ELECRAFT K3 Assembly Manual
High-performance 160 – 6 meter transceiver
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- Assembly manual (84 pages) ,
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- Page 1 LECRAFT 160 – 6 M ERFORMANCE ETER RANSCEIVER K3 K SSEMBLY ANUAL PRELIMINARY September 10, 2007 Copyright © 2007, Elecraft, Inc. All Rights Reserved Elecraft • www.elecraft.com P.O. Box 69 • Aptos, CA 95001-0069 (831) 662-8345 • Fax: (831) 662-0830...
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Page 2: Table Of Contents
Contents Introduction............................... 1 Customer Service and Support..........................1 Technical Assistance ............................1 Preventing Electrostatic Discharge Damage .................... 3 How ESD Damage Occurs..........................3 Preventing ESD Damage............................. 3 Preparing for Assembly ..........................4 Overview of the Kit............................. 4 Tools and Test Equipment Required ........................6 Unpacking and Inventory ............................ - Page 3 Appendix A, Illustrated Parts List ...................... A1 Appendix B, K3 Functional Block Diagram..................B1 List of Figures Figure 1. Assembled Basic K3/10 (Less Top Cover)....................5 Figure 2. Screw Sizes Used in Assembly........................ 7 Figure 3. Typical Standoff............................8 Figure 4.
- Page 4 Figure 46. Mounting the DSP Board........................33 Figure 47. Mounting the Front Panel Assembly on the Chassis................34 Figure 48. R36 Test Point............................. 35 Figure 49. U12 and U13 Test Points........................35 Figure 50. Installing KREF3 Board........................36 Figure 51.
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Page 5: Introduction
Introduction This is the assembly manual for the Elecraft K3 High Performance 160 – 6 meter transceiver modular kit. Full details of the Elecraft K3 and its options, including specifications, installation, operation, troubleshooting and maintenance instructions are included in the Owner’s Manual which accompanies this kit. - Page 6 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.
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Page 7: 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 8: Preparing For Assembly
• 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 9: Figure 1. Assembled Basic K3/10 (Less Top Cover)
KNB3 CRYSTAL BOARD FILTER(S) K3 MIXER BOARD FRONT PANEL SHIELD FRONT PANEL K3 DSP BOARD ASSEMBLY (INCLUDING K3 FRONT PANEL KSYN3 K3 DSP AND KREF3 BOARD BOARD (HIDDEN) K3 FRONT PANEL BOARD BOARDS) Figure 1. Assembled K3/10 (Less Top Cover). -
Page 10: Tools And Test Equipment Required
8. RF 50-ohm dummy load with low VSWR across the range of 160 meters through 6 meters. 9. Power supply 13 VDC nominal (11-16 V). A power cable is provided with your K3, You’ll need to connect it to your supply: red wire to positive and black to negative. -
Page 11: 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 many not fit together properly. In some places, using the wrong size screw may damage components. -
Page 12: 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 13: Assembly
These are all pre-installed and tested at the factory. The use of SMDs minimizes stray coupling in RF circuits, reduces system cost, and allows the K3 to fit in a modest-size enclosure, compatible with home or field operation. - Page 14 5 volts and the other 8 volts. Both are heat-sinked to the right side panel. The low-power amp module is capable of up to 12 W power output, and in the case of the K3/10, is the final amplifier stage.
