ELECRAFT K3 Assembly Manual
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ELECRAFT K3 Assembly Manual

High-performance 160 – 6 meter
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Download this manual See also: Owner's Manual, Assembly Manual
E
K3
LECRAFT
H
-P
160 – 6 M
IGH
ERFORMANCE
ETER
T
RANSCEIVER
K3 K
A
M
IT
SSEMBLY
ANUAL
Rev D, December 26, 2007
Copyright © 2007, Elecraft, Inc.
All Rights Reserved

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  • Page 1 LECRAFT 160 – 6 M ERFORMANCE ETER RANSCEIVER K3 K SSEMBLY ANUAL Rev D, December 26, 2007 Copyright © 2007, Elecraft, Inc. All Rights Reserved...

  • Page 2: Table Of Contents

    Contents Battery BT1 Installation Procedure ....52 Introduction............1 KBPF3 General Coverage Receive Option ..53 Customer Service and Support......1 KBPF3 Description........53 Technical Assistance ........1 KBPF3 Installation ........53 Preventing Electrostatic Discharge Damage ... 3 Power Amplifier Jumper Block ......54 How ESD Damage Occurs........3 Finishing the Enclosure ........

  • Page 3: Introduction

    Repair / Alignment Service (We want to make sure everyone succeeds!) If necessary, you may return your Elecraft product to us for repair or alignment. (Note: We offer unlimited email and phone support to get your kit running, so please try that route first as we can usually help you find the problem quickly.)
  • Page 4 What is covered: During the first year after date of purchase (or if shipped from factory, date product is shipped to customer), Elecraft will replace defective or missing parts free of charge (post-paid). We will also correct any malfunction to kits or assembled units caused by defective parts and materials.

  • Page 5: Preventing Electrostatic Discharge Damage

    How ESD Damage Occurs Whenever an object containing a static charge touches a circuit in your K3, current will rush into the circuit until the components reach the same voltage as the source of the static charge. If the voltage or current that passes through a component in your K3 during that brief period exceeds its normal operating specifications, it may be damaged or destroyed.

  • Page 6: Preparing For Assembly

    Use a grounded anti-static mat on your work bench. If you choose to use a soldering iron to work on your K3 for any reason, be sure the iron is ESD-safe with a grounded tip tied to the same common ground used by your mat or wrist strap.
  • Page 7 (OPTIONAL 8-POLE FILTERS SHOWN) K3 MIXER BOARD FRONT PANEL SHIELD FRONT PANEL K3 DSP BOARD ASSEMBLY (INCLUDING KSYN3 K3 FRONT PANEL K3 DSP AND KREF3 BOARD (HIDDEN) BOARD K3 FRONT PANEL BOARD BOARDS) Figure 1. Assembled K3/10 (Less Top Cover).

  • Page 8: Tools And Test Equipment Required

    9. Power supply 13 VDC nominal (11-16 V) with a cable and Anderson PowerPole connector. A power cable kit is provided with your K3 if you do not have a suitable cable with the required Anderson PowerPole connector. The power supply must be capable of providing at least 3 Amperes for a K3/10 and 20 Amperes for a K3/100.

  • Page 9: Unpacking And Inventory

    A number of different types and sizes of screws and washers are used in the assembly. It is very important that you use the screw specified in each location or your finished K3 may not fit together properly. In some places, using the wrong size screw may damage components.

  • Page 10: Standoffs

    Lock Washers Two types of lock washers are used in the K3 (see Figure 4). It is important that you use only the type specified and put the washers exactly where indicated. Failing to use the correct type may result in short circuits to nearby circuit traces.

  • Page 11: Assembly

    Observe ESD precautions when handling the circuit boards and whenever you are working on your K3 with the covers off. Failure to observe ESD precautions may result in your K3 not operating at all, or operating but not meeting normal factory performance...

