freecalypso-docs: CMU200-maintenance-notes annotate

annotate CMU200-maintenance-notes @ 87:78d4d362c086

FC-handset-spec section 2.4.1: update for PWT melodies and BUZM

author	Mychaela Falconia <falcon@freecalypso.org>
date	Fri, 15 Apr 2022 04:55:26 +0000
parents	7fc66c5b54dd
children	2ac06a49dfbc

rev	line source
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	1 Rohde & Schwarz CMU200 instrument is an absolutely essential piece of test
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	2 equipment for anyone in the business (or hobby) of designing and building his
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	3 or her own personal cellphones of 2G and/or 3G variety. I (Mother Mychaela)
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	4 currently only work with GSM, but depending on installed hw and sw options,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	5 CMU200 instruments also support AMPS, IS-136, IS-95 (CDMA 2G) and both WCDMA
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	6 and CDMA2000 varieties of 3G.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	7
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	8 Over the course of owning and maintaining a CMU200 instrument since 2017 and
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	9 having had to repair it twice now (as of 2022-01), and having conversed with
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	10 another CMU200 owner who had to repair his instrument in the same way, I
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	11 started observing a pattern in that many of these instruments are now failing
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	12 in the field in exactly the same ways. All of these failures happen in the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	13 RXTX board, and the purpose of this article is to educate other CMU instrument
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	14 owners about these failures and most importantly, how to repair them.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	15
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	16 Credit attribution
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	17 ==================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	18
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	19 I sincerely thank Michael Katzmann, NV3Z / VK2BEA / G4NYV, for his invaluable
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	20 help in reverse-engineering the insides of the culprit RXTX board, identifying
84 d2fef140ed53 CMU200-maintenance-notes: typo fix Mychaela Falconia <falcon@freecalypso.org> parents: 83 diff changeset	21 various critical components on that board, including the ones that habitually
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	22 fail, and identifying Eccosorb-caused galvanic corrosion as the root cause of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	23 these failures. Without his help, I would not have made it this far!
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	24
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	25 What is this RXTX board
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	26 =======================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	27
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	28 This board is common among CMU200, CMU300 and CRTU-RU instruments from R&S - or
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	29 at least these are the ones I know - maybe there are others I don't know about.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	30 This board encapsulates the instrument's main RF Rx and Tx chains: on the Rx
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	31 side it takes RF input from the front end and performs triple (or quadruple,
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	32 explained later in this article) IF downconversion to 10.7 MHz IF3, and on the
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	33 Tx side it takes 13.85 MHz IF3 input and upconverts it to RF output, going
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	34 through IF2 and IF1 in the process - triple or quadruple IF in both directions,
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	35 as explained in more detail later in this article.
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	36
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	37 Every CMU200 instrument always has one RXTX board - it is an absolutely required
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	38 component irrespective of option configurations. The hardware architecture of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	39 this instrument also has a place for an optional second RXTX board, providing a
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	40 complete second Rx and Tx channel - however, as far as I can tell, CMU200
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	41 software won't do anything with it, i.e., there are no test modes or
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	42 applications in CMU200 software repertoire that can make use of a second RXTX
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	43 board. Instead it seems that configurations with two RXTX boards are better
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	44 supported on the CRTU-RU platform - but I know next to nothing about that one.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	45
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	46 Also note: if your CMU200 is equipped with Aux Tx model B96 (as opposed to B95),
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	47 there is an output from that B96 add-on that goes to the front end input that
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	48 was originally meant for second RXTX.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	49
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	50 RXTX board failures
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	51 ===================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	52
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	53 In terms of externally visible symptoms, almost all CMU200 units are now failing
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	54 in the same ways:
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	55
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	56 1) If Tx side fails, the visible symptom is completely absent or extremely weak
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	57 output, and the internal loopback test fails with no signal detected at any of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	58 the frequencies in the test sequence. A key point is that this failure mode is
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	59 independent of the selected output frequency.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	60
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	61 2) If Rx side fails, different frequency ranges are affected differently. As I
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	62 shall explain momentarily, there are two different IF1 Rx paths inside the RXTX
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	63 board: one handles the frequency range from > 1200 to <= 2200 MHz, and the other
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	64 handles lower (<= 1200 MHz) and higher (> 2200 MHz) input frequencies. When a
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	65 given RXTX board develops Rx path failure, this failure happens separately in