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Page 15: Rf Board And Chassis Assembly Procedure
Observe ESD precautions when handling the circuit boards and whenever you are working on your K3 with covers off. Failure to observe ESD precautions may result in your K3 not operating at all, or operating but not meeting normal factory performance specifications due to damaged components. -
Page 16: Figure 6. Installing 2D Fasteners On Rf Board
4-40 3/16" (4.8 mm) BLACK PAN HEAD SCREWS 4-40 SPLIT LOCK WASHERS 2D ON THE ESD SENSITIVE! BOTTOM OF BOARD WEAR A GROUNDED SIDE FLUSH WRIST STRAP OR TOUCH WITH EDGE AN UNPAINTED METAL GROUND BEFORE HANDLING THE RF BOARD. WIDE SHOULDER ON 2D TOWARD EDGE Figure 6. -
Page 17: Figure 10. Installing Q3 Hardware On Rf Board
Install hardware to attach the heat sink of Q3 to the RF board near the rear left corner as shown in Figure 10 and Figure 12 on page 14. #4 INTERNAL TOOTH LOCK WASHER #4 NUT ESD SENSITIVE! CIRCUIT WEAR A GROUNDED BOARD WRIST STRAP OR TOUCH AN UNPAINTED METAL GROUND... -
Page 18: Figure 12. Rf Board Partially Assembled
ESD SENSITIVE! WEAR A GROUNDED WRIST STRAP OR TOUCH AN UNPAINTED METAL GROUND BEFORE HANDLING THE RF BOARD. FASTENER FASTENER NOISE BLANKER STANDOFF FASTENER FASTENER MIXER STANDOFF FASTENER FASTENER CRYSTAL I.F. FILTER(S) Figure 12. RF Board Partially Assembled. -
Page 19: Figure 13. Installing The Low Power Amplifier (Lpa)
Install the Low Power Amplifier (LPA) board in the cutout on the RF board as shown in Figure 13. The LPA board is held in place by its connectors until the bottom cover is installed.. TOP VIEW ESD SENSITIVE! WEAR A GROUNDED POSITION THE WRIST STRAP OR TOUCH LPA BOARD SO... -
Page 20: Figure 14. Installing Front Panel Shield
Mount the front panel shield on the RF board as shown in Figure 14, then mount a 2D fastener on each ear at the top of the shield as shown. Be sure the 2D fasteners are oriented with the widest part between the two holes and the edge toward the outside as shown. -
Page 21: Figure 16. Installing Side Panel Feet
K3. The right side panel with the feet attached is shown in Figure 16. Install the four rubber side feet in the holes in the right side panel as shown in Figure 16. Press each foot through the hole from the outside (the solid black painted side), then tug on the inside with your needle-nose pliers until the shoulder has opened on the inside of the panel to hold the foot securely in place. -
Page 22: Figure 18. Mounting Left Side Panel
When installing the side panel in the next step, if the threaded holes in the 2D fasteners don’t line up properly with the holes in the side panel, loosen the screws attaching the 2D fasteners to the RF board and front panel shield so they can move slightly to align the holes. Then retighten the screws after installing the side panel. -
Page 23: Kant3 Or Kat3 And Rear Panel
Circuit 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 24: Figure 22. Mounting 2D Fastener For Kant3 Standoff
If you are installing the KAT3, install the second SO239 connector in the ANT2 position on the rear panel using two 4-40 1/4” (6.4 mm) black pan head screws, two 4-40 split lock washers and two 4-40 nuts just as you did for the ANT1 connector. -
Page 25: Figure 25. Installing The Rear Panel
Position the rear panel on the K3 chassis assembly so that the holes in the corners of the top and bottom lips line up with the 2D fastener holes as shown in Figure 25. Secure the rear panel with a 4-40 3/16” (4.8 mm) black flat head screw at the top corners, and 4-40, 3/16”... -
Page 26: Kio3 Interface
LARGE PLUG IN PLACE (NOT USED IF KAT3 OPTION IS INSTALLED) ALIGN CUTOUT ON SMALL PLUG WITH FLAT SIDE IN HOLE Figure 27. Installing Rear Panel Hole Plugs. Peel the backing from the self-adhesive serial number label and attach it to the back panel as shown in Figure 28. -
Page 27: Kio3 Interface Installation Procedure
The Digital IO board plugs into the KIO3 Main board. It includes a DE-9 serial port connector for use with an external PC, and a DE-15 accessory connector for external band decoders (such as the KRC-2), transverters (such as the Elecraft XV-series), and similar devices. It is also the connector to which direct FSK or PSK signaling is applied. -
Page 28: Figure 31. Preparing The Kio3 Board For Installation