  • Page 12: Rf Board And Chassis

    RF Board Description The RF PCB (Printed Circuit Board) is the heart of the K3 transceiver, both physically and electrically. During assembly, it serves as an attachment point for other PCBs as well as chassis panels, acting as the glue that holds things together.
  • Page 13 Install the two KBPF3 standoffs shown in Figure 8. Even if you didn’t purchase the KBPF3 general coverage option, the standoffs and hardware are included in the K3 kit to make installing the option easier at some future date. Note that these standoffs have only one lock washer between each standoff and the RF board.
  • Page 14 Locate the crystal I.F. filters. Two types of filters are available: standard 5-pole filters and optional 8-pole filters (see Figure 10). One standard 5-pole 2.7 kHz filter is supplied. If you have elected to equip your K3 with the optional 8-pole 2.8 kHz filter, it has been supplied instead of the 2.7 kHz filter. If you have purchased additional filters, they may be installed now as well.
  • Page 15 Install the filters as shown in Figure 10. Refer to the list of filters you created in Table 1 to determine which filter to install at each location. CAUTION 1) Do not use screws longer than 1/4” (6.4 mm) to mount the filters. Use your ruler to measure the screws before installing them.
  • Page 16 ESD SENSITIVE! WEAR A GROUNDED WRIST STRAP OR TOUCH AN UNPAINTED METAL GROUND BEFORE HANDLING THE RF BOARD. FASTENER FASTENER PA JUMPER BLOCK (PREINSTALLED) KBPF3 STANDOFFS FASTENER FASTENER CRYSTAL I.F. FILTER MIXER STANDOFF FASTENER FASTENER Figure 11. RF Board Partially Assembled.
  • Page 17 Install the Low Power Amplifier (LPA) board in the cutout on the RF board as shown in Figure 12. The LPA board is held in place by its connectors until the bottom cover is installed.. TOP VIEW ESD SENSITIVE! POSITION THE LPA BOARD SO THE THREE CONNECTORS...
  • Page 18 STANDOFF PC BOARD AND STANDOFF Figure 13. Installing Front Panel Shield. Mount the K3 mixer board on the RF board as shown in Figure 14. The mixer plugs into Z1 on the RF board. MIXER 4-40 1/4" (6.4 mm) ZINC...
  • Page 19 K3 (see Figure 19). Set the right side panel aside for now. Check the inside (partially painted) of both panels to ensure no masking tape is covering any screw holes. If found, peel it off.

  • Page 20: Kant3 Or Kat3, Right Side And Rear Panels

    KANT3 or KAT3 Description The basic K3/10 includes a KANT3 antenna input module. If you’ve ordered a KAT3 antenna tuner, the KANT3 is not required and will not be supplied with the kit. In either case, the module plugs into the RF board at the back-right corner.
  • Page 21 Figure 19. Installing Side Panel Feet. Position the right side panel against the K3 to verify how it will fit against the RF board. When it is oriented correctly, the three holes along the bottom edge will line up with the holes in the 2D fasteners on the RF board and two holes in the side panel will be aligned with the tabs on voltage regulators U12 and U13.
  • Page 22 At the upper rear corner of the side panel you just identified in the previous step, mount a 2D fastener as shown in Figure 20, using a black 4-40 1/2” (13 mm) flat head screw. Remember that flat head screws are measured from the flat top to the end of the threads.
  • Page 23 Attach the bottom lip of the rear panel to the 2D fasteners at the rear corners of the RF board with 4-40, 3/16” (4.8 mm) black pan head screws. (Note that all the screws used on the bottom of the K3 are black pan head screws.)
  • Page 24 Attach the right side panel to the RF board assembly four 4-40 3/16” (4.8mm) black flat head screws: three along the bottom and one at the top front into the 2D fastener on the front panel shield. Do not use washers. Note that there are two open holes for screws to secure voltage regulators U12 and U13.

  • Page 25: Kio3 Interface

    If you have purchased the KXV3 option with your kit, go to the Installation Procedure in the KXV3 manual and install the option now, following the instructions in the Special Note to K3 Kit Builders. Otherwise mount the small blank panel in the space directly above PADDLE, KEY, PTT and KEY OUT connectors on the rear panel as shown in Figure 28.
  • Page 26 Figure 29. Preparing the KIO3 Board for Installation. Install the KIO3 Main board with the Audio I/O daughter board attached into the K3 as shown in Figure 30. The KIO3A main board plugs into J76 on the RF board. If the KXV3 is installed, the coaxial TMP cable fits between the KXV3 and KIO3 boards.
  • Page 27 The DB9 multi-pin connector on the KIO3 Digital I/O daughter board may have jackscrew nuts installed on the connector. (Jackscrew nuts are shown in Figure 32). If so, remove them. They will be reinstalled shortly. Install the KIO3 Digital I/O daughter board as shown in Figure 31. Be careful to support the KIO3 main board as shown while pressing the daughter board in place.

