ELECRAFT KFL1-4 Assembly And Operating Instructions Manual Download Page 5 | Manualshive

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When handling capacitors in the following steps, do not pull on the leads or bend them

excessively, since they can be quite fragile. In the case of capacitors with pre-formed leads, there is no
need to remove any bends. The short, pre-formed portion of the leads can remain exposed (above the
board) after installation.

Sort all of the capacitors, arranging them by value. This will make it easier to locate the correct

capacitor values during assembly. (Some small capacitor values may be labeled in more than one way. This
is explained page 9 of the K1 Owner's Manual. Also refer to the parts list, which shows alternate labeling.)

Install the capacitors listed below, but do not solder yet. Complete one row of the list before moving to

the next (the arrows in the list serve as a reminder). Start with capacitor C13 (68 pF), which is located near
the left end of the PC board, then go on to C11, C9, etc.

__ C13, 68 ("68")



__ C11, 68 ("68")



__ C9, 2 pF ("2") or 2.2 pF (2r2)

__ C12, 68 ("68")

__ C14, 68 ("68")

Using the list above, double-check each capacitor's value.

This step should not be skipped, since it

may be difficult to remove capacitors after they are soldered in place.

Trim and solder the leads of all capacitors installed so far.

C10 may be

4.7 pF

("4r7"), or

5 pF

("5"). To locate the position for C10, first find relays K2 and K3.

C10 is directly between the two. Install C10, then trim and solder.

Install the capacitors listed below, which are separated into three groups. After installing all the

capacitors in a group, double-check the values, then trim and solder the leads.

__ CL, 120 ("121")



__ CM, 120 ("121")



__ CN, 100 ("101")

__ CP, 100 ("101")

__ CJ, See note 1 below

__ CK, See note 2 below

__ C15, .047 ("473")

__ C16, .047 ("473")

__ C17, .047 ("473")

__ C43, .001 ("102")



__ C44, .001 ("102")



__ C45, .001 ("102")

__ C21, 100 ("101")

__ C22, 27 ("27")

__ C23, 180 ("181")

__ C24, 82 ("82")

__ C25, 180 ("181")

__ C26, 27 ("27")

__ C27, 100 ("101")

__ C28, 330 ("331")



__ C29, 56 ("56")



__ C30, 560 ("561")

__ C31, 150 ("151")

__ C32, 560 ("561")

__ C33, 56 ("56")

__ C34, 330 ("331")

Notes:

1-

CJ may be 2.7 pF ("2r7") or 3.3 pF ("3r3").

2 - CK may be 4.7 pF ("4r7") or 5 pF ("5").

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Summary of Contents for KFL1-4

Page 1: ...r 15 meters The KFL1 4 is the same size as the 2 band K1 filter board KFL1 and can simply be plugged into the K1 transceiver with no other required changes The 4 band filter board is fully compatible with the KBT1 battery option and the KAT1 automatic antenna tuner ATU With most antennas the ATU will find a good match on all four bands The KFL1 4 covers the frequency ranges listed below These rang...

Page 2: ...C19 C35 C45 Capacitor 001 µF 102 0 1 lead spacing E530074 12 C15 C16 C17 Capacitor 047 µF 473 E530025 3 C46 Capacitor 0 1 µF 104 0 1 lead spacing E530020 1 C1 C8 CA CH Trimmer capacitor 1 40 pF E540002 16 J1 Conn 3 pin female E620009 1 J2 Conn 10 pin female dual row 5 pins per row E620045 1 K1 K8 Miniature DPDT relay E640010 8 L1 L6 T1 T4 Toroidal inductor T37 6 core see text E690013 10 P1 P2 P3 C...

Page 3: ... iron or one with a wide tip may damage components pads or traces Locate the KFL1 4 PC board and identify the top and bottom sides The side of the board with the label KFL1 4 is the top Orient the board so that the top side is facing up The large notch in the board should be to the lower right Locate the position of resistor R1 along the front edge of the board top side The label R1 appears to the...

Page 4: ... clean shiny solder joint and fill the hole It should take no more than 2 3 seconds to solder each lead Do not trim the leads Place relays K1 K8 at their indicated locations DO NOT bend the relay leads to hold the relays on the board as this can cause mechanical stress Note that the relays can only be installed one way due to a gap between pins Carefully flip the board over using a hardcover book ...