Figure 31. 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 32. The KIO3A main board plugs into J76 on the RF board. Endure the connectors are fully mated so the standoffs line up with the screw holes on the rear panel. -
Page 29: Front Panel And Dsp
LED brightness, etc. – are produced by the MCU. The Front Panel also contains a large amount of flash and other memory. This allows the K3 to be re- programmed with the newest firmware by a simple download from the Internet. It also enables the K3 to remember your favorite settings, particular configuration preferences, and the last setting of most controls when power is removed from the radio. -
Page 30: Front Panel Assembly Procedure
The K3 is Digital Signal Processing (DSP)-based to enable it to provide a rich set of features to help combat QRM and QRN while at the same time generating some of the cleanest signals to be found in Amateur radio today. -
Page 31: Figure 35. Preparing The Front Panel Board For Mounting, Part 1
Remove the protective backing and mount the two self-adhesive pads in the corners on the back of the front panel board as shown in Figure 35. When removing the protective backing, be sure you do not pull the adhesive material off of the pad with the backing. Mount three standoffs on the back of the front panel board as shown in Figure 35 . -
Page 32: Figure 37. Mounting The Front Panel On The Front Panel Board
Inspect the front panel board to verify the following: Three 4-40 5/8” (15.9 mm) standoffs are mounted on the back as shown in Figure 35. Two 4-40 5/8” (15.9 mm) standoffs are mounted on the front as shown in Figure 36. Two 2-56 5/16”... -
Page 33: Figure 39. Mounting Vfo Encoders
Place the VFO A encoder assembly (the one without the nut threaded on the shaft) in the opening near the center of the board so the shaft protrudes through the opening under the LCD. Orient the encoder so the pins mate with the connector on the front panel board as shown in Figure 39. -
Page 34: Figure 41. Installing Lcd Cover
Ensure the LCD cover is free of dust, smudges and fingerprints, then mount it over the LCD as shown in Figure 41 oriented so the beveled edges are away from the panel. Tighten the screws only until they come into firm contact with the trim panel. -
Page 35: Figure 43. Mounting Friction Knobs
Press small knobs on the four controls under the left end of the LCD: SHIFT/LOW, HI/WIDTH, SPEED/IN and OUT/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 43. Align the flat in the knob with the flat on each shaft before pressing each knob in place. -
Page 36: Figure 45. Mounting The Vfo B Knob
Mount the last knob on the VFO B encoder shaft to the right (under the pushbutton switches) as shown in Figure 45. Note that this knob takes only one felt washer. PLACE FELT PLACE THE KNOB ON THE WASHER OVER SHAFT SO IT RESTS ON THE ENCODER SHAFT THE FELT WASHER AND... -
Page 37: Figure 46. Mounting The Dsp Board
Mount the DSP board on the front panel board as follows. When you are done, the front panel assembly will look like Figure 46. ESD SENSITIVE: Wear a grounded wrist strap or touch an unpainted metal ground before touching the DSP or front panel boards. Place the front panel assembly face down on a soft, clean surface to protect the finish. -
Page 38: Resistance Checks
Figure 47. Mounting the Front Panel Assembly on the Chassis. Resistance Checks The following resistance checks confirm that the main power busses in the K3 aren’t shorted to ground somewhere. 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 39: 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 13.8VDC power supply to the 12VDC IN connector on the rear panel. Do not connect a key,... -
Page 40: Kref3
The KREF3 module’s 49.380-MHz temperature-controlled crystal oscillator (TCXO) is the common signal source for the K3’s synthesizers. This signal is also divided by 6 to provide the 8.230-MHz signal used by the second receive and transmit mixers. Firmware is used to compensate for any small drift in the TCXO and its derived signals, resulting in excellent stability (with the high-stability option, better than +/- 0.5 PPM over the 0... -
Page 41: Ksyn3
KSYN3 Circuit Description Low phase noise is key to both receiver and transmitter performance. In the K3’s synthesizer module (KSYN3), we start with a clean, wide-range voltage-controlled oscillator (VCO). The VCO is placed near the desired band of operation using 128 carefully-selected L-C combinations, which keep the ratio of fixed capacitance to tunable capacitance (varactor diodes) as high as possible. -
