGH = Transmit mode, LOW = Receive mode 0 = Receive
Drain7 7 17 40M Active = 60 or 40 Meter Band 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 8 Copyright FlexRadio Systems, 2010

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.

Revision 0.1 9 Copyright FlexRadio Systems, 2010

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.

Revision 0.1 10 Copyright FlexRadio Systems, 2010

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.)

Revision 0.1 11 Copyright FlexRadio Systems, 2010

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

==

Revision 0.1 12 Copyright FlexRadio Systems, 2010

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"

Revision 0.1 13 Copyright FlexRadio Systems, 2010

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.

==

Revision 0.1 14 Copyright FlexRadio Systems, 2010

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.

Revision 0.1 15 Copyright FlexRadio Systems, 2010

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.

Revision 0.1 16 Copyright FlexRadio Systems, 2010

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.

Revision 0.1 17 Copyright FlexRadio Systems, 2010

 Appendix "A"
Schematic, PTRX (Transceiver) Board

Revision 0.1 Copyright FlexRadio Systems, 2010

 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
Switch 3 to 1 CODEC
1.6 - 2.3 MHz ADL5531 Mike In
Switch
74CBT3253
2.3 - 3.5 MHz USB
ANT/XV-TX 3.5 - 5.2 MHz A->D PTT In
-20 QSD THS4520 TAS1020B
dB Key In
5.2 - 7.7 MHz
+0 dBm TX Level I2S USB /
7.7 - 11.4 MHz BUS LED
CONTROL
11.4 - 17.0 MHz QSE
D->A Spkr/Headset
17.0 - 25.3 MHz Audio Out

25.3 - 37.6 MHz 26 kHz

LPF 24C128
37.6 - 54.0 MHz EEPROM
BITE Clocks I2C
BUS
CVT25-38.4 Johnson PTT Out
0 - 120 MHz Div by 2 I2C PTT/INT In
AD9951 I2C BUS
MUX I2C BUS
38.4 MHz
LPF Line In/Out
LO-I
DDS 120 SPI BUS FlexWire
0 - 60 MHz
10 MHz MHz 74HCT08
LO-Q Level Switch
Doubler SPI
20 MHz SN65LVDS34D Shift Control
74LVC74D To PA Gate
SN74LVC1G04 2 ea. PCA9555
SPI BUS I2C EXPANDER
 5V-PA/12
C1 Flat Cable Assignments
SSQ-105-01-F-D .1u 1.) SPI5-LOAD
9 10 +12V 2.) Ground

