ELECRAFT K2/100 Manual Download Page 73

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Parts Placement Drawings

(Top Side)

KPA100 REV B

2002 ELECRAFT

BIAS SET

(SOCKET)

TD62083

MAX1406

16F872

FAN-
FAN+

RFC8

RFC6

RFC7

RFC9

T1-4

T1-5

100K

RFC4

RFC1

C26

C10

GND

C11

R31

GND

C38

C35

C39
C44

C37

C42

C36

C43

K11

L12

L11

L10

C2D

C2B

C6G C6F

C6C

C6E

C2E

C2C

C2A

C6D

C3A

C3J

C28

C12

C95

R29

D17

D16

C88

C87

R26

C69

R27

C70

RP1

R24

R25

C49

C48

D12

C86

D14

C82

R14

R13

C76

D11

C64

C79

D13

C67

C51

R35

R34

R20

R19

C66

L18

C63

C62

C61

C60

C59

C58

R32

R30

R23

C23

R10

TP1

C89

C68

C25

C85

C71

C72

C73

R22

C81

C80

Q12

R21

R16

R15

C30 C33 C34

C90

C50

TP2

TP4

L16

C31

C77

C52

C57

Note: C82 is not used. The space shown for it should be empty.

Summary of Contents for K2/100

Page 1: ...1 Appendix G 100 W Stage and RS 232 I O K2 100 Rev H3 July 24 2017 E740035...

Page 2: ...sembly Part II 28 Alignment and Installation 45 Using the K2 100 at High Power 57 Remote Control using the RS 232 Port 60 K2 100 Specifications 65 Troubleshooting and Repair 66 Circuit Details 70 Sche...

Page 3: ...aft com manual k2a2binstr pdf Pre Wound Toroids Available The toroids used in the KPA100 are not difficult to wind and full instructions are provided If you prefer not to wind them yourself you can ob...

Page 4: ...arranty service you should fully complete the assembly carefully following all instructions in the manual Who is covered This warranty covers the original owner of the Elecraft product as disclosed to...

Page 5: ...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 Picture Ref Designator s QTY Description Part C5B 1 Cap 18 pF 18 5 500...

Page 6: ...8 C89 C90 8 Cap 01 F 103 5 50V mono 0 2 LS E530009 C36 C42 C43 C77 4 Cap 015 F 153 or 15N 5 250V mono 0 2 LS E530082 C31 1 Cap 22 F 22J63 5 63V mono 0 2 LS E530295 C48 C49 C52 C53 C54 C55 C56 C57 C61...

Page 7: ...0 amps E620062 HDWR 2 Mounting plate for J3 E620063 MISC 1 Spring pin 3 32 x 1 4 2 4 x 6 4 mm stabilizing pin for P3 E700071 J1 J4 2 Connector 2p female housing 0 156 spacing 12V and RF connectors E62...

Page 8: ...3 Q4 2 Transistor NPN MJE182 TO 225AA package E580016 Q5 Q8 2 Transistor NPN 2N3904 TO 92 E580017 Q6 Q7 2 Transistor MOSFET 200 V ZVN4424 TO 92 E580005 Q10 Q11 Q12 3 Transistor MOSFET 60 V 2N7000 TO 9...

Page 9: ...rked part number should include 392 E510000 SP1 1 Speaker 4 ohms 3W E980007 T1 1 Transformer small binocular toroid core gray approx 0 5 x 0 75 E680014 T2 1 Transformer large binocular toroid core gra...

Page 10: ...xide 2 spares E700015 HDWR 5 Screw 4 40 x 3 16 undercut flathead black oxide 1 spare E700025 HDWR 19 Screw 4 40 x 1 4 panhead 2 spares E700005 HDWR 3 Screw 4 40 x 1 4 flathead 1 spare E700063 HDWR 5 S...

Page 11: ...self adhesive Q3 Q4 E980052 MISC 1 BNC connector cap plastic to cap K2 s BNC antenna jack E980006 MISC 26 ft Enamel wire 22 red for all low pass filter toroids E760018 MISC 9 ft Enamel wire 26 red fo...

Page 12: ...rol board mod E760008 MISC 1 ft Stranded Teflon insulated wire 22 gray for T1 E760020 MISC 2 ft Stranded Teflon insulated wire 18 gray for T2 E760021 MISC 3 Cable tie 3 E980002 MISC 1 Allen wrench 05...

