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Configuring the "Dream Station" - FLEX-8000/6000 with the PGXL/TGXL/AG for Proper Operation

Ken Wells
Updated

Author:  Ken Wells - NM9P

Here is the proper way to configure the FLEX-6000/FLEX-8000 "Dream Station" for seamless operation.

INTRODUCTION:

This information is for configuring an "All-Flex" station.  Configuration information for interfacing with other brands of radios will be addressed in another document.

These procedures have been verified using the software listed below.  It is recommended that you have installed the latest software/firmware that is at or greater than the versions listed below:

NOTE: It is strongly recommended that you read the Release Notes for each software release before you install the utilities on your computer or UPDATE the Firmware.  This is a "best practice" before installing new software or firmware.

Downloading and reviewing the User Guides for the different equipment is highly recommended.

 

SmartSDR Software User Guide v3.x – FlexRadio

FLEX-6400M and FLEX-6600M User Guide v3.x – FlexRadio

Power Genius XL User Guide – FlexRadio

Tuner Genius XL User Guide (4o3a.com)

ANTENNA GENIUS User Manual v4.1 (4o3a.com)

 

Understanding the Control Signal Flow between the FlexRadio, PGXL, TGXL, and Antenna Genius:

Two basic streams of control data are shared between the various pieces of equipment.

A) The FLEX-6000/FLEX-8000, sends Band, Frequency, Mode, and TX/RX Antenna information (A/B) to the PGXL, TGXL, and Antenna Genius via the Ethernet Connection. (Shown as Blue Lines in the illustration.)

B) The TGXL and Antenna Genius share Tuning Memory and Antenna Port Selection (1-8) with each other via the link established in the TGXL "Device Settings > Genius Integration > Antenna Genius" tab. 
(Shown as the Yellow Line in the illustration.)

Dream Station Signal Flow.jpg

Powering Up Your "Dream Station:  The FlexRadio / Genius "Dream Station" is a very complex system with multiple devices dependent upon one another.  It is important to power up the station in the proper sequence so all devices can establish the required communication channels with each other.

Always power the station up in this order:

  1. The FlexRadio:  Power it up and wait until it is fully booted up with a Solid Green light on the power button before powering anything else up.
  2. The PGXL:  Wait until it is fully booted up.
  3. The TGXL:  Wait until it is fully booted up.
  4. The Antenna Genius:  Wait until it is fully booted up.
  5. Then start SmartSDR and the Windows Utilities for the other devices in the same order, waiting until one program is up and running before opening the next.

NOTE:  If you power up the PGXL too soon after the radio or "power-cycle" the PGXL OFF and back ON too quickly, it may not properly establish communications with the radio.  If this happens, turn the PGXL OFF and wait about 10-15 seconds.  Then turn it back on.

 

Now, let's configure your station:

Since this is a complex integrated system, a step-by-step approach to building your system is used.  You will add and configure one piece of equipment at a time, testing it to ensure it operates properly before adding the next piece of equipment. 

This may seem to be more complicated and time-consuming but if there are connection or configuration errors, it is easier to troubleshoot one device at a time, rather than trying to troubleshoot the whole system all at once, which will take a LOT more time and effort than the step by step approach.  The time you save will be your own.

 

1) CONNECTING YOUR EQUIPMENT TO YOUR NETWORK:

Since there are so many pieces of equipment, it may be advisable to get an inexpensive, metal-cased 5-port or 8-port ethernet switch and connect your radio, PGXL, TGXL, AG, and computer (or Maestro) to the switch.  Then connect a line from your switch to the router.  This will ensure optimal data transfer between all five (5) pieces of equipment, even if the router is offline or overloaded.

It is recommended that you edit your router's DHCP Server to provide "Reserved IP Addresses" to all of your equipment so that they will always receive the SAME IP address every time they power up on the network.  (Some routers call this "Local Statis" or "Manual IP")    (Otherwise, if something is powered off for a long time, the router may assign a different IP Address to the device, which will "break" port forwarding or other equipment-to-equipment linkage which is dependent upon IP Addresses.)

(Since you are configuring a high-power station, you may want to add RFI protection by wrapping several turns of the switch's power cable through a MIX-31 Snap-on ferrite.  You may wish to pass several loops of your ethernet cables through an FT-240-31 toroid, or at least the long run to your router.)  