  • Page 28: Front Panel And Dsp

    Front Panel and DSP Front Panel and DSP Description The Front Panel is a large plug-in module that provides the K3’s user interface (LCD, switches, shaft encoders, potentiometers, and LEDs) as well as the microcontroller (MCU) and parameter storage (EEPROM and FLASH).
  • Page 29 On the front side of the board, mount four standoffs as shown in Figure 34. IMPORTANT! 1. Place the split lock washers between the standoff and board as shown in the figure. This is important to establish the correct spacing between the board and the front panel.
  • Page 30 Install the two soft foam light blockers at the ends of the LCD display as shown in Figure 35. Remove the paper strip covering the adhesive on each blocker and stick that side against the board (or the lip at the base of the switch buttons) so it stands up between the switches and the LCD.
  • Page 31 Place the front panel board face up on your work surface, then set the front panel over it as shown in Figure 37. Check the following: The MIC connector is in the hole and its flange is not caught behind the panel. The flange should be slightly above the panel as shown.
  • Page 32 Place the VFO A encoder in the opening near the center of the front panel board so the shaft protrudes through the opening under the LCD. Be careful to avoid dropping the lock washer into to the space between the front panel board and the front panel.
  • Page 33 CAUTION! In the following steps you will attach the plastic LCD cover and VFO A trim panels to the front cover using small screws. Do not over-tighten these screws. Tighten the screws only to the point were you feel some resistance. It is very easy to strip the threads, especially the screws holding the LCD cover.
  • Page 34 Place the larger of a pair of concentric knobs over the RF/SQL - SUB control as follows (See Figure 43): CAUTION! Do not over-tighten the set screws in the knobs in the following steps or you may crack the knobs! Use only enough torque to hold the knobs in place. Turn both shafts fully clockwise Place the larger knob over the shafts.
  • Page 35 Press small knobs on the four controls under the left end of the LCD: SHIFT/LOW, HI/WIDTH, SPEED/MIC and CMP/PWR. These knobs are all the same size. The four controls are encoders that rotate continuously, so the knobs have no index marks. The knobs are held in place by a friction spring as shown in Figure 44.
  • Page 36 Mount the last knob on the VFO B encoder shaft to the right (under the pushbutton switches) as shown in Figure 46. Before tightening both set screws, adjust the position of the knob against the felt washer to produce the desired amount of drag for smooth movement without the knob turning too freely. PLACE ONE FELT PLACE THE KNOB ON THE SHAFT WASHER OVER...
  • Page 37 Secure the DSP board to the front panel board with three 4-40 1/4” (6.2 mm) zinc pan head screws and split lock washers as shown in Figure 47. ESD SENSITIVE! 4-40 1/4" (6.4 mm) #4 SPLIT LOCK ZINC PAN HEAD WASHER (3 PLACES) SCREW (3 PLACES) STANDOFF...
  • Page 38 Remove both side panels from the chassis as follows. This will allow you to see the connectors that must mate properly when attaching the front panel assembly. Remove the two screws shown in Figure 49 so the 2D connector and standoff remain attached to the side panel.
  • Page 39 Look at the two multi-pin connectors on the top of the RF board to see if they are engaging the corresponding connectors on the front panel assembly (see Figure 51). Adjust the position of the RF board or the front panel assembly to ensure they are mating properly. ADJUST POSITION OF FRONT PANEL AND RF BOARD SO THE PINS OF BOTH CONNECTORS ENGAGE LEFT SIDE...
  • Page 40 Secure the front panel assembly at the bottom lip to the 2D fasteners at the forward edge of the RF board with two 4-40 3/16” (4.8 mm) black pan head screws. If you removed the screw from the 2D fastener as shown in Figure 51, replace it and the lock washer. Replace the right side panel (the panel with the feet) as follows: Start four 4-40 3/16”...