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	66 each of these two IF1 Rx paths. The resulting symptoms vary: if only one of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	67 the two IF1 Rx paths fails, then only that frequency range will be affected,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	68 or if both fail, the observed loss will typically be different between the two
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	69 frequency ranges. The failure symptom is unexpected large attenuation:
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	70 sometimes around 5 to 6 dB of loss, othertimes as much as 25 dB of loss.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	71
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	72 The internal loopback test invoked from the Maintenance menu is a good first
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	73 step in diagnosis. In this test the instrument software configures both Rx and
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	74 Tx chains to connect to RF1 (and then RF2 if you press Continue), and then it
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	75 tests a longish list of different frequencies in sequence, spanning the full
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	76 range from 10 to 2700 MHz. For each test frequency, the instrument software
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	77 configures both the signal generator and the Rx chain, and it reports what was
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	78 measured on Rx vs. what was put out on Tx. The test is considered a failure if
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	79 nothing was received or if the Rx signal level was too far from the expected
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	80 value, otherwise the test is declared as passed.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	81
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	82 If the loopback test fails at every frequency with no signal detected, then you
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	83 don't really know what's going on, and you will need to manually test Rx and Tx
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	84 separately (using an external spectrum analyzer and an external signal
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	85 generator) in order to figure out what is broken. However, out of the commonly
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	86 observed failure modes, dead Tx will produce this symptom.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	87
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	88 If the Tx side is OK but Rx IF1 filters (one or both paths) have gone bad, the
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	89 visible symptom in the loopback test will be Rx signal level that is lower than
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	90 it should be. The instrument software may declare the test as either passed or
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	91 failed depending on the magnitude of the error: in this Mother's experience,
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	92 when one of the two IF1 paths on my CMU200 developed a loss of some 5.8 dB, the
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	93 loopback test was reported as passing - but a closer look at the numbers in the
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	94 report window showed the unexpected attenuation.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	95
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	96 Because different input frequency ranges are handled via different Rx paths as
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	97 explained in the following section, when Rx IF1 filters fail, the loss behaviour
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	98 will be frequency-dependent. In the internal loopback test, you will see one
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	99 behaviour for frequencies from 10 to 1200 MHz, then a marked change for
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	100 frequencies from 1205 to 2200 MHz, and then another change (most likely a
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	101 reversion to low frequency behaviour) at the highest frequencies above 2200 MHz.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	102
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	103 We do not currently know if there are any other failure modes elsewhere in the
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	104 CMU200 instrument that can also cause a stepwise change in behaviour at these
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	105 frequency cutover points. It is my (Mother Mychaela's) suspicion that the front
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	106 end may have some filters too, each covering a wide frequency swath, with
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	107 instrument software switching these filters depending on the configured
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	108 listening frequency - but we don't know for certain if any such additional
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	109 filters are there or not. If you find yourself wondering whether the problem
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	110 you are seeing is in the RXTX board or the front end, the best way to narrow it
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	111 down would be to remove the semi-rigid coax pieces that carry RF between the two
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	112 and use an external spectrum analyser to look at the Tx output from the RXTX
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	113 board and/or the Rx output from the front end.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	114
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	115 RXTX board architecture explained
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	116 =================================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	117
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	118 Unfortunately R&S' official service manual for CMU200 instruments is only a part
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	119 swapper guide: it tells you which boards do what in general terms and tells you
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	120 how to remove and replace each part, but no schematics, and no detailed
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	121 explanation of what happens inside each board. They do provide a little bit of
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	122 info: I draw the reader to the block diagram on page 3.2 of this manual - this
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	123 block diagram does provide an important starting point for understanding what
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	124 happens inside the RXTX board - however, it is simplified and incomplete.
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	125
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	126 In the Tx direction, 13.85 MHz IF3 comes in from the digital board - or from
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	127 B68 board in WCDMA test modes. This Tx IF3 is mixed with Tx LO3 to produce
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	128 Tx IF2. This Tx IF2 is fixed at 487.52 MHz, thus one would think that Tx LO3
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	129 frequency ought to be fixed as well - but it seems to be a synthesized variable
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	130 frequency, and the manual describes it as "LO3TX with small tuning range".