C275
7 8 GND 3.) SPI5-CLK

.1u
5 6

GND
3 4 4.) +12V
1 2
5.) SPI5-DATA
XVRX
J1G$1

.1u
P2 6.) Ground

C4
+3.3V
GND 7.) +5
D1 SPI5-LOAD/8
8.) +5
SD-73100 SPI5-CLK/8 9.) RF
GND

5.1k
R3
R1 10.) Ground

3.32k
619 SPI5-DATA/8

R4
GBLC03C FRTENDA/11
IC1 FRTENDB/11
GND

GND
R5
PE42641 619

.1u
C3
R6

16
619

2
RFTP1

VDD

NC
ANT 13 RF1 4

GND
V1

GND
10MW TX/COM
15 RF2
J2G$1
.1u

ANT 11
C6

8 RF3 RFC
BPFI/2

R73
0
D2
6 RF4 3
V2
SD-73100

GND
GND
GND
GND
GND
GND
GND

PAD
GND
5.1k
R2

C7 R8 C8 R9

1
5
7
9
10
12
14
GBLC03C 3.32k 3.32k
10n 10n
GND GND

GND
+3.3V
BITE/5
10 MHz Input C13
.1u BAS70-00-V-GS08 1M IC2
X1 T1 D3 74AHC1G04DBV
R87
.1u

6 1
C5

R72
2 2 4
4 3
20MHZ/9
D4 100
1267W

TC4-1T 1M
BAS70-00-V-GS08
C15
L1

R7 R10 +3.3V
.1u 10k
GND
FRONT END
.1u
C16

GND Copyright FlexRadio Systems 2009, 2010

VCC

GND
5

10 MHz Doubler GND

IC2P
GND
3

Test 10 MHz Multiplier GND

 +3.3V BAND 1 37.6 - 56 MHz MaxiSpring +3.3V

PE4259 K1 K2 PE4259
L2 C21 L3 C22 L4 C23 L5 C24

6
VDD RF1 1 1 RF1 VDD
5 RFC RFC 5
3 307n 307n 307n 307n 3
51p 82p 82p 51p
CTRL GND RF2 RF2 GND CTRL

C31
91p 130p 91p

10n
C25 C26 C27

GND
GND GND GND GND GND
GND
BAND01/11

10n
C33
+3.3V BAND 2 25.3 - 37.6 MHz MaxiSpring +3.3V

PE4259 K3 K4 PE4259
L6 C36 L7 C37 L8 C38 L9 C39

6
VDD RF1 1 1 RF1 VDD
5 RFC RFC 5
3 491n 491n 491n 491n 3
75p 110p 110p 75p
CTRL GND RF2 RF2 GND CTRL

C46
10n
4

4
C40 150p C41 200p C42 150p

GND
GND

BPFI/1 GND GND GND GND GND

BAND02/11
10n
C48

+3.3V +3.3V
BAND 3 17.0 - 25.3 MHz Delevan

PE4259 K5 C49 C50 C51 C52 PE4259 K6 BPFO/3

L10 L11 L12 L13
6

6
VDD RF1 1 1 RF1 VDD
5 RFC RFC 5
3 680n 680n 680n 680n 3
110p 180p 180p 110p
CTRL GND RF2 RF2 GND CTRL

C56
10n
4

4
C53 220p C54 300p C55 220p

GND
GND GND GND GND GND
GND

BAND03/11
10n
C57

+3.3V +3.3V
BAND 4 11.4 - 17.0 MHz Coilcraft CS1812

PE4259 K7 C58 C59 C60 C61 PE4259 K8

L14 L15 L16 L17
6

6
VDD RF1 1 1 RF1 VDD
5 RFC RFC 5
3 1.2u_CS 1.2u_CS 1.2u_CS 1.2u_CS 3
150p 220p 220p 150p
CTRL GND RF2 RF2 GND CTRL

C65
10n
4

4
C62 300p C63 390p C64 300p

GND
GND GND GND GND GND
GND

BAND04/11
10n
C66

Band 4 - 11.4 - 17.0 MHz

Band 8 - 2.3 - 3.5 MHz
Band 2 - 25.3 - 37.6 MHz
BANDPASS FILTER BANK - HIGH
Band 5 - 7.7 - 11.4 MHz Copyright FlexRadio Systems 2009
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 - 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
 +3.3V +3.3V
BAND 5 7.7 - 11.4 MHz Delevan 1812 Iron Core, Unshielded
K9 PE4259 C67 C68 C69 C70 PE4259 K10
L18 L19 L20 L21

6
VDD RF1 1 1 RF1 VDD
5 RFC 1.8u 1.8u 1.8u 1.8u RFC 5
3 220p 330p 330p 220p 3
CTRL GND RF2 RF2 GND CTRL

C74
10n
4

4
C71 430p C72 620p C73 430p

GND
GND GND GND GND GND GND
BAND05/11
10n
C75
+3.3V +3.3V
BAND 6 5.2 - 7.7 MHz Coilcraft FS
K11 PE4259 C76 C77 C78 C79 PE4259 K12
6 L22 L23 L24 L25

6
VDD RF1 1 1 RF1 VDD
5 RFC 2.4u_FS 2.4u_FS 2.4u_FS 2.4u_FS RFC 5
3 360p 560p 560p 360p 3
CTRL GND RF2 RF2 GND CTRL

C83
10n
4

4
C80 680p C81 1n C82 680p

GND
GND GND GND GND GND
GND

BAND06/11
10n
C84

+3.3V +3.3V
BAND 7 3.5 - 5.2 MHz Coilcraft FS
BPFI/2 K13 PE4259 C85 C86 C87 C88 PE4259 K14 BPFO/4
L26 L27 L28 L29
6

6
VDD RF1 1 1 RF1 VDD
5 RFC 3.9u_FS 3.9u_FS 3.9u_FS 3.9u_FS RFC 5
3 470p 750p 750p 470p 3
CTRL GND RF2 RF2 GND CTRL

C92
10n
4

4
C89 910p C90 1.3n C91 910p

GND
GND GND GND GND GND
GND

BAND07/11
10n
C93

+3.3V BAND 8 Coilcraft FS 2.3 - 3.5 MHz +3.3V

K15 PE4259 C94 C95 C96 C97 PE4259 K16

L30 L31 L32 L33
6

6
VDD RF1 1 1 RF1 VDD
5 RFC 5.6u_FS 5.6u_FS 5.6u_FS 5.6u_FS RFC 5
3 750p 1.3n 1.3n 750p 3

C101
CTRL GND RF2 RF2 GND CTRL

10n
4

4
C98 1.3n C99 2n C100 1.3n

GND
GND GND GND GND GND
GND

BAND08/11
10n
C102

BANDPASS FILTER BANK - MIDDLE

Copyright FlexRadio Systems 2009
 +3.3V +3.3V
BAND 9 1.6 - 2.3 MHz CoilCraft FS
K17 PE4259 C103 C104 C105 C106 PE4259 K18
L34 L35 L36 L37

6
VDD RF1 1 1 RF1 VDD
5 RFC 10u_FS 10u_FS 10u_FS 10u_FS RFC 5
3 910p 1.3n 1.3n 910p 3
CTRL GND RF2 RF2 GND CTRL

C110
10n
4

4
C107 2n C108 3n C109 2n

GND
GND GND GND GND GND GND
BAND09/11
10n
C111
+3.3V +3.3V
BAND 10 0.88 - 1.6 MHz CoilCraft FS
K19 PE4259 C112 C113 C114 C115 PE4259 K20
6 L38 L39 L40 L41

6
VDD RF1 1 1 RF1 VDD
5 RFC 10u_FS 10u_FS 10u_FS 10u_FS RFC 5
3 2.7n 5.6n 5.6n 2.7n 3
CTRL GND RF2 RF2 GND CTRL

C119
10n
4

4
C116 3.3n C117 4.7n C118 3.3n

GND
GND GND GND GND GND
GND

BAND10/11
10n
C120

C9 NP C10 NP
+3.3V +3.3V
BPFI/3 BAND 11 0.49 - 0.88 MHz CoilCraft FS BPFO/5
K21 PE4259 C121 C122 C123 C124 PE4259 K22
L42 L43 L44 L45
6

