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2. Ref Pin VDC Ref Pin VDC Ref Pin DI A 13 33 Ql D 13 5 Q7 B on K 10 4 G 0 34 02 13 8 5 1 77 08 K 13 5 Q2 D 4 44 C D3 A 9 0 G 3 44 E K 13 5 S 4 44 09 D4 K 0 3 03 D 4 45 05 K 5 8 G 3 44 E D6 K 5 8 5 4 45 07 K 13 5 Q4 E 0 23 B 0 94 C 2 14 5 2 24 2 14 13 5 06 13 5 6 Appendix Parts Placement Drawing Top Includes KXPD1 KXB30 and KXAT1 boards KX1 REV B1 2003 ELECRAFT RP4 L 6 0 1 D e C37 RP RP5 0 Bl 53 54 CY R12 0 1 L 0 C10 19 C24 52 O EJ IL D3 C 1 KXPD1 REV KXPD1 REV 2003 2003 ELECRAFT ELECRAFT ELECRAFT REV B1 COPYRIGHT 2003 G Appendix F Parts Placement Drawing Bottom Includes KXPD1 KXB30 and 1 boards KXAT1 ATU REV B 2003 ELECRAFT R2 R1 REFL FWD nej Hs D 4 ELECRAFT REFERENCE once to show band twice quickly to change bands 12 amp ELECRAFT 1 2 VFO KNOB Hold to set keyer 2 FUNCTIONS speed with E TUNING RATE s Tap for 10 100 Hz a 8 hold for 1 kHz e 5 kHz in LSB USB TUNE Key downs MENU BAND RIT 05e D 20 receive modes Hold MENU BAND o p switch after w 10 HZ 10
3. TRANSCEIVER 12V 6 ELECRAFTKXI RE ANT RF GAIN 1 0 0 5 2 0 10 HZ 100 HZ FILTER POWER A la Q PADDLE OWNERS MANUAL ELECRAFT 1 Ultra Portable CW 9 Owner s Manual Revision B November 3 2003 Copyright 2003 Elecraft LLC All Rights Reserved Elecraft www elecraft com P O Box 69 Aptos CA 95001 0069 831 662 8345 Fax 831 662 0830 2 ELECRAFT Table of Contents INTRODUCTION Z i E E S aan GS 3 SPECIFICATIONS uyu lt uuu ate S m u 5 PREPARATION FOR ASSEMBLY i ico uu LL uu 11 Su gu 6 ASSEMBLY PART E Eu X 14 ALIGNMENT AND TEST PART Leads dda u Tua a a aqsu ds Den 27 ASSEMBLY Lu uu U J ws u 30 ALIGNMENT AND TEST PART 43 l
4. a w 48 ALIGNMENT AND TEST PART lF Lu u veces u whe uu 58 FINAL ASSEMBLY u ku E A E ana aa uama 60 OPERATION uu A us L A u umu 2 SS E us 62 OPTIONS ETERNI 71 DETAINEES secs rece 1 u A i A 72 PARTS RZ uyu OOo RYE E A E N E SAT aa APPENDIX SCHEMA TIC m S u du cance uu u Qm u au uka p a uu u APPENDIX B BLOCK GR ANC APPENDIX C 8 225 AL APPENDIX D TROUBLESHOOTING u q u u uku u i SS au Ga S u a sa APPENDIX E PARTS PLACEMENT DRAWINGS 5 22 55 2 L u u L L us APPENDIX F QUICK T APPENDIX ELECRAFT Introduction The KX1 is a compact multi band CW transceiver optimized for backpacking and travel use With internal battery internal automatic antenna tuner log book lamp and plug in keyer paddle it offers a high level of integration Unlike most transceivers the KX1 s controls are located on the top of the cabinet and keyer paddle attaches at the front This trail
5. VFO Lock Unlock Holding RIT 10 100 locks LOC or unlocks nor the VFO knob When the VFO is locked rotating the knob will have no effect on the VFO frequency or RIT offset and tapping or holding the knob will not change the tuning rate The knob can still be used for changing the CW keying speed or accessing the menu Operating Frequency Calibration The VFO display accuracy should about 200 Hz without calibration Using the BFO and DDS calibration procedures below you can improve accuracy to typically 10 Hz Before calibration the KX1 should be turned on and allowed to stabilize at room temperature for 15 minutes BFO Calibration This procedure compensates for the difference between your BFO frequency and the nominal value 4913 00 kHz 1 Select 40 or 30 meters LSB receive mode 2 In the menu set BFO to 00 and DDS to 00 Exit the menu ELECRAFT 3 Tune in a strong station at a known frequency as accurately as possible You can zero beat an unmodulated carrier tune for 0 Hz audio pitch or tune in an AM broadcast or reference station such WWV Write down the frequency shown dial 4 Switch to USB re tune the signal and write down this frequency 5 Subtract the lower reading from the higher reading then divide the result by two Example USB 10000 10 kHz LSB 9999 90 kHz Subtracting LSB from USB leaves 0 20 kHz and dividing by 2 yields 0 10 kHz T
6. Transmit Receive L C Appendix C KX1 BLOCK DIAGRAM W Burdick E Swartz Rev A 10 04 00 Appendix D KX1 Assembly Photographs 5 5 3 TERT Ge D I board top view Assembled PC board bottom view with top cover installed Appendix Troubleshooting TOP COVER REMOVAL 1 Remove the three flat head screws that hold the PCB to the top cover 2 remove the VFO knob 3 Flex the front edge of the top cover outward slightly while pulling upward gently on the key jack The key jack should pop out of its hole 3 Lift out the PCB 1 NOTE If you need to transmit with the top cover removed will not have a heatsink Turn the power control R4 fully counter clockwise to limit power to 0 5 watt or less To prevent damage to the PA transistor limit transmit time to 3 seconds keydown 10 seconds key up 1 TOP COVER INSTALLATION 1 Place the top cover onto the PC board Align switch caps with their holes using a long tool inserted between PCB and top cover 2 Snap the key jack into its hole by pushing down gently 3 Secure the PCB to the top cover using three 4 40 x 1 4 flat head screws 4 Install the VFO knob General Troubleshooting Procedure Look your problem in the Troubleshooting Tables Closely examine PC boards for poor solder joints and incorrect broken or missing components Check voltages using the
7. 14 MHz band using Set the VFO to approximately 14100 kHz LJ If a monitor receiver or transceiver is available connect a very short antenna wire 1 to 3 feet to its RF input and set it to the KX1 s indicated VFO frequency AN Do not remain in TUNE mode for more than 5 to 10 seconds at a time If you cannot hear the in the monitor receiver or if you suspect there s a problem cancel TUNE mode immediately and see Troubleshooting Put the KX1 into TUNE mode by holding MENU You should see tun on the display Listen for the KX1 s signal in the monitor receiver and or check the wattmeter indication then exit TUNE mode by tapping any switch A The wattmeter should indicate approximately 3 to 4 watts with a 12 14 V supply If power is significantly lower than this the could be drawing more current than your power supply or battery can handle or R4 may not be set fully clockwise If neither of these seems to be the problem see Troubleshooting 59 40 Meter Transmit Test LJ Switch to 40 meters 7 MHz Set the VFO to about 7100 KHz Put the KX1 into TUNE mode by holding MENU BAND You should see tun on the display Listen for the KX1 s signal in monitor receiver and or check the wattmeter indication then exit TUNE mode by tapping any switch A If 40 meter power output is less than 3 to 4 watts with a 12 14 V supply see Troub
8. LJ Install the following inductors below R19 near the center of the board L10 micro smaller size 33 uH org org blk L8 micro size 18 uH brn gry blk L9 micro size 100 uH brn blk brn Zi In the next step you will install a diode which must be oriented in the proper direction Be certain to align the banded end of the diode over the band on the circuit board LJ Install diode D4 1N4148 on the lower edge of the board to the right of L9 31 Install varactor D5 1SV149 as follows When you are finished the top of the varactor must no be more than 5 16 7 9 mm above the board Locate the outline for D5 on the board It is near the center of the board immediately to the right of resistor pack RP5 Orient the varactor according to the printed outline on the board The varactor may have a beveled back instead of a rounded back as shown on the board See Figure 10 Insert the varactor leads in the solder pad holes The varactor has a third lead that has been clipped close to the body Space the varactor up off of the board slightly to ensure this lead does not short to the board Solder one lead then check to ensure that the top of the varactor is no more than 5 16 7 9 mm above the board If necessary reheat the joint while adjusting the height of the varactor Solder the second lead and trim both leads LJ Follow the same procedure to install varactor D6 18V149 D6 is located above D5 32 Zi
9. The KXB30 adds 30 meter coverage to the and also greatly increases receive sensitivity in the 5 9 6 4 MHz SWL segment with 40 m selected 30 meters is an excellent band for day and night operation and is popular with QRPers Being a WARC band it is off limits for contests and 15 thus a haven for those not interested in contest operation WWV or WWVH provide universal coordinated time announcements at 10 000 MHz and many AM broadcast stations can be heard in the 9 10 MHz band The B30 menu entry must be set to ON to use the 30 m band Plug In Keyer Paddle KXPD1 The KXPD1 paddle offers a rugged lightweight alternative to traditional keyer paddles or hand keys It plugs directly into the front of the 1 and is ergonomically designed for operating comfort The KXPDI is retained by a thumb screw to prevent movement during keying and can quickly be reversed for left or right handed operation 71 Automatic Antenna Tuner KXATI With the internal automatic antenna tuner installed you can connect unbalanced random length antennas directly to KX1 An inexpensive home made balun can be used with balanced lines In many cases the ATU will provide a 2 1 or better match on all bands Once you ve tuned up an antenna the tuner s and C settings will be recalled instantly when the band is changed The provides SWR and power information for the KX1 display in TUNE mode Also during normal
10. DOT DASH or DASH DOT pattern This can improve sending efficiency Mode default has more forgiving timing and is similar to Curtis keyer IC mode A Mode B is similar to Super CMOS Keyer III mode B CFB CW Feedback Control 10 40 WPM or OFF When CW feedback is on audio Morse code is sent in response to all switch or menu activity and S meter mode provides freq announcements during VFO movement page 67 SIG S Meter Scale and Zero Set Zero parameter range is 30 99 adjusted using VFO knob Set for zero bars indication in S meter mode with no signal Scale parameter range is 2 6 adjusted by tapping BAND and RIT With approx S9 20 dB signal injected adjust for 6 bars BFO BFO Calibration Sets BFO calibration offset 0 99 kHz See page 68 DDS DDS Calibration Sets DDS frequency reference scaling 99 PPM parts per million See page 68 B30 30 m Band Enable Set to ON if KXB30 option is installed covers 30 m and improves 49 m SWL reception page 71 BAT Low Battery Voltage Set Sets the low battery warning threshold voltage see page 62 for recommendations ATU ATU Mode See manual If the antenna tuner option is not installed parameter appears as RCL STO Memory Recall Store To recall tap 1 2 or 10 100 To store hold to switch to STO then tap 1 2 or 10 100 One memory can be assigned as the High Priority memory for quick recall see page 67 CW Message Play Record To play tap 1
11. LJ Solder one of the tabs and then check the position of the jack It must be centered within the printed outline on the board with the connector opening parallel with the edge of the board Be sure the jack is resting directly against the board There must be no gap between jack and the board If necessary reheat the soldered tab and adjust the position of the jack LJ When you are satisfied with the position of the jack solder the remaining two tabs then recheck the first tab be sure it is properly soldered ELECRAFT Test fit two pin plug P1 directly below J1 Orient P1 so locking ramp that sticks up alongside the pins is on the side farthest from J1 as shown on the printed outline on the board LJ Place the shell for the mating jack over the pins of P1 to protect your fingers and while holding P1 directly against the board solder one of P1 s pins Check the following If necessary reheat the soldered pin and adjust P1 is oriented so the locking ramp is on the side farthest from P1 is sitting vertically and resting flat against the board LJ Solder the second pin of P1 to the board then touch up the tack soldered connection as needed to form a good joint A If J3 is not aligned correctly as described in the next step the front cover will not fit during final assembly LJ Install J3 at the center of the bottom edge of the board using the same procedure to ensure it is square inside the silk screened
12. friendly format is ideal for hand held or lap top operation e g when sitting on the ground using a camp chair reclining or even standing The KX1 is also at home on a table or desk providing an optimal display viewing angle without the need for a tilt stand The unique plug in keyer paddle is both physically reversible for right or left handed use The transceiver covers the full 40 and 20 meter bands and optionally 30 meters The VFO is based on a DDS direct digital synthesis IC so it can also tune well outside each band covering many popular SWL band segments A variable bandwidth crystal filter permits reception of SSB and AM as well as CW facilitating cross mode contacts and broadcast reception The KX1 s internal six cell battery pack can be changed in seconds with the removal of two thumb screws The battery provides 1 to 2 watts power output which represents a good tradeoff between battery life and communications efficiency An external 12 V supply increases output to about 4 watts Low receive mode current drain 32 mA typ results in battery life of 20 hours or more The low battery warning threshold can be adjusted to match the battery type used The KX1 uses a 3 digit LED display that is physically rugged and extremely efficient It requires just 1 to 2 milliamps total current in moderate lighting conditions and about 10 mA at its brightest setting The operator can optionally configure the display to turn off
13. 3 037 7 1004F C50 2 E yo u2 39 L i 4 T I ua TT i F4 97 R8 AD9834 005 42 644 L C47 ET 6 8k 20 2 01 0 022 T 220 2 if 94 g AD B 6 57 57 57 ji J8 L 46 3 ER v en bz R30 c45 470 C49 42 AGND 216 2 3904 x 22 8 1000 1000 Ant C30 01 4 117 R4 A Vdd Vin 22 Ff og 4 5 5 16 fo C34 100 D Vdd sien S 4i 25 2166 5 22 50 MHz 6 cap rsync 18 101 KEB pT n 4 af 7T DGND 14 5 R11 gt gt x 97 8 SDATA 13 8 4 D Date R27 bottom of PC board 11 03 03 stay steep 12 254124 10 11 7 22 Riog cat Surface mount device Low pass Filter PSEL RESET 4 7 30 meter module connections ppen IX 10K LOW DRIVER PASS Q4 Q5 FILTER BUFFER Q1 LOW PASS E FILTER WithVFO 7000 00 kHz and RX Mode Normal CW Fdds RX 11913 6 kHz BAND PASS FILTER Fdds TX 7000 00 kHz i 9 MCU RCV CRYSTAL DETECTOR ui FILTER U5 U4 4 9136 MHz DISPLAY L AND CONTROLS BFO 4 913 MHZ KEY
14. Note Limit TUNE time to 10 seconds on 10 seconds off Ifa is installed you ll see ATU for a few seconds during TUNE followed by the power output e g P2 0 Tapping any switch will cancel TUNE and flash the SWR e g r1 0 If no ATU is installed the display will show tun since the itself does not include power metering You ll still need to tap a switch or the keyer paddle to exit TUNE mode even in the non ATU case RIT DISP Selects display mode Selects frequency nor S meter bargraph or battery voltage BAT display mode In S meter mode the frequency is re displayed whenever the VFO is moved S meter mode functions as Frequency Announce mode if audible CW feedback is enabled page 67 Battery display mode can be used during transmit or receive in transmit mode it overrides the bargraph or TUNE display The remaining switch combinations are described in the Advanced Operating Features section RIT CW LSB USB receive mode page 66 MENU 10 100 Turns Switch CW off page 68 10 100 High Priority memory page 67 10 100 Locks unlocks page 68 ELECRAFT Menu Functions 65 To access the menu tap MENU You can then scroll through menu entries by rotating the VFO knob see list below Hold to display a menu entry s parameter then change t
15. brown E E540005 LED White 1 3 4 size E570014 D2 D3 Diode Shottky IN5817 ES E560008 D5 D6 Diode varactor 1SV149 EZ E560005 IDA Diode switching 1N4148 560002 Diode 47 zener 1N4756A E560013 051 LED display 3 digit 7 segment 1 570013 247THAILAND Conn barrel Mating connector for J1 Conn R A PCB mount bushing Conn 1 8 stereo Jack Miniature three circuit plug that mates with J3 Conn 1 8 stereo Jack with switch ELECRAFT E620026 E620032 E620075 E620027 E620033 E620028 ELECRAFT Conn 2 pin female housing 0 1 spcg for internal battery E620021 Crimp pins for J5 package of 2 E620022 Conn 5 pin female 0 1 spcg Conn 3 pin female 0 1 spcg Conn 2 pin female 0 1 spcg E620051 E620009 E620066 Toroid on T37 6 core Yellow 26 enamel L1 13t L2 14t See text for winding instructions E680013 Inductor on FT37 43 core Black 6T 26 See text for winding instructions Ee Transformer wound on FT37 43 core Black 8T 2T 26 See text for winding instructions 5 ELECRAFT min larger size RF choke 6 8 uH blu gry gld AN Do not mix these L6 Note L6 may be physically larger than L7 in some 1 E690044 with resistors Keep them kits This is normal in their own envelope min larger size RF choke 4 7 uH yel vio gold E690042 until instructed to instal
16. 4 to 6 seconds c Add more solder and feed more wire into the solder as the enamel melts Continue tinning the wire up to the edge of the core and then slowly pull the wire out of the solder d Ifany enamel remains on the lead scrape it away using your thumbnail or sharp tool 2 Burning The insulation can be burned off by heating it with a butane lighter for a few seconds Use sandpaper to remove the residue then tin the bare wires 3 Scraping Use a sharp tool to scrape the insulation away Work carefully and gently do not nick the wire Work around the entire circumference of the wire to remove all of the enamel and tin the bare wires LJ Place L2 over the printed outline on the board and thread its leads through the solder pads 41 LJ Pull the leads tight so the toroid is sitting upright and against the board Check to see that some tinned lead is visible above the pad near the toroid when the wire is pulled tight If necessary remove the toroid and tin the lead closer to the core It won t matter of the tinned wire touches the core itself The toroid core is not a conductor L Solder both leads Use your DMM to check for continuity across solder pads It should be less than 1 ohm If it is higher you probably have a poorly tinned toroid lead Sometimes the leads look like they are soldered but because there is a film of enamel still on the lead it is not making contact with the solder pad If the resist