2) Configure your radio's Transmit Profile 

Run SmartSDR for Windows and connect to your radio.

Go to the "Settings > Radio Setup > TX" tab and Set the TX Delay to 40. This provides a time delay after the radio PTT is engaged before the radio starts sending RF.  This prevents "hot-switching" the amp with RF before the other equipment is in a ready state.

NOTE: If operating CW, the CW Delay MUST be greater than the TX Delay to ensure that the first elements sent are not truncated.  

3) CONNECT THE PGXL TO THE RADIO:

  • Connect Radio ANT1 to PGXL DRIVE A  (Be careful, it is easy to cross-connect the DRIVE and OUTPUT lines and the A-SIDE and the B-SIDE connectors.  Visually inspect ALL cable connections.  Do not attempt to remember which is which while reaching around the back of the equipment.   
  • Connect the PGXL OUTPUT A to your Antenna.
  • No other physical connections are needed for the Flex-6000 and PGXL.

        If you plan to use two antennas:

  • Connect Radio ANT2 to PGXL DRIVE B  
  • Connect the PGXL OUTPUT B to your second Antenna.
  • Connect the PGXL to your network with an ethernet cable.
  • Connect the Power Cable to the PGXL
  • Turn ON the PGXL using the rocker switch on the back panel.

4) Configure the PGXL:

  • Open the PGXL Windows Utility
  • Select the "Local Devices" tab
  • Click on the Listing for your amplifier and click on "Connect."
  • Select "Update" if you are updating to a new PGXL software release.

Click on the "Gear" Icon" and select "Device Settings."

Network Tab : 

  • "Name" your Amplifier something more personal, if you wish.
  • Select "DHCP" to instruct the PGXL to request an IP Address from your router upon boot-up.
  • nothing else is needed on the Network tab for local operation.

CAT/CI-V Tab:  No settings should be made here for an All-Flex Station.

FlexRadio Tab:

  • Enable the "Port A" box
  • Click on the "Serial Number" Pull-down menu and select the serial number of your FlexRadio. 
    (This links the amp to your radio for Band/Frequency/Mode information.)

  • Select ANT1 in the TX Antenna pull-down.  (This tells the amplifier to link Port A of the Amplifier to the Radio Slice that is set to transmit on ANT1 of the radio.
    NOTE:  This is NOT an internal antenna switch for the amplifier.  You cannot transmit on DRIVE A of the amp and send the output to OUTPUT 2 of the Amp.)
  • For "PTT source," select "LAN" 
    (This tells the PGXL to get its PTT signal from the radio via the LAN, not the RCA jack)

  • (If you want to use the B-Side of the amp, enable the Port B Box and repeat the configuration for the Port B, using ANT2 in the TX Antenna pull-down.)

OTHER Tab:

  • Use the slider to control the brightness of the amplifier's background panel lights.
  • FAN Mode:  Set this to Standard for quieter operation. Se this to CONTEST mode if you transmit frequently and require additional cooling.
  • MEffA - For now, leave it off.

Important: Click "Save" and the amp will commit these changes to memory and reboot.

 

SET THE "BAND DATA SOURCE" 

  • Right-click on the wide box to the right of the A channel indicator.  It will open a pull-down menu.
  • Select "FLEX" from the menu.
  • Now your Radio's "Nickname" should show in the box. and the display should show the band and "Bias Mode" of the amp (AB or AAB)
  • (If using Side B of the amp, repeat this for the Side B Box.)
    Note, if you do not have a slice with TX ANT2 designated, you will not see the radio's name or any band data showing in the display for Side B.

TEST THE AMP:

  • NOTE:  When using the Power Genius Amplifier, you should have the FlexRadio's Internal ATU in BYP (bypass) mode.  Turn the ATU MEM OFF (the MEM button should not be BLUE)  If the amplifier is in Operate Mode, you cannot tune an antenna THROUGH the amplifier, you will only be tunning the input of the amplifier.