6
VDD RF1 1 1 RF1 VDD
5 RFC 15u_FS 15u_FS 15u_FS 15u_FS RFC 5
3 5.1n 12n 12n 5.1n 3

C128
CTRL GND RF2 RF2 GND CTRL

10n
4

4
C125 6.8n C126 9.1n C127 6.8n

GND
GND GND GND GND GND
GND

BAND11/11
10n
C129

+3.3V +3.3V
BAND 12 (BYPASS)
K23 PE4259 PE4259 K24
6

6
VDD RF1 1 1 RF1 VDD
5 RFC RFC 5
3 3

C130
CTRL GND RF2 RF2 GND CTRL

10n
4

GND
GND GND
GND

BAND12/11
10n
C131

BANDPASS FILTER BANK - LOW

Copyright FlexRadio Systems 2009

Note: 5.1n = 1.8n +3.3n

 RFTP2
+3.3V
R86 3.32k R85 619 +5V
IC3
C132 C11 R16 3.30
BPFO/4 ADL5531
C28 .1u

C135 1267W
R74 0 +3.3V 10n 330u

L46
K25

1
3
4
6
8
GND

16
SEQ: 0, 1, 3, 2

2
PE4259 GND GND

NC
NC
NC
NC
NC
C134
QSD

6
NC T2

VDD
RF1 VDD IC4

.1u

.1u
4 RF1 13 1
V1 RFC RFIN RFOUT 7 R11
5 2 6 1 7 6
RF2 15 R83 3 2
1Y 1C0
5
QSD-QP/6
95.3 1C1
11 ANT RF2 GND CTRL 4 3 4
240 1C2 QSD-IM/6

4
RFC RF3 8 5 3
PAD CLIN 1C3
TC4-1T

61.9

61.9
R81

R82
C137 R12

P$1
3 RF4 6 9 10
V2 GND GND 2Y 2C0 QSD-QM/6
11
10n +3.3V 95.3 2C1
20 dB
GND
GND
GND
GND
GND
GND
GND

12
PAD

2C2 QSD-IP/6
Attn GND 13
2C3
GND
14
12
10
9
7
5
1

14
A

2.87k
1.0 V 2

R13
B
1
1G
GND IC27 2G
15
~QSD/11
PE42641 C138

1.20k
74CBT3253PW

R15
R14
TXA/11 +3.3V 10u LO-I/10
619
R19 LO-Q/10
TXB/11 K26 GND GND QSE
IC5
619 PE4259 7 6

6
1Y 1C0 QSE-QP/6
1 RF1 VDD T3 5
ATN/11 RFC 1C1
5 6 1 4
1C2 QSE-IM/6
3 2 3
1C3
C18 RF2 GND CTRL 4 3
3.32k

3.32k

4
9 10
R84

R21

10n TC1-1T 2Y 2C0 QSE-QM/6

11
2C1
GND GND 12
2C2 QSE-IP/6
13
2C3
+3.3V
GND
GND GND 14
A
2
B
1
BITE/1 1G

2.00k
1.25 V 15

R18
2G ~QSE/11
GEN/11 74CBT3253PW
C143

1.20k
R20
+3.3V +5V C144
10n
10u
GND
GND GND

QSD / QSE
VCC

VCC
16

16

C146 QSD QSE C147

Copyright FlexRadio Systems 2009
.1u IC4G$2 IC5G$2 .1u
GND

GND
8

GND
 2.4 Hz HPF 34 kHz LPF
R24 R25 L48
QSD-IP/5 L1LP/7

330u
C148
100 1.60k 915W

THS4520
C150

12

10
11
C151

9
2.7n

CM
VOUT-
VIN+
/PD
.1u
PAD
R26
PAD
8 16
C152 C32 C35 C153 C154 VS+ VS- 120 C155
7 15
VS+ VS-
6 14
4.7n .1u 10u 10u .1u VS+ VS- R27 12n

VOUT+
5 13
VS+ VS-

VIN-
IC6
120

CM
NC
C156

1000W
C157
GND .1u GND

L49

4
2.7n

C158
330u
R28 R29 L50
QSD-IM/5 L1LM/7
100 1.60k 915W
+3.3V

1000W
From QSD To TLV320 Line 1 In

L51
R30 R31 L52
QSD-QP/5 L1RP/7
330u
C161
100 1.60k 915W

THS4520
C162

12

10
11
C163

9
2.7n

CM
VIN+
/PD

VOUT-
.1u
PAD
R32
PAD
8 16
C164 C34 C43 C165 C166 VS+ VS- 120 C167
7 15
VS+ VS-
6 14
4.7n .1u 10u 10u .1u VS+ VS- R33 12n

VOUT+
5 13
VS+ VS-

VIN-
IC7
120

CM
NC
C168
C169
GND .1u GND
1

4
2.7n
R34 R35 L53
QSD-QM/5 L1RM/7
330u
C171

100 1.60k 915W

R36 R37
QSE-IM/5 HPLP/7
Remove GROUND under OpAmp
47u
C172

C173 12.7 C174 12.7

Narrow bandpass for QSE?
.15u .15u
R38 R39
QSE-IP/5 HPLM/7
47u
C175

12.7 12.7
To QSE
R40 R41
From AIC33 HP Out BASEBAND PROCESSING
QSE-QM/5 HPRP/7 Copyright FlexRadio Systems 2009
47u
C176

