Elecraft_K-2_KPA-100_user_2002.pdf

Appendix G, 100-W Stage and RS-232 I/O (K2/100) Rev A, May 13, 2002 1 Downloaded by? RadioAmateur.EU 2 Table of Contents Introduction.3 Preparation for Assembly.3 Tools Required.3 Pre-Wound Toroids.3 Parts Inventory.3 Assembly, Part I.11 Initial Tests.20 Assembly, Part II.24 Alignment and Installation.41 Receiver Tests.44 SWR Bridge Null Adjustment (C1).44 Power Calibration (R26 and R27).45 Temperature Calibration (CAL tPA).45 KPA100 Power Supply Test.45 Fan Test.46 External Amplifier Keying Test (PA KEY).46 Bias Current Adjustment.46 Transmit Tests.47 Installation.48 Using the K2/100 at High Power.49 Power Supply.49 Antenna.49 Controls.50 Remote Control using the RS232 Port.51 Control Board Preparation.51 RS-232 Interface Setup and Test.52 Computer Control.53 K2/100 Specifications.56 Troubleshooting and Repair.57 Circuit Details.60 KPA100 Schematic.61 Parts Placement Drawing.63 3 Introduction Appendix G describes assembly of the K2/100 transceivers internal 100-watt final output stage (KPA100 board). The PC board includes two conservatively- rated RF power transistors, low- pass filters, SWR bridge, monitoring circuits, speaker, and an RS232 interface. Filter switching, T- R sequencing, and other configuration is handled by the K2/100s main microcontroller. KPA100 assembly and installation should be done only after the transceiver has been aligned and tested at the 10-watt level. Preparation for Assembly With all equipment that operates at high power levels, proper assembly and alignment are critical for safe and reliable operation. Follow the instructions carefully and make all of the recommended measurements. Do not substitute components or perform any assembly steps out of order. Please read the following information regarding tools and toroids before proceeding. Tools Required The following tools are required to build this kit: Flush-cutters (Hakko CHP-170, Xcelite 170, etc.). Ordinary diagonal cutters are not suitable for flush-cutting (trimming leads very close to the board). Temperature-controlled soldering station with a fine-point, 800-degree (F) tip. Do not use a high-wattage iron or gun with small components, since this can damage pads, traces, or the parts themselves. Larger iron or soldering gun. This will be used only for installation of power transistors, output transformer, and DC power wiring. A low-wattage iron cannot be used for these steps. Digital Multimeter (DMM). A DMM with capacitance measurement capability is desirable, though not required. Refer to our web site for tool sources and solder recommendations. Pre- Wound Toroids The toroids on the KPA100 board are not difficult to wind, and detailed instructions are provided (beginning on page 24). All toroids must be wound and prepared correctly, or the power transistors may be damaged. If you prefer not to wind the toroids yourself, you can obtain a full set of pre-wound toroids (with leads stripped and tinned) from an Elecraft- qualified source. A toroid order form may have been supplied with your kit. You can also find ordering information at . You do not need to send your cores or wire to the winding service. Parts Inventory Set the heat sink and painted panels aside until needed. Leave them wrapped to protect their finish. You should do a complete inventory (parts list starts on page 4), which will take 2 to 3 hours. If anything is missing, contact Elecraft. Color codes and other markings are shown in parentheses. Refer to Appendix A of the owners manual for additional parts photos. Some components in this kit can be damaged by static discharge. Before handling diodes, transistors, and ICs, touch a grounded, unpainted metal surface, or use a wrist strap. Parts List Notes: LS = lead spacing (0.1 = 2.5 mm, 0.2 = 5 mm, 0.4 = 10 mm.) In some cases, two capacitor types will have the same value but different voltage ratings or lead spacing (LS). To avoid assembly errors, you must positively identify these capacitors and keep them separate from each other. Use your DMM to verify values if possible. Parts shown in bold are for use on the K2 RF or Control boards. Flat-head screws are measured from the top of the head; pan head screws are measured from beneath the head. 4 PictureRef. Designator(s)QTYDescriptionPart # C5B1Cap., 18 pF (18), 5%, 500V or 1KV disc, 0.2 LS (may have black band)E530088 C3B,C4B2Cap., 27 pF (27), 5%, 500V or 1KV disc, 0.2 