Weird Issue when Operating FT8 on Flex-6500 -- HELP!

Jerry Gardner

I've got a Flex-6500 running SmartSDR v1.11.12. I've had no issues operating FT8 with WSJTX with this rig for years, but today I'm seeing a weird issue.

When I start WSJTX and it's running in receive mode about every second I can hear a relay inside the 6500 pull in and the audio frequency in the headphones shift up a few Hz. After about a second. the relay releases and the audio shifts back down. WSJTX doesn't decode anything due to the audio frequency shifts as the relay pulls in and releases. Powering the rig off and on stops the repetitive relay action, but as soon as I start WSJTX, it starts again. If I exit WSJTX after the relay clicking starts, the relay continues to click until I power-cycle the rig. Even exiting SmartSDR doesn't stop the clicking.

I haven't changed the WSJTX settings in years. Is this a WSJTX configuration issue or an issue with the Flex-6500? How do I fix this?

Update: The last time I power-cycled the 6500, the calibration cycle seemed to take longer than usual, and I heard the relay clicking repetitively during startup. It never finished the calibration and displayed "Timeout" on the front panel and the blinking green power button LED turned red.

The rig is not overheating. The ambient temperature in the shack is 64F.

Further update: After the calibration failure mentioned above, I power cycled the 6500 again and this time the calibration succeeded and the rig powered up normally.

After further experimenting, I found that the relay clicking won't start happening if I power up the rig and leave it in receive mode. If I try to contact another station on FT8, the clicking will start during transmit and will persist in receive mode after that until the rig is power cycled. The relay clicking isn't just annoying—the audio frequency shifts associated with it make it impossible to decode any FT8 stations in WSJTX.

Jerry Gardner

Further update: it has nothing to do with WSJTX. I powered up the rig in SSB mode and left it sitting there and the relay clicking eventually started. This time, the relay only clicks intermittently. It starts clicking, will click for a few seconds, and then stop, before starting up again a minute or two later.

So what are relays used in this rig for? To switch bandpass filters?

KD0RC

Hi Jerry, I would do a factory reset (export your profiles first).

I would also upgrade to 4.1.5. It is free and brings you years of bug fixes and improvements. Your basic functionality remains at the V1 level unless you purchase SmartSDR+ which will jump your functionality up to V4.

If that doesn't help, submit a help desk ticket.

Jerry Gardner

Thanks, Len

I downloaded 4.1.5 and installed it. After lots of updating of the rig's firmware, everything came up and worked fine for about 20 minutes, and then the relay click issue returned. Bummer.

I've submitted a help desk ticket.

KD0RC

Hi Jerry, did you try the factory reset?

Martin AA6E

Check DC supply voltage? Connectors good?

73 Martin AA6E

Erika - KØDD

6500 is a great radio. Responds very well to the 4.1.5 os. CRC electrical cleaner on the power connector and the power cord radio end. And adding a voltage monitoring flex application. Im still using one showing temp and voltage. The power poles are tin plated not silver and tarnish. I have to clean mine every few months. Also. It maybe time for a really good internal cleaning... the tiny fans inside the cage on the chips can act up. Very fragile. But version 4 ssdr will alert you to fan speed errors. Might be time for a good cleaning and all production upgrades session at the mothership. Erika DD

Jerry Gardner

Hi Len.

No, I didn’t try a factory reset. How do I do that?

KD0RC

Hi Jerry, here is a link to a post on how to do the reset

https://www.google.com/url?sa=t&source=web&rct=j&opi=89978449&url=https://helpdesk.flexradio.com/hc/en-us/articles/27696483436699-How-to-Factory-Reset-your-FLEX-6000-FLEX-8000-Radio&ved=2ahUKEwjc5f6U7JCTAxXCI0QIHVoeN5oQFnoECCAQAQ&usg=AOvVaw0qCUZsP07CqQ30nSUmGDxR

Jerry Gardner

Thanks for the link, Len.

I tried the factory reset, and it went okay. Unfortunately, it didn't fix my issue. The relay clicking comes back about 15-20 minutes after the rig boots up.

Thanks for the suggestion, Erika. I cleaned the power pole connectors, but that didn't help either. I also checked the supply voltage, and it was normal.

Here's a screenshot of WSJTX's waterfall showing what this issue does to received audio. The bottom of the waterfall is before the clicking started, and as you can see, the FT8 signals look clean and normal. The top of the waterfall is after the clicking starts, and you can see the signals are smeared out and undecodable.

Jerry Gardner

I took the rig apart and it looks pristine inside. Not really any dust at all. My ham shack is also my lab and I have HEPA air filters that run 24/7. Yes, there are relays—dozens of them!