How to Remove and Install the FLEX-5000A Top and Side Panels
Content provided by: FlexRadio Systems Engineering
WARNING: Remove the power cable from the FLEX-5000A before attempting this procedure.
Required Tools:
Removing the Side Panels
The side panels of the FLEX-5000A are not secured with screws. They are attached with a friction fastener are are easily pried off with a minimal amount of effort.
Step 1. If you look closely at the side rails, you will notice little indentations in them. This is to allow you to remove the side panels. See figure 1 below
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Figure 1 - Side Panel showing access indention
Step 2. Using the flat blade of a very small screwdriver insert it into the side indention. See Figure 2 below
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Figure 2 - Inserting a screwdriver into the side panel indention
Step 3. GENTLY pry the side panel away from the side the FLEX-5000A. See Figure 3 below.
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Figure 3 - Removing the side panel.
Step 4. Repeat the procedure for the other side. Both side panels must be removed in order to remove the top and/or bottom panels
Removing the Top Cover
The top cover is fastened to the radio using four (4) Torx screws and is lifted off with you hands.
Step 1. Remove the four (4) screws fastening the top cover to the chassis using the T-20 Torx driver. There are two (2) on each side. See Figure 4 below. The yellow circle indicates where the retaining screws are located.
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Figure 4 - Location of the Torx retraining screws.
Step 2. Using your hands, place your thumbs on the dark gray side support pieces and using your fingers grip the lip of the panel and flex it out slightly, while lifting up. You may need to push down with your thumbs for added assistance. Once it ‘pops’ loose, do the same to the other side. Refer to figures 5a and 5b below
Removing the Bottom Cover and Fan Plate
The bottom cover is removed in the same manner as the top cover, but below the bottom cover is the Fan Plate. The fan plate must be removed to gain access to the bottom of the FLEX-5000A
Step1 . Turn the FLEX-5000A and place it upside down on your workspace.
Step 2. Remove the four (4) screws fastening the bottom cover to the chassis using the T-20 Torx driver. There are two (2) on each side.
Step 3. Using your hands, place your thumbs on the dark gray side support pieces and using your fingers grip the lip of the panel and flex it out slightly, while lifting up. You may need to push down with your thumbs for added assistance. Once it ‘pops’ loose, do the same to the other side.
Step 4. Using the #2 Phillips screwdriver, remove the (4) Sheet Metal screws and washers holding the fan plate in place. Do NOT remove the four (4) Phillips screws closest to the fan. See figure 6 below. Note the retaining screw locations designated by the yellow circles.
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Figure 6 - Location of the Fan plate retaining screws
Step 5. Once the fan plate retaining screws are removed, lift the fan plate up, from either side of the FLEX-5000A just enough for you to reach in and GENTLY wiggle the fan connector from side to side while lifting up to remove it. See Figures 7a and 7b below.
Installing the Top Cover
Step 1. Locate the TOP cover. Orient it so that the vent holes are at the back of the FLEX-5000A. Carefully align it with the four corner pieces, and gently press down. You should hear it snap into place. You will know it is seated correctly if it is level with the four corner pieces. See Figures 8a and 8b below
Step 2. Next, re-install the four (4) Torx screws to secure the top cover to the FLEX-500A.
Installing the Fan Plate and Bottom Cover
When re-installing the bottom cover, the fan must be connected and the fan plate has to be installed first. It is very important that the fan power cable be re-installed correctly to prevent the FLEX-5000A from over heating during normal operation.
Step 1. Set one side of the fan plate along the side of the FLEX-5000A with the fan power cord at the back of the transceiver. (See Figure 7a) The power connector is keyed, so it will only go on one way. If you look at the connector, you’ll notice it has two vertical ribs on one side. Install the connector so that the white plastic piece, on the transceiver board, and the side of the fan with the ribs go together.
WARNING: There is a similar connector on the TRX board labeled "COM1" that can easily be confused with the fan power connector. In Figure 9 below the COM1 connector is in the foreground, oriented parallel with the side of the FLEX-5000A and circled in red.
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Figure 9 - Location of the fan power connector with the COM1 connector in the foreground.
Step 2. Re-install the four (4) sheet metal screws, you removed initially, to secure the Fan plate assembly. Refer to Figure 6 above. DO NOT OVER TIGHTEN THE SCREWS OR YOU MAY STRIP THE THREADS OF THE SCREWS.
Installing the Side Panels
The side panels install easily and require no tools.
Step 1. Align the side panels on the side of the FLEX-5000A and gently press inward until they snap in. Excessive force is not required.
This KB article may reference additional files that are available on the FlexRadio Systems web site Downloads page. Please use the URL(s) below to download the referenced materials.
An Adobe Acrobat Reader may be required to open the file.You can download Adobe Acrobat from here.![]()
KB Source Document(s):
None Referenced
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| System Dependencies | |
| Minimum PowerSDR Version: | N/A |
| Applicable Hardware: | FLEX-5000 |
Content provided by: FlexRadio Systems Engineering
WARNING: Remove the power cable from the FLEX-5000A before attempting this procedure.