  • Change bands on the radio and ensure that the amp is tracking the band and mode. 
    (It will display "AAB" for SSB and AM, and "AB" for CW, RTTY, Digital, and FM).
  • Temporarily connect the amp OUTPUT A to a high-power Dummy Load.  (Every high power station should have a dummy load for testing).
  • Select RX ANT1 and TX ANT1 on your slice in SSDR.
  • Set the TUNE Power button to 10 Watts.
  • Hit the TUNE Button and watch the power output meter on the PGXL to check for good output.
  • Release the TUNE Button. Then increase to 20 watts and test again.
  • If all is well, test at 40 and 50 (after resting your dummy load) and note the power output is good.
  • It is not recommended to drive the amp with more than 70 Watts.

    NOTE:  When operating the PGXL with a 120 Volt power source, the amplifier will have reduced gain (12 dB rather than a nominal 15 dB), and will only put out 600 - 700 Watts, depending upon the band, AC Voltage Supply, and SWR.

  • Now connect a well-matched antenna to the OUTPUT A connector and test on the air.
  • Begin by using low RF power levels to ensure your house and ham shack do not react badly to high-power RF.  If your radio shuts down or equipment behaves unexpectedly in the shack or home, you may have a radiated or Common Mode RF issue that must be addressed before resuming high-power operation.

5) CONNECT THE TGXL TO THE PGXL:

  • Connect the PGXL OUTPUT A to the TX A input of the TGXL
  • Connect the Antenna to the ANTENNA A output of the TGXL

    If you plan to use ANT2/SIDE B:

  • Connect the PGXL OUTPUT B to the TX B input of the TGXL
  • Connect your second antenna to the ANTENNA B Output of the TGXL.
  • Connect the TGXL to your network with an ethernet cable.
  • Connect the Power to the TGXL
  • Turn ON the TGXL using the small rocker switch next to the power connector.

6) Configure the Tuner Genius XL:

  • Open the TGXL Windows Utility
  • Select the "Local Devices" tab
  • Click on the Listing for your Tuner and click on "Connect."
  • Select "Update" if you are updating to a new TGXL software release.

Click on the "Gear" Icon" and select "Device Settings." (Just as you did with the PGXL Utility)

Network Tab : 

  • "Name" your Tuner something more personal, if you wish.
  • Select "DHCP" to instruct the TGXL to request an IP Address from your router upon boot-up.
  • nothing else is needed on the Network tab for local operation.

CAT/CI-V Tab:  No settings should be made here for an All-Flex Station.

FlexRadio Tab:

  • Enable the "Port A" box
  • Click on the "Serial Number" Pull-down menu and select the serial number of your FlexRadio. 
    (This links the Tuner to your radio for Band/Frequency information.)
  • Select ANT1 in the TX Antenna pull-down.  (This tells the Tuner to link Port A of the Tuner to the Radio Slice set to transmit on ANT1 of the radio.
    NOTE:  This is NOT an internal antenna switch for the Tuner.  You cannot transmit on TX A of the Tuner and send the output to ANTENNA 2 of the Tuner.)
  • For "PTT source," select "LAN". (This tells the TGXL to get its PTT signal from the radio via the LAN, not the RCA jack)

  • (If you desire to use the B-Side of the Tuner, enable the Port B box and repeat the configuration for the Port B, using ANT2 in the TX Antenna pull-down.)

Genius Integration Tab:

  • Power Genius Section:  Nothing should be set in this section when using a FLEX-6000/FLEX-8000.

  • Antenna Genius Section:  You will configure this with the Antenna Genius's MAC Address when we Configure the Antenna Genius.

The "Other" Tab:

  • Port A - RX BYP:  Select if you want the tuner to bypass Antenna A when in receive mode.
  • Port B - RX BYP:  Select if you want the tuner to bypass Antenna B when in receive mode.

  • Port A - Tune PTT Out:  not needed in an All-Flex station.  (For other amplifiers, if NOT checked, it does not send the PTT line from the Tuner to the Amp, so the amp is not keyed up when the tuner is tuning the antenna.)
  • Port B - Tune PTT Out:  same as above, but for Port B.
  • Band Configurator: This allows you to set custom "Minimum SWR" settings for each antenna on a per-band basis.  You can also set the tuner to bypass whole bands or a segment of each band (for cases where the Tuner is not needed on certain bands or certain band segments. (for example, your 80 Meter Dipole may be resonant in the middle of the band, but needs tuning on the edges.)

