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K1EL K44 Assembly Manual

Cw keyboard/reader kit
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K1EL
K44-KIT CW Keyboard/Reader Kit Assembly Guide
Introduction
This document will describe how to assemble and test the K44 Keyboard/Reader Kit. The assembly of a K44 is
not very difficult, but is probably not a good "first kit" since there many challenging assembly steps. Before you
start working on the kit you will need to gather the following items
1)
A low wattage (40W) soldering iron or pencil or temperature controller solder station.
2)
Good grade of Rosin core solder, Please do not use ACID CORE Solder !!
3)
A good pair of wire cutters, small pliers, assorted screwdrivers, and a 5/64" Allen wrench
4)
A Volt Ohmmeter or DVM is required for several assembly steps
5)
A magnifying glass is very helpful
6)
Power supply providing a voltage between 8 to 13 VDC (9VDC is optimum) at about 250 ma.
7)
Optional: An audio signal generator or radio receiver with a calibrate function.
It is very important to take your time and carefully follow the instructions and assembly photos.
The main tasks are 1) Identify components, install them in the correct board location and then do a good job
soldering them in place. Experienced builders will have no problem with the process but others will have to take
their time and carefully examine the board photos and refer to the bill of materials often. Please don't assemble
the kit in a manner other than as described, the order of the steps is very important from a mechanical
perspective and if you don't follow them you can end up with a kit that can't be completed.
As mentioned, these instructions assume you have basic electronic kit building experience and can identify
different types of electronic components. Photos are provided which will greatly aid in assembling the kit
correctly. The instructions don't provide component by component instruction but more of a general section by
section flow. The biggest enemy of kit success is poor soldering, so please take care with each solder joint, and
use just enough heat to get a good connection. A good joint should be both shiny and smooth. Even experienced
builders can benefit from reading Appendices A, B & C at the end of this document.
Bill of Materials
The bill of materials is listed below. The first step is to inventory and identify all parts ahead of time. This will
allow the assembly to proceed smoothly. Let us know if you are missing any parts.
Reference Des.
R10
R8,R12
R16
R13,R14,R11,R20
R21,R23
R15,R17,R18,R19,R22,
R3,R4,R1,R7
R9
R6
R2
R5
C3,C4
C1,C16,C19,C2,C21
C14,C15,C20
C22,C23,C5,C6,C13
C7
C11,C12
C9
C17,C18,C8
K44 Kit Assembly Guide Rev A PCB
Qty
Part Description
1
100 ohm Resistor
2
10K ohm Resistor
1
47 Ohm Resistor
6
470 Ohm Resistor
9
4.7K Ohm Resistor
1
47 ohm
1
5.76K Ohm 1% Resistor
1
33.2K Ohm 1% Resistor
1
66.5K Ohm 1% Resistor
2
.001uF Capacitor (102)
8
.1uF,Capacitor (104)
5
.01uF,Capacitor (103)
1
.1uF Capacitor (104)
2
.012uF Mylar Cap (123)
1
.47uF Capacitor (104)
3
33uF Electrolytic Cap
5/20/2020
Package
Other Info
1/8 Watt
Brn Blk Brn
1/8 Watt
Brn Blk Org
1/8 Watt
Yel Violet Blk
1/8 Watt
Yel Violet Brn
1/8 Watt
Yel Violet Red
1/2 Watt
Yel Violet Blk
1/8 Watt
Blue Axial
1/8 Watt
Blue Axial
1/8 Watt
Blue Axial
Ceramic Disk
.2" spacing
Ceramic Disk
.2" spacing
Ceramic
.2" spacing
Mylar film
.2" spacing
Mylar film
.2" spacing
Ceramic
.2" spacing
Radial
.1" Spacing
Rev A
Check Off
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Page 1

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Summary of Contents for K1EL K44

  • Page 1 Rev A Introduction This document will describe how to assemble and test the K44 Keyboard/Reader Kit. The assembly of a K44 is not very difficult, but is probably not a good “first kit” since there many challenging assembly steps. Before you start working on the kit you will need to gather the following items A low wattage (40W) soldering iron or pencil or temperature controller solder station.
  • Page 2 14 pin DIP socket for U4 and U6 (Keyer & Console PICs) _________ MISC 8 pin DIP socket for U2 (PSoC) _________ MISC 10” length of hook up wire MISC Heatsink _________ K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 2...
  • Page 3 K44 Kit Assembly Instructions First task is to assemble the K44 PC board. It will progress in sections, a picture will accompany each section. We will start with the resistors, the color codes are listed in the parts list. We recommend verifying values with an ohmmeter.
  • Page 4 IC sockets. Final installation in this section is diode D1 with the polarity marker on the left as shown. Figure 2 – Section 2: Capacitor, Sockets, Ferrite, and D1 Installation K44 Kit Assembly Guide Rev A PCB 5/20/2020...
  • Page 5 1. You will have to carefully bend the IC pins in to get them to insert into PC board. See picture below. Complete this section with Q1, flat side aligned with the silkscreen. Carefully bend IC leads Figure 3 – Section 3: LED, IC, and Q1 Installation K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 5...
  • Page 6 2.5mm connector, center pin positive, that will work fine. Current rating must be greater than 100 mA. Double check that the center pin of the power connector is positive with respect to the shell and then plug it into J5. The K44 does have a polarity protection diode but it’s worth the extra step to make sure the cable is right.
  • Page 7 K44-KIT CW Keyboard/Reader Kit Assembly Guide Rev A Following are some close ups of the board to help verify part placement, Note that R10 is not installed: Figures 5 & 6 – Close Up Views K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 7...

