ELECRAFT KAT500 Owner's Manual
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ELECRAFT KAT500 Owner's Manual

ELECRAFT KAT500 Owner's Manual

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E
LECRAFT
KAT500 A
A
UTOMATIC
NTENNA
T
UNER
O
'
M
WNER
S
ANUAL
Revision B4, November 30, 2012
Copyright © 2012, Elecraft, Inc.
All Rights Reserved

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  • Page 1  LECRAFT KAT500 A UTOMATIC NTENNA UNER ’ WNER ANUAL Revision B4, November 30, 2012 Copyright © 2012, Elecraft, Inc. All Rights Reserved...

  • Page 2: Table Of Contents

    Setup ................................. 3   Cabling ................................3  Elecraft K3 Transceiver and KPA500 Amplifier using DB15 Interface Cables..........3  Elecraft K3 Transceiver and KPA500 Amplifier with Separate Key Line ............. 5  General Cabling Requirements ........................7  Interface Cable Wiring ............................9 ...

  • Page 3: Introduction

    If you purchased your KAT500 as a kit, turn to page 16 for assembly instructions. Quick Start To quickly set up and get started with your KAT500 Automatic Antenna Tuner, turn to page 3 to hook up the unit and page 9 for operating instructions.

  • Page 4: Specifications

    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 time of original order, are not covered by this warranty. If the Elecraft product is being bought indirectly for a third party, the third party's name and address must be provided to Elecraft at time of order to insure warranty coverage.

  • Page 5: Setup

    The KAT500 can be used with any 1.8 through 54 MHz transceiver in the 20 to 1000 watt output range, although the KAT500 integrates most closely with the Elecraft K3 transceiver and the KPA500 amplifier.
  • Page 6 Computer interface cable (supplied). USB connector to 3.5 mm T-R-S connector. Not required for normal operation, but used for controlling the KAT500 from a personal computer, customizing the KAT500’s operation or for updating firmware (see Utility Program on page 14).

  • Page 7: Elecraft K3 Transceiver And Kpa500 Amplifier With Separate Key Line

    RF power while the KAT500 is tuning. You may add other equipment that requires the amplifier be inhibited in series with this circuit as shown. The circuit inside the KAT500 is a simple relay closure, so it does not matter which connector goes into each jack.
  • Page 8 Figure 2. Cabling Diagram: Elecraft K3, KPA500 and KAT500 Using DB15 Interface Cables with Separate Key Line.

  • Page 9: General Cabling Requirements

    General Cabling Requirements The KAT500 works well with equipment other than the Elecraft K3 transceiver and KPA500 amplifier. Figure 3 shows the cables used with any transceiver and amplifier combination and Figure 4 shows the cables used with a stand-alone transceiver or transmitter. See the notes on page 8 for details about each cable.
  • Page 10 RF power while the KAT500 is tuning. You may add other equipment that requires the amplifier be inhibited in series with this circuit at any point. The circuit inside the KAT500 is a simple relay closure, so it does not matter which connector goes into each jack.

  • Page 11: Interface Cable Wiring

    Interface Cable Wiring See Cabling on page 3 to see how too connect your KAT500 with your other equipment. Depending upon your equipment and the setup that you choose, you may need one or both of the following cables that are not supplied with your KAT500.

  • Page 12: Operation

    Antenna Selection: No DB15 Cable Interface If you are not using a K3 or you do not have a DB15 cable connected between your K3 and the KAT500, you must make the KAT500 change bands by applying RF power. Only a very brief pulse of RF is needed.

  • Page 13: Tuning

    Set up your transceiver to supply RF power between 10 and 100 watts to the KAT500 and apply RF power to begin the tune cycle. The KAT500 will not respond to less than 10 watts of RF drive. For most accurate tuning, apply at least 20 watts. You will hear relays operating until the selection of inductance and capacitance has been found that yields a low SWR.

  • Page 14: Fine Tuning

    Manual or Auto mode but only bypasses the tuning elements in that frequency segment. If the SWR remains above 2.0:1 after a tune operation, the KAT500 will hold the key line open to protect your amplifier from the high SWR load.

  • Page 15: Alternate Tuning Commands

    Bandswitching When using the KAT500 with an Elecraft K3 transceiver and KPA500 amplifier, the KPA500 and KAT500 will change bands at the same time as the K3 when they are interconnected with the DB15 interface cable (Figure 1 cable or Figure 2 cable Some non-Elecraft amplifiers may be damaged if the KAT500 opens the key line while the amplifier is producing full RF output.

  • Page 16: Fault Conditions

    At any setting up to 1499, the KAT500 will open the key line immediately as long as the RF power is below that level, and then close the key line when transmit power drops to zero. The Elecraft KPA500 amplifier is designed to both open and close the key line at full power without damage.

  • Page 17: Antennas

    AUTO which the KAT500 will bypass the tuning network. Also, you can set an SWR threshold at which the key line will not close to enable the external amplifier to protect it from excessive SWR. These thresholds can be set the same for all bands, or individual values can be entered for each band.

  • Page 18: Kit Assembly Procedure

    Use a grounded anti-static mat on your work bench.  If you choose to use a soldering iron to work on your KAT500 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.