17. 63 VFO Knob Tuning Rate Switch This control adjusts the VFO frequency RIT offset next page keyer speed next page and is also used in the menu page 66 Tapping the knob selects 100 Hz or 10 Hz VFO steps Holding it for 0 5 seconds selects 1 KHz or 5 kHz VFO steps depending on the receive mode page 66 It is also used in along with other switches to activate certain advanced features Transmit frequency ranges The transmits only in the ham bands 7 0 7 3 10 10 10 15 and 14 0 14 35 MHz Transmit will be prevented once you move a few kHz outside of each band and you ll see END flashed on the display Potentiometers RF GAIN Sets the receive RF gain Normally set fully clockwise but can be rotated counter clockwise to attenuate strong signals FILTER Adjusts the receive crystal filter bandwidth over a range of about 300 to 2000 Hz Narrow bandwidth settings can be used to reduce interference from nearby signals when copying CW Wider bandwidth settings are useful for copying SSB and AM AF GAIN Sets the receive audio output level The sidetone volume can be set higher or lower in relation to receiver audio using the STL menu entry page 65 POWER LEVEL R4 internal This trimmer potentiometer is accessible through a hole in the bottom cover and can be set using a small tuning tool or flat blade screwdriver AN For best performance keep R4 set fully clockwise unless you must reduce
18. 69 Lamp Switch Set LAMP ON to turn on the lamp at the front left edge of the 1 The lamp can be used to illuminate a log book placed in front of the or as a flashlight In an emergency it can be used for visible signaling The white LED used is extremely efficient Its current requirement varies with supply voltage from about 5 mA at 7 V to 15 mA at 14 V You can substitute a red LED if desired LED Display The 3 digit LED display shows the operating frequency S meter or power output bargraph menu entries etc Brightness and on time are programmable see LED page 65 You can also use audible CW switch feedback in addition to the display page 67 Brightness The display is most useful in low to moderate lighting situations where it requires only about 1 3 mA total current Brighter settings are also available that require up to 10 mA If the display is too dim when the is first turned on you can quickly select maximum brightness and simultaneously enable CW feedback on switch press by holding one of the three pushbutton switches when the KX1 15 turned on see Power Switch above Decimal Points The decimal point shifts to indicate the VFO tuning rate and is flashed when RIT 15 enabled Bargraph In S meter mode the bargraph indicates received signal strength see SIG page 65 On transmit it shows 1 bar per 0 5 W output if the ATU is installed and 1 bar otherwise
19. A small 2 Phillips a small flat blade for slotted screws and a very small flat blade about 0 1 in or 2 5 mm wide with an insulated handle to adjust the trimmer caps Needle nose pliers Small point diagonal cutters Flush cutting type is required Xcelite MS54 5J or equivalent Digital Multimeter DMM for voltage checks and confirming resistor values A DMM with capacitance measurement capability is desirable but not required 50 ohm dummy load capable of handling 5 watts minimum Magnifying glass or visor ELECRAFT We strongly recommend that you use a conductive wrist strap and anti static mat during assembly These items are available at very low cost from Jameco Mouser and other electronics suppliers Refer to www elecraft com for tool sources and solder recommendations ELECRAFT Soldering and Desoldering Zi Use adequate ventilation when soldering avoid inhaling smoke or fumes Always wash your hands after handling solder as lead residue is highly toxic Solder Recommendations We recommend small diameter 02 to 03 rosin core solder similar to Kester type 44 Solder with 2 silver is used by some builders and will work equally well If you use a minimum of solder there will be no need to clean PC boards The use of acid core solder water soluble flux solder or any corrosive or conductive flux or solvent is likely to damage components and or PC boards Soldering When applying solder use the
20. DATA ev E 470 16 Ci 6 2 R44 c2 1 91 47 Bandwidth MUTE 534 27 Lamp 16 R29 9N On Off uc el 0 1 Product Det 22K R15 Lt R1 4 7 TE 5 8 2 K H re Y and BFO jo 1M RF Gain 20 z L 3L 2 x 541 4 100K 100K L8 J309 DN C17 C20 10yF R21 2 5 ELE N 18uH L9 n 04 2 7K Em ke E 5 V Gi G2 C22 2 3 R18 2 7 T E F 01 f L6 4 6 7 x x ES e 3 ce is s t BYPASS C27 C56 C15 06 R19 2 c 3 3M lt ev 150 TT 50 68 01 NE602 1 8K lt gt 6 v 05 o 8 07 151149 U4 R25 2N4124 82 227 0 1 RS 2 9 Crystal Filter HH lo AEA c23 R28 001 f L10 56 J309 4 mp 100 cai J 1 8K 4 914 2 Ci4 L ce T 1 4VDC no signal 0 6VDC max HU x y 4 KIA J309 X5 4 913 MHz E Z D VSMTR 5 D4 R5 20 o gt s AGC 144148 7 120 T o Qo B 5 lt gt 2 4124 2 14 MHz R31 L C52 1K eT R20 55 4 1K U7 5V 15 l 22 2 24 i J4 C39 C38 TPs76427 5 Mt C53 AF Gain 0 1 1049F 5 8 2 R26 U 57 10uF Y lt na 22 Ph Spk FEES L4 l 108 er2 4 BS SE C54 ones Spkr 4 2 2 T o4 L3 56 gt wow pn ak C35
21. DC Voltage Table at the end of this section Error Messages If you see a message such as E 10 on the LED look up the corresponding entry in the Troubleshooting Tables Error messages can usually be cleared by pressing any switch However the cause of the message should be investigated before continuing to operate the transceiver E 1 Troubleshooting Tables There are five troubleshooting tables listed below Within each table problems are identified by 2 digit numbers for cross referencing purposes In most cases you ll know which table to look in based on the symptoms you observe If in doubt start with the General Troubleshooting table Some problem identifiers have corresponding error messages see above General Troubleshooting Display and Control Circuits VFO Receiver Transmitter and Keyer 00 19 20 39 40 59 60 79 80 99 General Troubleshooting 00 19 Problem Troubleshooting Steps 00 Unit appears to be completely dead when power switch is turned on no display no audio possible smoke hot components etc Make sure your power supply is connected turned on and not plugged in backwards Check fuses examine cables for open short If the top cover is removed make sure you don t have a screw inserted into the tab of the PA transistor Q6 this will short the 12V line Measure 6 and 5 regulated power supply voltages 20 Check the MCU U1 26 01 LED problem See contro
22. DMM to verify that the resistance between adjacent pins is 100k ohms Note the dot at one end indicating pin 1 DOTINDICATES PIN 1 PLACE IN ROUND SOLDER PAD LAST THREE DIGITS OF NUMBER INDICATES VALUE 104 100K OHMS Figure 4 Installing Resistor Packs LJ Find the outline for RP5 on the top of the circuit board With the board face up so that KX1 is in the upper left corner the outline for 5 is just to the left and above the notch at the center of the lower edge of the board ELECRAFT LJ Insert 5 with Pin 1 of the pack in the round solder pad The round pad is farthest from the edge of the board Zi Be careful to orient the resistor packs so the dot next to Pin 1 on the pack is at the round solder pad on the board Once soldered in place it is almost impossible to remove the pack without destroying it Wet your soldering with small amount of solder touch it to one of the pins to tack solder it in place LJ Check the position of RP5 to verify that the pins at both ends are inserted as far as they will go into the board as shown in Figure 4 then solder and trim all ten leads Follow same to install six pin resistor pack 2 102 above and to the left of RP5 Pin 1 goes at the top pointing toward the printed outline for C51 Install ten pin resistor pack RP4 10k 103 below U2 in top left quadrant of the board Pin 1 goes to the left pointi
23. MISC bottom cover E100173 MISC E740056 MISC Wire 26 red enamel Um E760002 MISC Wire 26 green enamel 0 on E760004 MISC Knob 1 15 dia 1 980072 Red plastic filter w two adhesive strips Packaged MISC with serial number label and thermal pad in a small 1 980073 envelope MISC IC socket ultra low profile 28 pins 1 E620074 ELECRAFT MISC Large Allen wrench MSC 05471057 5 64 MISC Sandpaper E980004 E850090 Thermal pad Normally shipped in the same envelope with the Serial Number label E700002 1 N Handle with care ESD Sensitive KX1 PCB w pre mounted parts U2 U7 Z2 Empty Pom Ius eee PE PCB is Part No E100174 6 Heat shrink tubing 15 3 980037 980024
24. SWL Shortwave Listening Tips Tuning Range The 1 can tune a wide range on each band 40 5 9 5 MHz 30m 8 12 5 MHz 20m 12 16 5 MHz The useful tuning range is actually somewhat smaller since signals will fall off as you tune outside the ham bands note the exception to this described in the next paragraph Using the KXB30 on 30 and 40 meters If you have the KXB30 option installed you ll be able to use the 30 m ham band and nearby SWL segments But this option has another important function its tuning capacitors will be turned on automatically on 40 meters if you tune below 6 7 MHz This re resonates the band pass filter at about 6 2 greatly improving sensitivity in the popular 49 meter SWL segment 5 9 6 4 MHz Tuning AM or SSB signals The FILTER control should be set fully clockwise when listening to broadcast stations While you can listen to AM or SSB stations in any of the KX1 s three receive modes CW LSB USB LSB or USB provide two advantages elimination of the CW receive offset and 5 kHz rather than 1 KHz tuning steps You can use 10 Hz steps to fine tune zero beat AM signals Frequency Memories and High Priority Memory Commonly used SWL frequencies can be store in frequency memories If you often switch to a time reference such as WWV at 5 10 or 15 MHZ you can designate the associated memory as high priority for quick access see page 67 ELECRAFT Options 30 Meter Module
25. VFO frequency is 7100 00 kHz tapping BAND will first show 7 then 100 then return to the appropriate display for your selected tuning rate LJ To change bands tap BAND twice quickly This will trigger the MHz kHz display in this case showing 14 then 100 14100 00 kHz Tapping or double tapping BAND also stores the present frequency for the next power up or band change LJ Set the POWER switch to OFF Disconnect power source from J1 LJ Remove the VFO knob and set it aside for reinstallation later LJ Wrap the cover and put it in a safe place until it is needed Zi Leave microcontroller U1 in its socket during the remainder of the assembly process Be sure to observe ESD handling precautions at all times 30 Assembly Part II In this section you will assemble and test the receiver circuits The transmitter circuits will be assembled in Part III LJ Position the board face up with in the upper left corner LJ Install R19 1 8 brn gry red 1 4 watt to the right of RP5 near the center of the board LJ Turn the board over so that J1 is in the upper right corner Install the following 1 4 watt resistors in the lower left quadrant of the board Form the leads as required so the resistors lie directly against the board within the printed outlines R21 2 7k red vio red R14 47 ohms yel vio blk R18 3 3 megohm org org grn R29 22k red red org R5 4 7k y
26. Verify the correct orientation of each electrolytic capacitor The side of the capacitor with the strip and minus sign must face away from the sign printed on the board Examine both sides of the PC board closely for solder bridges cold solder joints or unsoldered components Resistance Checks LJ Make the resistance checks listed below with your DMM s negative lead connected to circuit board ground at the hole next to capacitor C6 Resistance Test Point 74 pins 2 amp 3 5 ohms U 04 all other pins U U5pin4 5 6 amp 8 U5 all other pins gt 10k U6 pin 3 5 ohms U6 pins 4 5 6 amp 8 21k U6 all other pins gt 10 ELECRAFT Alignment and Test Part II LJ Temporarily mount the VFO knob on the shaft of encoder 71 AN Due to the small size of the KX1 s front panel knobs are not appropriate for use on the RF GAIN FILTER and AF GAIN controls The shafts of these potentiometers which are knurled and have molded index marks are designed to function as knobs L Unwrap the cover and set it near the circuit board so you can see the legends identifying the controls and their functions LJ Set AF GAIN fully counter clockwise minimum volume LJ Make sure the POWER switch is turned OFF S2 LJ Plug your power supply or battery into J1 LJ Turn on power to the KX1 The 3 digit LED display should show the operating frequency If not disconnect the power sourc
27. an SSB signal is correctly tuned in and you transmit the SSB station will hear you at about a 600 Hz pitch Receiver performance considerations Several strong internally generated signals can be heard outside of the ham bands If one of these signals falls near an AM signal of interest try switching sidebands to reduce interference Note on 20 meters USB and nor CW receive modes provide somewhat better sensitivity than LSB mode See Circuit Details for an explanation 7 These signals originate either at the DDS or from mixing products and are typical for a superhet receiver using a low Strong signals appear at the following frequencies in kHz with the applicable sideband shown in parentheses 5895 USB 6141 USB 6358 LSB 6550 USB 7989 LSB 9148 both 9826 both 14740 both 14981 both Additional weak signals can also be heard but in general will be masked by band noise ELECRAFT Using Frequency Memories Three frequency memories are available on each band accessed using the RCL recall menu entry In addition to VFO frequency the receive mode CW LSB USB is saved on a per memory basis Any one memory can be designated as High Priority when it is stored as described below This allows you to quickly switch to one often used memory such as WWV or a net and back To store First tap MENU and scroll to RCL menu entry memory recall Hold to change the menu entry to STO st
28. be set to defaults and band 1 will be selected Try a full reset 33 U1 may be damaged or inserted backwards 33 Configuration data or menu problem If a menu parameter is out of range or can t be modified EEPROM may need to be reinitialized See Advanced Operating Features VFO 40 59 Problem Troubleshooting Steps 40 General VFO Note small amount of DDS drift may DDS problem occur due to aging of components and frequency jumps or drifts heating cooling of the cabinet Check 14 MHz LPF components L4 L5 C50 C52 and buffer Q1 R31 Make sure supply voltage is above 6 5V Check values of R8 R6 R7 RP4 RP3 Check 5V and 2 7V regulator output 23 Check installation of Z2 and U2 both surface mount use magnifying glass 41 Can t tune VFO or VFO may be locked see Operation RIT offset VFO or RIT offset may be at end of range See 40 above 42 No DDS output See40 Receiver 60 79 Problem Troubleshooting Steps 60 Low audio Ifyou hear normal audio output on one band output from receiver but not all bands see 62 or general receiver sure you have headphones or speaker gain problem connected turn AF GAIN clockwise Check the key jack for a short to ground Make sure RF GAIN is fully clockwise Re peak the band pass filters Check for ground shorts the LPF BPF If you don t hear any hiss at the receiv
29. close to the body Insert the leads in the solder pad holes and bend them out on a 45 degree angle on the opposite side of the board to hold the resistor in place Zi Components MUST be tight against the board or the case may not close properly during final assembly This is especially true of components on the bottom of the board where there is very little clearance between the board and the battery packs Check the position of the resistor to ensure it is centered in printed outline and flush against the board as shown in Figure 3 Solder and trim the leads ENSURE MARKINGS AGREE WITH INSTRUCTIONS IN TEXT BODY OF PART AGAINST THE BOARD SOLDER amp TRIM LEADS FLUSH A Figure 3 Installing Fixed Resistors LJ Locate the printed outline for R28 on the back of the board It is about 3 4 2 cm down from the top edge near the center 15 LJ Bend the leads of resistor R28 1 8k brn gry red 1 4 watt to fit in the holes indicated on the board Note that the leads should NOT be bent close to the body of the resistor like you did for R8 Fit the leads so the body of the resistor sits against the board within the outline then bend them outward at about a 45 degree angle to hold the resistor in place Solder leads to R28 and trim them flush with board AN From this point forward instructions to install a component mean to position it within its outline against the board solder and trim the leads