  • Page 8: Lcd Installation

    LCD Installation This is the most challenging step in assembling a K44. Please read through the entire procedure so that you fully understand how it is done. If you make a mistake here, it will be very difficult to fix it so go slowly and follow each step closely.
  • Page 9 Now slide this loose sub-assembly in place into the enclosure base. Carefully fit the display notches over the threaded studs on the front panel. Note that the header should naturally seat into both the LCD module and K44 board, if you find yourself forcing anything you probably have something misaligned.
  • Page 10 Rev A Attach the K44 PC board to the base with two 4-40 screws. Then fix the LCD display to the front bezel with two 4-40 nuts. Use just enough force to hold the display in place so it is nearly flat against the front panel and centered in the DO NOT USE A NUT DRIVER, tighten by finger force only !!! enclosure display window.
  • Page 11 Figure 15 – Gently adjust header for equal pin alignment Now carefully solder the two end pins on the LCD module and then two end pins of the header to the K44 board. It’s easier to get at pin16 on the K44 board since it is further away from D2’s LED housing.
  • Page 12 Now it’s time to work with the rotary encoder. Locate the rotary encoder and encoder PCB seen below. Make sure the threaded encoder shaft fits into its mounting hole on the K44 enclosure’s front panel. You may need to remove some paint on the inside of the enclosure hole to get it to fit.
  • Page 13 Figure 21 - Encoder on encoder PCB Solder the 5 wires from the encoder PCB to the K44 PCB as shown, starting with E1 to E1, then E2 to E2, E3 to E3, S1 to S1, and finally S2 to S2. Avoid hitting the plastic wire insulation with your soldering iron.
  • Page 14 K44-KIT CW Keyboard/Reader Kit Assembly Guide Rev A   Figure 22 - Encoder PCB attached to main K44 PCB Peel off the thin protective film from the front of the LCD display.   Figure 23 - Don’t forget this step or the display will appear foggy !
  • Page 15 Reference the picture above to see how this is done. Be careful when tightening the nut, it’s easy to slip and scratch the front panel. Now attach the rotary encoder knob using a small Allen wrench. Figure 25 – Placement of encoder flat washer and hex nut K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 15...
  • Page 16 PIC and PSoC versions along with other status as indicated in the figure below. If the display contrast is not satisfactory, we will show how to adjust it in step 3. After the LED test completes, the K44 will send an ‘R’...
  • Page 17 K44 and hit the ALT and then F1 keys and you should see CWR On displayed. Now in order to feed audio into the K44 you will need to make up an audio cable. This will consist of an 1/8”...

  • Page 18: Final Assembly

    Paddle to XCVR Input Figure 29 – K44 Back Panel Connections Final Assembly To install the top cover, reference the following picture. Angle the top cover and get the rear connectors to start to go into the cover. Then fold the cover down to meet the front panel and push it forward so the three 1/8 inch connectors poke out the back evenly.
  • Page 19 This is an optional install and is not required for normal operation of the K44. R10 routes post filter audio to the ring of Audio In jack on the back panel. The intent was to provide a way for the user to extract in band audio from the K44 and feed it to an audio amplifier.
  • Page 20 Rev A CW Keyboard Theory of Operation This section will cover the CW keyboard portion of the K44. It can be helpful to read through this to get familiar with the circuitry if you are debugging the K44. As shown in the block diagram below, two PIC processors share the task of converting keystrokes to Morse code.
  • Page 21 CW Reader settings such as gain and noise filtering. The K44’s LCD interface is a fixed format at 16 characters by 2 lines. The interface is compatible with most, if not all, LCD displays based on the Hitachi HD44780 controller I.C. So if you prefer to use your own enclosure and display you can.
  • Page 22 K1EL K44-KIT CW Keyboard/Reader Kit Assembly Guide Rev A K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 22...
  • Page 23 K1EL K44-KIT CW Keyboard/Reader Kit Assembly Guide Rev A K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 23...
  • Page 24 K1EL K44-KIT CW Keyboard/Reader Kit Assembly Guide Rev A K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 24...
  • Page 25 K1EL K44-KIT CW Keyboard/Reader Kit Assembly Guide Rev A K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 25...
  • Page 26 K1EL K44-KIT CW Keyboard/Reader Kit Assembly Guide Rev A K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 26...

  • Page 27: Appendix A - Kit Construction Hints

    Soldering Irons can remain hot for many minutes after being turned off. Never touch the tip to see if it is hot. Place the tip on a wet pad to test for temperature. Wear safety glasses to protect your eyes from flying objects. K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 27...

  • Page 28: Appendix C - Soldering Basics

    4. Apply solder around the outside edge of the pad as in Fig. C2. If the pad and lead are at the correct temperature, the solder will flow around the connection. Figure C2 - Spread solder around the work 5. Remove the solder and then remove the iron: K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 28...
  • Page 29 6. Allow the joint to cool and visually inspect for defects or other problems. You should have a solder joint with a bright shiny finish and a profile like that shown in Fig. C4. Figure C4 - Solder quantity comparison K44 Kit Assembly Guide Rev A PCB 5/20/2020 Page 29...