  • Page 41: Resistance Checks

    Resistance Checks The following resistance checks confirm that the main power busses in the K3 aren’t shorted to ground. If any of the values measured are lower than specified, inspect the unit carefully for loose hardware that is caught between components on the boards or for improperly mated connectors.

  • Page 42: Initial Power On Check

    K3 passes the resistance tests above before proceeding. CAUTION! If you see or smell smoke when applying power, turn the K3 off and remove the power cable immediately, then locate the source. Connect your 13.8 VDC power supply to the 12VDC IN connector on the rear panel. Do not connect a key, microphone or other accessories to the K3 at this time.
  • Page 43 Mount the TCXO module on the KREF3 board as shown in Figure 57. The bottom of the module should rest against the socket. Be certain the leads go into the corner holes in the socket and the black dot is oriented toward connector J6 as shown.

  • Page 44: Ksyn3 Synthesizer

    The KSYN3 module is a high-performance, wide-range synthesizer covering 8 to 46 MHz. It uses a crystal- filtered DDS (direct digital synthesis) reference. This in turn drives a VCO with a high C/L ratio, resulting in very low phase noise. See Theory of Operation, KSYN3, in the K3 Owner’s Manual for more information. KSYN3 Installation Procedure Inspect the bottom of the KSYN3 board to ensure no leads are higher than the chokes as shown below.
  • Page 45 Install the KSYN3 board on the back side of the front panel shield as shown in Figure 61. The KSYN3 board plugs into J73 on the RF board. Be sure the connectors are aligned so that all the pins go into the corresponding socket holes on J73.

  • Page 46: Loudspeaker

    Install the three TMP cables between connectors on the KREF3 board, the main RF board and the KSYN3 board as follows. Handle the connectors by the finger-grip area shown in Figure 62, especially if you unplug a connector. Do not pull on the coaxial cable to unplug a connector! When mating the connectors, be sure the plugs are fully inserted as shown in Figure 62.
  • Page 47 Mount the chassis stiffening bracket on the underside of the cover as shown in Figure 64. Do not use washers. CHASSIS STIFFENER TOP COVER 4-40 3/16" (4.8 mm) INSIDE SURFACE BLACK FLAT HEAD SCREW (3 PLACES) SPEAKER GRILL OPENINGS Figure 64. Attaching Chassis Stiffener to Top Cover. Trim the grill cloth to cover the speaker grill openings and overlap the four holes for the loudspeaker mounting screws.
  • Page 48 SPEAKER WIRE EXITS TOWARD REAR STIFFENER TRIM AND POSITION GRILL CLOTH SO IT DOES NOT TOUCH STIFFENER #4 INTERNAL TOOTH #4 NUT LOCK WASHER SPEAKER MOUNTING FLANGE FIBER WASHER GRILL CLOTH TOP COVER 4-40 3/8" (9.5 mm) BLACK FLAT HEAD SCREW Figure 65.

  • Page 49: Kpa3 Shield

    The KPA 3 Shield is part of the optional KPA3 100-watt amplifier module. It isolates the high-level RF circuits in the KPA3 from the rest of the K3 and provides mechanical support for the amplifier module itself. KPA3 Shield Installation Procedure Remove the shield from the KPA3 Option kit and position it over the holes in the RF board as shown in Figure 67.
  • Page 50 Attach the shield to the RF board and to the rear panel as shown in Figure 68. The screws, washers and nut are in the KPA3 Option kit. The standoffs are part of the K3 kit hardware. 4-40 3/8" (9.5 mm) BLACK FLAT HEAD SCREW WITH #4 INSIDE TOOTH LOCK WASHER AND #4 NUT INSIDE.

  • Page 51: Bottom Cover

    Bottom Cover Bottom Cover Description The bottom cover is divided into two parts, the rear and forward sections. The rear section is thicker than the forward section to act more efficiently as a heat sink for the LPA transistors. The bottom covers attach to standoffs as well as the 2D fasteners on the bottom of the RF Board.
  • Page 52 Identify the bottom cover forward section by test fitting it on the bottom of the K3. The forward section is the thinner panel with a notch along one edge (see Figure 71). One side of the cover is fully painted. That is the outside. The other side has areas of bare metal left to ensure good electrical contact with the other cabinet parts.