30. flush on the opposite side LJ Locate the two 200 ohm red blk brn 1 8 watt fixed resistors and R7 They are about half the size of the 1 4 watt resistors you just installed LJ Install the 1 8 watt resistors in the spaces shown just to the left of R8 near the top of the board 200 ohms red blk brn 1 8 watt R7 200 ohms red blk brn 1 8 watt Zi Components may be soldered one at a time or in groups Leads can be trimmed either before or after soldering 16 Zi Save the longer clipped component leads Several of them will be needed for grounding wires and a jumper Install the following 1 4 watt resistors the bottom side of board Their locations are in the lower right quadrant of the board when it is oriented the so outline for J1 is in the upper right corner R16 1k brn blk red R17 1k brn blk red R22 300 ohms org blk brn R23 470 ohms yel vio brn LJ Turn the board over top face up and orient it so that the KX1 lettering is in the upper left corner and the notch is on the lower edge LJ Install the following 1 4 watt resistors about 3 4 2 cm to the left of the notch and about 3 4 2 cm up from the lower edge of the board R12 6 8k blu gry red R13 22k red red org ELECRAFT LJ Locate resistor pack RPS 100 ohm 104 RP5 is a ten pin in line package whose number on the side ends in 104 see Figure 4 If you are in doubt about the value use your
31. hole in the pad aligned with the hole in the cover see area so the edge of the tape is not visible from the front of the unit Be Figure 22 careful not to cover the pushbutton switch holes with the tape POSITION THERMAL PAD OVER SANDED AREA AS SHOWN Q6 MUST PRESS AGAINST THE PAD TO PROVIDE EFFICIENT HEAT TRANSFER AND TO PREVENT AN ELECTRICAL SHORT TO GROUND DO NOT COVER PUSHBUTTON HOLES Figure 23 Installing Display Filter Figure 22 Installing Thermal Pad ELECRAFT LJ In the following steps you will install power amplifier transistor Q6 25 2166 Q6 is mounted so that the front panel top cover will act as a heat sink Begin by studying how the final assembly will look with the circuit board mounted in the case see Figure 24 then follow the steps below exactly as given LJ Bend Q6 s leads in a gentle 90 degree curve Note that the flat side of the transistor faces away from the circuit board Wrapping the leads around a round screwdriver shaft or drill bit helps avoid sharp kinks in the bend 4 40 X 1 4 FLAT HEAD FRONT TOP PANEL 53 LJ Locate the silk screened outline for Q6 at the top edge of the circuit board Install the 3 16 4 76 mm standoff on the circuit board using a 3 16 pan head screw and two split washers as shown in the figure The split washer under the standoff is important to reach the proper height so Q6 will come in contact with the cover Pla
32. in Figure 19 Strip the insulation and tin all four leads like you did for the other inductors 3 2 1 TIN ALL FOUR LEADS UP TO THE CORE Figure 19 Winding Transformer T1 Install toroidal transformer first follows It will easter to thread all four leads through the proper holes in the board if you install it before L3 Thread the leads through the holes in the board Double check to ensure you have the right leads in the right holes see Figure 19 The inductor stands up vertically over the printed outline You will notice that lead 4 cannot be pulled tight without dislodging the turns This is normal Leave enough slack in that lead to avoid disturbing the position of the winding Solder all four leads Used your DMM to check for continuity between pins 1 and 2 and 3 and 4 The resistance must be less than 1 ohm in both cases If it is higher you probably have a poorly tinned toroid lead It must be fixed before continuing ELECRAFT LJ Install toroidal inductor L3 and solder both leads Check for continuity less than 1 ohm between the solder pads Zi Do NOT attach L3 or T1 to the circuit board with adhesive or other compounds They should be supported only by their leads Install two pairs of standoffs holes at edges of board as shown in Figure 20 The front panel top cover will attach to the short standoff One pair of standoffs installs near J8 and K2 on the bottom fac
33. it 15 installed LJ Turn the board over so the bottom is facing up and jack J1 is in the upper right corner 37 LJ Open the package for four crystals X2 X3 X4 and X5 The four crystals are identical N While installing crystals in the following steps be careful not to flow too much solder onto the leads Too much solder may wick through the plated hole and cause a short to the case under the crystal were it cannot be seen Install crystal 2 4 9136 follows Insert X2 4 9136 into board over the printed outline just below electrolytic capacitor C7 The crystal may go into the holes either way around Note the location of the ground solder pad near the crystal Remove the crystal and solder to the case a discarded component lead no more than 3 16 4 5 mm above the bottom of the crystal where it will go straight down through the ground solder pad If desired you may attach the ground lead after installing the crystal Place the crystal on the board threading the leads through the solder pad holes While holding the crystal vertical and firmly against the board wet your soldering iron with a drop of solder on the tip and tack solder one of the crystal leads Check to ensure the crystal is flat against the board and perpendicular to the board If necessary reheat the lead while adjusting the position of the crystal Solder and trim the remaining crystal and ground leads 38 LJ Install remai
34. keying it provides an indication of power output on the LED bargraph 1 bar per 0 5 watts Without the ATU installed the KX1 displays tun in TUNE mode and 1 bar during keying 72 Circuit Details While reading this section refer to the Block Diagram Appendix B and schematics Appendix C Receiver The receiver is a single conversion superhet using down conversion to a low intermediate frequency I F of about 4 915 MHz Down conversion minimizes complexity and receive chain noise while the low I F allows adequate CW selectivity with a variable passband 3 pole crystal filter The use of active mixers keeps current consumption low compatible with portable operation DDS VFO The VFO is based on a low power DDS direct digital synthesis IC A crystal oscillator provides the reference signal for the DDS ensuring excellent frequency stability over a wide temperature range While a DDS based VFO does not offer the same signal purity as an L C VFO or PLL synthesizer it is a good choice for a portable station that will most often be used by a single operator well removed from strong nearby stations It is also extremely frequency agile allowing coverage of both ham bands and SWL bands The unit chosen AD9834 requires a minimum of components and draws only 5 to 8 milliamps ELECRAFT The DDS output is filtered by low pass filter LA L5 C50 52 In order to provide adequate roll off of non harmonic spurs about 14 MHz when
35. measure due to noise pickup Shaded areas show transmit mode measurements using TUNE Ref Pin VDC Ref Pin VDC Ref Ul 1 50 Ul i8 00 U2 7 0 0 U3 4 0 0 05 5 4 44 2 5 0 19 0 0 8 132 5 0 0 6 5 57 3 4 6 20 50 9 0 0 6 5 9 7 4 95 4 4 9 21 50 10 0 0 7 5 9 8 5 62 5 4 9 22 50 11 0 0 8 n c 06 1 139 6 34 23 49 12 00 U4 1 1 26 2 1 39 7 1 4 24 5 0 13 0 0 2 0 0 3 0 0 8 0 0 25 50 14 0 0 3 0 0 4 439 9 0 8 26 47 15 25 4 0 0 5 447 10 0 9 2T 50 16 nc 5 2 97 6 5 54 11 00 28 50 17 wc 6 593 7 5 04 2 00 02 1 1 15 18 00 7 2 99 8 5 62 13 5 0 2 118 19 0 32 8 126 U7 1 5 0 14 00 3 141 20 0 32 US 1 139 2 0 0 15 0 0 4 269 U3 1 n c 2 1 39 3 5 0 16 0 0 5 2 69 2 0 0 3 0 0 4 1 17 17 00 6 2 69 3 0 0 4 444 5 2 69 5 DC Voltage Table Transistors and Diodes NOTES Measurements were made with a 50 ohm dummy load connected and a supply voltage of 13 V The 30 meter option was installed KXB30 ATU was removed In general your measurements should be within 10 of the values shown Pins NOT listed in the table should indicate 0 0 volts DC Pins marked with are hard to measure due to noise pickup Shaded areas show transmit mode measurements using TUNE
36. operating at 40 meters the filter s knee is set just above the 20 m band edge Because of this LSB receive mode on 20 meters is less sensitive LSB on this band requires a mixer injection frequency of 4 9 14 18 9 MHz which is significantly attenuated by the DDS filter Transmitter On transmit the DDS outputs the actual carrier frequency so no transmit mixer stage is required Q1 Q4 and Q5 form a 3 stage buffer for the DDS signal Maximum power output from the final stage Q6 is about 4 to 5 watts depending on the supply voltage Q7 in the receive band pass filter limits the signal voltage that can reach the receive mixer when the rig is in transmit mode Microcontroller A low power microcontroller U1 MCU is used to control the transceiver and handle user interface elements such as the display and switches The MCU communicates with the optional ATU the VFWD DATA line at about a 2 kHz data rate UI runs at just below 4 MHz to avoid band edge spurs The provides SWR and power information for the KX1 display in TUNE mode During normal keying it provides an accurate indication of power output 1 bar per 0 5 watts Without the ATU installed the KX1 displays only a qualitative power output indication see page 64 ELECRAFT 1 Appendix A KXI Parts List Zi Many parts are static sensitive including parts pre mounted on the circuit board Wear a grounded wrist strap or ground yourself freque
37. or 2 To record hold to switch to REC then tap 1 or 2 Auto repeat see page 66 66 Advanced Operating Features Recording and Playing CW Messages The 1 provides two message memories of 48 bytes each CW messages can only be recorded using the 5 internal SetINP to PDn or PDr to use the internal keyer To Record Tap MENU and locate the PL Y menu entry change it to REC by holding then tap either 1 or 2 The display will show 048 indicating that 48 bytes of storage are available in this buffer This number will count down toward 0 as long as you are sending Whenever you stop sending completely up to two standard length word spaces will be inserted To stop recording tap any switch If you do this before starting to send the original message contents will be preserved To Play Tap MENU and locate the PL Y menu entry then tap either 1 or 2 Message play can be canceled at any time by hitting any key or by tapping the keyer paddle You can also change the keyer speed while messages are playing using the VFO knob To use Auto Repeat Locate the PL Y menu entry as before but then hold either a The message will then play back continuously until you tap another switch or hit your key or paddle You ll see RPT on the display between message transmissions Setting the Auto Repeat Interval The length of
38. part However it s helpful to familiarize yourself with the color code The color code chart see Figure 2 shows how to read the four color bands on 546 resistors For example a 1 500 ohm 1 5 5 resistor has color bands BROWN GREEN RED and GOLD 1 resistors are similar but use five bands three significant digits a multiplier instead of a gold or silver tolerance band and a fifth and to indicate the tolerance Since the bands usually fill the length of the resistor body the fifth band is wider to indicate that the value should be read starting at the other end For example the first four bands on a 1 50 1 resistor are BROWN GREEN BLACK BROWN The multiplier value is 1 rather than 2 in this case because of the third significant digit If in doubt about a resistor s value use a DMM It may be difficult to see the colors on some resistors Do not be concerned with minor deviations of your DMM reading from the expected value Typical errors on most DMMs and the tolerances of the resistors normally produce readings that are slightly different from the value indicated by the color bands RF chokes and other small molded inductors look very much like short resistors They have color bands that represent the same numeric values as resistors but because the inductors are short it may not be obvious how to read them In general the multiplier or tolerance bands are closer to the end than the first digit just the opposite of the
39. power to conserve battery life This control should not be adjusted frequently trimmer potentiometers have a finite life 100 200 rotations 64 Pushbutton Switch Functions There are three small pushbutton switches below the display A fourth pushbutton switch 1s built into the VFO knob TAP a switch to access its upper function white label 91821 a switch for 1 2 second to access its lower function yellow label Some switches can be held combination as described at right Note The MENU BAND and switches can also be used at power on to select maximum LED display brightness and turn on CW feedback on switch press at 10 20 or 30 WPM see page 67 Switch TAP and Functions MENU Displays the menu see next page EDIT Edits current menu parameter BAND One tap shows frequency MHz first then kHz L or U is added in LSB or USB modes Two quick taps selects the next higher band Allows speed adjustment using VFO control 8 50 WPM without transmitting RIT Turns RIT on off When RIT is on the decimal point will flash slowly VFO knob will then vary only the receive frequency in 20 Hz steps 5 kHz Zeros RIT offset 10 100 Selects 10 or 100 Hz VFO steps Selects 1 kHz VFO steps 5 kHz USB LSB modes ELECRAFT Switch Combinations MENU BAND TUNE Initiates TUNE mode key down
40. resistor pack 5 Locate electrolytic capacitor C38 10 uF 35 v and inspect leads One lead should be shorter than the other The capacitor body will have a stripe and a minus sign above the shorter lead Locate printed outline for C38 to left of RP3 on top face of the circuit board Note that there are two solder pads for the capacitor leads one is round and one is square A plus symbol is printed next to the square pad ELECRAFT LJ Insert electrolytic capacitor C38 10 uF 35 v with the longer lead passing through the square solder pad with the symbol next to it and the shorter lead through the round pad Bend the leads to hold the capacitor in place against the board sure that capacitor is tight against board and solder leads Use a ruler to verify that the top of the capacitor is no more than 5 16 7 9 mm above the board see Figure 8 After soldering trim the leads flush with the bottom of the board Zi All electrolytic capacitors MUST be installed with their leads oriented to observe the polarity markings as described above LJ Install electrolytic capacitor C10 10 pF 35 v below resistor at the bottom edge of the board Observe the proper polarity as you did for C38 above and be sure the capacitor is no higher than 5 16 7 9 mm above the board Turn board over so bottom is and the outline for 11 15 in the upper righ
41. right corner of the board C54 56 pF 56 to the left of C47 C49 1000 pF 102 below C54 C48 1000 pF 102 next to C49 C46 470 pF 471 next to C54 ELECRAFT LJ Locate C45 68 pF 68 or 680 LS 0 2 Be sure that you do not confuse this capacitor with C56 also 68 pF but with 0 1 lead spacing that has not been installed yet Note C45 may be a much larger disc type which would not fit in the location for C56 But if both are small you ll need to go by the lead spacing LJ Install capacitor C45 to the left of C46 in the upper right quadrant of the board LJ Install capacitor C26 120 pF 121 pillow style disc ceramic about 1 2 1 3 cm below C45 Be careful not to put this capacitor in the space for C44 When C26 is installed the space for C44 between C26 and C45 should be empty LJ Test fit capacitor 4 7 pF 4 7 pillow style disc ceramic next to the lower right corner of the encoder The bottom of the round capacitor body should touch the board If the ceramic coating on the leads runs down too far to allow it to sit against the board remove the excess by squeezing the coating with long nose pliers It will crumble and can be scraped away from the lead LJ Install capacitor C1 4 7 pF 4 7 making sure the bottom of the round body is touching the board 33 Zi The following capacitors must be mounted closer to the board than the others They are installed in the area beneath the optional KXB30 30 meter m
42. that the EEPROM configuration memory on the microcontroller has been initialized to default values This message will appear only once and can be cleared by tapping any of the three pushbutton switches 00 0 is a portion of the VFO frequency which is set to 7100 00 the first time you turn power on The display format will be described in a later step Zi After a few seconds the display turns off automatically if you haven t touched the VFO knob or pressed any switches This is intended to extend battery life Moving the VFO knob or operating one of the pushbutton switches will turn it on again The display time out is programmable This will be discussed in the next section ELECRAFT Voltage Checks LJ Connect your DMM s probe to circuit board ground at the screw hole next to capacitor Use the probe to check the following DC voltages U1 pin 1 540 25 Vdc U3 6 6 0 25 Vdc D2 anode Supply voltage D2 cathode banded end supply voltage 0 3 Vdc approx LJ Leave your DMM s probe connected to the circuit board ground and set your DMM for a 200 to 300 millivolt AC range Check the AC voltage at the following pins A higher voltage than shown may indicate a problem with one of the voltage regulators as explained in the note below D2 anode lt 20 mV AC rms D2 cathode banded end lt 20 mV AC rms Ul pin 1 20 mV rms U3 pin 6 20 mV AC rms Zi The 2 7 V and 6 V reg