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	131 Calculations done by Michael VK2BEA put Tx LO3 at 473.67 MHz (needs
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	132 confirmation), but it is still not clear why it is a synthesized frequency
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	133 "with small tuning range", as opposed to simply fixed.
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	134
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	135 Tx IF2 of 487.52 MHz is then passed through a pair of identical SAW filters,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	136 Sawtek 855272 - two cascaded identical filters, with an amplifier in between.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	137 This SAW filter has a center frequency of 479.75 MHz with 20 MHz bandwidth,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	138 thus the passband spans from 469.75 to 489.75 MHz. Notice how Tx IF2 of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	139 487.52 MHz stands just 2.23 MHz away from the edge of the passband - is it
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	140 intentional? What are they filtering? Without original design notes, we can
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	141 only guess. As I shall explain later in this article, one of these two Tx IF2
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	142 SAW filters is a component prone to failure.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	143
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	144 [Note from Michael VK2BEA: "The LO frequency is only 13.85 MHz from the IF. It
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	145 makes sense to shift this to the edge of the passband to help the suppression
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	146 of LO feed through. Also explains the use of SAW filters (sharp skirts) and
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	147 that there are two."]
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	148
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	149 After these cascaded SAW filters, Tx IF2 is mixed with LO2. Unlike LO1 and LO3,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	150 there is only one LO2 for both Rx and Tx, and it is fixed at 1329.6 MHz. When
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	151 Tx IF2 at fixed 487.52 MHz is mixed with LO2 at fixed 1329.6 MHz, the output of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	152 this mixer will always contain two frequencies: 842.08 MHz and 1817.12 MHz.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	153 These are the two possible Tx IF1 frequencies, and there is a frequency-
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	154 selective filter for each of these two Tx IF1 modes. Based on the final output
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	155 frequency to be generated, instrument control software selects either low or
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	156 high Tx IF1, controlling switches before and/or after the filters. I have not
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	157 investigated to see if the frequency ranges for high vs. low Tx IF1 are the same
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	158 as on the Rx side or not - maybe they are the same, maybe they are different.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	159
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	160 After Tx IF1 output is combined or switched from the two filters, it is mixed
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	161 with Tx LO1 to produce an output that may or may not be final RF. The mixer
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	162 that does this job is MACOM SM4T, which is one of the larger, prominently
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	163 visible components on the board. Tx LO1 has "large tuning range and very fine
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	164 frequency resolution used for setting the desired transmitter frequency" - quote
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	165 from the manual; by doing some frequency arithmetics, we can see that this Tx
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	166 LO1 tuning range needs to span from 1827.12 to 3042.08 MHz in order to produce
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	167 output frequencies from 10 to 2200 MHz starting from 842.08 MHz or 1817.12 MHz
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	168 IF1. (LO1 - IF1 is the desired output frequency, whereas the sum will be a
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	169 much higher frequency above 2.7 GHz - I presume that the latter must be
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	170 suppressed by some LPF somewhere.)
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	171
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	172 The "RF" output from Tx SM4T mixer (LO1-IF1 as explained above) is indeed the
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	173 final RF output going to the front end for output frequencies below 2200 MHz.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	174 In the uppermost frequency range of 2200 to 2700 MHz, a fourth mixer and LO
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	175 stage come into play - NOT shown on the block diagram in the manual! In this
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	176 highest frequency range, the output from SM4T mixer should be considered a
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	177 fourth IF - but because it is not covered at all in the manual and not named,
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	178 we have to invent our own name for it. I (Mother Mychaela) propose that we
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	179 call it IF0, and refer to the corresponding LO as LO0 - this way we remain
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	180 consistent with official naming that puts IF1 closest to RF and IF3 closest to
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	181 digital.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	182
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	183 The preliminary analysis by Michael VK2BEA is that Tx LO0 frequency is fixed at
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	184 3318.46 MHz (same as its counterpart on the Rx side), with IF0 (taking the place
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	185 of lower RF) ranging from 1118.46 to 618.46 MHz (reverse range) to produce final
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	186 output frequencies of 2200 to 2700 MHz. However, these numbers have NOT been
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	187 confirmed by actual measurements yet.