  • Page 53: Knb3 Noise Blanker

    KNB3 Noise Blanker Description The KNB3 is one of two noise blanker systems in the K3. It is a narrow I.F. pulse blanker that plugs into the RF board. See Theory of Operation, Noise Blanker in the K3 Owner’s Manual for more information KNB3 Installation Install the standoff for the noise blanker as shown in Figure 73.

  • Page 54: Battery Bt1

    BT1 is a 3-volt lithium coin cell that provides the operating voltage for the real-time-clock IC (RTC) on the front panel when the K3 is turned off. Depending on the type of cell, BT1 could last from 2 to 10 years, thanks to the extremely low current drain of the RTC –...

  • Page 55: Kbpf3 General Coverage Receive Option

    KBPF3 board should rest on top of the standoffs and be parallel with the RF board underneath. KPA3 SHIELD (IF INSTALLED) STIFFENER NOT SHOWN FRONT OF K3 ESD SENSITIVE! 4-40 1/4" (6.4mm) ZINC PAN HEAD SCREW 4-40 SPLIT LOCK WASHER KBPF3 BOARD NO LOCK WASHER BETWEEN KBPF3 BOARD AND STANDOFF Figure 76.

  • Page 56: Power Amplifier Jumper Block

    If you have the KPA3 100-watt amplifier and plan to install it before operating your K3 on the air, you may leave this panel off. Otherwise, install the larger blank panel in the opening on rear panel with a 3/16” (4.8 mm)

  • Page 57: Bottom Covers

    Bottom Covers Turn the K3 over so the bottom is exposed. Position the forward section of the bottom with the feet and bail toward the front as shown in Figure 78. Attach the cover with seven 3/16” (4.8 mm) black pan head screws at the positions shown.

  • Page 58: Top Cover

    Figure 79. Connecting Speaker to KIO3 Board. Place the top cover on the K3 with the tab at the rear extending under the lip of the rear panel. Secure the top cover with six 4-40 3/16” (4.8 mm) black flat head screws along the front and rear edges of the cover. You may find it necessary to loosen screws at the top of the side, front and rear panels to adjust their position so the top cover fits properly.

  • Page 59: Test And Calibration

    Holding (~1/2 sec.) activates the function labeled beneath the switch. Initial Power Checks Connect your 11-16 VDC power supply to the red and black 12VDC IN connector on the back of your K3. Don’t connect anything else to your rig until instructed to do so.

  • Page 60: Synthesizer Calibration

    Filter Setup Turn to the Crystal Filter Installation and Setup section of your Owner’s Manual and perform the following procedures. If you have installed standard Elecraft 5-pole filter(s) you will need the FREQ OFFSET data you recorded earlier on page 12.

  • Page 61: Other Calibration Procedures

    The wattmeter is reasonably accurate as it is supplied. However, if you have an accurate external wattmeter you can adjust the K3 to match its readings at low power (5 watts), high power (50 watts), and, if you have the KXV3 module installed, at 0.5 milliwatts output at the KXV3 transverter interface.