    NOTE:  The Bypass Start and Stop frequencies must be entered in KHz, not MHz.
    For example:  on 40 Meters, enter them as 7110 and 7275 -- NOT as 7.110 or 7.275

 

Important: Click "Save" and the Tuner will commit these changes to memory and reboot.

 

TEST THE TGXL:

  • Now test with the Radio, Amp, and Tuner connected to a single antenna or two antennas, if you are using ANT2/DRIVE B / Port B.)
  • Make certain that the radio, amplifier, and tuner are responding to band and frequency changes.
    Check to be sure that the tuner is properly tuning the antenna(s)

    NOTE: To TUNE the antenna with the TGXL, you should have the FlexRadio's Internal ATU in BYP mode.  Turn the ATU MEM OFF (the MEM button should not be BLUE)

  • To TUNE the TGXL, Adjust the TUNE Power Slider on the radio to 10-30 Watts.
    Press the TUNE button on the TGXL (Not on the radio).  The Tuner will automatically set the radio into TUNE Mode and tune the antenna.

    NOTE:  It has been reported that tuning at 25 Watts seems to give the best and fastest match.

  • When the tuner has successfully tuned the antenna on that frequency, it will briefly display a message in GREEN text on the Control Panel and the main window of the TGXL Utility.
  • The TGXL has 20 frequency tuning memories per antenna, per band.  You will need to "train" the tuner by starting at the lower frequency end of the band and tuning the antenna to save the memory.  Then move up about 20 KHz and tune again.  Repeat until you get to the end of the band.
  • When you have fully tested the Radio/PGXL/TGXL and everything works, now it is time to connect and configure the Antenna Genus.

7) CONNECT THE ANTENNA GENIUS TO THE TGXL:

  • Connect the TGXL ANTENNA A output to the Antenna Genius OUT A connector.
  • (If you plan to use ANT2/Side B of the radio/PTGL/TGXL, then connect the TGXL ANTENNA output B to the Antenna Genius OUT B connector.)
  • Connect your different antenna leads to Antenna Ports 1 through 8 of the Antenna Genius.
  • Connect the Antenna Genius to your network with an ethernet cable.
  • Connect the Power connector to the Antenna Genius

8) Configure the Antenna Genius:

  • Power up the Antenna Genius
  • Open the Antenna Genius Windows Utility

The first time you open the Antenna Genius Utility, you will need to click on the "Available Devices" link.

This will open the "Port Chooser" so you can select if you wish to configure the Antenna Genius to use only Port A, Only Port B, or BOTH Ports (SO2R).

(The most common configuration for the "Dream Station" will use the "SO2R" option.)

This will open the Antenna Genius Control Panel.

  • Click on the "Gear" Icon" and select "Device Settings"

  • Select the "Basic Information" tab

  • In the "Name" box, give your Antenna Genius another name, if you wish.
  • Click "SAVE"

Click on the "Gear" Icon" again and select "Device Settings"

  • In the "Antenna Genius Settings" Window, Select the "Bands > FlexRadio" tab.
  • It will open up boxes for "FlexRadio Integration - Port A" and "FlexRadio Integration - Port B" In the right-hand column.
  • Use the "Serial Number" pull-down to select the radio's serial number you wish to associate with the TGXL  (If you only have one FlexRadio, it will only show the one serial number.)

    NOTE:  If the TGXL has previously been linked to a different FlexRadio, its serial number may still be in displayed.  BE SURE to select the right radio by verifying its serial number.

  • Use the "Antenna" pulldown to select "ANT1"
  • Use the "PTT" pulldown to select "LAN."

  • (If you plan to use PORT B, repeat the above procedure, but select ANT2 from the Antenna Pull-Down menu)

Select Save and Reboot.  The Antenna Genius will commit these changes to memory and reboot.

  • Click on the "Gear Icon" again.
  • Select the Device Information" menu item
  • From the "Device Information" Screen, find the Serial Number. of the Antenna Genius.
  • Write down the 3x2 character ID Number of your Antenna Genius (in this example:  C7-F1-DE)
  • Click the "X" to close the window. 
    (Don't write down the ID number in the picture.  Use the ID of your own Antenna Genius.)

