802.11n router disassembly: can be upgraded to upgrade firmware

The ZyXEL X650 is a mid-range 802.11ac router that, while no longer in production, offers impressive performance for its class. It supports up to 867 Mbps on the 5 GHz band and 300 Mbps on the 2.4 GHz band, making it a solid choice for most home networks. I obtained this unit for free when purchasing the SiliconDust HDHomeRun Prime tuner, and at the time, it was available for around $34.99. Unlike the N150R, which is an 802.11n device, the X650 represents a step up in terms of wireless speed and reliability.

Before diving into the details, let’s take a closer look at what comes in the box. The packaging includes a quick-start guide, a user manual, and a CD with installation software. Alongside these, there's a wall adapter and, of course, the router itself. The design is clean and modern, with several passive cooling vents on the top and sides—no fan required, which is a nice touch for quiet operation.

Inside the router, you’ll find a well-organized PCB with several key components. There are two large chips with heat sinks, likely handling the main processing tasks. One notable feature is a physical switch that allows users to disable the Wi-Fi radio entirely, which can be useful for security or power-saving purposes. The router also has four rubber feet, each concealing a screw that secures the casing. Removing them gives access to the internal components.

Upon disassembling the case, the PCB reveals a number of important parts. The main chip appears to be a Realtek RTL8197D, used as the SoC for the router. This is paired with a Realtek RTL8812AR for the 5 GHz Wi-Fi subsystem and an RTL8192CE for the 2.4 GHz band. There’s also a mini PCIe slot, which houses an Edimax EW-7822MAC card. This suggests that the X650 shares hardware with other models, such as the Edimax BR-6478AC, which has similar specifications but includes a USB port.

Interestingly, the PCB also has several unpopulated connectors, possibly for future expansion or different firmware configurations. Some components have labels starting with "D," which may indicate placeholder parts or unused features. These could be left over from a more advanced model, suggesting that the X650 might have had a higher-end variant that was never released.

The router also features a 512 MB DDR2 SDRAM from Nanya Technology and a Macronix MX25L3206E 4MB flash memory. On the back of the board, the layout is relatively sparse, indicating that the design focuses on efficiency rather than complexity. Despite its age, the X650 still holds up well, especially if you’re willing to install third-party firmware like OpenWRT or DD-WRT.

However, one major drawback is that ZyXEL stopped providing firmware updates for the X650 around 2013. This has led to some software issues and bugs. In contrast, Edimax, which uses the same hardware in their BR-6478AC model, has offered better long-term support. Some users have successfully flashed Edimax firmware onto the X650, improving stability and performance. Just keep in mind that without a real USB port, some features may not work as expected.

Overall, the ZyXEL X650 is a great example of how hardware can outlive its original firmware support. With the right modifications, it can still serve as a reliable and powerful router, proving that even older devices can find new life with the right upgrades.

1.0mm Male Header

1.0mm (.039″) Pitch Pin Headers

Overview

Antenk offers a variety of high quality and competitively priced 1.0mm pitch single, dual, three, quad row pin (male) headers used in many board-to-board PCB connections, fitting small-sized, densely-packed devices.


This low-profile component is made from high-temperature thermoplastic and is offered with several means of connections and mounting styles such as through-hole (THM) or surface mount (SMT) and can be in vertical (straight), elevated or at a right angle configuration/orientation dissipating current of about 1.0 A or less.


The pin (male) header is generally mated with receptacle or stackable header connectors (female sockets). This types of pin headers are suitable for PCB board to board connection or for signal transmission application.


Applications of 1.0mm Pitch Pin Headers

Its small size is most suitable for PCB connections of small equipment and devices such as WiFi equipment, gaming consoles, measurement instruments, and other equipment in need of a special interface to become interconnected


Mount Type: Through-hole vs Surface Mount

At one side of this pin header is a series of pins which can either be mounted and soldered directly onto the surface of the PCB (SMT) or placed into drilled holes on the PCB (THM).


Through-Hole (Poke-In)

Best used for high-reliability products that require stronger connections between layers.

Aerospace and military products are most likely to require this type of mounting as these products experience extreme accelerations, collisions, or high temperatures.

Useful in test and prototyping applications that sometimes require manual adjustments and replacements.

1.0mm vertical single row header, 1.0mm vertical dual row header, 1.0mm Elevated single row pin header, 1.0mm Elevated dual row pin Header, 1.0mm Right-angle single row header and 1.0mm Right-angle dual row header are some examples of Antenk products with through-hole mount type.


Surface-Mount

The most common electronic hardware requirements are SMT.

Essential in PCB design and manufacturing, having improved the quality and performance of PCBs overall.

Cost of processing and handling is reduced.

SMT components can be mounted on both side of the board.

Ability to fit a high number of small components on a PCB has allowed for much denser, higher performing, and smaller PCBs.

1.0mm Right-angle Dual Row pin header, 1.0mm SMT Single row pin header, 1.0mm SMT Dual row pin header and 1.0mm Elevated Dual Row Pin Header are Antenk`s SMT pin headers.

Soldering Temperature for 1.0mm Pitch Pin Headers

Soldering SMT pin header can be done at a maximum peak temperature of 260°C for maximum 60 seconds.


Pin-Type: Vertical (Straight) and Right-Angle

1.0mm pitch headers may be further classified into pin orientation as well, such as vertical or straight male header or right-angle male header.


Vertical or Straight Pin (Male) Header Orientation

One side of the series of pins is connected to PCB board in which the pins can be at a right-angle to the PCB surface (usually called "straight" or [vertical") or.

Right-Angle Pin (Male) Header Orientation

Parallel to the board's surface (referred to as "right-angle" pins).

Each of these pin-types have different applications that fit with their specific configuration.


PCB Connector Stacking

Elevated Pin Header Orientation

Elevated pins aka Stacked Pins or Mezzanine are simply stacked pin headers providing an exact distance requirement between PCBs that optimizes electrical reliability and performance between PCB boards.


Profile Above PCB

This type of configuration is the most common way of connecting board-to-board by a connector. First, the stacking height is calculated from one board to another and measured from the printed circuit board face to its highest insulator point above the PCB.


Single, Dual or Multiple Number of Rows

For a 1.0mm straight or vertical male pin header, the standard number of rows that Antenk offers ranges from 1 to 2 rows. However, customization can be available if 3 ,4 or n number of rows is needed by the customer. Also, the number of contacts for the single row is about 2-50 pins while for dual row, the number contacts may vary from 4-100 pins.


Pin Material

The pins of the connector have been designed with copper alloy. With customer`s demand the pins can be made gold plated.


Breakaway design

The pin headers are also equipped with a breakaway design making them fully compatible with their female receptacles.


Custom 1.0mm Pitch Pin Headers

Customizable 1.0 mm pitch pin headers are also available, making your manufacturing process way faster as the pins are already inserted in the headers, insulator height is made at the right size and the accurate pin length you require is followed.


Parts are made using semi-automated manufacturing processes that ensure both precision and delicacy in handling the headers before packaging on tape and reel.


The tape and reel carrier strip ensures that the headers are packaged within accurately sized cavities for its height, width and depth, securing the headers from the environment and maintaining consistent position during transportation.


Antenk also offer a range of custom Tape and reel carrier strip packaging cavities.



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ShenZhen Antenk Electronics Co,Ltd , https://www.antenk.com

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