43. the cover with three 4 40 x 1 4 flat head screws Do not over tighten any of these screws ELECRAFT LJ Turn the unit face down on a soft surface and measure the resistance between either solder pad for toroid L3 and ground It should be 500 ohms If it is less you must find the cause before proceeding Check the hardware around Q3 The most likely cause 55 LJ Find the battery holders and inspect the bottom of one Note the ridges and nubs that provide a space for wires under the holder The holder has one wire running between two molded ridges that connect the opposite corner cells together will be that the shoulder washer has slipped out or the metal tab on the L In the following steps you will install and wire the battery transistor is touching the case instead of the thermal pad holders First study the wiring drawing in Figure 25 The two holders are wired in series The wires must run against the bottom cover and Install the knob on encoder shaft under the holders as shown to avoid interfering with other components when the case is closed ROUTE BLACK WIRES UNDER BATTERY HOLDER AND AROUND SCREW BE SURE WIRES LIE FLAT AND DO NOT CROSS OVER EACH OTHER RED BLACK 2 3 4 7 CM CUT TO MATCH 2 LENGTH RED REMOVE PAINT FROM AROUND HOLE ON INSIDE OF COVER ROUTE RED BLACK WIRE UNDER 4 10 2 RED BATTERY 3 1 4 8 3 AROUND CORNER NUB SPLICE MUST
44. the terminal marked on the circuit board If you got them backward press gently with a thin screwdriver or knife blade in the slots on the housing to release the terminals RED WIRE MUST GO IN THIS SIDE RED WIRE HOUSING BLACK WIRE Figure 26 Assembling Battery Supply Jack J5 Zi We strongly recommend the use of 1 5 volt cells preferably 2 9 AH lithium Energizer type L91 or alkaline 1 2 volt cells e g NiMH can also be used but have some drawbacks See page 62 for details This completes Part of the Assembly 58 Alignment Test Part Make sure is turned off Connect a 12 to 14 V 1 amp power supply or battery to J1 Make sure trimmer R4 is fully counter clockwise drive level Connect an antenna that is adequate for receiver testing 0000 Plug in a pair of stereo headphones a speaker at 12 LJ Turn on the KX1 If the display doesn t appear turn the KX1 off and disconnect the power supply Check resistance from the tab of Q6 to ground and from pin 1 of the MCU UI to ground Both should be over 500 ohms If the tab of Q6 measures low resistance look for D7 installed backward or a solder bridge across the pins of Q6 If pin 1 of the MCU measures low put on a wrist strap or touch ground and remove U1 then re check the resistance If it s still low you could have a short on the 5 volt or 2 7 volt lines LJ Switch to voltmeter display mode using BAND t
45. transmit power set too high for your battery or power supply the supply voltage may drop so low on transmit that resets the MCU U1 try a higher supply voltage or fresh batteries If there s no ATU installed verify that J7 ATU connector is bypassed with a jumper between pins and 3 92 Current drain too high on transmit You may have power set higher than the final amplifier can achieve for a given load or power supply voltage resulting in overdrive of transmitter stages Reduce power to see if normal current drain is restored Damaged PA transistors or other components could cause inefficiency in any stage of the transmitter Check all DC voltages and components signal trace if necessarily 86 95 Keyer Problem If the keyer is generally erratic when transmitting and seems to get worse as power is increased you probably have RF leaking into the keyline Try bypassing your key with 001 uF capacitors also try 100 uH chokes in series with the paddle connections Seek a better antenna match Improve your ground system E 4 DC Voltage Table Integrated Circuits NOTES Measurements were made with a 50 ohm dummy load connected and a supply voltage of 13 V The 30 meter option was installed KXB30 and ATU was removed In general your measurements should be within 10 of the values shown Pins NOT listed in the table should indicate 0 0 volts DC Pins marked with are hard to
46. way a resistor On small inductors the color bands may be centered on the body ELECRAFT If you sort out the inductors before starting assembly you will be able to positively identify each inductor from the color bands listed in the Parts List USED ON 196 RESISTORS FIRST DIGIT SEE TEXT SECOND DIGIT TOLERANCE MULTIPLIER GOLD 5 SILVER 10 MULTIPLIER X 1 X 10 X 100 X 10K X 10K X 100K X 1M COLOR DIGIT Black Brown Red Orange Yellow Green Blue Violet Gray White Silver Gold 0 1 2 3 4 5 6 7 8 9 Figure 2 Resistor Color Codes ELECRAFT Identifying Resistor Packs Resistor packs combine a number of resistors in one component with multiple leads They may be in line packages with 6 or 10 leads in a row or they may be in 16 pin dual in line pin DIP packages similar to many integrated circuits Like integrated circuits pin 1 of each component is identified by a dot near it Some resistor packs are symmetrical That is they can be installed either way However some are not ALWAYS follow the instructions and orient the resistor pack exactly described in the procedure The value of the resistor pack is indicated in the last three digits shown on the package The numbering scheme is similar to capacitors The first two digits indicate the first and second most significant digits and the third digit is a multiplier For example 391 indicates 390 ohms and 104 indicat
47. 0 HZ FILTER LOCK UNLOCK power is displayed A EDIT SPEED CLR 4 HOLD 1 kHz RIT VFO knob L TUNE L pisP DISP display mode Hold BAND RIT norm Smtr battery LAMP POWER L 2 i Q HIGH PRIORITY MEM ee o AF GAIN BAND VFO knob SWITCH CW MENU knob RX MODE sideband Hold MENU RIT norm LSB USB RIT CLR Tap for RIT on off hold for RIT clear MENU EDIT to enter menu hold to edit except RCL and PLY use VFO knob to scroll menu or modify parameters LED LED LEVEL tap BAND or RIT 1 IAMBIC MODE or B BATTERY WARNING THRESHOLD LED TIMEOUT use VFO knob AUDIBLE CW FEEDBACK AUTO TUNER MODE see ATU manual STL SIDETONE VOLUME LEVEL 0 3 OFF or 10 40 WPM in 5 WPM steps MEMORY RECALL tap 1 2 or VFO STP SIDETONE PITCH 500 700 Hz SLO S METER ZERO SET STORE EDIT tap 1 2 or VFO hold rather than tap high priority T R QSK DELAY 0 900 ms SHI S METER SCALE MESSAGE PLAY tap 1 or 2 tap VFO AUTOREPEAT DELAY 0 255 sec B30 30 M BAND on off knob for CW test mode 0 RECORD EDIT tap 1 or 2 INP KEYING DEVICE Hnd PDn PDr CAL VFO CALIBRATION see manual
48. 5 to 60 seconds after any front panel control has been used Operation without the display is possible if the CW feedback feature is turned on audio Morse code This provides audible announcement for the VFO dial menu text and all controls Additional operating features include instant band selection nine frequency memories three VFO tuning rates receive incremental tuning RIT USB LSB receive on all bands and an S meter display mode The built in keyer offers Iambic modes A and B and two message buffers In an emergency two of the front panel switches can be configured for use as a manual key or keyer paddle Despite its compact size and many built in accessories the 1 is easy to build The basic unit consists of a single printed circuit board with no surface mount components to install the three surface mount parts used are pre installed Assembly and test are completed in phases to simplify any needed troubleshooting and only a few alignment steps are required We dlike to thank you for choosing transceiver and hope it meets your expectations for ultra lightweight portable operation Wayne Burdick Eric Swartz WA6HHQ Customer Service Information Technical Assistance If you have difficulty with kit construction operation or troubleshooting we re here to help You may be able to save time by first consulting our web site www elecraft com or by posting your question on Elecraft e ma
49. EEDED GENTLY FORM THE LEADS TO ALLOW THE CAPACITOR TO SIT CLOSER TO THE BOARD SOLDER amp TRIM LEADS Figure 7 Installing Fixed Capacitors LJ Solder and trim the leads on capacitor C31 20 LJ Following the same procedure install capacitor C30 01 uF 103 next to C31 LJ Turn the board top face up so that KX1 is in the upper left corner In the following steps you will install several capacitors on the top of side of the board Be sure that the top of no capacitor is more than 5 16 7 9 mm above the board Be especially careful of the larger electrolytic capacitors see Figure 8 Use a ruler as needed to check the height 5 16 in 7 9 mm MAX Figure 8 Maximum Height of Capacitors on Top of Board LJ Install capacitor 01 uF 103 directly above diode D3 on the left edge of the board LJ Install capacitor C37 01 uF 103 between D2 and resistor pack RP3 LJ Install capacitor C12 1 uF 104 between D2 and the socket for U1 ELECRAFT LJ Install capacitor C5 1 uF 104 below the socket for U1 near the bottom edge of the board LJ Install the following capacitors between the socket for U1 and the bottom edge of the board C25 27 pF 270 C24 27 pF 270 LJ Install the following capacitors to the right of resistor pack RPS C32 01 uF 103 C33 01 uF 103 Install capacitor C55 01 uF 103 on the bottom edge of board about 1 1 4 2 to right of
50. In the following steps you may be installing some capacitors with leads closer together than the hole spacing in the circuit board Form the leads of these capacitors as shown in Figure 12 Be sure the top of the capacitor is no higher than 5 16 7 9 mm above the board see Figure 7 Figure 12 Forming Capacitor Leads LJ Install the following capacitors above and to the right of the 3 digit LED display C50 39 pF 39 or 390 lead spacing 15 0 2 C51 100 pF 101 LS 0 2 C52 22 pF 220 LJ Install capacitor C16 1 uF 104 between varactors D5 and D6 LJ Install capacitor C4 27 pF 270 between molded inductors L8 and 1 10 LJ Install capacitor C8 1 uF 104 directly above molded inductor L9 ELECRAFT LJ Install capacitor C2 27 pF 270 between capacitor C55 and diode D4 on the lower edge of the board LJ Install capacitor C21 1 uF 104 at the lower right hand corner of the board LJ Install the following capacitors between the printed outlines for potentiometers R2 and R3 in the lower right quadrant of the board C17 1 pF 104 C18 1 uF 104 C19 022 uF 223 LS 0 2 Install capacitor C22 01 uF 103 on the right hand edge of the board above the printed outline for J4 LJ Install capacitor C27 150 pf 151 directly above L6 in the upper right hand quadrant of the board LJ Install the following capacitors in the upper right quadrant of the board C47 220 pF 221 in the upper
51. LIE FLAT ON BOTTOM TUCK EXCESS RED WIRE KEY JACK J3 AND CRYSTALS ON THE UNDER BATTERY HOLDER BOTTOM OF THE CIRCUIT BOARD FIT IN THIS AREA Figure 25 Wiring the Battery Holders REMOVE PAINT FROM AROUND HOLE ON INSIDE OF COVER 56 Begin removing paint from around holes inside of the bottom cover where it will attach to the stand offs on the circuit board There are two holes one at each end of the cover see Figure 25 LJ Select one battery holder and cut the red wire to 3 1 4 8 3 cm in length Strip 1 4 6 mm of insulation off of the end These are stranded wires Be careful not to knick or break the strands Leave the black wire its full original length Zi Repeated insertion and removal of the 2 56 screws used in the following steps may result in stripping the threads in the bottom cover To avoid this study the illustration and instructions carefully before inserting the screws In the event that the 2 56 screw threads do become stripped you ll need to replace the supplied screws with longer screws along with 2 56 hex nuts Mount this holder right hand position as shown Figure 25 using two 2 56 screws Do NOT over tighten the screws as this may strip the threads Be sure the wires exit at the left end as shown LJ On the second holder cut the wires as follows Red cut to 2 3 4 7 cm in length and strip the insulation off of 1 4 6 mm at the end Black cut
52. T identifies an iron powder core The number following the T specifies the outside diameter in hundredths of an inch in this case 0 37 inches 9 4 mm The suffix 6 refers to a specific mix of iron powder You cannot tell what mix of iron power is used by looking at the core so they are painted with specific colors The 6 cores are painted yellow Ferrite cores are indicated in the parts list by the letters in the part number The KX1 uses FT37 6 cores Like the iron powder cores the 37 refers to the outside diameter The 46 identifies the type of ferrite used These cores are not painted They are dark grey 10 Tools You will need the following tools to build this kit Fine tip temperature controlled ESD safe soldering station with 700 to 800 F tip 370 430 C Recommend a spade tip approx 0 05 1 3 mm wide Do not use a high wattage iron or soldering gun since this can damage pads traces or the parts themselves IC grade small diameter 031 solder Kester 44 or equivalent AN DO NOT use acid core solder water soluble flux solder additional flux or solvents of any kind Use of any of these will void your warranty Desoldering tools and supplies are invaluable if you make any modifications or need to do any repairs Narrow solder wick or good vacuum desoldering tool such as the Soldapullt model DS017LS are recommended See Soldering and Desoldering on page 11 for more information Screwdrivers
53. a lead can be removed To do this you ll need solder wick desoldering braid and or a vacuum desoldering tool It also takes some practice number of suggestions are provided below The best strategy for avoiding de soldering is to place all components properly the first time Double check values and orientations and avoid damaging parts via ESD ELECRAFT When removing components Don t pull a lead or pin out of a hole unless the solder has been removed or you are applying heat Otherwise you can literally pull out the plating on the plated through hole Limit soldering iron contact to a few seconds at a time Use small size solder wick about 0 1 or 2 5 mm wide Use the wick on both the top and bottom pads when possible This helps get all of the solder out of the hole f you use a vacuum desoldering tool solder sucker use a large unit Small solder suckers are not very effective The safest way to remove ICs and other components with more than 3 leads is to clip all of the pins at the body of the device first then remove all of the pins individually You may damage pads and traces by trying to remove such components intact Invest in a PC board vice with a heavy base if possible This makes parts removal easier because it frees up both hands If in doubt about a particular repair ask for advice from Elecraft or from someone else with PCB repair experience ELECRAFT Assembly Notes Each step i
54. ance is greater than 1 ohm remove the toroid clean and re tin the leads and reinstall it LJ Wind and install L1 using the same procedure except that L1 has 13 turns Use the second yellow toroid core for L1 Zi Do NOT attach L1 or L2 to the circuit board with adhesive varnish etc The toroids will be adequately supported by their leads Adhesives or other compounds may damage the enamel wire Bend discarded 1 4 resistor lead into U shape insert it into J7 pins 1 and 3 J7 is the 3 pin connector adjacent to antenna jack J2 do not insert the wire into the 2 pin connector J8 This jumper completes the antenna circuit when the optional KXATI is not installed 42 LJ Your kit includes an extra 22 k resistor red red orange for use at R32 This resistor is not present on the Revision B or B1 PC boards It must be soldered in place in the location shown below on the bottom of the board between pins 2 and 3 of U4 LM386N It could also be soldered across the pins of C19 nearby which may be easier Trim and bend the leads approximately as shown 525 FARE 7 p M y 21 2 4 LJ Make sure R32 is pressed flat against the bottom of the board Its leads must not be touching any adjacent pads traces or components ELECRAFT Visual Inspection LJ Verify correct orientation banded end of diode D4 using the parts placement drawing Appendix F LJ
55. ar they have very different electrical properties You must use the yellow cores for L1 and L2 The transceiver will not work if you use the wrong cores See Identifying Toroid Cores page 9 for more information O Wind L2 first as follows Cut a 13 33 cm length of red enameled wire Sew the long end of the wire through the hole in the core for a total of 14 turns as shown in Figure 15 Count one turn each time the wire passes through the center of the core There are no half or quarter turns when winding toroid Match the winding direction shown in the figure or the leads won t line up with the solder pads on the circuit board Spread the turns around the core so the finished result looks like Figure 16 Prewound toroids are available from an Elecraft approved source See www elecraft com for details ELECRAFT REMOVE INSULATION SEE TEXT Figure 16 Toroidal Inductor L2 Zi In the next step the toroid leads will be stripped and tinned The leads must be prepared correctly to provide good electrical contact when installed ELECRAFT Strip the insulation and tin leads of both inductors using one of the following techniques l Heat Stripping a Place small amount of solder a k a a blob of solder on your soldering iron b Insert the clipped end of the wire into the hot solder If the iron is hot enough you should see the insulation bubble and vaporize after