C177 12.7 C178 12.7

.15u .15u
R42 R43
QSE-QP/5 HPRM/7
47u
C179

12.7 12.7

28 kHz LPF 67 Hz HPF

 +3.3V

L54 IC8 +3.3V

TPS79318
1267W C180 C181 5 1
DOUT/8 OUT IN
1.8 V
.1u 10u
DIN/8 C182 C183 C184

GND
4 3
NR EN
WCLK/8 L55 GND .1u 10u 10u
C185
BCLK/8 1267W 3.3 V

2
.1u
L56 3.3 V
MCLK/8
1267W GND
C187 C188 C189 C190

10u
C191 C186
.1u 10u .1u 10u
FROM QSD

.1u

3.3 V
BASEBAND
C196 C194 C193 C192

GND
10u

GND 1.8 V
L1LP/6 IC9 HPLP/6 TO QSE
16

37
38
39
40
41

44

36

24
17
25
10u

HPLM/6 BASEBAND

DOUT
MCLK

WCLK
AVDD_ADC

BCLK

DIN

IOVDD

DVDD

DRVDD
DRVDD
AVDD_DAC
3 18
L1LM/6 LINE1LP HPLOUT
4 19
LINE1LM HPLCOM HPRP/6
10u

5
LINE1RP HPROUT
23 AUDIO AMP
+5V

C195
6 22
L1RP/6 LINE1RM HPRCOM HPRM/6

10u

GND
GND
10u

7
LINE2LP
L1RM/6 8
LINE2LM TLV320AIC33IRGZ MONO_LOP
27 IC10
9 28 47n TPA0233 C197
LINE2RP MONO_LOM
C200
C198

C201 C199
10

3
LINE2RM
VDD 330u
.1u

C14 L57 650W 10n

1u
11 29 R17 R44 5 6 3 J3
AVSS_ADC

AVSS_DAC
MIC3L LEFT_LOP RIN RO
14 30 511 10k
IO/DVSS
MIC3R LEFT_LOM
SELECT

/RESET

DRVSS
DRVSS
13 31 L58 650W

1u
GPIO1
GPIO2

MICBIAS RIGHT_LOP R45

MFP3
MFP2
MFP1
MFP0

12 32 9 10 2
SDA

PAD
SCL

MICDET RIGHT_LOM R69 511 LIN LO

C202 1
C12 10k C203
2
SD BYP
4 330u
15

48
47
46
45
43
2
1

33
35
34

42

21
20

26

PAD

LINE_OUT
7 1 SPEAKER
47n ST/MO FILT 10n HEADPHONES
GND PAD
LINE_IN

GND +5V
C204

P$1
MIC_IN

GND R75 C205

GND 1u
I-SDA/11 10k GND
1u
I-SCL/11 Q2 GND GND
MICROPHONE FDV303 GND

C2
1u
+5V ~CRESET/8 C242
FWLO/12
.1u
FWLI/12 FlexWire Line In/Out
J4-1
+3.3V

J4-2
J4-3
J4-4 L59 650W
2.2k
R46

R67 100
J4-5
J4-6
J4-7 MPTT/8
CODEC
J4-8 R68 100 Copyright FlexRadio Systems 2009
C206 L60
C207 C208 650W C209 C210
.1u
10n 10n 10n 10n

GND GND GND GND GND

 +3.3V
Review USB Power chokes

C211
IC11

.1u

GND
24C128 DRESET/9
1 8
A0 VDD SPI~CSDDS/9
2 7
A1 PTC PTC/11 C-SCL/11
3 6
A2 SCL SPI-CLK/9
+5V 4 5
VSS SDA C-SDA/11
SPI-DATA/9

10.0k
C47 27p

R89
IC12 GND
C212
1 6 C133 27p
IO1 VCC
2 5 .1u C213 33p C136
IO2 IO4 MCLK/7
GND 27p
3 4 GND
GND IO3
GND QG2 BCLK/7 C139 27p
TPD4E0014DRLR
GND 6 MHz DIN/7
GND IC13A
1
33p DOUT/7 3
C214 SPI5-LOAD/1
2
WCLK/7

~CRESET/7 7408PW
IC14 Level Translator
1n 100p
C216 C215

GND
2 4
R49

44
43
42
41
40
39
37
38
36
35
34
32
3.09k 74LVC1G04DBV
~LED/12

/RESET

/CRESET
CDATO
CDATI
SCL

MCLKO2
MCLKO1
SDA
/VHEN

CSCLK

CSYNC

CSCHNE
46 23
XTALO P1.0
47 24 IC13B
J5 GND XTALI P1.1 PTT-OUT/12
48 25 4
PLLFILI P1.2
4 1 26 6
GND R50 PLLFILO P1.3 SPI5-CLK/1
3 4 L62 3 3 27 5
D+
D-
2
1
1.47k R51 5
6
MCLKI
PUR IC15 P1.4
P1.5
29
30 7408PW
VCC DP P1.6
1 2 7 TAS1020B 31 IC13C
R52 24.9 DM P1.7
90W 4 8 9
DVSS1 DVDD1