Page 5: ... __ C11 68 68 __ C9 2 pF 2 or 2 2 pF 2r2 __ C12 68 68 __ C14 68 68 Using the list above double check each capacitor s value This step should not be skipped since it may be difficult to remove capacitors after they are soldered in place Trim and solder the leads of all capacitors installed so far C10 may be 4 7 pF 4r7 or 5 pF 5 To locate the position for C10 first find relays K2 and K3 C10 is direc...

Page 6: ...be installed in a later step Install the ceramic resonator Z1 Z1 looks like a capacitor with three leads and can be oriented in either direction Limit soldering time to 2 or 3 seconds on each pin to avoid altering Z1 s oscillation frequency Trim Z1 s leads after soldering i Before crystals X1 X4 can be installed you ll need to choose whether to set up your K1 for 80 kHz or 150 kHz VFO coverage1 Th...

Page 7: ...2 Re check the crystal frequencies then solder and trim the leads Cut four 1 2 12 mm bare wires Solid hookup wire or discarded component leads can be used Referring to Figure 2 insert bare wires into the grounding holes provided near each crystal Fold each wire over the top of the crystal and solder it on top Keep soldering time below 5 seconds at a time if it takes longer your iron may not be hot...

Page 8: ...specified It is not necessary to use an inductance meter to precisely match the inductances shown on the schematic All the toroid cores used on the KFL1 4 board are type T37 6 yellow 0 37 19 mm in diameter If you aren t yet familiar with toroidal inductors please read the information on page 13 of the K1 owner s manual titled Identifying Toroid Cores Locate the component outline for inductor L1 at...

Page 9: ...eads so that a clean solder joint will result Leads must be tinned up to the edge of core the core itself is non conductive Review Figure 4 which shows the part of the leads to be stripped and tinned If you have a padded vise such as a Panavise clamp L1 into it with its leads horizontal ready for heat stripping and tinning Don t over tighten the vise as this might crack the toroid core If you don ...

Page 10: ...ll L2 through L6 in the same manner as L1 using red enamel wire and the turns counts listed below Remember that each pass through the core counts as one turn The turns spacing should be adjusted so that the winding occupies about 80 of the core as shown in Figure 4 __ L2 10 turns 8 20 cm __ L3 11 turns 9 23 cm __ L4 16 turns 12 30 cm __ L5 15 turns 11 28 cm __ L6 16 turns 12 30 cm i Do not use adh...

Page 11: ... the second winding be careful not to damage or apply heat to the first winding This could result in a short between turns altering the inductance Prepare the leads of the second winding Examine all four leads and nearby turns with the magnifying glass Make sure that no adjacent turns or leads are shorted or melted together Install T3 vertically as indicated by its component outline near trimmer c...

Page 12: ... and lead 3 on the bottom Heat strip and tin leads 3 and 4 The second winding uses 8 turns of green enamel wire Start just to the left of lead 4 working counter clockwise and covering about half of the first winding Leave lead 2 long about 1 25 mm Re check the turns count and sense of this winding Lead 1 terminates on the top 2 on the bottom Fold lead 2 down behind the core as shown in Figure 6b t...

Page 13: ...1 on the top side Then examine the placement of P1 closely If it is tilted or is not flat against the board re heat the solder while pressing down on the connector Check one more time to be sure that P1 is installed on the bottom side as shown in Figure 7 If P1 is in the right position solder the remaining pins Do not trim the leads Install P2 and P3 in the same manner as P1 on the bottom side of ...

Page 14: ...with the K1 Remove 1 4 6 mm of insulation off of each end Insert this wire into pins 2 and 10 of J2 as shown in Figure 8 The pins on J2 are counted from left to right and top to bottom as shown Figure 8 i Before handling U1 in the next step touch an unpainted grounded metal surface Carefully straighten the leads of U1 PIC16C621A as shown in Figure 9 The two rows of pins must be straight and parall...