56. are about right for indoor daytime use 0 and 1 are suitable in low lighting and 5 or 6 in bright lighting LJ Rotate the VFO knob to select the desired LED timeout 5 to 60 seconds or INF for infinite i e never times out As you rotate the knob the timeout period is flashed e g t10 for 10 seconds Note When the LED times out it will go blank However in very low lighting or darkness you may see a slight residual illumination LJ Tap MENU once to return to menu scroll mode then tap it again to return to the frequency display CW feedback on switch press can be used in lieu of the display This is described in the Operation section 29 Frequency Display and Band Change The display shows three digits of the operating frequency Which three digits are shown depends on which tuning rate you ve selected 1 kHz 100 Hz default or 10 Hz At 7100 00 kHz the three tuning rates produce the following displays 7100 00 7100 00 7100 00 LJ To select 1 KHz steps press and hold the VFO knob from now on we ll indicate this as hold Then try rotating the knob No decimal point is displayed at this step size To select 10 Hz or 100 Hz steps tap the VFO knob 1 tap 10 100 Hz The tuning rate alternates between 10 and 100 Hz steps as you tap and the decimal point moves accordingly LJ You can check the MHz and kHz digits at any time by tapping BAND For example if the
57. ce Q6 s leads in holes in circuit board Do not solder them until instructed to do so CIRCUIT BOARD FORM LEADS IN GENTLE CURVE DO NOT MAKE SHARP 90 BEND 25 2166 TRANSISTOR la SHOULDER WASHER 3 16 STANDOFF 0 31 7 87mm SPLIT WASHER SPLIT WASHER 3 16 PAN HEAD SCREW Figure 24 Installing Power Amplifier Q6 54 LJ Position the shoulder washer in the hole in Q6 s heat sink tab as shown Temporarily secure Q6 to the standoff with the 4 40 flat head screw Tighten the screw enough to hold Q6 securely and parallel to the circuit board LJ Use your long nose pliers to adjust the leads so the flat side of the transistor is parallel to the circuit board It must be facing AWAY from the board It will rest against the thermal pad you installed in the top cover and must make good contact to transfer heat efficiently Solder three leads to Q6 Trim them flush on the bottom side of the board LJ Remove the flat head screw holding Q6 The soldered leads should hold the shoulder washer in place Zi NEVER re install a screw in the tab of Q6 when the unit is out of its case for testing The metal tab of Q6 is connected to the side of the power supply and the screw will short the supply to ground if the rig is turned on This may cause serious damage to the circuit board or other components LJ Conduct a thorough visual inspection of the board Use a magnifier Check espe
58. cially for the following Diode D4 is oriented correctly as shown in the Parts Placement diagram in Appendix F All joints soldered with no shorts between solder pads All components installed On the bottom are some labeled pads that will have no wires in them They are connection points for the KXB30 30 meter band module These pads are labeled D 5 and three pads labeled ELECRAFT LJ Connect your DMM ground lead to one of the metal stand offs mounted on the board and make the following resistance checks Q4 Emitter terminal farthest from edge of board 20 to 24 ohms Q4 Base center terminal gt 10k Q4 Collector nearest edge of board 10k Q5 Emitter terminal farthest from edge of board 50 to 70 ohms Q5 Base center terminal gt 10k Q6 collector metal tab 500 ohms LJ Place the three button caps on the pushbutton switches Press down on each cap to snap it in place Fit the board into cover follows The control shafts will fit through the holes If the pushbutton switches don t line up properly with the holes in the cover use a long tool to reach between the cover and the circuit board to nudge the caps into the holes Finally you will need to push down gently on the key jack to make it snap into its hole in the cover Check the standoffs at both ends and confirm that they are resting against the cover LJ Secure the board to
59. control VFO drift Display 1 2 x 5 3 x 3 0 3 x 13 5 x 8 cm 1 4 x 5 8 x 3 0 3 5 x 15 x 8 cm 9 oz 0 25 excluding options 7 14 V 8 V min recommended 32 mA typ with headphones 300 700 mA varies with supply voltage and power output setting 5 0 9 5 and 12 0 16 5 MHz 7 0 7 3 and 14 0 14 35 MHz DDS with 50 MHz crystal reference 50 Hz per hour after 5 minute warm up at 25 C 3 digit LED w bargraph mode audio CW feedback on keypress KXB30 option adds 8 0 12 5 MHz receive and 10 1 10 15 MHz transmit Adding this module also greatly improves sensitivity in the 49 meter band 5 9 6 4 MHZ On all bands the useful receive range is smaller than the VFO tuning ranges shown due to input band pass filtering Transmitter Max power output approx 9 V supply 12 V supply Spurious content Load tolerance Sidetone pitch Keyer Receiver Sensitivity LF Selectivity Audio output 1 5 2 W 3 4 W 40 dB 3 to 4 W 2 1 or better SWR recommended 500 700 Hz in 10 Hz steps 8 50 WPM Iambic modes and 2 message buffers auto repeat Approx 0 2 u V for 10 dB S N N 4 915 MHz single conversion 3 pole variable bandwidth crystal filter approx 300 2000 Hz 0 5 watt peak into 8 ohm load stereo plug required Assembly Overview of the KX1 The KX1 chassis consists of a top and bottom cover Figure 1 components including controls and c
60. d This may make alignment more difficult if you re using a tool with a long metal shaft rather than a tuning tool with just a metal tip This is not a safety hazard but you may need to remove the tool after each adjustment to check the signal amplitude The PC board revision letter can be found in the upper left hand corner of the PC board on the top side LJ Tap BAND twice quickly to select 14 MHz band LJ While listening to atmospheric noise or a weak CW signal peak trimmer capacitors 20A and 20B If the peak is not clear reduce the signal input level the AGC may be getting activated Do not turn the RF GAIN control counter clockwise as this will broaden the tuning peaks making them more difficult to identify AN If you don t hear band noise or signals be sure you installed the jumper across the outer pins of J7 as described on page 41 LJ Tap BAND twice quickly to select the 7 MHz band Set the VFO to about 7100 kHz ELECRAFT Switch to appropriate antenna this band if available use the wire antenna recommended earlier LJ While listening to noise or a weak signal peak trimmer 40 AGC and S Meter Test LJ Turn the KX1 on and connect an antenna or signal generator S meter display mode provides bar graph to indicate approximate received signal strength To select this mode hold BAND You ll see a brief bar graph test pattern then the disp
61. d at both ends Solder and trim all 13 pins on the display Install encoder Z1 as follows Z1 mounts to left of transistor Q7 Test fit Z1 on the board It will only go one way The side with three terminals is nearest the top of the board Press down on 71 until the small nubs at each corner rest directly against the board It is very important that Z1 be fully seated against the board Solder two pins on opposite corners of the encoder then recheck to ensure it is sitting against the board If necessary reheat the solder and press down on the encoder to position it Solder the two large tabs to the plated ring around the edge of the mounting holes Apply only enough solder to make a good mechanical and electrical connection between the tab and circuit board Do NOT try to fill the holes with solder Solder and trim all five pins 26 Visual Inspection LJ Verify correct orientation banded end of diodes D2 and D3 using the parts placement drawing Appendix F LJ Verify the correct orientation of each electrolytic capacitor The side of the capacitor with the strip and minus sign must face away from the sign printed on the board LJ Examine both sides of the PC board closely for solder bridges cold solder joints or unsoldered components ELECRAFT Resistance Checks the resistance checks listed below with your DMM s negative lead connected to the circuit board ground at the scre
62. e immediately Locate the source of trouble before proceeding 43 Relay Test BAND twice quickly to change bands You should hear relays and K2 switching LJ If necessary use BANDI again to return to 7 MHz Sidetone Generator and Audio Amplifier Plug in a pair of stereo headphones at 14 at right end of the board and rotate the AF GAIN control clockwise to about 12 o clock L Tap and use VFO knob to locate the STL sidetone level menu entry Since you have no antenna connected you may hear some digital switching noise as you rotate the VFO knob or press switches LJ The sidetone level is set by editing the STL menu parameter Hold to show the parameter and turn on the sidetone You can then rotate the VFO knob to vary the sidetone level from 0 3 Select a comfortable level then tap MENU to turn off sidetone and return to the STL display Note STL sets the sidetone volume level in relation to normal received audio The AF GAIN control sets the overall volume for both received signals and sidetone 44 Select sidetone pitch menu entry STP using VFO knob Hold to turn on the sidetone and edit the pitch parameter The pitch can be varied from 500 to 700 Hz using VFO knob Select the desired pitch then tap 10 end parameter edit and return to STP LJ Tap MENU again to return to
63. e down so the printed outline for power connector jack J1 is in the upper right corner LJ Locate the printed outline for C39 to the left of the outline for J1 on the board LJ Test fit a 1 104 capacitor in the solder pad holes for C39 Position the capacitor so that about 1 16 1 mm of lead shows above the surface of the board If necessary gently straighten the leads using long nosed pliers Do not tug on the leads Squeeze and bend them with your pliers as needed O Solder and trim the C39 s leads LJ Bend C39 down against the board as shown in Figure 6 Figure 6 Positioning C39 Against the PCB LJ Locate the outline for capacitor C31 along the top edge of the board just to the left of the outline for J1 19 LJ Test fit a 1 104 capacitor in the solder pad holes for C31 Use a ruler to verify that the top of the capacitor is no more than 5 16 7 9 mm above the board Normally these capacitors will be well below that height limit but if necessary gently straighten the leads using long nosed pliers so it will sit closer to the board and meet the height requirement While forming the leads do not tug on them Squeeze and bend the leads with your pliers to straighten them Slight chipping of the epoxy around the leads will not harm the capacitor BE SURE THE NUMBERS SHOWN IN PARENTHESIS IN THE TEXT APPEAR ON THE BODY THERE MAY BE OTHER MARKINGS AS WELL 1 5116 7 9 MAXIMUM IF N
64. e of the board and the other pair installs in the hole near J1 and P6 TOP FACE OF BOARD Y 5 16 STANDOFF NO WASHER HERE SPLIT WASHER 3 4 STANDOFF Figure 20 Installing Standoffs on Circuit Board 51 LJ Place the front panel top cover face down on a soft cloth to avoid scratching it LJ Remove the paint from around the screw holes where the short standoffs will contact the front panel as shown in Figure 21 Use sandpaper or a sharp knife Clean the panel thoroughly to remove all of the residue when you are done LJ Inspect the area where the thermal pad will mount and be certain there are no burrs that could poke through the thermal pad Burrs are most likely to be found around the hole Sand file any rough edges smooth SAND AREA SMOOTH FOR GOOD CONTACT WITH THE THERMAL PAD IT IS NOT NECESSARY TO REMOVE ALL OF THE PAINT FROMTHIS AREA REMOVE PAINT FROM AREA WHERE STANDOFFS WILL TOUCH THE PANEL Figure 21 Preparing Top Cover for Installation 52 ELECRAFT LJ Locate the thermal pad Leave it on the backing paper while you LJ Position the red filter over the LED display opening Use the remove the piece filling the hole near one end Then remove the clear tape to secure it on the top and bottom edges as shown in Figure backing and place the pad on the inside of the cover over the area you 23 Even though the tape is transparent keep it outside of the window sanded with the
65. eck the markings on each device to be sure you have the correct one before soldering it in place O Hold S2 vertical and against the shoulders on the tabs with your finger on the slide and tack solder the center pin to hold it in place Install U8 781 05 next to pushbutton switch 55 as follows Alien the flat side of the device as shown by the printed LJ Inspect the switch to be sure it is perfectly vertical and not tipped ree Pigure 10 to either side If necessary reheat the pin and adjust the switch s Insert the device into the solder pad holes until the top of the position device is less than 5 16 7 9 mm above the board Use a ruler to confirm the height If necessary remove the device 1 it cl h to th O When you are satisfied that the switch is perfectly straight solder a a ROO EU Oe i board the two end pins Resolder the center pin last as needed to create a good joint Solder and trim all three leads Use the same procedure to install slide switch S1 to left of crystal X1 S1 also may be mounted oriented either way FLATTENED ROUNDED BACK on BACK CN PCB OUTLINE Figure 10 Transistor Orientation Guide ELECRAFT LJ Install 09 77L06 below 5 on the lower edge of the board using the same procedure that you used for U8 above Be sure the top of the device is no more than 5 16 7 9 mm above the board LJ Install transistor Q7 2N4124 The position for Q7 is in t
66. ed up with the notched end of the socket the end closest to the edge of the board 27 Press down very firmly on U1 If it is not seated far as possible into its socket the pins may not make good contact LJ Temporarily mount the VFO knob on the shaft of encoder Z1 Align the set screw with the flat side of the encoder shaft and tighten it using the Allen wrench supplied Zi You may notice some side play in the encoder shaft This is normal in miniature shaft encoders with an integral pushbutton switch LJ Set slide switches 51 and 52 to the OFF position LJ Connect an 8 to 14 VDC power supply to J1 with the positive lead to the center pin A mating connector for J1 is supplied with the kit LJ Unwrap the cover and set it near the circuit board so you can see the legends identifying the switches and their functions Zi If any test or alignment step fails refer to the Troubleshooting section Appendix 28 LED Tests When testing the lamp following step look directly at the white LED It is very bright LJ Switch 51 LAMP On and verify that D1 lights then turn it Off Switch S2 POWER On If you see or smell smoke or a component feels hot to the touch switch S2 Off and disconnect the power source immediately Locate the source of trouble before proceeding LJ You should now see either E10 or 00 0 on the 3 digit LED display E10 is an informational code that indicates
67. el vio red R20 1k brn blk red R15 1 megohm brn blk grn R25 10 ohm brn blk blk ELECRAFT LJ Open the envelope containing the seven molded inductors and sort them to be certain you know which is which before you install the first one Compare the color codes you find on each inductor with the list below The color bands are very small Use a magnifier as needed to be sure of the colors e 14 Micro smaller size 2 2 uH red red gold 15 Micro size 5 6 uH grn blu gold L6 Mini larger size 6 8 uH blu gry gold L7 Mini size 4 7 uH yel vio gold L10 Micro size 33 uH org org blk 18 Micro size 18 uH brn gry blk 19 Micro size 100 uH brn blk brn Zi Do not pull on the inductor leads while handling them They are more easily damaged than the resistors or capacitors LJ Turn the board so the bottom face is up with jack J1 in the upper right corner ELECRAFT LJ Install the following inductors below R6 and R7 in the upper right quadrant micro smaller size 2 2 red red gold L5 micro size 5 6 uH grn blu gold Turn board face up with KX1 in the upper left corner Install the following inductors to left of U3 on the right side of the board L6 mini larger size 6 8 uH blu gry gold If the lead spacing on L6 is larger than the hole spacing in the board bend the leads back under L6 to fit in the holes L7 mini size 4 7 uH yel vio gold
68. eps Step 1 Hold BAND and MENU together on power up releasing the switches after the LED test You Note Checking the firmware revision by holding MENU BAND or should see E09 Step 2 Tum powerotf and back on gain you on power up also sets the LED to high brightness and enables 1 CW feedback on switch press at 10 20 and 30 WPM respectively If gin E Os Taponyowitel then you turn the KX1 back off before accessing the menu the LED Pe Beene brightness and CW feedback will revert to their previous settings 70 Operating Tips Antennas When you re using low power a good antenna and ground system can make a big difference There are many references on antennas available including the ARRL Antenna Handbook QRP Frequencies Low power enthusiasts can be found at certain watering hole frequencies on each band listed below KHz An asterisk indicates European or alternative QRP frequencies 40 m 7040 7030 30 m 10106 10116 20 m 14060 Calling and Listening Calling CQ with low power may be frustrating unless you have a very good antenna Expect to spend far more time istening Keep transmissions short especially when working other QRP stations which will often be at or even below the noise level Narrower filters less than 500 Hz and slower code speeds less than 20 WPM should be used when conditions are marginal ELECRAFT
