ELECRAFT KPA500 Assembly Instructions Manual Download Page 1

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LECRAFT



KPA500

IGH

-P

ERFORMANCE

160

–

ETER

MPLIFIER

SSEMBLY

NSTRUCTIONS

Rev F4, August 25, 2013

Summary of Contents for KPA500

Page 2: ...shers 6 Overview of the Kit 7 Assembly 8 Bottom Cover Feet 8 Power Supply Module 11 Interlock Switch and Left Side Panel Feet 14 Rear Panel 16 RF Power Amplifier Low Pass Filter PA LPF Module 21 Rectifier Board 22 Mounting the Rear Panel Assembly 25 Power Supply Wiring 29 Front Panel Assembly 38 Top Cover and Side Handle 42 Appendix A Illustrated Parts List A1 i Elecraft manuals with color images ...

Page 3: ...perate it If you open the KPA500 after installing it and applying mains power 1 Turn off the KPA500 by tapping the front panel ON switch and wait until the fan stops The fan drains the power supply to a safe voltage 2 Place the rear panel rocker switch in off O position and disconnect mains power from the rear panel There are no dangerous voltages present in the KPA500 during the assembly of the k...

Page 4: ... For kits before requesting warranty 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 Elecraft at the time of order Elecraft products transferred by the purchaser to a third party either by sale gift or other method who is not disclosed to Elecraft at the ...

Page 5: ...h your other hand or any part of your body Use a grounded anti static mat on your work bench No soldering is required but if you choose to use a soldering iron for any reason be sure your iron has an ESD safe grounded tip tied to the same common ground used by your mat or wrist strap We strongly recommend you take the following anti static precautions listed in order of importance to avoid trouble...

Page 6: ...sed in the correct locations as described in the procedure All dimensions given in the assembly procedure are provided in both US customary often called English and metric measurements The native dimensions of the parts are in US Customary units Approximate metric equivalents are given to assist those more familiar with that system to identify the correct parts Screws A number of different types a...

Page 7: ...nd to end as shown in Figure 2 Standoffs threaded for 2 56 and 4 40 screws are used Figure 2 Typical Standoff Lock Washers Two types of lock washers are used in the KPA500 see Figure 3 It is important that you use only the type specified and put the washers exactly where indicated Adding washers or placing the washers in the wrong position may cause parts to fail to fit together properly Figure 3 ...

Page 8: ...left is the power supply dominated by the toroidal power transformer Largely hidden by the I O board is the power supply module that contains the regulators and other components of the power supply except the rectifiers The rectifiers are mounted on a separate board near the front that uses the Z bracket for a heat sink The I O board provides the circuitry needed by the RS232 AUX and other rear pa...

Page 9: ...s applied when tightening screws Use the correct size hand tool and apply only moderate torque Do not use a power screwdriver Bottom Cover Feet Locate the bottom cover and install the tilt stand as shown in Figure 5 First mount one of the feet on the bottom fully painted side of the cover taking care to position it with the cut away for the stand as shown in the figure Use the correct length screw...

Page 10: ...tracted Identify the front edge of the bottom cover That is the edge that is elevated when the tilt stand is in the down position Note that there is a hole at each corner of the bottom cover Install a 2D fastener in each corner hole so it extends off of the front or back edge of the bottom cover as shown in Figure 6 Be sure the 2D fasteners are Mounted on the inside partially painted side of the b...

Page 11: ...e fastener will be flush with the edge Don t be too concerned with getting the 2D fasteners precisely straight You ll adjust them later Figure 6 Installing 2D Fasteners in the Bottom Cover Remove any tape or tape residue you may find on the inside partially painted surface or on the outer surfaces of the raised sides covering the unpainted area as shown in Figure 6 ...

Page 12: ...20 size I C s mounted at one end Figure 7 Power Supply Module I C s Remove the paper backing from the thermal insulator and carefully place it on U3 so that it completely covers all the exposed metal as shown in Figure 8 The other two I C s do not need insulators Figure 8 Thermal Insulator Mounted on U3 ...

Page 13: ...shown or the larger holes will not line up with the holes in the side panel Figure 9 Power Supply Module Heat Spreader Orientation Attach the heat spreader to the three I C s as shown in Figure 10 Bend the I C leads as shown to allow you to use a screwdriver to tighten the screws Be sure to install the nylon shoulder washer in the hole of U3 the I C with the thermal insulator so the screw does not...

Page 14: ...preader If the shoulder washer is installed correctly the shoulder will center the screw in the hole in the tab on U3 so it passes through without touching it and the washer keeps the screw head and lock washer from touching the tab After you have confirmed there is no short between the metal tab on U3 and the head spreader carefully bend the heat spreader and integrated circuits back to vertical ...