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	188
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	189 On the Rx side the same process happens in reverse, but the specific frequencies
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	190 used for IF1, IF2 and IF3 are slightly different. At first there is a stage
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	191 that only kicks in for frequencies above 2200 MHz (bypassed otherwise), and
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	192 then there is an SM4T mixer (identical to the one on Tx side) that takes in RF
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	193 and Rx LO1 to produce Rx IF1. High-side injection is used, i.e., Rx LO1 is
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	194 programmed to generate frequency equal to the external RF of interest PLUS the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	195 desired Rx IF1 output.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	196
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	197 Rx LO1 is programmed as follows by the instrument control software:
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	198
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	199 * Rx IF1 will be at 1816.115 MHz (call it high) if the listening frequency is
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	200 <= 1200 MHz or > 2200 MHz;
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	201
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	202 * Rx IF1 will be at 843.085 MHz (call it low) if the listening frequency is in
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	203 the intermediate range, i.e., 1200 MHz < RF <= 2200 MHz.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	204
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	205 In addition to programming Rx LO1 to produce the desired IF1 per the logic
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	206 above, the software also controls switches that select one or the other IF1
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	207 filter: either the filter that passes low IF1 or the one that passes high IF1.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	208
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	209 The filters used for low and high IF1 modes are the same on both Rx and Tx
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	210 sides. (The actual frequencies are slightly different, but in each case they
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	211 fit within the passband of the common filter parts.) The filter for low IF1 is
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	212 Murata DFC3R836P025HHD, package marking 836 CD, and the one for high IF1 is
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	213 DFC31R84P075HHA, package marking CR. The two filter packages are NOT the same
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	214 mechanically: the low IF1 filter is physically larger. Both parts are ceramic
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	215 monoblock filters from the same family, and it seems that these filter parts
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	216 were originally made for mobile phones, not for RF metrology instruments: the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	217 "836 CD" filter is for AMPS uplink band, and the "CR" filter is for DCS downlink
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	218 band.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	219
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	220 On the Tx side of the board there are only two IF1 filters: one for low Tx IF1
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	221 and one for high Tx IF1. However, on the Rx side there are 3 of these ceramic
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	222 filters in total: two for high IF1 (two cascaded identical filters with an
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	223 amplifier in between) and just one for low IF1. Why am I covering these filters
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	224 in so much detail? You probably guessed it: they are components that fail, as
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	225 will be covered shortly.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	226
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	227 After the selection of either low or high IF1 filter, Rx IF1 coming out of the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	228 selected filter (either 843.085 MHz or 1816.115 MHz) is mixed with LO2, which is
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	229 shared between Rx and Tx sides and fixed at 1329.6 MHz. The output of this
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	230 mixer is Rx IF2 at 486.515 MHz. This Rx IF2 then passes through a pair of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	231 cascaded Sawtek 855272 filters, two identical filters with an amplifier in
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	232 between, exactly the same as on the Tx side. Then there is Rx LO3 and the final
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	233 mixer, producing Rx IF3 at 10.7 MHz that goes to the digital board, to the rear
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	234 panel BNC output and to the WCDMA board (B68) if the latter is present.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	235
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	236 Frequency conversion tables
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	237 ===========================
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	238
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	239 Michael VK2BEA worked out a pair of frequency conversion tables, one for Rx and
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	240 one for Tx. Here are these tables, with further corrections by Mother Mychaela:
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	241
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	242 Rx frequency conversion, RF to IF1:
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	243
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	244 RF (MHz) LO0 (MHz) IF0 (MHz) LO1 (MHz) IF1 (MHz)
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	245 ----------------------------------------------------------------------
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	246 10-1200 1826.115-3016.115 1816.115
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	247 1200-2200 2043.085-3043.085 843.085
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	248 2200-2700 3318.46 1118.46-618.46 2934.575-2434.575 1816.115
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	249
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	250 Rx frequency conversion, IF1 to IF3:
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	251
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	252 IF1 (MHz) LO2 (MHz) IF2 (MHz) LO3 (MHz) IF3 (MHz)
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	253 --------------------------------------------------------
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	254 1816.115 1329.6 486.515 497.215 10.7
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	255 843.085 1329.6 486.515 497.215 10.7
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	256
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	257 Tx frequency conversion, IF3 to IF1:
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	258
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	259 IF3 (MHz) LO3 (MHz) IF2 (MHz) LO2 (MHz) IF1 (MHz)
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	260 ---------------------------------------------------------