69. er output troubleshoot the AF amplifier 65 Check the 6V regulator 20 62 Signal loss only on one band Re do alignment on affected band Check the band pass and low pass filters and crystal for this band Check functioning of the relays change bands then measure relay leads that should be open or shorted for that band E 3 65 AF amplifier not working Use the STL menu entry to set a sidetone level of 3 If you hear a strong tone the A F amplifier RF U4 is probably working and the problem is likely to be with the mixer RF U6 or other RF board circuits Signal trace through the receive chain backwards by touching a tool or wire to various points along the receive path Check all DC voltages in the receiver Inspect the A F amp circuits 70 AGC or S meter not working Check R5 D4 C53 Q9 R20 C8 and L9 for incorrect values or unsoldered leads Transmitter and Keyer 80 99 Problem Troubleshooting Steps 80 General Transmitter problem If power output is too low go to 86 If power output slowly increases during key down go to 88 If current drain on transmit is too high for the given power level go to 92 If the transmitter output power seems to be unstable go to 88 If the transmitter stops transmitting by itself go to 90 If the keyer isn t working properly go to 95 86 Power output is low or zero Make sure the power output control R4 is set
70. es 100 000 ohms 100K Identifying Capacitors Capacitors are identified by their value and the spacing of their leads Small value fixed capacitors are usually marked with one two or three digits and no decimal point If one or two digits are used that is the value in picofarads pF If there are three digits the third digit is a multiplier For example a capacitor marked 151 would be 150 pF 15 with a multiplier of 10 Similarly 330 would be 33 pF and 102 would be 1000 pF or 001 uF Exceptions are described specifically in the text and parts list Fixed capacitors with values of 1000 pF or higher often use a decimal point in the value such as 001 047 or 2 2 This is the value in microfarads 1 uF is equal to 1 000 000 pF The lead spacing is noted in the Parts Lists for most capacitors If two different types of capacitors have the same lead spacing will indicate which one to use When lead spacing is important both the value and the lead spacing is shown in the assembly procedure For example LS 0 1 means that the lead spacing is 0 1 inch 2 5 mm Identifying Toroid Cores Several toroidal inductors are used in the 1 It is important to use the correct type of core This can be determined from the color and size Two types of cores are used in the KX1 Iron powder cores and ferrite cores If you mix them up your KX1 will not operate properly The iron powder cores used are type T37 6 The
71. every 100 VFO steps i e every 10 kHz if 100 Hz tuning is selected This is useful for finding a specific frequency The tic sound is a low tone high tone or low high tone for 10 Hz 100 Hz and 1 or 5 kHz VFO steps respectively Frequency Announce mode is turned on in the same was as S meter mode hold the DISP switch combination BAND RIT When you select announce mode AF for announce frequency will be displayed and the letter A will be sent in CW Holding the DISP switch combination again will switch to battery display mode B and back to normal mode N 68 Switch CW Sending CW using Front Panel Switches In an emergency the BAND switch can be used as a hand key or the BAND and RIT switches can be used as keyer paddle To enable this feature first use the INP menu entry to specify hand key HND or one of the paddle modes P Dn P Dr Next press and hold the MENU switch and 10 100 simultaneously to toggle Switch CW on and off You ll see btn button when switch CW is and paddle when it is off When switch CW is enabled and INP is set to HND hand key the normal functions of the BAND switch are not available In addition if INP is set to the functions of the switch are not available To use the normal functions of these switches turn off Switch CW mode as described above
72. fully clockwise If the top cover is removed make sure you don t have a screw inserted into the tab of Q6 Unplug the ATU KXAT1 and insert a jumper between pins 1 and 3 of J7 connect a dummy load at J2 If this solves the problem see the KXATI manual s troubleshooting section Check power output when using a 500 dummy load if the output is correct on a dummy load but not when using an antenna your antenna 1s probably not matched You may have a short in the LPF or BPF or an incorrect LPF component value Check relays 25 Examine L3 L1 and L2 for poorly stripped leads Check T1 for backward windings Check all DC voltages in the transmitter Q1 Q4 Q5 Q6 Signal trace through the transmitter to find where signal 15 lost using an RF probe Check for any components getting hot 88 Power output fluctuates If you stay key down TUNE mode for several seconds it is normal to see some increase in power this is due heating of the final amplifier transistor If power goes up and down significantly during normal keying you may have a poorly matched antenna OR you may have power set too high for your battery or power supply to handle try reducing power or replacing batteries If the transmitter is unstable oscillating even when connected to a 50 O load you may have an incorrect component value or a toroid winding error 86 90 Output power drops to zero suddenly If you have
73. h KX1 in the upper left corner Install potentiometer R2 B10K as follows Locate the printed outline for R2 next to electrolytic capacitor C20 on the right side of the board This is the CENTER of the three outlines Position R2 B10K so the three signal pins and two large mounting tabs are in the holes in the board Press down on the potentiometer until it rests solidly against the board on the two metal nubs next to each mounting tab and the shaft extends straight up at right angles to the board Solder one of the smaller pins then recheck the alignment to make sure the pot has not been moved Solder and trim the remaining small pins Solder the two large pins using just enough to make a good electrical and mechanical joint between the tab and the plated hole Do NOT try to fill the hole with solder Install potentiometers R1 and R3 following the same procedure R1 B1K above R2 R3 below R2 40 AN In the following steps you ll wind and install toroidal inductors L1 and L2 They must be wound as exactly indicated in the instructions or the transceiver will not operate correctly LJ Turn the board bottom face up with J1 in the upper right corner Locate the printed outlines for L2 and L1 in the upper left corner near J2 Locate the four toroid cores There are two yellow T37 6 cores and two dark gray FT37 43 cores Use the yellow cores to make L1 and L2 A Although the yellow and gray cores look simil
74. he desired CW feedback speed or 2 hold the MENU BAND or switch down at power on which forces CFB to 10 20 or 30 WPM respectively This also sets the LED to 67 maximum brightness and reports the firmware revision on the display and in CW Differences between LED display and CW feedback 1 All zeros are converted to long T s and decimal points are sent as R a CW standard derived from the word radix In the DDS and BFO menu entries the minus sign is sent as N For example a BFO parameter of 16 would be sent NRI 2 Some 3 letter text strings are reduced to a single letter These include RIT on R RIT off O RIT clear C VFO lock L VFO unlock U nor LS B USB receive modes L U and nor announce batt display modes N A B Frequency Announce display mode A is discussed below 3 When using the menu you can scroll quickly past menu entries if desired which will truncate sending of associated text in CW The PLY Play menu entry is truncated to P 4 The VFO frequency can be checked at any time by tapping BAND once The frequency will be announced in MHz and kHz prefixed by U or L in USB or LSB mode and followed by R if RIT is turned on The kHz part of the frequency and R for RIT if applicable is also sent when you select the fast tuning rate 5 Frequency Announce display mode provides audible tics every 10 VFO steps and reports the kHz digits
75. he parameter using the VFO knob Note PLY and RCL behave differently there is no need to enter edit mode to use them See table for details Tap MENU skip tapping MENU to return to scrolling Another tap of MENU will return you to normal operation Edit Shortcut You can and jump directly into editing the last used menu entry by holding Menu Entry Description Usage Details LED LED Display Control Tap BAND and RIT to select display brightness 0 5 VFO knob selects on time 5 to 60 sec in 5 sec increments or for infinite STL Sidetone Level There are four sidetone volume levels 0 3 AF GAIN also affects sidetone level STP Sidetone Pitch Pitch range is 500 to 700 Hz in 10 Hz steps 600 Hz recommended to match BFO offset T R Transmit Receive Delay The QSK delay can be set from 0 to 900 ms 20 ms recommended for casual operation RPT Message Repeat Interval Sets CW message auto repeat interval 0 to 255 seconds See page 66 INP Input Device Selection Select Hnd hand key or external keyer or PDn P Dr internal keyer paddle norm rev With PDn selected J3 tip is DOT and ring is DASH PDr is the reverse IAB Iambic Mode With a two lever paddle e g Elecraft KXPD1 you can use iambic keying holding both paddles repeats
76. he upper right quadrant of the board about 1 2 5 cm down from the top edge and 1 3 4 4 4 cm from the right hand edge Be certain the top of the transistor is no more than 5 16 7 9 mm above the board LJ Install 8 pin integrated circuit U3 4427 in the space provided near the right hand edge of the board about 1 1 4 3 3 cm down from the top edge as follows Test fit U3 to see if the pins line up with the holes in the solder pads on the board If needed straighten the pins like you did for resistor pack RP5 see Figure 5 Identify the end of U3 where pin 1 is located It will have a notch a dimple or both at this end see Figure 11 Insert U3 into the solder pad holes with the notched pin 1 end lined up with the notch on the printed outline Spread out the pins on the opposite corners to hold U3 in place then solder and trim all 8 pins NOTCH DIMPLE AT PIN 1 Figure 11 IC Alignment 25 LJ Install 3 digit LED display DS1 as follows Insert the 3 digit LED display in the space bounded by resistor packs RP1 RP2 RP3 and RP4 The pins on DS1 allow it to be inserted only one way Hold the display against the board and tack solder pins at the opposite corners Inspect the display carefully to ensure that it is firmly against the board at both ends If necessary reheat one of the pins and adjust the display It is very important that the display be fully seated and resting directly against the boar
77. heat the lead while pressing down on the capacitor Solder the remaining lead and trim both leads LJ Install the following electrolytic capacitors using the same procedure C23 100 uF 10 V about 3 4 1 9 cm above C53 C20 10 uF 35 V above C23 C35 100 uF 10 V next to C50 above the upper right corner of the 3 digit display Zi If you re not wearing an anti static wrist strap be especially careful to touch a ground frequently while installing integrated circuits U4 U5 and U6 in the following steps 35 LJ With the board face up so that KX1 is in the upper left corner locate the printed outline for U4 on the right hand edge of the board below U3 Install integrated circuit U4 LM386 as follows Straighten the pins as necessary see Figure 5 Orient the U4 so that the notch at the end is over the notch in the printed outline on the board and pin 1 is in the round solder pad see Figure 11 Bend the pins at opposite corners of the U6 outward slightly to hold it in place Check to be sure that U4 is resting against the shoulders of all 8 pins on the top of the board Solder and trim all 8 pins NE612 NE602 SA612 and SA602 integrated circuits are all functionally identical Any of these may be supplied for use at U5 and U6 LJ Install U5 NE SA612 or NE SA602 near L10 and L8 at the lower center of the board Use the same technique you used above Zi In the following step U6 must be ful
78. his is the BFO correction 6 If the LSB reading was the lower of the two set the BFO menu parameter to the BFO correction value in this example 10 If the USB reading was the lower one set the BFO parameter to the negative of the correction in this example 10 7 Exit the menu You should now be able to switch between LSB and USB receive modes without re tuning the VFO DDS Calibration This procedure compensates for any error in the 50 MHz reference oscillator The BFO calibration procedure above must be performed first 1 Select 40 or 30 meters and LSB or USB receive mode Don t use CW nor mode as this introduces a receive offset 2 Tune the VFO to the exact specified frequency of a reference signal Example For WWV at 10 MHz you must tune to exactly 10000 00 kHz as indicated on the KX1 s display You might start with 5 kHz steps hold the VFO knob but then switch to 100 Hz and finally 10 Hz steps as you get closer by tapping the knob 3 Edit the DDS menu parameter While listening to the reference signal use the VFO knob to adjust the parameter so that the signal is properly tuned in If it is an unmodulated carrier tune for zero beat 0 Hz audio If it s a voice signal tune for most natural sounding audio Then exit the menu ELECRAFT 69 Checking the Firmware Revision Resetting to Factory Defaults Hold any switch on power up to display the revision e g 1 01 Reset to defaults takes two st
79. ight corner The jack has six plastic nubs that hold it up off of the board slightly The pins will be flush with the solder pads on the bottom of the board LJ Solder one pin and carefully recheck the position of the jack to be sure all the plastic nubs are against the board If necessary reheat the soldered pin while pressing down on the jack Solder remaining pins careful working around R15 R25 with your soldering iron ELECRAFT Zi The optional KXAT1 ATU module plugs directly into connectors J6 J7 and 18 which you ll install in the following steps They MUST be positioned vertically not tilted or the ATU module cannot be installed LJ Turn the board bottom face up with jack J1 in the upper right corner LJ Install two pin jack J8 on the board just below antenna jack J2 in the upper right corner as follows Hold the jack vertical with your finger while tack soldering one pin Carefully inspect the jack to ensure it is vertical with respect to the board and both ends of the jack are down against the board Solder the pins reheating the one you tack soldered last to ensure a good joint LJ Install the following jacks using the same procedure J7 three pins just above J2 in the upper left corner J6 five pins just below J1 in the upper right corner LJ Separate the three potentiometers according to their values Two 1k pots B1K One 10 k pot B10K 39 Turn the board top face up wit
80. il forum elecraft mailman gth net Telephone assistance is available from 9 A M to 5 P M Pacific time weekdays only at 831 662 8345 You can also send e mail to support elecraft com Please use e mail rather than call when possible since this gives us a written record of the details of your problem Repair Service If necessary you may return your completed to us for repair Contact Elecraft before mailing your kit to obtain the repair shipping address as well as information on repair fees Kits that have been soldered using acid core solder water soluble flux solder or other corrosive or conductive fluxes or solvents cannot be accepted for repair see Warranty The following information should be provided to expedite repair your name address and phone number your e mail address if applicable and a complete description of the problem Shipping First seal the unit in a plastic bag to protect the finish from dust and abrasion Use a sturdy packing carton with 3 or more of foam or shredded paper on all sides Seal the package with reinforced tape Neither Elecraft nor the carrier will accept liability for damage due to improper packaging Cover the to address label with clear tape ELECRAFT Elecraft s 1 Year Limited Warranty This warranty is effective as of the date of first consumer purchase Before requesting warranty service you should complete the assembly carefully following all instruct
81. ions in the manual What is covered During the first year after date of purchase Elecraft will replace defective parts free of charge post paid We will also correct any malfunction caused by defective parts and materials You must send the unit at your expense to Elecraft but we will pay return shipping What is not covered This warranty does not cover damage due to electrostatic discharge ESD correction of assembly errors or misalignment repair of damage caused by misuse negligence or builder modifications or any performance malfunctions involving non Elecraft accessory equipment The use of acid core solder water soluble flux solder or any corrosive or conductive flux or solvent will void this warranty in its entirety Also not covered is reimbursement for loss of use inconvenience customer assembly or alignment time or cost of unauthorized service Limitation of incidental or consequential damages This warranty does not extend to non Elecraft equipment or components used in conjunction with our products such repair or replacement is the responsibility of the customer Elecraft will not be liable for any special indirect incidental or consequential damages including but not limited to any loss of business or profits ELECRAFT Specifications General Size H x W x D Cabinet Overall Weight Supply voltage Current drain Receive Transmit Bands covered MHz Receive Transmit Frequency