Page 15: ...d be used rather than an analog VOM volt ohm meter To make the measurements touch your DMM s and leads to the indicated points The Filter board schematic pages 23 and 24 may help you troubleshoot any incorrect readings Note The symbol means greater than and means less than Your DMM may indicate infinite resistance all digits flashing or a flashing 1 for readings that are listed as greater than som...

Page 16: ...ndicating that the self test found the VFO signal missing Tap the BAND switch twice quickly to change the band If you don t hear any relays switching refer to Troubleshooting in this manual as well as the K1 owner s manual troubleshooting section Appendix E Since this is a four band module you can continue to tap quickly to switch to each remaining band The frequencies of the four bands may not be...

Page 17: ... is ever required always adjust the 10 MHz trimmers before the 7 MHz trimmers since the capacitance on 7 MHz is the sum of the two For the same reason 18 21 MHz settings must be aligned before 14 MHz Figure 11 Using a small flat blade screwdriver or tuning tool set all sixteen trimmers so that their adjustment slots are roughly perpendicular to their flat sides see Figure 11 You ll need one of the...

Page 18: ...Tune the trimmers slowly If you don t hear any change leave C5 and C6 at their mid points Adjust CE and CF in the RF filter alternately Tune slowly and listen for increased signal strength If you don t hear any change move C5 and C6 to slightly different settings then peak CE and CF again Continue to peak all four trimmers for this band until no further improvement is noted You may find it necessa...

Page 19: ...nd WPM switches together During TUNE the power in watts will be shown on the LCD e g P2 0 Hitting the key or pressing any switch except WPM and WPM will cancel TUNE If the output jumps up to well above 2 watts during alignment exit TUNE mode then re enter it again For an explanation of how transmit ALC works see footnote 3 on page 47 of the K1 owner s manual Put the K1 into TUNE mode Adjust C5 C6 ...

Page 20: ... Filter boards R36 can be mounted on the bottom of the board if desired making it easier to get to 3 Remove the jumper on the Filter board between J2 pins 2 and 10 If you soldered a jumper between these two pins on the bottom of the Filter board unsolder and remove it 4 Install the Filter board using just the center of the three screws 5 Place the KAT1 s two standoffs in their appropriate location...

Page 21: ...low on all bands the supply voltage may be low Max output should be typically 5 watts at 12 V and somewhat higher at 14 volts You could lose a significant amount of voltage between the supply and the K1 if the power leads are too small use 20 AWG wire or larger Verify power with a known calibrated wattmeter if possible Check the values of R34 R36 and R37 on the RF board As a last resort change R11...

Page 22: ... and C4 in parallel with C1 and C2 20 meters T3 T4 and associated capacitors make up the RF band pass filter which is used in both transmit and receive modes via the T R switching diodes on the RF board Since this filter must cover a 3 1 frequency range 7 21 MHz with only a single inductance value both input and output use tapped connections to their associated transformers i e autotransformer cou...

Page 23: ... 5 6 100 CN 100 CP CL CM 2 7 3 6 4 5 KFL1 4 4 1 2 3 T1 3 1 2 4 T2 3 4 1 2 T3 047 C17 3 4 1 2 T4 The selected band determines which if any relays are in the SET position 40 m K1 K2 K3 K5 K7 K8 20 m K2 K4 K6 15 m none 30 m K1 K3 K4 K5 K6 K7 K8 2 All variable capacitors are 8 50 pF ceramic trimmers 3 K1 K8 are latching relays shown in the RESET position 68 68 120 120 15m 20m 30m 40m 15m 15m 15m 20m 2...

Page 24: ...4 5 6 7 8 9 J2 To ATU P2 Note 1 Note 1 I O Controller 40 30 m 20 15 m C25 180 C32 560 L2 L5 C22 C24 C26 C29 C31 C33 RY COM 2 7 3 6 4 5 2 7 3 6 4 5 8 1 K4 RFC1 1 8 K8 1 8 K7 001 C41 001 C45 001 C44 8 1 K2 8 1 K1 8 1 K3 8 1 K6 8 1 K5 R1 001 C42 001 C40 001 C37 001 C19 001 C35 001 C39 100 001 C36 001 C38 100µH 27 82 27 56 150 56 0 5µH 0 42µH 0 5µH 0 86µH 0 73µH 0 86µH Filters Low Pass AGC OFF 6A RY C...

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