P3.2,/XINT
16 21 8

/MRESET
24.9 C217 C218 DVSS2 DVDD2 SPI5-DATA/1
28 33 10

EXTEN
/RSTO
DVSS3 DVDD3
120W

TEST
45 2 IC28 +5V

P3.0
P3.1

P3.3
P3.4
P3.5
NC1
NC2
AVSS AVDD
L63

47p 47p 7408PW

GND GND GND 5 1

OUT IN

47p
9
10
11
12
13
14
15
17
18
19
20
22
C219 C220 C221 C222 TPS79333-DBV
5V-USB/12

GND
4 3
~MRESET/12

C45
.1u .1u .1u 10u NR EN
C223 C17
GND
~DOT/12 L65
GND +3.3V

2
.1u .1u
~DASH/12 C224 C225 1267W
GND GND GND
FW-PTT-IN/11 .1u 10u
MPTT/7 C~INT/11
GND

+5V +3.3V
STREAMING USB CONTROLLER
VCC

IC13D Copyright FlexRadio Systems 2009

14

VCC
5

12 C226 C227
11
.1u IC13P IC14P .1u
13
GND
GND
7

7408PW
GND

GND
 +3.3V IC16 IC17 +3.3V
TPS79318 TPS79318
DDS-1.8V-DIGITAL DDS-1.8V-ANALOG
1 5 5 1
IN OUT OUT IN

C170
C231 C232 C235

C149
C145 68p C159
C228 C236 C237

GND

GND
3 4 4 3
EN NR .1u .1u NR EN
C230

68p
C233 10u +3.3V 10u C238 1u

68p
1u 68p .1u

2
.1u .1u

.1u
C234
GND
GND
GND IC18 GND
+3.3V

C140

C160

C142
2 4
DVDD AVDD
34 6 C239 C240 C241
DVDD AVDD
13
AVDD .1u .1u .1u

68p

47p

330p
43 16
DVDD_I/O AVDD
18
R53 1.20k AVDD
+3.3V +3.3V 36 19
RESET AVDD
25 GND
RFTP3 AVDD RFTP4
QG1 1 27
I/O_UPDATE AVDD
4 NC/TS 1 29

GND

GND
VCC K27 PE4259 AVDD
45 T4
6 SYNC_CLK

C19
C244 1 RF1 VDD TC1-1T

.1u
3 24
RFC DAC_RSET
5 9 23 3 4
.1u 2 REFCLK DACBP DDS/10
GND OUT R55 1.00k 3 IOUT
21
RF2 GND CTRL R76 0 8 2 R77 0
REFCLK
2

CVT25-38.4 20

R54
IOUT
C246 10 37 1 6

1k
GND CRYSTAL_OUT IOSYNC
GND 44
SYNC_IN
C247 .1u C248

C141
GND 11 GND

3.9k
R56
CLKMODESELCT
46 C249
.1u OSK 1u
12
LOOP_FILTER .1u

68p
35
PWRDWNCTL
39
CS
5 GND GND GND
AGND
C44
.1u

38 7
SDO AGND
40 14
20MHZ/1 SCLK AGND
41 15
SDIO AGND
17
AGND
3 22
DGND AGND
33 26
DRESET/8 DGND AGND
47 28
DGND AGND
42 30
DGND AGND
48 31
DGND AGND
EXP 32
EXP AGND

AD9951EP
GND GND

REF-SEL/11

SPI~CSDDS/8 DDS
SPI-CLK/8 Copyright FlexRadio Systems 2009

SPI-DATA/8
 Changed T5 to TC4-1T

Changed IC20 to SN65LVDS34D

+3.3V

C30 68p
+3.3V

C250
GND GND GND GND

.1u
IC19A
15p 27p 27p 15p RFTP5
4 5
R90
IC20 GND

1
PRE Q LO-I/5
C251 C252 C253 C254 2
D 24.9
100n 120n 100n 8
1A

VDD
2 3
DDS/9 1Y CLK
L66 L67 L68 6 1 7 1 6
R78 0 1B CLR Q
2

R79
200
C255 C256 C257 C258 4 3 6 74LVC74D
2A

GND
3
15p 27p 27p 15p 2Y
5
T5 2B
IC19B
GND GND GND GND TC4-1T R91

4
10 9
PRE Q LO-Q/5
12
D 24.9
GND
11
CLK
120 MHz Low Pass Filter 13 8
CLR Q
SN65LVDS34D
74LVC74D

Johnson Counter

+3.3V

LO QUADRATURE GENERATOR
14
C29

VCC

C259 Copyright FlexRadio Systems 2009

.1u IC19P
68p

GND
7

GND GND
 +3.3V

C260
+3.3V

.1u

GND

2.2k

2.2k

2.2k

2.2k

2.2k

2.2k
R57

R58

R59

R60

R61

R62
IC21
1 14
A0 VDD
2 13
A1 SDA C-SDA/12
3 12
A2 SCL
4 11 CPU I2C BUS
5
/INT0 /INT
10
C-SCL/12
SD0 SC1
6 9
7
SC0 SD1
8
C~INT/8
INTERNAL I2C BUS VSS /INT1