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	261 13.85 473.67 487.52 1329.6 1817.12
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	262 13.85 473.67 487.52 1329.6 842.08
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	263
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	264 Tx frequency conversion, IF1 to RF:
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	265
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	266 IF1 (MHz) LO1 (MHz) IF0 (MHz) LO0 (MHz) RF(MHz)
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	267 ------------------------------------------------------------------
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	268 1817.12 1827.12-3017.12 10-1200
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	269 842.08 2042.08-3042.08 1200-2200
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	270 1817.12 2935.58-2435.58 1118.46-618.46 3318.46 2200-2700
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	271
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	272 Notes:
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	273
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	274 * In Michael's original version each table covered the full chain from RF on
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	275 one end to IF3 on the other end, but I (Mychaela) had to split each table
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	276 into two in order to fit within 80 columns.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	277
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	278 * The numbers for LO3 (473.67 MHz for Tx, 497.215 MHz for Rx) are from Michael;
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	279 I (Mychaela) have not verified them.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	280
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	281 * All details for the IF0/LO0 stage (upper frequency range) are from Michael;
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	282 his notes indicate that the numbers are confirmed for Rx, but not for Tx.
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	283
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	284 How these RXTX boards fail
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	285 ==========================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	286
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	287 There are 3 specific components on this RXTX board that have been seen to fail
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	288 over and over in the field:
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	289
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	290 * The second of the two cascaded IF2 SAW filters (Sawtek 855272) on the Tx side
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	291 often fails, breaking the Tx chain (output totally gone or extremely weak)
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	292 for all frequencies. Note that there are a total of 4 identical Sawtek 855272
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	293 filters on this board (2 on Rx side, 2 on Tx side), and only one of the four
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	294 fails: Tx side, second filter in the cascade.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	295
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	296 * The "836 CD" filter on the Rx side is prone to failure. When it fails, the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	297 visible symptom is severe attenuation in measured Rx signal levels for input
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	298 frequencies in the 1200 MHz < RF <= 2200 MHz range. Only the Rx side filter
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	299 fails, not the identical one on the Tx side!
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	300
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	301 * One of the two cascaded "CR" filters on the Rx side likewise fails - this time
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	302 it is the first one in the cascade. The other two identical "CR" filters on
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	303 the same board (the second in cascade for Rx and the one for Tx) are likewise
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	304 NOT seen to fail.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	305
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	306 The root cause of all 3 component failures has been traced to galvanic corrosion
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	307 caused by direct contact between these components and Eccosorb RF absorber foam.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	308 The complete RXTX board assembly consists of the traditional PCBA plus heavy
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	309 metal shields on both sides; the front and back metal shield pieces are custom-
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	310 made for this board, with individually shielded cavities matching different
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	311 sections of the board. Some (not all) of these cavities are filled with a
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	312 special black foam called Eccosorb - it is an RF absorber, presumably added to
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	313 lower the Q of these cavities to prevent parasitic oscillations. Trouble occurs
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	314 when this Eccosorb foam comes into direct contact with metal surfaces of
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	315 components on the board: the result is galvanic corrosion, a process that takes
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	316 many years before it results in component failure. The reason why only 3
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	317 particular filter components fail is because they got the bad luck of residing
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	318 in cavities with Eccosorb - the other identical components that don't fail
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	319 reside in cavities without Eccosorb.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	320
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	321 [Note from Michael VK2BEA: "The copper surface of these filters form an integral
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	322 part of the component. It is this copper that forms the cavity of the combline
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	323 filter. When this is compromised by corrosion, the filter is detuned and there
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	324 is leakage causing excessive loss."]
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	325
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	326 It appears that R&S only noticed this design flaw toward the end of "product
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	327 life" of these instruments, probably because failures occur only after many
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	328 years. Some of the newer boards have had modifications to prevent contact
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	329 between Eccosorb and the two troubled Rx filters, either by way of thinner
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	330 Eccosorb fill or by way of an added plastic barrier. It is not clear if these
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	331 modifications were applied to newer produced RXTX boards from the start, or if
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	332 they are a result of field service repairs.