Page 15: ...the rubber over time Place the foot tip up on a solid work surface Position the panel with the outside fully painted side toward the foot with the hole in the panel against the tip and press down The tip should slip through the hole without further help If necessary grip the tip and pull with your long nose pliers working it from side to side until the shoulder opens against the inside of the pane...

Page 16: ...e difficult Figure 14 Mounting the Left Side Panel on the Bottom Cover Mount a 2D fastener at the top of the left side panel near the front end The fastener goes on the inside surface of the panel parallel with the top edge and with the wide shoulder against the panel see Figure 15 Figure 15 Mounting a 2D Fastener on the Left Side Panel Mount another 2D fastener at the top of the left side panel n...

Page 17: ...rovided for your KPA500 off of its protective backing and place it on the rear panel as shown in Figure 16 Figure 16 Mounting the Serial Number Locate the terminal strip board and the flat terminal strip insulator If not already done bend down one side of each terminal as shown in Figure 17 Figure 17 Preparing the Terminal Strip Board ...

Page 18: ...l on the rear panel The DMM should indicate whatever it normally shows when the probes are not touching Install the fan with the finger guard over the large opening in the rear panel as shown in Figure 19 Each screw must pass through a spacer between the ears on the fan housing as shown Orient the fan so the wires pass through the slots in the fan housing and through the opening provided in the pa...

Page 19: ...ed Also note that the connectors have a flat on opposite sides of the threaded sections Recommend you orient the connectors with the flats on the sides for the most pleasing appearance Figure 20 Installing the RF INPUT and RF OUTPUT Connectors Install the ground lug as shown in Figure 21 Figure 21 Installing the Rear Panel Ground Lug ...

Page 20: ...ry module as shown in Figure 22 Figure 22 Installing the Power Entry Module Connect the ground wire you installed earlier to the power entry module as shown in Figure 23 Figure 23 Connecting the Ground Wire to the Power Entry Module ...

Page 21: ...of pins Figure 24 Mounting Cables on the I O Board Check the I O board D sub connectors for jackscrew nuts see Figure 24 Remove them if present Install the I O module on the rear panel as shown in Figure 25 Note that the module installs with the bottom of the pc board facing upward just under the mains power entry module Figure 25 Installing the I O Module in the Rear Panel Set the Rear Panel asse...

Page 22: ...ssembled tested and aligned Take care not to disturb or stress any of the inductors Also there are two screwdriver adjusted potentiometers on the lower board Do not disturb these adjustments Place the PA LPF module on your work table as shown in Figure 26 Be sure it is oriented as shown Figure 26 Placing the PA LPF on the Work Table ...

Page 23: ...figure Figure 27 Mounting the Z Bracket on the PA LPF Module Rectifier Board Locate the rectifier board and the four thermal insulators Place one insulator over each rectifier so it covers the entire metal area and lines up with the hole in the rectifier tab as shown in Figure 28 Figure 28 Placing Thermal Insulators on the Rectifiers ...

Page 24: ...ows when the probes are not touching Place the Z bracket with the rectifier board and PA LPF module attached on your work table with the heat sink down then gently position the bottom cover assembly you completed earlier over it as shown in Figure 30 Locate and pull the gray wire attached to the power supply module to the rear and route it through the hole in the Z bracket as shown The connector i...

Page 25: ...the left side panel and install the right side panel as shown in Figure 32 The weight of the PA LPF module may flex the Z bracket slightly The unit will be somewhat top heavy in this position but it best protects the PA LPF assembly toroids from accidentally being pushed down against the bottom cover until the side panel is in place Install the screws that thread into the PA LPF module heat sink f...

Page 26: ...wo larger holes where you will install the handle later Leaving the handle off now makes it easier to stand the unit on that side if desired while connecting the internal power supply wiring in the following steps Figure 33 Installing Right Side Panel 2D Fasteners Mounting the Rear Panel Assembly Connect the 270V wire from the power supply module to the PA LPF module as shown in Figure 34 This is ...

Page 27: ...ll be out of the way for the next steps then place the rear panel assembly directly behind the KPA500 chassis It will stand upright resting on the fan housing Connect the 10 wire ribbon cable to the power supply module as shown in Figure 36 Note the brown wire pin 1 must go to the end of the connector nearest the KPA500 side panel To do so it makes a 1 2 turn twist Be certain the connector engages...

Page 28: ...le to the Power Supply Module Connect the RF INPUT coaxial cable and the RF OUTPUT twisted pair to the PA LPF module as shown in Figure 38 The miniature TMP type coaxial connector is a friction fit Insert the connector up to where it begins to widen to form the ears on either side Note If you ever need to remove this connector always grab it by the metal ears not by the coaxial cable Figure 38 Con...