I-SDA/7 PCA9542A E-SCL/12

GND
+3.3V

C261
I-SCL/7 E-SDA/12 EXTERNAL I2C BUS

.1u

GND
IC22
FW-PTT-IN/12 (FlexWire)
1 24 E~INT
INT VDD
23 4
SDA I/O0.0
22 5
+3.3V

SCL I/O0.1
6
I/O0.2
21 7
A0 I/O0.3 BAND05/3
2 8
A1 I/O0.4 BAND08/3
3 9
R47 A2 I/O0.5 BAND02/2
10
I/O0.6
11
2.2k I/O0.7 PTC/8
R48 GND
13
I/O1.0 FRTENDB/1
14
2.2k I/O1.1 FRTENDA/1
15
R70 I/O1.2 BAND04/2
16
I/O1.3
17
2.2k I/O1.4
18
I/O1.5
19
I/O1.6
20
I/O1.7
12
VSS

PCA9555PW
GND
+3.3V
C262
.1u

GND

IC23
1 24
INT VDD
23 4
22
SDA I/O0.0
5
~QSD/5
SCL I/O0.1 ~QSE/5
6
21
I/O0.2
7
REF-SEL/9
A0 I/O0.3 GEN/5
2 8
3
A1 I/O0.4
9
TXB/5
A2 I/O0.5 TXA/5
10
I/O0.6 BAND07/3
11
I/O0.7 BAND11/4
GND
13
I/O1.0 BAND10/4
14
I/O1.1
I/O1.2
I/O1.3
15
16
BAND12/4
BAND01/2 FILTER AND SWITCH CONTROL
17 Copyright FlexRadio Systems 2009
I/O1.4 BAND03/2
18
I/O1.5 BAND09/4
19
I/O1.6 BAND06/3
20
I/O1.7 ATN/5
12
VSS

PCA9555PW
GND
5 Volt J6
3 +3.3V
2
5V-PA/1
Source
1
5V-USB/8
Select GND
MA03-1 R63 R64
GND GND8 R65 2.2k 2.2k
C263

+3.3V
~MRESET/8 KEY
1k 10n
J7

5
ON-OFF 4 3 3
~DOT/8

1
L69 650W
~LED/8 2
+5V SW1 +3.3V 1
6 1 L70 650W C264
IC25 ~DASH/8
6 13 10n
IN1 OUT1
7 14
IN2 OUT2
C20 C266

3.90k
R71 GND
16
R80
330u 1u PG
1.00k

5 15
10k
R88

EN FB/NC
+3.3V +3.3V
C267

C229
GND 1 20 IC26
GND GND

.1u
2 19
GND GND 10u
GND Q4 3 12 1 6
GND GND IO1 VCC GND
2N7002 9 11 2 5
GND GND IO2 IO4
10 PAD GND 3 4

2.2k
R66
GND PAD GND IO3
+12V
GND
TPS76833QPWP
TPD4E0014DRLR
GND GND GND GND
10n 10n 1n FLEXWIRE
DB-9
C268 C269 C270
J8-1
FWLI/7 J8-2
J8-3
Q3 J8-4
FDV303 J8-5
PTT-OUT/8 E-SCL/11 J8-6
J8-7
J8-8
TEST POINTS GND E-SDA/11 J8-9

GROUNDS POWER C271 C274 J8-G

FW-PTT-IN/11 FWLO/7
GND GND1 +5V
+5 10n .1u
GND GND2 +3.3V
+3.3
GND GND3 GND
GND GND4
+3.3V

SPI BUS (3.3 V) I2C BUS

SPI-CLK/9 TP7
TP8 C-SCL/11 I/O AND POWER
VCC

TP2 C276
SPI-DATA/9
5

TP4 C-SDA/11 Copyright FlexRadio Systems 2009

TP3 .1u
SPI~CSDDS/9 GND6 GND IC24G$3
GND GND5
GND

GND
2

GND
 Flat Cable Assignments Mike Connector Assignments FlexWire Assignments
1.) SPI5-LOAD
1.) N.C. 1.) Ground
2.) Ground
2.) N.C. 2.) LINE INPUT
3.) SPI5-CLK
3.) Mike Bias (+5V) 3.) PTT OUT (New, was GND)
4.) +12V
4.) Mike Ground 4.) PTT IN (New, was interrupt)
5.) SPI5-DATA
5.) Mike In 5.) Ground
6.) Ground
6.) Mike PTT In 6.) I2C-SCL
7.) +5
7.) Ground 7.) I2C-SDA
8.) +5
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 I2C ADDRESS ASSIGNMENTS
1 x 4 pattern on 0.1 in. grid 2 x 3 pattern on 0.1 in. grid
1.) USB / CPU - I2C MASTER ONLY
TP7 TP3 TP2 GND 2.) CODEC - 0011 0000
BCLK MCLK
3.) EEPROM - 1010 0000
TP9 TP11
4.) I2C MUX - 1110 0000
CLK CS DATA GND
DIN WCLK 5.) EXPANDER 0 - 0100 0000
TP10 TP12
6.) EXPANDER 1 - 0100 0010
DOUT
TP13
GND