Page 13: ...r band red toward the left Make sure R28 is seated flat on the board with no excess lead length exposed This is necessary to keep the resistor from touching the heat sink which will be attached later...

Page 14: ...less in length a b Figure 2 i The leads on small capacitors are fragile Do not pull on the leads or bend them excessively Sort all capacitors into groups by capacitance value Start by grouping them b...

Page 15: ...oke for use at RFC11 BRN BLK BRN color code 0 4 lead spacing Do not use one of the miniature 100 H RF chokes which has a much smaller lead spacing Install RFC11 on the bottom side of the board Its loc...

Page 16: ...diode type Next reverse the leads the DMM should show an open circuit indication flashing 3 000 or 0 000 etc Near the ELECRAFT label you ll find a short jumper location identified by a ground symbol U...

Page 17: ...diagonal corner pins on each relay Inspect the 11 relays closely to make sure that they re seated flat against the PC board If not re heat the corner pins one a time while pressing down on the relay O...

Page 18: ...below All are 500 V or 1KV 1000 V disc with 0 2 lead spacing These capacitors are located on the left side of the board between the two rows of relays K3 K12 Note Some of these capacitors are arranged...

Page 19: ...not solder yet Figure 4 shows P1 as viewed from right side of the board The plastic part of the connector must be on the top side of the board with the long end of the pins pointed up The short ends...

Page 20: ...the component outline Trim the pins on the bottom after soldering Shortened Tab Back edge of PCB Figure 6 Transistor Q3 MJE182 will be installed on the bottom side of the board near the board cutout f...

Page 21: ...problems may be difficult to troubleshoot Note The pin 1 end of ICs can be identified by a notch or dimple as shown in Figure 8 This end must be oriented toward the notched end of the component outli...

Page 22: ...ttom side Locate J8 the 9 pin D connector and temporarily place it in its indicated location far right side of the board Note that the leads of capacitors C97 C99 on the bottom of the board interfere...

Page 23: ...listed below touching the DMM s and leads to the indicated points The lead will go to ground in all cases except the first measurement relay coils i The symbol means greater than Your DMM may indicat...

Page 24: ...0 1 F capacitor 104 Use a capacitor with 0 2 lead spacing Note If you have an older Control board rev XC that does not include C42 solder the 0 1 F capacitor between pins 4 and 8 of U3 LMC6482 on the...

Page 25: ...KAF2 board if applicable Secure the Control board to the Front Panel board with the hardware removed earlier Locate the pre assembled ribbon cable Lay the cable flat as shown in Figure 13 with the bl...

Page 26: ...irmware or later Check the label to determine the revision If it s older than 1 06 a new 28 pin IC 16C72A or 16F872 should have been supplied with your KPA100 kit Install it at this time with pin 1 of...

Page 27: ...in 15 0 to 0 1 U1 pin 20 5 0 U1 pin 27 5 8 U1 pin 28 5 7 U2 pin 10 12 15 U4 pin 1 12 15 U4 pin 11 5 0 U5 pin 1 0 to 0 1 U5 pin 7 0 to 0 1 U6 pin 6 0 to 0 5 Tap MENU then tap DISPLAY to bring up the K2...

Page 28: ...ne for L4 at the left side of the board near relay K5 Compare this component outline to Figure 16 which shows two views of a typical toroidal inductor L4 will be mounted vertically as shown at the rig...

Page 29: ...ard Solder the leads of L4 When soldering make sure that the solder binds well to the leads If the lead appears to be an island in a pool of solder it is not making good contact remove the toroid and...

Page 30: ...gauge red enamel wire for each inductor 3 Wind 37 turns on each core as shown in Figure 19 Figure 19 Prepare the leads of L16 and RFC1 as before Install L16 located near relay K2 Install RFC1 located...

Page 31: ...ntinuity between the 1 and 4 pads of T3 If you get a reading over 1 ohm remove T3 and prepare the leads again Transformer T4 also uses a bifilar winding Cut two 11 28 cm lengths of 26 enamel wire one...

Page 32: ...l be attached to the KPA100 PC board Unwrap the rear panel Orient it with the antenna jack at the left If masking tape usually green in color is present on the inside surface of the rear panel you ll...