83 a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	333
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	334 How to repair failed boards
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	335 ===========================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	336
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	337 All 3 of the failing filter components (one SAW filter part and two ceramic
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	338 monoblock filter parts) are now unobtainium. However, because so many of these
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	339 RXTX boards fail in exactly the same ways, our community at large is now
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	340 accumulating a very substantial "graveyard" of failed boards, and here is the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	341 good news: we can make one good board out of every two failed ones. Suppose
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	342 that every RXTX board in our community's collective inventory has fully failed,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	343 leaving no failure-free boards - what now? Here is the recipe for making one
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	344 good RXTX board out of two fully failed ones:
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	345
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	346 1) Out of the two failed boards, choose one to be the part donor and the other
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	347 to be the part recipient.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	348
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	349 2) Take the part donor board and harvest 3 parts from it: one of the 3 Sawtek
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	350 855272 filters that aren't subject to corrosion, and the two IF1 filters
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	351 (one 836 CD and one CR) from the Tx side. Tx side IF1 filters aren't in
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	352 contact with Eccosorb and thus don't corrode, and 3 out of the 4 SAW filters
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	353 are likewise safe - hence we expect that every "dead" RXTX board can still
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	354 serve as a donor of good parts in this manner.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	355
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	356 3) Take the part recipient board and transplant the donor parts onto it,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	357 replacing all 3 corroded filters.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	358
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	359 4) Before putting the repaired board back into its metal casing, cover all
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	360 corrosion-prone components with Kapton tape, preventing direct galvanic
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	361 contact with Eccosorb - this way the newly transplanted uncorroded components
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	362 won't suffer the same fate.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	363
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	364 RXTX disassembly instructions
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	365 =============================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	366
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	367 Before you can start working on an individual RXTX board, you first need to pull
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	368 it out of your CMU. Disassembly instructions are provided in the official part
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	369 swapper guide from R&S (which they call "service manual"), but here is the gist:
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	370
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	371 * Using a Torx T20 screwdriver, remove the 4 rear feet and lift the sleeve part
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	372 of the instrument case.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	373
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	374 * Remove two small Phillips screws that secure the cover over the main board
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	375 cage, and lift that cover off.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	376
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	377 * Unhook all MMCX little coax connections from the RXTX board: 3 on the top side
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	378 (IF3 interface) and one on the bottom (netclock input).
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	379
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	380 * Loosen and remove the two semi-rigid coax pieces that connect RF between the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	381 RXTX board and the front end. In this Mother's opinion, this step is the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	382 least pleasant of all, but it is unavoidable.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	383
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	384 * After ensuring that nothing remains connected to the RXTX board on the bottom
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	385 side, pull the board out from the top.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	386
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	387 Once you got the complete RXTX board assembly out, how do you extract the actual
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	388 board out of the metal casing? The not-immediately-obvious answer is that you
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	389 don't need to remove all of the screws, instead there are shortcuts that will
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	390 save you a lot of pain:
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	391
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	392 * There are two smooth thin metal plates, one on the front side of the board
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	393 (facing toward the front of the CMU when installed) and one on the back side.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	394 Each is secured with a small Phillips screw. You only need to remove the one
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	395 on the front side. You don't need to remove the thin metal plate from the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	396 back side of RXTX assembly - doing so will only add more clutter and loose
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	397 parts to your lab bench while the board is disassembled.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	398
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	399 * Once you remove the thin metal plate from the front side of your RXTX
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	400 assembly, you will see all of the many screws that hold together the sandwich
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	401 of two heavy metal pieces with the board in the middle. These screws are
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	402 Torx T8.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	403
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	404 * Put the board down on your bench so that the side that faces the front of the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	405 CMU when installed (the side with the T8 screw heads) will become the top,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	406 with the rear side becoming bottom.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	407
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	408 * Each of the T8 screws passes through thread in the top metal piece, a hole in
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	409 the PCB, and then thread in the bottom metal piece. As you loosen these