I2C (INTERNAL COMPUTER) BRIDGE ASSIGNMENTS

1 x 3 pattern on 0.1 in. grid

SCL TP8
PORT AND CONNECTOR DEFINITIONS
SCA TP4 Copyright FlexRadio Systems 2009

GND GND

NOTE: Jumper SCA to GND to remove EEPROM from address space

 Appendix "B"
Schematic, PPA05 (RFPA) Board

Revision 0.1 Copyright FlexRadio Systems, 2010

 Relay Switched
Low Pass Filter Bank

160 M

80 M
RD00HVF1 RD16HHF1
Switch 60/40 M Relay ANT

30/20 M

17/15 M
Adj Adj
Bias Bias 12/10 M
6V
Switch
6M
Bias Control

Bias control, T/R control

Filter Bank 13.8 V Input

13.8 V
TPIC6B595 DC Power
SPI Relay Driver Filtering

FLEX-1500 5V
Reg.
5 Watt Linear PA
Version 2010 MAR 05
6V
Reg.
TO FLEX 1500 MAIN BOARD SPI BUS (5V)
 +12V/1 +12V +12V
L20 L17

C61 C63 1267W C62 160W C102

C54
10n
GND
.1u 100u 470u .1u

.1u
C55
GND GND GND GND

C96
10u

DM+
1u
C101
GND T3 XFMR_0.5BINOC

R2
1

DM-
C56
GND
240p 0
LPF-IN/2
Q1 R9
RD00HHS1 T1 RD16HHF1 NP
3 Q3G$1 J3
4 R17
D 2 D

C51
.1u
R1 5 R3
10 G 1 1 G
S S NP
GND

R5
R7
49.9
GND C21 C97 C98 GND

C50 49.9
1u
10n .1u 1u
LPF-OUT/2

GND
C20 C99 C100

C52
.1u
10n .1u 1u
GND
~ 2.6 V 10

C95
10n
+5V ~ 4.9 V 9
GND J1G$1
8
ANT
3
4
5 SD-73100
+6V +12V
R20
10.0k

GND

1
3
L16 1 12
R11
10.0k

R6 R10 D1 GND

R13
1.8k
C53

D3
PE4259
2.00k 1267W GBLC03C

3
3
6 2 K15
XMIT/4

VDD RF1
C47 2 2 .1u

BAS70
GND GND TX2SA-12V
4 C48 C64
2k

1
1

CTRL GND RF2

C60 .1u R8
GND

5 RFC
.1u 10n

K16
2k

R14
3.24k
1u
GND GND
GND GND
GND GND GND
R19
1k

RF-I/O/4 GND RF POWER AMPLIFIER

R4 R15 Copyright FlexRadio Systems 2009
XMIT/4
3.24k 10.0k
GND
 +12V +12V
C32 12p C33 15p C19 3.6p

C83
.1u
GND
6 Meters

GND
.1u
C79
LPF-IN/1 L7 L8 L21 LPF-OUT/1

1
9
4
9
4
1
130n 169n 169n
K1 K2
TX2SA-12V TX2SA-12V

8
5
3
8
3
5

12
10
10
12
C1 18p C2 68p C3 68p C49 24p

GND
10n
C69
GND GND GND GND

C65
6M/4 10n
GND

C34 12p C35 39p

+12V +12V
12/10 Meters
C84
.1u

L9 L10
GND

GND
.1u
1
4
9
9
4
1

C80
307n 246n
K3 K4
TX2SA-12V TX2SA-12V

LPF-IN-A
5
3
8
8
3
5

12
10
10
12

C22 82p C23 180p C24 75p

GND GND GND

GND
C66
10n

10n
C70
10M/4
GND

C36 22p C37 56p

+12V +12V
17/15 Meters
C85
.1u
LPF-OUT-A

L11 L12
GND

GND
LPF-IN-A/3

.1u
1
4
9
9
4
1

C81
380n 307n
K5 K6
TX2SA-12V TX2SA-12V LPF-OUT-A/3

5
3
8
8
3
5

12
10
10
12

C25 120p C26 220p C27 82p

GND GND GND

GND
C67
10n

10n
C71
15M/4
GND

C38 39p C39 200p C40 150p

+12V +12V
30/20 Meters
C86
.1u

L13 L14 L15

GND

GND
.1u
1
4
9
9
4
1

C82
538n 307n 307n
K7 K8
TX2SA-12V C45 TX2SA-12V

5
3
8
8
3
5

12
10
10
12

C28 150p C29 220p 36p C30 180p C31 82p

GND GND GND GND GND

C68
10n

GND
GND

10n
C72
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
6M
 C7 39p C8 120p
+12V +12V
60/40 Meters