82. l circuits 24 02 BAT LO displayed Battery voltage may be below the level set in the BAT menu entry Recharge the battery as soon as possible 03 No audio See Receiver troubleshooting table 60 05 Current drain is excessive on receive Check regulated voltages 20 look for a component that s warm to the touch 06 Supply voltage drops when is on Check receive mode current drain 05 Battery not fully charged 07 Error in actual vs See Operation section C AL menu entry displayed frequency 08 Freq drift or See VFO troubleshooting table 40 instability 09 EEPROM E09 on display See Advanced Operating initialization pending Features Resetting to Factory Defaults 10 EEPROM was just initialized You may see E10 one time on power up or if you install a new version of the firmware All KX1 parameters are set to defaults 15 END or P 0 is displayed on keydown END TX out of range see specifications 0 CW test mode see PLY menu entry Display and Control Circuits 20 39 Problem Troubleshooting Steps 20 Regulated input voltage must be gt 6 5V voltage s incorrect Unplug ATU option and re check f 6V is too low lt 5 7V go to 22 f 5V is too low lt 4 7V go to 23 If 2 7V is too low lt 2 5V go to 23 21 General problem Check switch resistance open closed RP2 with switches or
83. l micro smaller size RF choke micro smaller size RF choke micro size RF choke _ s ti Ormen io micro smaller size RF choke 100 uH brn blk brn micro smaller size RF choke 33 uH org org blk Note Either or both orange bands may appear to be brown Connector 2 pin male with locking ramp 0 1 1 E620024 spacing for internal battery 3 E690013 E690041 E580009 E580006 Q1 Q2 Q3 Transistor 7309 309 04 7 08 09 Transistor 2 4124 Transistor NPN 253904 E580017 E580007 eo Transistor NPN power 2SC2166 ELECRAFT R1 R3 Pot 1K linear panel mount no bushing E520013 Pot 10K linear panel mount no bushing E520014 E520008 Pot 100 ohm trimmer Resistor 6 8K 1 4 watt 5 s E500021 E500024 E500090 E500115 E500047 E500005 E500004 E500013 E500003 E500023 E500114 E500019 E500028 E500054 RI 27K 1 4 wat 5 red viowred 19 28 Resistor 1 4 watt 75 brn gry red peas Resistor 470 ohms 1 4 wat 54 R10 R14 Resistor 47 1 4 watt 5 yel vio blk R26 R27 R30 Resistor 22 1 4 watt 5 red red blk R11 R25 Resistor 10 ohms 1 4 watt 5 brn blk blk 390 ohms 8R 16 pins 391 E510023 RP3 RP4 Rpack 10K 5R 10 pins 103 51 52 Slide Switch SPDT mount 0 5 50V 53 54 55 Momentary contact switch 6mm MISC Ke
84. lay may go blank or show one or more bars LJ Tune in a strong signal Whenever you move the VFO the S meter bargraph will replaced with the frequency display Once the signal is tuned in the AGC should be activated as indicated by an increase in S meter reading The S meter zero point and scale can be adjusted if necessary using the SIG menu entry page 65 AN Since the KX1 uses audio derived AGC the initial code element from a very strong station may be heard at a louder volume This is due to the time it takes for the AGC detector capacitor C53 to charge This effect is lessened somewhat by the limiting action of 04 AF amp since 04 is operated from a low voltage See schematic Appendix B Each bar corresponds to roughly two S units so that 4 or 5 bars indicates about an S 9 signal ELECRAFT Receive Current Drain Test Optional The current drain in receive mode is about 32 mA with the LED menu entry set to 0 1 or 2 If the current drain is significantly lower or higher than this it could indicate a problem To check the current drain set your DMM for DC milliamps and temporarily insert the DMM in series between the KX1 and the power supply Turn the KX1 on and note the current mA 47 Operating Frequency Calibration Optional The operating frequency display may be off by as much as 200Hz until calibrated due to variations in the 50 MHz reference oscillator and BFO com
85. leshooting LJ If both bands have adequate output power but 20 meters is higher you should adjust the windings of toroidal inductor L2 To do this squeeze the turns of L2 together slightly so that they occupy only about 70 of the core s circumference With L2 at its optimal turns spacing for best harmonic rejection 20 meter output will be about 0 3 to 0 6 watts lower than 40 meters Keying Test Connect a paddle or hand key to the KEY PADDLE jack LJ Key the KX1 while listening in the monitor receiver The keying should sound clean and stable During keying one bar will be shown on the LED bargraph If the 1 ATU is installed the bargraph will instead show approximate power output in 0 5 watt increments 0 to 3 watts LJ Turn the KX1 off and disconnect the power supply key or paddle and antenna 60 Final Assembly LJ Be sure that you removed the paint from around the bottom cover holes see Figure 25 LJ Three self adhesive feet are supplied for the bottom cover Three feet provide excellent stability on uneven surfaces Position the feet on the bottom as shown in Figure 27 T KEY PADDLE JACK ON THIS SIDE Figure 27 Installing Feet ELECRAFT L Place the serial number label inside the top cover as shown in Figure 28 Note The label is placed on the inside to protect it during field operation You can easily check the serial number when necessary by removing two thumb screws and p
86. ly seated before soldering or it will interfere with the optional KXB30 30 module A different installation method will be used LJ Install U6 NE SA612 or NE SA602 near encoder 71 at the center of the board Solder just one pin of U6 LJ Re heat the soldered pin of U6 while pressing down on the it from the other side You may hear or feel it settle into a lower position on the board Once you re certain that it is mounted as close to the board as possible solder the remaining pins 36 Install transistor 09 2N4124 to right of U5 Be sure to orient the transistor according to the outline on the board see Figure 10 and insert the transistor so that the top is no higher than 5 16 7 9 mm above the board LJ Install transistor Q8 2N4124 as shown in Figure 14 Bend the leads so that the transistor body fits within the printed outline with the flat side facing up The round back of the transistor must lie against the circuit board so that the transistor does not exceed 5 32 3 9 mm in height above the board Figure 14 Installing Transistors Q2 Q3 amp Q8 The Round Back of the Transistor Must Rest Against the Board ELECRAFT LJ Install JFET transistors Q2 and Q3 using the same procedure as Q8 02 1309 to the right of Q8 Q3 J309 below Q2 Measure each transistor to ensure it does not exceed 5 32 3 9 mm in height above the board LJ On the bottom of the board check the leads for JFET Q2 and i
87. lytic capacitor C7 R27 22 ohms red red blk above 26 R10 47 ohms yel vio blk to the right of R27 R24 22k red red org on the top edge of the board above R10 ELECRAFT LJ Turn the board top face up with KX1 in the upper left corner Install the following capacitors in the area above encoder Z1 Be sure to check the each capacitor to ensure it is no more than 5 16 7 9 mm above the board C42 01 uF 103 to the left of electrolytic capacitor C35 on the top edge of the board C34 01 uF 103 to the right of electrolytic capacitor C35 on the top edge of the board C41 01 uF 103 near the upper left corner of encoder Z1 C43 1 uF 104 above C41 C44 022 223 near RF Gain potentiometer AN Wear your ESD wrist strap or touch a ground frequently while installing the transistors in the following steps LJ Install the following transistors Be sure the top of the transistors is not more than 5 16 7 9 mm above the board Q1 J309 directly to the right of the three digit LED display Q5 2N3904 near the upper left corner of encoder Z1 Q4 2N4124 above Q5 near the upper edge of the board 49 AN In the following steps you ll wind and install toroidal inductors L3 and transformer T1 They must be wound as exactly indicated in the instructions or the transceiver will not operate correctly LJ Turn the board bottom face up with J1 in the upper right corner Locate the printed outlines f
88. may be in backwards potentiometers Check resistance of potentiometers 22 6 V too low Remove ATU option and re check lt 5 7V Inspect 6V path on the KX1 PC board Check for U9 installed backwards Lift other component leads on the 6V line as needed to find cause of excess loading 23 5V too low lt 4 7V or 2 7V too low lt 2 5V Remove Ul from its socket Check for 08 installed backwards Check for U7 incorrectly installed surface mount use magnifying glass Use techniques given for 6V regulator above E 2 24 LED display problem 051 backwards check for shorts to ground on each pin MCU pin bent or broken U1 pin not soldered or shorted 25 Relay Problem Relays not soldered Check relay coil resistance pins 1 and 8 U3 TC4427 defective or backwards 27 26 Possible MCU problem Check all DC voltages on U1 Make sure U1 is not backwards has no bent pins and is seated firmly in its socket Check oscillator components X1 C24 C25 R22 Also see 33 if you suspect an error in a menu parameter etc 29 AuxBus problem no communication with ATU Look for short at J6 pin 5 U1 pin 2 or KXATI UI pin 17 Check voltage on J6 pin 5 see table 30 EEPROM test 1 failed 31 EEPROM test 2 failed 32 EEPROM data error If you E30 E31 or E32 on the LED one of the EEPROM tests has failed CW memories cannot be used Parameters will
89. minimum amount required to surround the component lead and make good contact with its printed circuit pad You don t need a fillet build up of solder To provide a good connection the solder must flow onto both the component lead and its PC board pad To ensure that both will be heated at the same time the tip of the iron should contact both the component lead and the PC board pad before solder is applied 11 Solder joints should be clean and shiny If a joint appears dull or has fine cracks it is probably cold Cold solder joints should be cleaned and re soldered First use solder wick desoldering braid to remove the old solder Then apply fresh solder If you have many cold solder joints it probably indicates that your soldering iron temperature is too low or that the tip or solder itself is defective New soldering iron tips must be tinned before they re used Allow the iron to warm up completely then apply solder and allow it to coat the entire tip After a few minutes wipe off the excess solder Use a sponge for wiping the iron tip and clean the sponge often 12 Desoldering The printed circuit boards used in the kit are double sided meaning that they have circuitry on both sides The component mounting holes are plated through to complete electrical connections between the two sides Removing components from double sided boards can be difficult since you must get all of the solder back out of the hole before
90. mponents You can discharge static by frequently touching an unpainted grounded metal surface 2 WEAR EYE PROTECTION before trimming any leads 3 WASH YOUR HANDS after handling solder Solder is a toxic substance 4 PROVIDE VENTILATION and avoid inhaling the fumes produced by soldering ELECRAFT LJ If you haven t done so already open the bag of components labeled KX1 MAIN BAG and sort the parts into groups Many of the components will be in small paper envelopes Do not mingle the contents of one envelope with another As you are instructed to locate particular components use the photographs in the KX1 PCB parts list in Appendix A to help identify them Zi The components pre installed on the circuit board are extremely static sensitive Wear a wrist strap or ground yourself before handling the board O Position the circuit board on your bench so that 1 is visible in the upper left corner This is the side of the board that will be directly under the front panel when the transceiver is completed This side will be referred to the as the top face of the board throughout the assembly procedure Components will be installed on both sides of the board LJ Turn the circuit board over so the bottom is facing up and orient it so the outline for J1 is in the upper right corner Find the outline for resistor R8 next to the outline for J1 ELECRAFT LJ Bend the leads of resistor R8 6 8k blu gry red 1 4 watt at right angles
91. mum recommended voltage 8 V when possible The KX1 will run from whichever 15 higher in voltage the internal battery or the external supply Transmit current drain will be 300 700 mA depending on the supply voltage Headphones or External Speaker The AF output jack J4 can accommodate either headphones or a small speaker 8 32 2 A stereo plug is required Earbud style headphones are recommended Sony MDR series or equivalent with sensitivity of 108 dB mW They are lightweight sensitive and mask wind noise well Antenna Any resonant antenna can be connected to J7 With the ATU you can connect random length wires often without any feedline see manual With a KXATI installed power and SWR will be displayed in TUNE mode and power output is shown on the bargraph during keying If no is installed the display will show one bar on transmit and tun in TUNE mode Keying Device You can connect a hand key or external keyer to J3 or connect a paddle such as the optional KXPD1 and use the KXI s built in memory keyer stereo plug is required You can also use the KXI s front panel buttons to send CW see page 68 ELECRAFT Controls and Display Power Switch Set POWER ON to turn on the KX1 If the LED display is too dim hold MENU BAND at power up This selects maximum LED brightness and also turns on audible CW switch feedback at 10 20 or 30 WPM respectively see page
92. n the assembly process is accompanied by a check box As you have noticed already symbol below is used to alert you to important information Zi Do not skip any steps You may adversely affect both the performance and appearance of the kit by using the wrong assembly order Installing Parts Follow the instructions carefully about the position of parts Many parts must be positioned exactly as shown as instructed or the case will not fit Before beginning assembly you should review the photographs in Appendix D to see what the completed PC boards look like You ll also find front and back views of each PC board in the Parts Placement Drawings Appendix F 13 IC Sockets Only one integrated circuit is mounted in a socket Do not use a different type of socket The one supplied is a low profile socket that provides just enough room for the case to fit together Do not use sockets on any ICs other than the one provided Mount the other ICs directly on the board as instructed Sockets will not allow the cover to close Also sockets in RF may cause improper circuit operation due to increased lead inductance and capacitance 14 Assembly Part I In Part L the control display and audio stages will be assembled and tested Later sections cover receiver Part II and transmitter Part assembly and test A BEFORE YOU START 1 WEAR A GROUNDED WRIST STRAP or ground yourself briefly before touching co
93. ng toward the outline for RP3 LJ Install ten pin resistor pack RP3 10k 103 to the left of RP4 Pin 1 of RP3 is at the top nearest the end of RP4 17 Locate resistor pack RP1 390 ohms 391 RP1 is in a 16 pin DIP package that looks much like an integrated circuit The resistance elements run across the package e g pin 1 connects to 9 through 390 ohms Test fit between 2 just below outline for 051 on the circuit board It is normal for pins of a DIP package to be slightly flared so they do not easily fit into the solder pad holes If necessary place RP1 so that an entire row of pins is against a smooth surface and straighten the pins as shown in Figure 5 e lt FLARED PRESS AND STRAIGHT ROCK TO STRAIGHTEN Figure 5 Straightening IC Pins Place 1 circuit board with 1 indicated dot top of RP1 in round solder pad Be sure it is seated all the way so the shoulders on the pins are against the board Solder and trim all 16 pins 18 Turn board face up so KX1 is in upper left corner Locate the printed outlines for diodes D2 and D3 near the center of the left of the board LJ Locate diodes D2 and D3 1N5817 Note that there 15 a band on one end of the diode body A diodes MUST be installed with the banded end of the diode over the band on the circuit board Install following diode
94. ning filter crystals using the same procedure you used for 2 X3 4 9136 X4 4 9136 5 4 9136 LJ Turn the board so the bottom face is up with J1 in the upper right corner and locate the printed outline for antenna jack J2 in the upper left corner Zi The next step requires an unusually large amount of heat for soldering Use a larger soldering tip if available LJ Position jack J2 on the board so it is sitting within the printed outline as shown in Figure 15 BOTTOM SIDE OF BOARD JACK CENTERED WITHIN PRINTED OUTLINE JACK BARREL MUST BE PARALLEL WITH BOARD Figure 15 Installing J2 ELECRAFT Zi Be certain the jack is mounted on the BOTTOM face of the circuit board as shown It is very difficult to remove this jack without damaging the board if it is installed incorrectly LJ Solder the center pin lead and recheck the alignment LJ Without disturbing the alignment of the jack solder one of the heavy ground nubs to the board Then re check the alignment Reheat the nub if necessary to correct any misalignment Zi The case will not close during final assembly if the jack is not aligned as shown Solder second nub on jack and make a final alignment check Zi If you fitted your soldering iron with a larger tip to install J2 replace it with a fine tip now LJ Turn the board face up with KX1 in the upper left corner LJ Fit headphone jack J4 in the printed outline in the lower r