Page 42: Ksyn3 Installation Procedure
KSYN3 Installation Procedure Install the KSYN3 board on the back side of the front panel shield as shown in Figure 52. 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 43: Kpa3 Installation
Procedure in the KPA3 manual that and install the option now, following the instructions in the Special Note to K3 Kit Builders. If you do not have the KPA3 module, install the larger blank panel in the opening on rear panel using a 3/16”... -
Page 44: Bottom Cover Installation
(Do not confuse this cover with section A which is the same size but has no rectangular holes.) Note that, on one side, bare metal is exposed in some areas. This side will face inside the K3. -
Page 45: 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 46: Battery Bt1 Installation Procedure
10-watt K3 configuration. If you have installed the KPA3 100-watt amplifier module in your K3, the chassis stiffening bracket is already in place. In that case skip this step. Otherwise mount the chassis stiffening bracket on the underside of the cover as shown in Figure 59. -
Page 47: Figure 60. Mounting Loudspeaker
Failing to install the fiber washers as shown in the next step or over-tightening the screws so that the speaker mounting flanges are distorted may damage the speaker, causing distorted, fuzzy sound. Mount the speaker using the hardware shown in Figure 60. Be sure to include the fiber washers between the speaker flanges and the grill cloth as shown. -
Page 48: Test And Calibration
Figure 62. 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 seven 4-40 3/16” (4.8 mm) black flat head screws: five on the top and through each side panel into the stiffing bracket. -
Page 49: Synthesizer Calibration
Connect a dummy load capable of dissipating 5 watts to the ANT1 output. If your K3 is equipped with a KAT3, be sure it is in bypass (press GROUP, turn VFO B to KAT3 and then turn VFO A as needed to display BYP, then exit the menu). -
Page 50: Kpa3 100-Watt Module Installation
KPA3 100-Watt Module Installation If you have the 100-watt module, turn to the KPA3 Option manual and follow the instructions to install it now. Be sure you have completed the above Test and Calibration procedures before installing the KPA3 module. -
Page 51: Appendix A Illustrated Parts List
Front Panel Printed Circuit Board Assembly E850242 ESD Sensitive. Follow ESD safe handling procedures. Keep in ESD-safe bag until installed. K3 DSP Printed Circuit Board Assembly E850233 ESD Sensitive. Follow ESD safe handling procedures. Keep in ESD-safe bag until installed. RF Board E850261 ESD Sensitive. - Page 52 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. KSYN3 Board E850260 ESD Sensitive. Follow ESD safe handling procedures. Keep in ESD-safe bag until installed. KIO3 Main Board E850237 ESD Sensitive. Follow ESD safe handling procedures. Keep in ESD-safe bag until installed. KIO3 Audio I/O Module E850236 ESD Sensitive.
- Page 53 KXV3 I/O option with your K3 kit. KIO3 Panel E100218SS Panel, Blank (KPA3 Fans) E850297 Note: This part is not supplied if you purchased the KPA 100 watt amplifier option with your K3 kit. Bezel (LCD cover), K3 E100195 A- 3...
- Page 54 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. Trim Panel, K3 VFO E100197 Serial Number Label E980137 Knob, VFO A Tuning E980093 Finger Grip, Main VFO Tuning Knob E980094 Knob, VFO B Tuning E980090 Knob, Concentric Shaft, Large E980092 Knob, Concentric Shaft,...
- Page 55 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. Loudspeaker with attached wire and E850300 connector Loudspeaker Shield E980087 Loudspeaker Grill Cloth E980053 #4 Fiber Washer E700031 Front Feet with Stand Bottom Feet with tilt stand E980098 Rear Feet SO239 Hole Cover E980135...
- Page 56 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. Nut, 4-40 E700011 Typical Nuts Nut, 6-32 E700069 Nut, 3/8” (9.5 mm) Hex E700125 Screw, 4-40, 3/16” (4.8 mm) Black, Flat E700025 Head Typical Flat Head Screw Screw, 4-40, 3/8” (9.5 mm) Black, Flat...
- Page 57 ELECRAFT ILLUSTRATION DESCRIPTION QTY. PART NO. Flat Washer E700137 Jackscrew Nut, 4-40 E700052 Grommet Bumper, 7/16” Round (Side E980141 panel feet) A- 7...
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