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	410 screws, you don't need to remove them all the way - instead loosen each screw
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	411 so that its far end comes out of the thread in the bottom metal piece, but
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	412 let it remain captive in the top metal piece. Letting the screws remain
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	413 captive in the top metal piece will reduce bench clutter while the board is
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	414 disassembled, and there is a lot less screwing and unscrewing work to be done,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	415 as there is no need to work through the thread in the top metal piece.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	416
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	417 Once you loosen all of the T8 screws, the top metal piece should lift off,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	418 leaving just the bottom metal piece and the PCBA. The bottom metal piece has
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	419 two thin metal pins sticking out of it; both the PCBA and the top metal piece
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	420 align on these two pins.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	421
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	422 When you lift the top metal piece (the one with the screws), the side of the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	423 board that will be immediately exposed to you is the side that faces the front
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	424 of the CMU when the board is installed. It is the Rx side, and you can confirm
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	425 that you are looking at the Rx side by noting that there are two "CR" filters
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	426 for high IF1, as opposed to just one. And chances are, right here at this step
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	427 in the disassembly process you will see the galvanic corrosion or the lead-up
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	428 to it.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	429
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	430 As you lift the top metal piece from the board, look at its inside and note the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	431 many individual cavities. Also note how some of these cavities are filled with
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	432 some black foam - that's the Eccosorb. And note how only some of the cavities
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	433 have Eccosorb in them, not all.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	434
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	435 Now look at the ceramic IF1 filters on the Rx side of the board. The one "CR"
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	436 filter that is NOT in contact with Eccosorb will be bright copper-colored (it
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	437 actually is copper), whereas the two filters that are in contact with Eccosorb
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	438 (one 836 CD, one CR) will often be green instead of copper-colored on their top
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	439 surface - that's patinated copper! Furthermore, there will typically be some
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	440 black Eccosorb material directly adhered to the corroding top surfaces of those
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	441 two unlucky filters.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	442
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	443 Now lift the PCBA off the two metal pins, separating it from the bottom metal
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	444 piece. Like you did with the top metal piece, observe the inside of the bottom
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	445 metal piece: note which cavities have Eccosorb in them and which don't. Then
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	446 flip the board over and look at its Tx side. You will see that there are only
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	447 two ceramic IF1 filters on this side (one 836 CD and one CR), and both should
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	448 be in pristine shape, bright copper-colored, no corrosion - these two are not
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	449 in contact with Eccosorb!
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	450
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	451 Now look at the two Sawtek 855272 filters on the Tx side. The one closer to
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	452 the middle of the board will often appear in worse physical condition that the
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	453 other 3 - and the culprit is once again in contact with Eccosorb.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	454
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	455 MACOM SM4T mixer corrosion
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	456 ==========================
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	457
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	458 Neither I nor my collaborator on this project have seen an RXTX board on which
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	459 either the Rx SM4T mixer or the Tx one went bad - i.e., we haven't seen a
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	460 failure in this part yet. However, this mixer is in contact with Eccosorb,
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	461 and looking visually at the collection of RXTX boards in my possession, I
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	462 (Mother Mychaela) see definite signs of corrosion - the metal surface of this
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	463 SM4T mixer component is beginning to corrode. Therefore, as a preventative
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	464 measure, I recommend cleaning off any Eccosorb that is adhered to this component
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	465 and then covering the component with Kapton tape before putting the board back
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	466 into its metal casing.
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	467
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	468 Unlike the failing filters, this MACOM SM4T mixer is still available new - but
a87d9ee278fb CMU200-maintenance-notes: new article Mychaela Falconia <falcon@freecalypso.org> parents: diff changeset	469 it's an expensive component, so let's protect these mixers from corrosion.
85 7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	470
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	471 [Michael VK2BEA notes: "The case of the mixer is purely for shielding and is
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	472 much thicker than the thin copper of the filter that is essential for
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	473 operation." Mother Mychaela's response: it may be so, but if you are going to
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	474 take the RXTX board out of your CMU, take it out of its metal casing and either
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	475 replace filters or at least cover them with Kapton tape for protection, it
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	476 won't hurt to put the same Kaptop tape on the mixers too - and the signs of
7fc66c5b54dd CMU200-maintenance-notes: updates from Michael VK2BEA Mychaela Falconia <falcon@freecalypso.org> parents: 84 diff changeset	477 corrosion are very real.]

FreeCalypso > hg > freecalypso-docs

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