Page 29: ...nel Assembly on the KPA500 Chassis Look through the top of the KPA500 and check the clearance of gray wire leading to the center pin of the RF output connector and the Z bracket If necessary bend the wire at the pin as needed for clearance as shown in Figure 40 A flat blade screwdriver is an excellent tool to bend the wire Figure 40 Checking RF Output Connector Center Pin Wire Clearance Check the ...

Page 30: ...es that could do serious damage to your KPA500 Connect the four wire cable from the power supply module to the power entry module as shown in Figure 41 This cable has four heavy wires black yellow blue and white with the white wire at the top The key prevents installing the plug incorrectly Figure 41 Connecting the 4 Wire Cable to the Power Entry Module Locate the long three wire cable attached to...

Page 31: ...3 Figure 43 Connecting the 60V and GND Wires to the PA LPF Module Connect the three remaining wires to the rectifier board mounted at the end of the Z bracket as shown in Figure 44 Each spade connector is marked with the color of wire it receives Route the black wire over the red and black wires passing around the end of the Z bracket to keep them in place They cannot be allowed to pass over the t...

Page 32: ...th leads from the power transformer installed in the following steps Figure 45 Overview of Power Supply Wiring Before Installing Power Transformer Temporarily remove the left side panel to provide room to install the power transformer Remove the screws shown in Figure 14 plus the screw in the 2D fastener at the top rear corner Do not remove the two screws holding the interlock switch Figure 12 Unp...

Page 33: ...f steel It may not be visible but it is easy to feel by testing the edge on both sides with your finger If present orient the washer with the sharp edge toward the bottom cover Tighten the hardware securely and check to ensure the bolt head is tight against the bottom cover Figure 46 Installing the Transformer Mounting Bolt and Bottom Rubber Disk Place one of the rubber disks on the bolt and move ...

Page 34: ...f the center PEM nut in the lip of the bottom cover as shown in Figure 48 Be sure the surface is clean and dry before attaching the bumpers When handling the bumpers take care not to touch the adhesive surface Figure 48 Installing the Power Transformer Bumpers ...

Page 35: ...range lead to the power supply module as shown Figure 49 Connecting the Orange Transformer Wire to the Power Supply Module Carefully lift the transformer onto the bolt without pulling the orange lead loose As you set it down be sure you don t have wires trapped between the transformer and the Z Bracket and press it toward the Z Bracket so it clears the bumpers as shown in Figure 50 Note that the b...

Page 36: ...not a flat washer It is slightly conical shaped and acts as a spring When properly installed the area around the center hole under the nut will be slightly higher than the outer edges The nut bearing down on the washer will tend to flatten it helping to hold the transformer securely The conical shape is very subtle To determine the correct orientation place the washer on a hard flat surface and pr...

Page 37: ...is not caught between the bumpers and the transformer Tighten the bolt and Nylock nut just until the transformer no longer moves when pressed against the bottom and then turn the nut between one and two turns further This will result in about 55 in pounds of torque on the nut and bolt If you have a torque wrench you may use it but it is not necessary Set the KPA500 on its bottom feet You should no...

Page 38: ...th this type of cable tie before Figure 54 shows the correct way to install them Install the ties as shown in Figure 55 After pulling each tie tightly around the wires cut off the excess where it exits the locking head Take care to ensure the yellow green and red wires can be attached either to the tap terminal on the rectifier module or to the parking terminals as shown in the figure Figure 54 Ca...

Page 39: ...igure 56 Installing the Front Panel Standoffs and Bezel Remove the front panel board from its ESD safe envelope Take care not to disturb the alignment of the LEDs Install the single square and 18 rectangular key caps as shown in Figure 57 The key caps simply push onto the shafts of the switches Be sure you install the rectangular caps horizontally so they will fit through the openings in the front...

Page 40: ...l If needed carefully adjust the position of the LEDs Secure the front panel board to the standoffs as shown in Figure 58 Figure 58 Installing the Front Panel Board Inspect the rows of LEDs on the front panel If any LEDs are out of line straighten them by running your finger or fingernail along them pressing the LEDs against the opposite side of the opening Optionally you can straighten the LEDs b...

Page 41: ...ce the front panel assembly in front of the KPA500 and connect the ribbon cables as shown in Figure 59 The wide cable may be longer than shown here Figure 59 Connecting the Front Panel Assembly to the KPA500 ...

Page 42: ...me of the screws near the front on the side panels particularly on left side panel since it is less rigidly held in place Be sure to tighten all the screws after the assembly is in place CAUTION The weight of the transformer can make the unit unstable if placed on its right side Ensure you have a good grip when handling the KPA500 and either stand it on the left side with the feet or place it upsi...

Page 43: ...idges are uncomfortable to hold Figure 62 Installing the Side Handle Locate the top cover and remove any masking tape found on the inside partially painted surface Mount two 2D fasteners and the interlock actuator on the bottom inside surface of the top cover as shown in Figure 63 The interlock actuator will press against the interlock switch on the side panel when the top cover is in place to ena...