Page 33: ...33 T4 5 6 GND J8 J3 J2 E1 FAN BLK RED BLACK RED B1 B2 B3 J7 J6 J2 J3 A2 A1 Fan Wires Solder Lug Figure 24...

Page 34: ...lock washers and two 4 40 nuts This hardware is shown in Figure 24 at top Cut two lengths of 20 insulated hookup wire one black 1 5 4 cm long and one red 1 25 3 2 cm Remove 1 4 6 mm of insulation from...

Page 35: ...e bottom The end view Figure 25b identifies contacts 1 and 3 The other end is contact 2 4 5 1 2 3 1 3 Top a b c Figure 25 Place T1 at its indicated location with the gap bottom side toward the PC boar...

Page 36: ...he free end of the wire back through both holes in the core as you did in a Pull on the wire so that the winding is tight The winding should then look like Figure 26b with two loops on the left side A...

Page 37: ...T2 s position Solder contact 3 over its full length Solder contact 2 over its full length Keep the iron tip away from nearby components especially potentiometers R26 and R27 Solder contact 1 over its...

Page 38: ...ted at the seven points marked H and S i The heat sink has a non conductive black oxide finish To ensure good electrical contact between the heat sink and PC board the finish will be removed at the se...

Page 39: ...mmed to less than 1 8 3 mm i The PC board will be attached to the heat sink temporarily in the next step This will position the power transistors correctly for soldering Do not install thermal pads at...

Page 40: ...er R38 and R39 The leads normally exit the body of the capacitor near the side opposite the markings so it will be easier to solder if this side is up as shown There are no solder pads The leads lay f...

Page 41: ...o the insulation to avoid leaving any exposed lead length Solder both wires Locate the two larger 2 pin housings and four of the large crimp pins for use at J1 and J4 Cut a 4 5 11 5 cm length of RG 17...

Page 42: ...42 Figure 33...

Page 43: ...re missed Unwrap the heat sink and place it on a soft clean surface Using sand paper remove the heat sink s black finish at the four areas shown in white in Figure 34 At point A be very careful to san...

Page 44: ...g 4 40 x 1 4 6 mm pan head screws and split lock washers Use a small handled Phillips screw driver to fasten the hardware tightly without risk of over tightening or stripping out the screw heads Secur...

Page 45: ...onnectors in the orientation shown in Figure 37 Look closely at the sides of the connectors Each has a small tongue on the right side and a groove on the left Slide the tongue on the right side of the...

Page 46: ...nserted between the sleeve and the insulation Be careful not to cut into the insulation itself Solder the red wire to a fuse terminal Insert the 8 20 cm red wire through a fuse holder half Remove 5 16...

Page 47: ...Q8 hardware as described in Part III of the basic K2 assembly instructions Do not over tighten any of the hardware Using a DMM on its lowest resistance scale measure resistance from the collectors of...

Page 48: ...be heard Plug the audio cable from the KPA100 J5 into the K2 s internal speaker jack RF P5 If this has any effect on the noise heard in the headphones you may have a short in the wiring of J5 Unplug...

Page 49: ...may be able to adjust C1 more accurately by measuring the reflected voltage directly using a DMM or an analog voltmeter Connect the lead to the ground jumper on the KPA100 board near U1 Touch the lead...

Page 50: ...Check your high current supply s voltage and current drain if it has built in metering The voltage should be the same as its no load voltage nominally 13 8V The current should be nearly zero Turn on...

Page 51: ...is is the most important KPA100 alignment step If your 20 amp power supply does not have accurate current measurement capability in the 0 1 amp range you ll need a DC milliammeter to set the bias curr...

Page 52: ...ding CW Set the POWER control for 20 watts You should hear the relays on the KPA100 switch into high power mode at the 11 watt point Enter TUNE mode for a few seconds maximum and make sure that power...

Page 53: ...or lower you must modify your Control board as described on page 60 before the RS 232 port can be used If you have already made this modification skip to the next step We recommend that you build a se...

Page 54: ...54 C C C Figure 40...

Page 55: ...gainst all of the standoffs it may need to be straightened If you do attempt to straighten it be careful not to bend any of the spring clips Secure the shield assembly to the standoffs using 4 40 x 1...

Page 56: ...f the panel When you re looking for the spring clip contact point four of the five side panel screw holes should line up with 2 D fasteners The fifth screw hole at the top middle of the side panel sho...