  • Page 62: Appendix A Illustrated Parts List

    Each board was tested and aligned for optimum performance at the factory. Any change to these adjustments will degrade the performance of your K3 or prevent its operation altogether. All user calibrations and adjustments are done in firmware using the front panel menus. These are described at the appropriate points in the assembly procedures and in the Owner’s Manual.
  • Page 63 ELECRAFT ILLUSTRATION DESCRIPTION PART NO. RF Board E850261 ESD Sensitive PA Jumper Block Assembly (pre-installed on E850322 RF board) Low Power Amplifier (LPA) Board E850256 ESD Sensitive. K3 Mixer Board E850257 ESD Sensitive.
  • Page 64 ILLUSTRATION DESCRIPTION PART NO. KNB3 Noise Blanker Board E850280 ESD Sensitive. KANT3 Antenna Input Module Note: E850248 This board is not supplied if you purchased the KAT3 automatic antenna tuner option with your K3 kit. KREF3 Board E850254 ESD Sensitive.
  • Page 65 ELECRAFT ILLUSTRATION DESCRIPTION PART NO. KSYN3 Board E850260 ESD Sensitive KIO3 Main Board E850237 ESD Sensitive. KIO3 Audio I/O Module E850236 ESD Sensitive.
  • Page 66 ELECRAFT ILLUSTRATION DESCRIPTION PART NO. KIO3 Remote I/O Module E850235 ESD Sensitive. E850262 Enclosure ELECRAFT ILLUSTRATION DESCRIPTION PART NO. Front Panel E100209SS Left Side Panel E100210 Right Side Panel E100211 Top Cover E100212...
  • Page 67 Panel, Blank (KPA3 Fans) Note: E850297 This part is not supplied if you purchased the KPA 100 watt amplifier option with your K3 kit. Panel, Blank (KXV3 I/O) Note: E850296 This part is not supplied if you purchased the KXV3 I/O option with your K3 kit.
  • Page 68 E850239 K3 FP Encoder Assembly Bag ELECRAFT ILLUSTRATION DESCRIPTION PART NO. Encoder Assembly E850239 E850249 I.F. Crystal Filter Bag (or Box) NOTE: If the optional 8-pole 2.8K filter is purchased instead (see next item) this filter is not supplied. ELECRAFT...
  • Page 69 Rectangular Insulator the size of the TCXO TCXO spacer (supplied only with E980146 optional KTCXO3-1 module) Tie Wrap, KREF3 TCXO. Module E980145 E850307 K3 Front Panel Bezels and Serial Number Label ELECRAFT ILLUSTRATION DESCRIPTION PART NO. Bezel (LCD cover), K3...
  • Page 70 E850229 SO239 Ant Connector Assembly Bag ELECRAFT ILLUSTRATION DESCRIPTION PART NO. SO239 (UHF) Female Panel Mount E850229 Connector with cable Screw, 4-40, 1/4” (6.4 mm) Black, Pan E700009 Head Lock Washer, #4, Inside Tooth E700010 Nut, 4-40 E700011 E850238 KIO3A Hardware Bag...
  • Page 71 E850263 K3 Miscellaneous Bag ELECRAFT ILLUSTRATION DESCRIPTION PART NO. TMP Cables E100282 Battery BT1 (CR2032) E850058 Loudspeaker Grill Cloth E850089 #4 Fiber Washer E700031 Bottom Feet with tilt stand E980098 Front Feet with Stand Rear Feet SO239 Hole Cover E980135...
  • Page 72 ELECRAFT ILLUSTRATION DESCRIPTION PART NO. Screw, 4-40, 3/16” (4.8 mm) Black, Flat E700025 Head Screw, 4-40, 3/8” (9.5 mm) Black, Flat E700131 Head Screw, 4-40, 1/2” (13 mm) Black, Flat E700132 Head Screw, 4-40, 3/16” (4.8 mm), Black, Pan E700015...
  • Page 73 E850241 Front Panel Hardware Bag ELECRAFT ILLUSTRATION DESCRIPTION PART NO. Felt Washer E700033 Knurled Nut (Phones Jack) E700138 Typical Standoffs Standoff, 2/56, 5/16” (7.9 mm) long E700122 Standoff, 4-40, 5/16” (7.9 mm) long E700121 Standoff, 4-40, 5/8” (15.9 mm) long E700003 Screw, 4-40, 3/16”...
  • Page 74 E980089 Knob, Concentric Shaft, Large E980092 Knob, Concentric Shaft, Small E980091 Knob, Small Encoder Shaft E980088 E850306 K3 Knobs and Band for VFO A ELECRAFT ILLUSTRATION DESCRIPTION PART NO. Knob, VFO A Tuning E980093 Finger Grip, Main VFO Tuning Knob...
  • Page 75 E850316 Carrying Handle Bag ELECRAFT ILLUSTRATION DESCRIPTION PART NO. Handle (strap, spring insert and two end E850316 caps) Screw, 6-32, 1/2” (13 mm), Black, Pan E700042 Head (in envelope) Lock Washer, #6, Split (in envelope) E700041 Nut, 6-32 (in envelope)

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