LSE530089 C5F1Cap., 33 pF (33), 5%, 500V or 1KV disc, 0.2 LSE530090 C3H1Cap., 39 pF (39), 5%, 500V or 1KV disc, 0.2 LSE530091 C5D1Cap., 47 pF (47), 5%, 500V or 1KV disc, 0.2 LSE530092 C4D1Cap., 56 pF (56), 5%, 500V or 1KV disc, 0.2 LS (may have black band)E530093 C5A,C6C2Cap., 68 pF (68), 5%, 500V or 1KV disc, 0.2 LSE530094 C3E,C5G2Cap., 82 pF (82), 5%, 500V or 1KV disc, 0.2 LSE530095 C4E1Cap., 120 pF (121), 5%, 500V or 1KV disc, 0.2 LSE530096 C3G,C4A,C5C,C5E, C6E 5Cap., 150 pF (151), 5%, 500V or 1KV disc, 0.2 LSE530097 C2B,C3C,C3J3Cap., 220 pF (221), 5%, 500V or 1KV disc, 0.2 LSE530098 C3A,C3D,C4C,C6F4Cap., 270 pF (271), 5%, 500V or 1KV disc, 0.2 LSE530099 C3F,C6A,C6B,C6G4Cap., 330 pF (331), 5%, 500V or 1KV disc, 0.2 LSE530100 C2D1Cap., 390 pF (391), 5%, 500V or 1KV disc, 0.2 LSE530101 C261Cap., 33 pF (33), 5%, 50V disc, 0.2 LS (do not confuse with C5F)E530064 C41,C952Cap., 100 pF (101), 5%, 200V disc, 0.2 LSE530034 C661Cap., 180 pF (181), 5%, 50V disc, 0.2 LS; voltage may not be markedE530008 C80,C812Cap., 4700 pF (472), 10%, 100V disc, 0.25 LSE530102 C2E,C83 alternate2Cap., 1000 pF (1000), 5%, 500V silver micaE530085 C2A,C6D,C833Cap., 1200 pF (1200), 5%, 500V silver micaE530033 C2C1Cap., 2200 pF (2200), 5%, 500V silver micaE530086 C841Cap., .001 F (102), 5%, 50V mono, 0.1 LSE530074 C25,C69,C70,C87, C88, CTRL- Ctxd 6Cap., .001 F (102), 5%, 50V mono, 0.2 LS (CTRL-Ctxd may be needed for K2 Control board; see text) E530001 C821Cap., 1200 pF (122), 5%, 50V mono 0.2 LSE530005 C711Cap., .0018 F (182), 5%, 200V mono, 0.2 LSE530104 C641Cap., .0018 F (182), 5%, 630V mono, 0.4 LSE530105 C7,C8,C9,C12C22, C24,C28,C29,C32, C50,C65,C72,C73, C74,C76,C97C99 27Cap., .01 F (103), 5%, 50V mono, 0.1 LSE530019 C37,C38,C39,C44, C46,C68,C89,C90 8Cap., .01 F (103), 5%, 50V mono, 0.2 LSE530009 C36,C42,C43,C774Cap., .015 F (153 or 15N), 5%, 250V mono, 0.2 LSE530082 C31,C672Cap., .033 F (333 or 33N), 5%, 250V mono, 0.2 LSE530083 C791Cap., .039 F (393), 5%, 200V mono, 0.4 LSE530103 5 PictureRef. Designator(s)QTYDescriptionPart # C48,C49,C52C57, C61-C63,C85,C86. RF-Crf 14 Cap., .047 F (473), 5%, 50V mono, 0.2 LS (RF- Crf may be needed for the K2 RF board; see text) E530025 C30,C33,C34,C754Cap., 0.1 F (104), 20%, 50V mono, 0.1 LSE530020 C10,C11,C23,C35, C58,C59,C40, CTRL-C42 8Cap., 0.1 F (104), 5%, 50V mono, 0.2 LS (CTRL-C42 may be needed for the K2 Control board; see text) E530011 C1,C272Cap., 5-30 pF ceramic trimmerE540001 C601Cap., 100 F, 16V electrolyticE530061 C511Cap., 470 F, 25V electrolyticE530084 D1-D88Diode, 1N4148E560002 D91Diode, SB530E560003 D10,D132Diode, 1N5404E560010 D11,D12,D143Diode, 1N4007E560001 D16,D172Diode, 1N5711E560004 E11Ground terminal, right angle PCB mount, 6-32 threadedE700012 FAN11Fan, 12 VE980046 J21Connector, SO239 (Antenna)E620064 J3, P32Connector, DC power, red housing (13.8 VDC input and mating conn., +)E620059 J3, P32Connector, DC power, black housing (13.8 VDC input and mating conn., -)E620060 MISC2PCB pin for J3, 25 amp right angleE620061 MISC2Crimp/solder terminal for P3, 30 ampsE620062 6 PictureRef. Designator(s)QTYDescriptionPart # HDWR2Mounting plate for J3E620063 MISC1Spring pin, 3/32 x 1/4 (2.4 x 6.4 mm); stabilizing pin for P3E700071 J1,J42Connector, 2p female housing, 0.156 spacing (12V and RF connectors)E620013 RF- P3, RF- P62Mating connectors for J1 and J4, 2p male, 0.156 spacing (K2 RF board)E620012 HDWR5Crimp/solder terminal for J1 and J4, gold color (1 spare)E620014 J51Connector, 2p female housing, 0.1 spacing (AF In)E620021 HDWR3Crimp/solder terminal for J5 (1 spare)E620022 J61Connector, 1/8 mono jack w/switch, PCB mount (ext. speaker)E620056 J71Connector, RCA jack, PCB mount (ext. PA key)E620057 J81Connector, DB9F, PCB mount (RS232 interface)E620058 MISC2Keying insert for ribbon cable connector (Shown approx. 4x actual size; may include large break-away tab) E700065 MISC1Connector, DB9M (serial I/O cable, K2 end)E620049 MISC1Connector, DB9F (serial I/O cable, PC end)E620048 MISC2Backshell for serial I/O cableE620050 K1-K1212Relay, SPDT, 12 VE640011 L1,L2,L13,L144Toroidal inductor, T50-2 core (iron powder, red, 0.5 dia.)E680005 L4-L8,L10-L128Toroidal inductor, T50-10 core (iron powder, black, 0.5 dia.) Note: One gray ferrite core of the same size is also supplied (see T4). The T50-10 iron power cores have a shiny, black finish, while the ferrite core is dull gray in color. Keep the two types separated. E680016 L15,L16,L183Tor