Required Tools:
- T-20 Torx driver
- #1 Phillips screwdriver
- Small flat blade screwdriver
Removing the Side Panels
The side panels of the FLEX-5000A are not secured with screws. They are attached with a friction fastener are are easily pried off with a minimal amount of effort.
Step 1. If you look closely at the side rails, you will notice little indentations in them. This is to allow you to remove the side panels. See figure 1 below
Figure 1 - Side Panel showing access indention
Step 2. Using the flat blade of a very small screwdriver insert it into the side indention. See Figure 2 below
Figure 2 - Inserting a screwdriver into the side panel indention
Step 3. GENTLY pry the side panel away from the side the FLEX-5000A. See Figure 3 below.
Figure 3 - Removing the side panel.
Step 4. Repeat the procedure for the other side. Both side panels must be removed in order to remove the top and/or bottom panels
Removing the Top Cover
The top cover is fastened to the radio using four (4) Torx screws and is lifted off with you hands.
Step 1. Remove the four (4) screws fastening the top cover to the chassis using the T-20 Torx driver. There are two (2) on each side. See Figure 4 below. The yellow circle indicates where the retaining screws are located.
Figure 4 - Location of the Torx retraining screws.
Step 2. Using your hands, place your thumbs on the dark gray side support pieces and using your fingers grip the lip of the panel and flex it out slightly, while lifting up. You may need to push down with your thumbs for added assistance. Once it ‘pops’ loose, do the same to the other side. Refer to figures 5a and 5b below
 Figure 5a - Side View |  Figure 5b - Front View |
Removing the Bottom Cover and Fan Plate
The bottom cover is removed in the same manner as the top cover, but below the bottom cover is the Fan Plate. The fan plate must be removed to gain access to the bottom of the FLEX-5000A
Step1 . Turn the FLEX-5000A and place it upside down on your workspace.
Step 2. Remove the four (4) screws fastening the bottom cover to the chassis using the T-20 Torx driver. There are two (2) on each side.
Step 3. Using your hands, place your thumbs on the dark gray side support pieces and using your fingers grip the lip of the panel and flex it out slightly, while lifting up. You may need to push down with your thumbs for added assistance. Once it ‘pops’ loose, do the same to the other side.
Step 4. Using the #2 Phillips screwdriver, remove the (4) Sheet Metal screws and washers holding the fan plate in place. Do NOT remove the four (4) Phillips screws closest to the fan. See figure 6 below. Note the retaining screw locations designated by the yellow circles.
Figure 6 - Location of the Fan plate retaining screws
Step 5. Once the fan plate retaining screws are removed, lift the fan plate up, from either side of the FLEX-5000A just enough for you to reach in and GENTLY wiggle the fan connector from side to side while lifting up to remove it. See Figures 7a and 7b below.
 Figure 7a - Lifting one side of the Fan Plate to expose the fan power cable |  Figure 7b - Location of the fan power connector on the TRX board |
Installing the Top Cover
Step 1. Locate the TOP cover. Orient it so that the vent holes are at the back of the FLEX-5000A. Carefully align it with the four corner pieces, and gently press down. You should hear it snap into place. You will know it is seated correctly if it is level with the four corner pieces. See Figures 8a and 8b below
 Figure 8a - Positioning the top cover on the FLEX-5000A |  Figure 8b - Properly installed top cover. Note the corner alignment. |
Step 2. Next, re-install the four (4) Torx screws to secure the top cover to the FLEX-500A.
Installing the Fan Plate and Bottom Cover
When re-installing the bottom cover, the fan must be connected and the fan plate has to be installed first. It is very important that the fan power cable be re-installed correctly to prevent the FLEX-5000A from over heating during normal operation.
Step 1. Set one side of the fan plate along the side of the FLEX-5000A with the fan power cord at the back of the transceiver. (See Figure 7a) The power connector is keyed, so it will only go on one way. If you look at the connector, you’ll notice it has two vertical ribs on one side. Install the connector so that the white plastic piece, on the transceiver board, and the side of the fan with the ribs go together.
WARNING: There is a similar connector on the TRX board labeled "COM1" that can easily be confused with the fan power connector. In Figure 9 below the COM1 connector is in the foreground, oriented parallel with the side of the FLEX-5000A and circled in red.
Figure 9 - Location of the fan power connector with the COM1 connector in the foreground.
Step 2. Re-install the four (4) sheet metal screws, you removed initially, to secure the Fan plate assembly. Refer to Figure 6 above. DO NOT OVER TIGHTEN THE SCREWS OR YOU MAY STRIP THE THREADS OF THE SCREWS.
Installing the Side Panels
The side panels install easily and require no tools.
Step 1. Align the side panels on the side of the FLEX-5000A and gently press inward until they snap in. Excessive force is not required.
This KB article may reference additional files that are available on the FlexRadio Systems web site Downloads page. Please use the URL(s) below to download the referenced materials.
An Adobe Acrobat Reader may be required to open the file.You can download Adobe Acrobat from here.
KB Source Document(s):
None Referenced