C90
.1u
L1 L2

GND

GND
.1u
1
4
9
4
9
1

C87
K9 1.5u 1.2u
K10
TX2SA-12V C46 TX2SA-12V

5
3
8
3
5
8

12
10
10
12
C4 330p C5 300p 300p C6 300p

GND GND GND GND

GND
GND GND GND GND

C73
10n

10n
C76
40M/4
GND

C9 91p C10 270p

+12V +12V
80 Meters
C91
.1u

L3 L4
GND

GND
.1u
1
9
4
4
9
1

C88
K11 2.2u 1.8u
K12
TX2SA-12V TX2SA-12V

8
5
3
3
5
8

12
10
10
12

LPF-IN-A/2 C11 330p C12 910p C13 330p LPF-OUT-A/2

GND GND GND

GND
GND GND GND GND
C74
10n

10n
C77
80M/4
GND

C14 150p C15 470p

L5 L6
+12V 10u 8.2u +12V
160 Meters
C92
.1u

L22 L23
GND

GND
.1u
1
9
4
4
9
1

C89
K13 10u 8.2u
K14
TX2SA-12V TX2SA-12V

8
5
3
3
5
8

12
10
10
12

C16 1.2n C17 2.2n C18 1n

GND GND GND

GND
GND GND GND GND
C75
10n

10n
C78
160M/4
GND

All Coils this page are Physical order on board is: 60/40 M LOW FREQUENCY LPF BANK
10 M Copyright FlexRadio Systems 2009
CoilCraft 1812 CS Series 80 M
17/15 M
160 M
30/20 M
6M
 Add DIODE +13.6 Volts
+12V INPUT
L19 L18 J2
F1 1
3
160W 160W 2
+5V +12V C59 C58 D4 MINI ATO C57 KLDX-0202
Flat Cable Assignments FUSE
.1u .1u S1A .1u
P1 1.) SPI5-LOAD GND
1 2 2.) Ground GND GND GND GND
3 4
5 6 3.) SPI5-CLK
7 8 C93 4.) +12V
RF-I/O/1 9 10
.1u 5.) SPI5-DATA
M05X2JTAG 6.) Ground
GND GND +5V
7.) +5 +12V IC1
8.) +5
C94 MC78T05 +5V
9.) RF 1 3
.1u VI VO

SPI5-LOAD
SPI5-CLK
SPI5-DATA
Test Points 10.) Ground
C43 GND C41
2

DATA GND 1u .1u

LOAD
GND GND GND
CLK
GND +5V
U1
TPIC6B595
GND +12V/1
1SS400T1G +6V

1
2
20
D2
NC VCC NC Switched 6 Volts
9 4 R12
~G D0 15M/2 U2 L78L06_D
12 RCK D1 5 4.7k +6V
8 6 160M/3 R16 8 Vin 1
~SRCLR D2 20M/2 Vout
13 7 Q4
SRCK D3 6M/2 NTR1P02T1 10 C44 C42
3 SERIN D4 14 4 NC NC
5
15 80M/3 GND
D5 10M/2
2
3
6
7

18 16 1u .1u
SEROUT D6
D7 17
40M/3
GND GND
GND GND GND
GND

11
19
10
XMIT/1
Test Points
GND1 GND XMIT

GND
GND2
GND3 INTERCONNECT AND POWER
GND4 Copyright FlexRadio Systems 2009
 Appendix "C"
PC Board Component View

Revision 0.1 Copyright FlexRadio Systems, 2010

 1

+ + + +

FlexRadio Systems Copr. 2010

 3 2 1

FlexRadio Systems Copr. 2010

1 2 3
 Appendix "D"
Test Points

Revision 0.1 Copyright FlexRadio Systems, 2010

 TEST POINTS

3.3 Volts

I2C Bus
+

SPI Bus (3.3 V)

+
+
+

I2S Bus
1.8 Volts
FlexRadio Systems Copr. 2010

3.3 Volts
(CPU Only)
1

5.0 Volts
 +5Volts

1 2 3
"XMIT" Test
Point

FlexRadio Systems Copr. 2010

SPI Bus
(5 Volt)

+6 Volts +12 Volts

(Keyed)

Driver
Bias
3 2 1

Adjust

Driver current
metering PA Bias Adjust
 Appendix "E"
Test Fixture

Revision 0.1 Copyright FlexRadio Systems, 2010

 FLEXWIRE

DB-9 CONNECTOR

1 Shield
GND
R1 1k RING
PHONES
AUDIO LINE-IN 2
Red
TIP
R2 1k White
3
PTT-OUT
SLEEVE
4
PTT-IN
Red RING
KEY
5
GND
TIP

6 White
I2C-SCL N.C.
Shield SLEEVE

I2C-SDA 7
N.C.

MICROPHONE -- RJ45
+12 VOLTS 8
N.C.
1
N.C. N.C.
9 White of Blue
AUDIO LINE-OUT
2
N.C. N.C.

3
N.C. +5V

4
N.C. GND

5
MIKE

Orange 6
MIKE PTT

7
N.C. GND

8
N.C. N.C.

NOTES:

1. FlexWire Line-Out drives Microphone In FLEX-1500 TEST FIXTURE

2. Speaker/Phones drive FlexWire Line-In Audio And Switching Test Cable
3. PTT-OUT from FlexWire drives FW-PTT-IN, MPTT, DOT, & DASH
 10 MHz

BNC to BNC Cable

10 MHz
USB
XVRX
USB to Host Computer
CONTROLLED
BNC to BNC Cable
XVRX
FLEX-1500 SIGNAL GENERATOR
XVTX/C
UNDER
BNC to BNC Cable
XVTX/C
TEST

POWER DUMMY
BNC to BNC Cable MASTER LOAD
ANT
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
 RFPA End TRX End

2 BLUE SPI5-LOAD 1

1 BLACK GND 2

4 GREEN SPI5-CLK 3

3 RED +12 Volts 4

ALL FEMALE PINS 6 WHITE SPI5-DATA 5

ALL MALE PINS

5 BLACK GND 6

8 ORANGE +5 Volts 7
CONNECTS TO BOTTOM
CONNECTS TO TOP
7 ORANGE +5 Volts 8
OF TRX BOARD
OF RFPA BOARD

10 9
RF - 50 Ohm Coax

9 10
GND GND

FLEX-1500 TEST FIXTURE

Board to Board Jumper Cable
 Appendix "F"
Bill of Materials

Revision 0.1 Copyright FlexRadio Systems, 2010