Open the TGXL Windows Utility. Click the "Gear" icon and open the "Genius Integration" tab.

  • In the "Antenna Genius" section of the tab, click on the Serial Number "Pull-Down" and select the ID Number of your Antenna Genius.

   

Click on "Save."  The TGXL will commit that data to memory and reboot.

 

Return to the Antenna Genius Utility: 

  • Click on the Antenna Genius "Gear" Icon and select "Device Settings"
  • In the "ANTENNAS" section, name each of the 8 Antenna to identify which antennas you have connected.  (You don't need to label unused antenna ports.)

  • Click on the box to the right of each antenna name to open the Antenna/Band Configuration.
  • Click on each band this antenna will be used for RX and TX. (Click on "none" if you want this antenna to be available for manual selection on bands it is not defined for use as well)
  • In the picture below, the Log Periodic antenna is being selected as being available for use on 20-6 Meters.  ("None" can be selected to make the antenna available for reception in between the ham bands)

Hit "Accept" when finished with that antenna port's configuration.

  • Open the next antenna configuration and repeat the process, until you have properly defined the bands on which each antenna will be used.  Hit "Accept."
  • When finished with all of the antenna configurations, hit "Save."  The Antenna Genius will Commit the changes to memory and reboot.

SPECIAL NOTES FOR 6 METER OPERATION:

  • Always keep power output below 800 Watts when using the Antenna Genius on 6 Meters.
  • It has been found that the best SWR and less attenuation will be achieved with Antenna Ports 2 and 7.
  • More precisely when using Side A and Antenna Port 2, or Side B and Antenna Port 7.

Now Test the Antenna Genius:

  • Open a slice on SmartSDR.  Select ANT1
  • Step your way through the bands and note if the Antenna Genius Control Panel shows only the antennas that have been enabled for that band (or if they have the "None" box selected"
  • If you have more than one antenna available for that particular band, click on the "A" to the left of the antenna's listing and ensure that the antenna changes properly.

  • Repeat until you have stepped through all the bands.
  • Change the Slice to use RX and TX ANT2.
  • Step through the antennas and click on the "B" icon to the right of the antenna listing to select that antenna.  Assure that the antennas change properly.
  • Now open a 2nd slice and set Slice B to use ANT2 and Slice A to use ANT1.  Put the slices on different bands.
  • Make Slice A the TX Slice and select an available antenna for that band.
  • Make Slice B the TX Slice and select an available antenna for that band. (You must select a different  antenna from the antenna used on slice A)
  • Step through the bands on Slice B and observe the interaction of the antenna selections for the A and B sides of the Antenna Genius Control Panel.
  • Change the TX Slice back to A and step through the bands.
  • NOTE: You cannot choose the same antenna from the Antenna Genius for BOTH slices if they are using different ANT1 or ANT2 settings on the radio.

The Final Test:

  • Select a slice, Band, and antenna output on the radio, and an antenna from the Antenna Genius.
  • Hit the TUNE Button on the Tuner Genius control panel and see if the antenna properly tunes.
  • Change to a different band and tune the antenna again.
  • Change antennas on the Antenna Genius to another available antenna, then hit TUNE on the TGXL and see if it tunes properly.
  • Change to the previous antenna and see if the AG remembers the previous tuning solution.
  • Change back to the previous band and see if the AG remembers the proper antenna and the TGXL remembers the tuning solution.

Special notes:

  • After making major configuration changes to the Antenna Genius, you may need to reboot it by removing the power connector, waiting 15 seconds, and reconnecting the DC power to the Antenna Genius.
  • You can select a different antenna for each band from the list of available antennas. 
    The Antenna Genius will remember the last antenna you used on that band and will automatically select that antenna when selecting that band unless the antenna is already in use by the "other side" of the radio.
  • When the Antenna Genius and Tuner Genius are properly configured, The Tuner Genius will remember 20 Tuning solutions Per Band for each antenna.
  • Once you have configured and tested the unit, you need to "train" the antenna tuner on each band and antenna.  As before, start at the bottom of the band and tune the antenna.   Then move up about 20 KHz and tune again.  Repeat for each available antenna on each band on which it is available.

This should complete the installation and configuration of your FlexRadio equipment.

Now go enjoy your FlexRadio "Dream Station!"

 

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