  • Page 19: Assembly Procedure

    Appendix A, to familiarize yourself with all of the parts and to ensure the kit is complete. If any parts are missing contact Elecraft for a replacement (see Customer Service and Support, page 1). Taking ESD precautions remove the printed circuit board from its ESD-safe envelope and install six 2-D fasteners as shown in Figure 6.
  • Page 20 Install the three pairs of standoffs on the pc board shown in Figure 7. Do not use lock washers. The standoffs alone establish the right height. Figure 7. Installing Standoffs on the PC Board. Locate the outline marked LB1 on the pc board. It is on the connector edge of the board next to the power connector (see Figure 8).
  • Page 21 Mount the angle bracket at LB1 on the pc board as shown in Figure 9. Note that it has a long and short side. Be sure the long side is against the pc board as shown. Figure 9. Installing the Angle Bracket. Locate the bottom cover.
  • Page 22 Turn the bottom cover over and place the four self-stick feet on the cover in the locations shown in Figure 11. Do not cover any of the holes in the bottom cover with the feet. The screw hole indicated will be used in the next step.
  • Page 23 Place the circuit board component side down on your work table and attach the thermal pad to resistor R6 as shown in Figure 13. Figure 13. Placing Thermal Pad on R6.
  • Page 24 Once you have done that and finished assembling your KAT500, you can remove and replace individual cabinet sections easily without further adjustments.
  • Page 25 Locate the rear panel and the four SO-239 connector assemblies. Leave the SO-239 connector assemblies in their packages until needed and do not bend or move the wire attached to each connector. The wires have been carefully pre-formed to fit in the KAT500.
  • Page 26 Inspect the inside surface of the rear panel and remove any tape or residue to provide a clean metal surface where shown in Figure 16. Figure 16. Preparing the Rear Panel. Remove the protective backing from the serial number label and press it onto the rear panel as shown in Figure 17.
  • Page 27 Install the XMTR SO-239 connector in the rear panel opening marked XMTR as shown in Figure 18. Take care not to bend the wire or move the solder lug. Place the flange of the connector inside the rear panel, and orient the connector so the lug on the wire points toward the ANT1 connector opening as shown.
  • Page 28 Mount the ground terminal at the end of the rear panel next to the ANT 3 connector as shown in Figure 20. Install the screw, lock washer and nut first and secure the nut so the screw cannot turn. Then add the two flat washers and the wing nut.
  • Page 29 Position the rear panel on the pc board/bottom cover assembly you assembled earlier as shown in Figure 22. Figure 22. Positioning the Rear Cover on the PC Board and Bottom Cover Assembly. Begin securing the rear panel to the pc board assembly with four jack screw nuts on the XCVR and AMP connectors as shown in Figure 23.
  • Page 30 Install the two pan head screws shown in Figure 24. Stop turning the screw indicated when the head reaches the rear panel. It threads into plastic and the threads will easily strip. Figure 24. Installing Rear Panel Pan Head Screws. Attach the wires leading to each of the SO-239 connectors to the screw posts on the pc board as shown in Figure 25.
  • Page 31 Turn the assembly over and secure the bottom lip of the rear panel to the 2D fasteners as shown in Figure 26. Figure 26. Installing Screws in Rear Panel Bottom Lip. Install the four standoffs shown in Figure 27. The standoffs pass through large holes in the pc board and mount on the bottom cover as shown.
  • Page 32 Figure 29. Preparing the Front Panel for Installation. Turn the KAT500 upside down on your table and mount the front panel as shown in Figure 30. Be sure that all of the LEDs and switches pass through the openings in the front panel.
  • Page 33 Set the KAT500 on its feet and confirm that all three switches operate smoothly and that all of the LEDs are in the front panel cutouts. The LEDs should protrude slightly so you can feel them by running your finger across the panel.
  • Page 34 In the following steps you will prepare and install the top cover. But before you do, check to ensure the screws inside the KAT500 are tight without over-tightening them:  The 11 screws along the sides of the pc board (Figure 6, page 17).
  • Page 35 Place the top cover on the KAT500 and secure it as shown in Figure 34. If all of the screw holes do not line up, rotate it a half turn. It only fits one way. You may need to loosen some of the other enclosure screws for the cover to fit properly.

  • Page 36: Appendix A Parts List

    QTY. PART NO. KAT500 PCB Assembly ESD Sensitive. Do not remove from E850566 its ESD-Safe packaging without first taking ESD precautions (see page 16). KAT500 Core Assembly – E850561 Wrapped Covers E850565 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. Bottom Cover...

  • Page 37: Wrapped Panels E850564

    Wrapped Panels E850564 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. Front Panel E100434SS Rear Panel E100435SS Side Panel E100436 Serial Number Envelope E850549 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. Serial Number Label E980236 Miscellaneous Bag E850562 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO.
  • Page 38 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. 8-32 Screw,1/2” (13 mm) Zinc Pan Head E700192 (Typical) 6-32 Screw, 1/4" (6.4 mm) Zinc Pan Head E700281 Lock Washer, #8 Split Ring E700203 Lock Washer, #4, Split Ring E700004 BNC Hole Cover E980136...

  • Page 39: Ant 1 So-239 Assembly E850553

    IMPORTANT: The following SO-239 Assemblies have wires pre-formed to fit in your KAT500. Each connector is different.  Do not mix them up.  Do not bend or reshape the wires. Ant 1 SO-239 Assembly E850553 ELECRAFT ILLUSTRATION DESCRIPTION QTY.

  • Page 40: Xmtr So-239 Assembly E850554

    XMTR SO-239 Assembly E850554 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. XMTR SO-239 Assembly E850554 4-40 Screw, 1/4” (6.4 mm) Black Pan Head E700174 4-40 Nut with Captive Star Washer E700191...

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