Radio backplane v2.5 and radio panel v1.2 design files (new)

Copyright Theo Deckers 2021

This documentation describes Open Hardware and is licensed under the CERN Open Hardware License OHL version 1.2  You may redistribute and modify this documentation under the terms of the CERN OHL v.1.2. This documentation is distributed WITHOUT ANY EXPRESS OR IMPLIED WARRANTY, INCLUDING OF MERCHANTABILITY, SATISFACTORY QUALITY AND FITNESS FOR A PARTICULAR PURPOSE. Please see the CERN OHL v.1.2 for applicable conditions.

Zip file with all below design files

Custom libraries common to all schematics and PCB layouts

KiCAD 5.0 mcp_panel symbol library with all the custom schematic symbols used in the schematics on this page. You need this only if you want to open the source schematics below in KiCAD. There is also a PDF variant of all the KiCAD schematics and layouts.

KiCAD mcp_panel layout footprint library with all custom layout footprints used in the PCB layouts on this page.  You need this only if you want to open the source PCB layouts below in KiCAD.

Detailed list of the electronic components used on all PCB’s

Revision 2.5 radio backplane design (tested)

This new rev2.5 radio backplane can be used with the old radio panel or the new radio panel designs below. The Captain radio backplane contains all the required multiplexers and LED drivers, a second version of the same backplane can be used for the First Officer radio’s and only contains connectors and a FET and two resistors for the backlighting.
The Captain and First Officer backplanes communicate via two 24-pin flatcables.

KiCAD 5.0 schematic (PDF)

KiCAD 5.0 PCB layout (PDF)

Gerber files (can be uploaded to a PCB manufacturer)

Interactive Bill of Materials (page takes some time to load). For a detailed description check this spreadsheet.

SimVim Arduino pin mapping overview

SimVim configuration file (save as data.cfg file in X-Plane SimVim plugin directory)

New universal B737 COM/NAV/ADF v1.2 radio panel with yellow 7.05 x 1.8 rectangle LEDs, ALPS dual axis rotary encoder and separate power connector
(tested)

The same universal B737 radio panel PCB can be used for the COM, NAV and ADF variant for Captain and First Officer.
The below Interactive Bill of Materials show which components need to be placed at each variant.

KiCAD 5.0 schematic  (PDF)

KiCAD 5.0 PCB layout (PDF)

Gerber files (can be uploaded to a PCB manufacturer, see the instruction at the bottom of this page)

Interactive Bill of Materials COM panel (page takes some time to load)

Interactive Bill of Materials NAV panel (page takes some time to load)

Interactive Bill of Materials ADF panel (page takes some time to load)

For a more detailed description of the required components check this spreadsheet.

For the ADF variant two 6 mm holes must be drilled for the toggle switches in the circles of the SWANT and SWADFON switches.
These switches must be wired to the SWvhf1 and SWvhf2 pin holes as indicated by the thick blue lines in below picture.
Extra warm white round 3 mm LED’s can be soldered to the LED pins of SWhf1, SWvhf2 and SWvhf3 (indicated by the green circles in below picture) for better panel backlighting.

Mechanical design files

COM top panel design (2.4 mm thick engraving plate smoke grey on white) DXF file

COM back panel design (3mm thick transparent PLA including 6 mm M3 spacers) STL file for 3D print DXF file (2D only!)

COM panel switch buttons design (transparent PLA) STL file for 3D print

COM panel button text plates design (1.6 thick engraving plate black on white) DXF file

NAV top panel design (2.4 mm thick engraving plate smoke grey on white) DXF file

NAV back panel design (3mm thick transparent PLA including 6 mm M3 spacers) STL file for 3D print, DXF file (2D only!)

ADF top panel design (2.4 mm thick engraving plate smoke grey on white) DXF file

ADF back panel design (3mm thick transparent PLA including 6 mm M3 spacers) STL file for 3D print, DXF file (2D only!)

ADF panel ADF/ANT text plate design (0.8 mm thick black on white engraving panel) DXF file

7-segment display frame design for COM and NAV panel (black PLA) STL file for 3D print

7-segment display frame design for ADF panel (black PLA) STL file for 3D print

Transfer button design for all panels (transparent PLA) STL file for 3D print

Test button design for NAV and ADF panels (black PLA) STL file for 3D print

Radio tune top knob for ALPS encoder (grey PLA) STL file for 3D print

Radio tune bottom knob for ALPS encoder (grey PLA) STL file for 3D print

Old universal B737 COM/NAV/ADF V1.0 radio panel with 5×2 mm rectangle LEDS and DIY dual axis rotary encoder (tested)

This design is compatible with the v2.5 radio backplane but uses wires in the 24 pin flatcable for power and ground while the new v1.2 radio PCB design has a separate power connector for this.

KiCAD 5.0 schematic  (PDF)

KiCAD 5.0 PCB layout (PDF)

Gerber files (can be uploaded to a PCB manufacturer, see the instruction at the bottom of this page)

Interactive Bill of Materials (page takes some time to load)

For a more detailed description of the required components check this spreadsheet.

‘Assemble and simultaneous test’ instruction for the radio panel:

Sketchup 3D model of the 3 mm acrylic clear or opal and 2.4 mm White/Smoke Grey Troply front panel designs.

Old universal B737 COM/NAV/ADF V1.0 radio panel with yellow 7.05 x 1.8 rectangle LEDs and DIY dual axis rotary encoder
(tested)

This design is compatible with the v2.5 radio backplane but uses wires in the 24 pin flatcable for power and ground while the new v1.2 radio PCB design has a separate power connector.

Uses the same schematic as above, only the LEDs above the frequency band switches have been rotated 90 degrees so that OSY5JA7234B LEDs can be used.

KiCAD 5.0 PCB layout (PDF)

Gerber files (can be uploaded to a PCB manufacturer)

Interactive Bill of Materials (page takes some time to load)

For a more detailed description of the required components check this spreadsheet.

Same SimVim configuration file and SimVim Arduino pin mapping overview as above

This design is part of a complete system of Master Arduino PCB, MCP PCB, two EFIS PCB’s, revision 2.5 radio backplane PCB (using a universal radio panel PCB design for 6 radios), MIP PCB, FMC master with 2 FMC keyboard PCB’s, four Overhead PCB’s (for the IRS, Electrical and Pressurization panels and using the multiplexers and LED drivers of a second MIP PCB for the remaining Overhead functions) and a stepper driver PCB for all the gauges.
Development and testing of these will take time, but once successfully tested  these will also be made available for free download in this blog.