Page 57: ...J3 is not switched This means that 12 14VDC will appear on the KPA100 board anytime your high current 20A supply is turned on This is typical of most compact HF transceivers and should not present a...

Page 58: ...he fan will switch to high speed at a heat sink temperature of about 40 degrees C It will turn off within 2 to 4 minutes after going back below 37 degrees C To exit parameter edit tap MENU once You ca...

Page 59: ...ol Excluded Frequency Range Transmit is disabled from 25 000 to 27 999 MHz in QRO mode CW Operation In CW mode the power output may rise to a few watts beyond the intended level then drop back slightl...

Page 60: ...you have located the trace use a sharp tool such as an X acto knife to make two small cuts near the location marked with an X Press down with the tip don t draw the knife across the trace since you ma...

Page 61: ...ications but should be saved as a spare Fold it against the cable jacket and secure it with tape Strip off 3 16 5 mm of insulation from each insulated wire Twist the strands of each wire together and...

Page 62: ...native is to use a terminal program such as Hyperterminal Run the terminal program Set it up for 4800 baud 2 stop bits 1 will also work 8 data bits no parity Turn off hardware handshaking RTS CTS If p...

Page 63: ...rmation Program K2 Configuration and Operating Notes CT DOS program requires a batch file to start up correctly for details see http www k1ea com hintkink htm In the batch file use the command COMTSRx...

Page 64: ...te wire must then be brought out from the connector at the K2 end and routed to a 1 8th inch stereo plug for the key jack You can optionally use two diodes or two transistors to take advantage of the...

Page 65: ...e circuits on the KPA100 are powered from the KPA100 s DC input jack For details see the Operation section of the this manual 5 Current varies with band supply voltage configuration and load impedance...

Page 66: ...his will be noticeable if you use end fed antennas with little or no feedline The cure may be to use a linear power supply relocate your computer or switch to coax fed antennas Loss of signals on all...

Page 67: ...00 MCU or its on chip EEPROM If it s just the CAL TPA indication it can be cleared by turning power off and back on Codes 3 5 and 6 are not presently used Miscellaneous PA menu parameter missing Make...

Page 68: ...00 MCU Table 3 KPA100 Diode DC Voltage Chart Ref Anode Cathode Ref Anode RX 0 10w Anode RX 11 110w Anode TX 0 10w Anode TX 11 110w Cathode RX 0 10w Cathode RX 11 110w Cathode TX 0 10w Cathode TX 11 11...

Page 69: ...0 4 B 0 45 Note 3 B 1 35 8 gnd 15 13 8 3 0 4 C 14 1 C 13 5 9 1 8 16 13 8 4 gnd Q5 RX E 0 0 Q5 TX E 0 3 10 2 4 17 0 7 5 nc B 0 0 100w B 0 8 11 5 18 13 8 6 0 4 C 14 1 100w C 13 3 Note 3 12 0 5 U3 IN 13...

Page 70: ...ed A to D converter inputs on the microcontroller In this case the bridge performs identically to the one in the KAT2 ATU In high power QRO mode Q10 and Q11 are turned on by the SCALE line from U1 Thi...

Page 71: ...047 C63 047 C60 100 F R9 10 2W 2W 22 3W 0 1 C58 R38 22 3W 0 1 1000 s m 4700 4700 1 6 2W 1 6 2W Z 1 16 Z 9 1 C53 047 C52 047 C54 047 C51 470 F C56 047 C55 047 C57 047 Z1 FB110 43 C49 047 C48 047 C85 04...

Page 72: ...200 R31 C90 01 OUT 0 OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 7 OUT 6 COM IN5 GND IN7 IN6 IN4 IN2 IN0 IN1 IN3 14 13 12 11 10 18 17 16 15 3 5 9 8 7 6 1 2 4 U2 T D62083 or ULN2803 12CT RL 5B nc 8T NC M FAN FA...

Page 73: ...7 C70 RP1 R24 R25 C49 C48 D12 C86 D14 C82 R14 R13 C76 D11 C64 C79 D13 C67 C51 R35 R34 R20 R19 C66 L18 C63 C62 C61 C60 C59 C58 R32 R30 R23 C23 R10 TP1 C89 C68 C25 C85 C71 C72 C73 R22 C81 C80 Q12 R21 R1...

Page 74: ...74 Parts Placment Drawing Bottom Side...

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