Page 44: ... need to loosen some screws on the side front and rear panels again to adjust the fit Fasten the top cover as shown in Figure 64 Figure 64 Top Cover Installation That completes the assembly of your KPA500 Kit Turn to your Owner s Manual for installation and operating instructions before you attempt to apply power or use your KPA500 IMPORTANT You must install the proper fuses in the rear panel fuse...

Page 45: ...ted Circuit Boards Each board is packaged in its own ESD safe bag identified by the part numbers shown below The photographs are provided to help you identify each board You may find that some of the components or component locations on the boards you receive are slightly different from those shown CAUTION In addition to taking ESD precautions be careful not to damage components on either side of ...

Page 46: ...PA500 Front Panel E850470 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Front Panel Metal 1 E100380 KPA500 Rear Panel E850469 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Rear Panel Metal 1 E100381 KPA500 Side Panels E850468 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Left Side Panel 1 E100379 Right Side Panel 1 E100378 ...

Page 47: ...IPTION QTY ELECRAFT PART NO Transformer Support 1 E100384 KPA500 Carry Handle Bag E850453 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Screw 8 32 3 8 9 5 mm Pan Head Black 2 E700223 Spacer 1 4 6 4mm Long 2 E700273 Handle with 2 End Caps 1 E980115 KPA500 Front Panel Bezel and Serial Number E850461 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Serial Number Label 1 E850187 Bezel Leave in protective...

Page 48: ... Rear Panel Bag E850454 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Power Entry Module Corcom 1 E620184 10 Wire Ribbon Cable 1 E850479 Fan Guard 1 E980177 Fan Assembly 1 E850415 40 Wire Ribbon Cable 1 E850478 ...

Page 49: ... 5 16 7 9 mm 1 E700221 Bolt Fully Threaded 5 16 7 9 mm x 3 5 L 8 9 cm 18 tpi 1 E700222 Washer Belleville 0 38 9 7mm Inside Diameter 1 E700225 Washer Fender 5 16 7 9mm Zinc 2 E700231 Front Feet with Stand Rear Feet Tilt Stand with Rear Feet 1 E980098 Screw 4 40 3 8 9 5mm Zinc Pan Head 2 E700036 Screw 4 40 7 16 11mm Zinc Pan Head 4 E700032 Screw 4 40 1 4 6 4 mm Zinc Pan Head 11 E700005 Lock Washer 2...

Page 50: ... 7 16 11mm Round Black 4 E980141 Shoulder Enhanced in Image Shoulder Washer 4 40 Black 5 E700001 Thermal Insulator 4 40 Adhesive 5 E700002 Rubber Bumper Self Adhesive 2 E700024 2D Fastener 10 E100078 Screw 6 32 1 4 6 4 mm Flat Head Black Anodized 10 E700186 Screw 4 40 5 16 7 9 mm Flat Head Black 10 E700027 Screw 4 40 1 4 6 4 mm Flat Head Black 5 E700082 Screw 4 40 3 16 4 8 mm Flat Head Black 21 E7...

Page 51: ...40 3 16 4 8 mm Black Flat Head 6 E700025 Standoff 4 40 5 16 7 9 mm Long 6 E700121 Screw 2 56 1 4 6 4 mm Black Pan Head 8 E700124 Lock Washer 4 Split Ring 12 E700004 Screw 4 40 3 16 4 8 mm Black Pan Head 6 E700015 KPA500 Rear Panel Envelope E850475 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Black Pan Head Screw Typ Screw 4 40 3 16 4 8 mm Black Pan Head 1 E700015 Screw 6 32 2 5 1 cm Black Pan Hea...

Page 52: ...ing 1 E700203 Lock Washer 4 Split Ring 6 E700004 Spacer 1 1 8 29mm Long 4 E700260 Board Terminal Strip 1 E980178 Insulator Terminal Strip 1 E980179 Solder Lug 4 2 E700162 Flat Washer 8 2 E700194 Jackscrew Nut 4 40 Zinc These may be supplied mounted on the I O board connectors 6 E700078 Washer Interior Tooth 4 12 E700010 Cable RF Input 1 E850414 Cable RF Output 1 E850413 Wire Green Input Module to ...

Page 53: ...odule Assembly ESD Sensitive 1 E850395 Rectifier Board 1 E850439 KPA500 Power Supply Assembly E850465 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Power Supply Module 1 E850404 PA LPF Assembly E870018 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO RF Power Amplifier Low Pass Filter PA LPF Assembly ESD Sensitive 1 E850467 ...

Page 54: ... Assembly E850466 ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO Power Transformer Rubber Disks Metal Disk Transformer Assembly w 1 Metal and 2 Rubber Disks Note The Rubber Disks may be a different color than shown 1 E850416 ...

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