95. nstall them The packaging may be a special plastic bag or the component s leads may be inserted in conductive foam Parts which are especially ESD sensitive are identified in the parts list and in the assembly procedures Wear a conductive wrist strap with a series 1 megohm resistor If you do not have a wrist strap touch a ground briefly before touching any sensitive parts to discharge your body Do this frequently while you are working You can collect a destructive static charge on your body just sitting at the work bench DO NOT attach a ground directly to yourself as this poses a serious shock hazard e Make sure your soldering iron is ESD safe and has grounded tip Use a grounded anti static mat on your work bench Inventory We recommend that you do a complete inventory using the parts lists in Appendix A Zi DO NOT HANDLE PARTS OR CIRCUIT BOARDS WITHOUT ANTI STATIC PROTECTION see Preventing Electro Static Discharge Damage above Do not remove the black foam from the leads of any parts This foam is further protection against static damage Many components are inside small envelopes and bags Open them one at a time and return all of the parts to the envelope before opening another Be careful to avoid mixing parts and putting them in the wrong bags or envelopes Identifying Common Resistors and RF Chokes The color bands that indicate the value of each resistor are shown in the text to help you identify each
96. ntegrated circuit U6 to be sure they are soldered and cut flush LJ Fold down against the board the capacitors you installed earlier as follows Measure each capacitor to ensure that it does not exceed 1 8 3 mm in height above the board C15 toward the printed on the board C3 over the pins for integrated circuit U6 C14 toward C3 and the pins for integrated circuit U6 C9 over the pins for Q2 away from the large hole in the board LJ Turn the board face up with KX1 in the upper left corner and locate the printed outline for trimmer CA just above transistor Q7 and the upper right corner of encoder 71 ELECRAFT LJ Install trimmer as follows Place a red trimmer in the CA position with the flat side of the trimmer over the flat side on the printed outline Press the trimmer down against the board and spread the pins to hold it in place Note that the adjustment for the trimmer is not visible from the top It is accessed from the bottom through the hole in the board Check to ensure the trimmer is sitting directly against the board and then solder and trim both pins Install trimmers CB using the same procedure as CB red directly below transistor Q7 on the right side of encoder 71 CC brown to the right of trimmer CB LJ Bend ceramic capacitor C1 so that it touches the side of trimmer CB This will ensure that it does not interfere with the 30 meter module option when
97. ntly while handling Do not handle more than necessary Do not remove parts with leads in black foam from the foam until they are installed Reference Designator Description C5 C8 C11 C12 C16 C17 C18 C21 C31 C39 C43 Capacitor 0 1 uF 0 1 LS 104 11 E530020 C3 C6 C9 C15 C22 C30 32 33 34 37 41 Capacitor 01 uF 0 1 LS 103 530019 42 55 C48 C49 Capacitor 1000 pF 596 50 V 0 1 LS 102 E530072 Capacitor 470 pF 5 50 V 0 1 LS 471 E530004 Capacitor 330 pF 5 50 V 0 1 LS 331 E530147 Capacitor 220 pF 5 50 V 0 1 LS 221 8530042 27 Capacitor 150 pF 5 50 V 0 1 LS 151 E530049 Capacitor 100 pF 5 50 V 0 2 LS 101 E530034 Capacitor 68 pF 5 50 V 0 2 LS 68 680 NOE C56 is is 68 pF but has 0 1 lead a i 1 1530150 2 530146 I 530036 4 530141 1 1 ER Capacitor 22 pF COG 5 50 V 0 1 LS 22 220 8530017 Capacitor 4 7 5 pF 5 50 0 1 LS 4 7 530048 ELECRAFT A2 C26 Capacitor 120 pF disc 121 1 530041 19 44 Capacitor 022 uF 50 V 223 2 530056 Capacitor 220 uF electrolytic 1 8530046 C23 C35 Capacitor 100 uF electrolytic low profile 2 E530149 C10 C20 C38 C53 Capacitor 10 electrolytic low profile 4 E530045 CA CB Capacitor trimmer 5 20 pF bottom adjust red 2 E540004 Capacitor trimmer 8 50 pF bottom adjust
98. odule The KXB30 module will not fit if these capacitors sit too high above the board LJ The capacitors installed in this step must be closer to the board than any of the previous parts you have installed After installation these capacitors must not exceed 5 32 3 9 mm in height 1 uF 104 to the right of molded inductor L10 C13 56 pF 56 to the right of C11 Use a ruler to verify that the above capacitors are no higher than 5 32 3 9 mm above the board 34 LJ Turn the board over so jack J1 is in the upper right corner and locate the printed outline for C15 just to the left of electrolytic capacitor C17 at the center of the board LJ Directly above the location for C15 is one of the soldered encoder pins If it hasn t been trimmed already trim it flush LJ Install the following capacitors so that about 1 16 1 mm of lead shows between the capacitor and the board so they can be folded down against the board like you did with C39 earlier DO NOT fold these capacitors down against the board until you are instructed to do so in later steps If you fold them now you will cover solder pads you must reach to install other parts C15 01 uF 103 01 uF 103 C14 330 pF 331 C9 01 uF 103 LJ Install relay K1 AGN2104H to the left of R28 in the upper left quadrant of the board as follows Position the relay on the board It will only fit one way Hold the relay in place and solder just one of it
99. om the left holder together to join them Make the joint small and smooth Solder it ELECRAFT LJ Slide the shrink tubing you placed on the red wire over the joint and shrink it in place to insulate the connection You can shrink it using hot air from a blow dryer or by simply placing your soldering iron very close to the tubing and allowing its radiant heat to shrink it If you place the barrel of a hot soldering iron the part just behind the tip where it almost touches the tubing and parallel to it the tubing should begin to shrink in about 30 seconds Repeat at two or three places around the tubing to shrink it evenly and snugly L Slide the excess red wire under the right hand holder as shown so the splice and wire lies down near the bottom cover When the unit is assembled the space between the battery holders is taken up by the Key jack J3 and the crystals on the circuit board LJ Line up the black wire with the red wire in the upper left corner that will go to the power plug Cut the black wire to the same length as the red wire and strip 1 4 from the end Locate crimp terminals and housing for plug 75 Figure 26 Crimp and solder the terminals to the stripped red and black wires 57 Insert terminals into housing until they latch Tug wires to verify that the terminals are locked in place LJ Double check your installation by attaching J5 to plug P1 and verify that the red wire goes to
100. onnectors are mounted on a single printed circuit board PCB Only three surface mount components are required and these are pre mounted to the board The top cover is also the front panel The controls face upward for convenient operation The printed circuit board mounts directly behind the front panel The automatic antenna tuner option KXAT1 plugs into the bottom of the main PC board at J6 J7 and J8 The optional keyer paddle KXPD1 plugs into the Keyer Paddle jack J3 at the front edge of the top cover The bottom cover is held in place by two thumbscrews Two three cell AA battery sockets are attached to the bottom cover and are wired in series to form a six cell pack The battery voltage is 7 2 or 9 V depending on the battery type Appendix D provides close up views of the top and bottom of the assembled PC board Figure 1 KX1 Overview ELECRAFT TUNING KNOB TOP COVER MAIN CIRCUIT BOARD OPTIONS PLUG INTO TOP AND BOTTOM OF THIS BOARD BOTTOM COVER WITH BATTERY ELECRAFT Unpacking and Inventory Preventing Electro Static Discharge Damage Problems caused by Electro Static Discharge ESD may be very difficult to troubleshoot because damaged components may still operate somewhat rather than fail completely We strongly recommend you take the following anti static precautions listed in order of importance to avoid trouble Leave ESD sensitive parts in their anti static packaging until you i
101. ons are described on page 71 62 This section covers all KX1 connectors controls and operating features For a one page Quick Reference see Appendix G Connections Internal Battery Connect the internal battery to P1 on the PC board Make sure the battery wires aren t pinched when you install the bottom cover Battery Selection For best performance use 1 5 volt cells 9 volts see table Energizer lithium type L91 or fresh Alkaline cells are recommended Lithium cells are more expensive but have high energy density a flat discharge curve and weigh less than Alkalines 1 2 volt cells e g can also be used but will provide lower output and reduced operating time and near end of charge will not meet the KXI s minimum supply voltage spec 7 V You must remove rechargeable batteries e g NiMH for charging Battery Voltage Amp Output Weight Type 6 cells hours watts 6 cells Lithium 2 8 2 9 1 5 2 0 3 Alkaline 9v 2 2 2 7 1 5 2 0 5 07 NiMH 7 2 1 6 2 3 0 75 1 0 5 07 Low Battery Warning If supply voltage drops below the value set in the BAT menu entry you ll see BAT LO on the LED every five minutes Set BAT to 7 5 V for Alkaline or Lithium cells 6 5 V for NiMH and 10 5 V for an external 12V battery ELECRAFT External Power Supply You can connect any 7 14 V DC power supply or battery to 11 although you should use the mini
102. or L3 and T1 near the top center of the board to the right of trimmer pot R4 LJ Locate the two dark gray FT37 43 cores E REMOVE INSULATION SEE TEXT Figure 18 Winding Inductor L3 Prewound toroids are available from an Elecraft approved source See www elecraft com for details 50 ELECRAFT LJ Wind toroidal inductor L3 on one of the FT37 43 cores as follows Cut an 8 20 cm length of red enameled wire Sew the long end of the wire through the hole in the core for a total of 6 turns Match the winding direction shown in Figure 18 Count one turn each time the wire passes through the center of the core There are no half or quarter turns when winding a toroid Spread the turns around the core so the finished result looks like Figure 18 Strip the insulation and tin the leads like you did earlier for L1 and L2 See page 41 Wind toroidal transformer T1 on remaining FT37 43 core as follows Cut an 8 20 cm length of red enameled wire Sew the long end of the wire through the hole in the core for a total of 8 turns Match the winding direction shown in Figure 15 Count one turn each time the wire passes through the center of the core There are no half or quarter turns when winding a toroid Spread the turns around the core so the finished result looks like Figure 16 Cut a 6 15 cm length of green enameled wire Wind two turns in between the other winding exactly as shown
103. ore then tap 1 2 10 100 VFO knob The display will flash 1 2 or 3 in response However if you hold rather than tap the switch that selects the memory that memory will become the high priority memory and the display will instead flash 1H 2H or 3H Exit the menu To recall MENU locate RCL then tap 1 2 10 100 The recalled frequency and mode will be displayed Exit the menu Switching to the High Priority memory First press and hold BAND 10 100 which will switch to the high priority memory if one has been assigned The stored receive mode will be used and if the band changed the ATU L C values will also be recalled If desired you can then restore your original band and frequency by holding 10 100 again Exception If you tap change receive modes in the interim the restore operation will be cancelled and the KX1 will remain on the new band Audible CW Feedback on Switch Press When CW feedback 15 turned on audio Morse code will be sent in response to all KX1 controls when using the menu etc This is useful when the display cannot be used such as in very bright sunlight or when eyes free operation is required Speeds from 10 to 40 WPM can be selected in 5 WPM steps To turn on CW feedback on switch press Either 1 set the CFB menu parameter to t
104. outline and flat against the board Be certain you mount the jack on the BOTTOM face of the board within the printed outline 23 LJ Turn the board over so the top face is up with KX1 in the upper left corner Zi Do not install caps on pushbutton switches 53 54 55 until instructed to do so later in the assembly process It is very easy to damage the caps while soldering adjacent parts LJ Position switch S5 on the board between RP2 and 5 it may be oriented either way that places the four pins in the solder pad holes With all four pins in the solder pad holes press down on 55 until the plastic bumps on the bottom of the switch body are touching the board Use a magnifier if necessary to be certain that the bumps on the bottom of the switch are against the board Each of the four pins should stick out through the solder pads on the bottom of the board about 3 32 2 4 mm When you are satisfied that switch is firmly against board solder and trim all four terminals LJ Install pushbutton switches S4 and S3 next to S5 using the same procedure ELECRAFT 24 LJ Test fit slide switch S2 along the edge of the board next to electrolytic capacitor C10 The switch can be oriented either way around Note that it rests on shoulders on the three terminals that determine its height above the board Zi Voltage regulators U8 and U9 are installed in the following steps These devices look very similar Double ch
105. ponents Accuracy can be improved to approximately 10 or 20 Hz using the BFO and DDS menu entries While it is possible to do operating frequency calibration at this time we recommend that it be done after assembly and test have been completed The calibration procedure is described on page 68 48 ELECRAFT Assembly Part In Part III you ll install and test the transmitter and lowpass filter components LJ Install zener diode D7 1N4756A next to resistor R30 Be sure to align the banded end of the diode over the band on the board LJ Remove the VFO knob if you haven t done so already LJ Install trimmer potentiometer R4 100 ohms 101 next to diode D7 and resistor R30 as follows Position R4 100 ohms 101 and hold it in place while tack R9 300 ohms org blk brn soldering one pin MIEL _ Check to be sure all the shoulders of all three pins are against DEI ph the board the solder and trim all three pins LJ Turn the board top face up with KX1 in the upper left corner Install the following 1 4 watt resistors to the upper left of encoder 71 R31 1k brn blk red Note On some boards R31 may be printed in reverse mirror image Set R4 fully counter clockwise LJ Turn the board bottom face up with Jack J1 in the upper right corner Install the following 1 4 watt resistors near the center of the top edge R30 22 ohms red red blk above relay K1 R26 22 ohms red red blk above electro
106. r external keyer PDN paddle normal or PDR paddle reverse Tap MENU twice to return to the VFO display The speed may varied from 8 50 WPM Display speed by holding SPEEDI then adjust it using the VFO knob Tap any switch to return to the frequency display The KX1 does not transmit when adjusting the keyer speed LJ While listening with headphones test the keyer paddle to verify that both dot and dash are working ELECRAFT Receiver Alignment There are two receive band pass filters to align The trimmer capacitors are adjusted through the bottom of the board as shown in Figure 17 The 14 MHz 20 meter filter has two adjustments labeled 20A and 20B on the PC board while the 7 MHz 40 meter filter has just one labeled 40 Two additional holes labeled 30A and 30B are provided for use with the optional 30 meter module The 14 MHz 20 m trimmers must be aligned first then the 7 MHz 40 m trimmer as explained in the following steps 20A 20B 40 BOTTOM OF BOARD 30B 30A Figure 17 Trimmer Adjustments Only one adjustment is required on 40 meters because the first tuned circuit is somewhat broadly resonant on this band allowing the use of a fixed capacitor 45 LJ Set the RF GAIN control fully clockwise Set the FILTER control fully clockwise LJ Plug in a pair of headphones or an external speaker and adj
107. s D2 1N5817 D3 1155817 With board face in upper left corner position 28 socket in the space provided for U1 in the lower left quadrant of the board The outline has SOCKET inside of it Zi DO NOT TRIM the 28 pin socket pins before or after soldering These pins are hollow and form the lower part of the socket for the IC pins ELECRAFT Zi Do not substitute a different socket for the one provided The very low profile of the supplied socket is required for the case to fit together during final assembly LJ Orient the socket so the notch at one end is toward the left edge of the board aligned with the notch in the printed outline LJ Hold the socket against the circuit board and tack solder pins at opposite corners of the socket Zi Do not overheat the socket pins Too much heat will melt the plastic socket Use only enough solder to make a good joint LJ Check to ensure that the socket is pressed against the circuit board at both ends If necessary reheat the pins at each end and press down on the socket so it rests directly against the board LJ Solder all 28 pins Double check your work and inspect each pin Use a magnifier if necessary If a pin is missed or poorly soldered it may make contact during initial testing but become intermittent later Such intermittents can be very difficult to troubleshoot Remember do not trim the socket pins ELECRAFT LJ Turn the board fac
108. s middle pins to hold it in place Re heat the soldered pin while pressing down on the relay This will ensure that it is flush against the PC board Solder the remaining pins Trim all of the pins as short as possible Install relay K2 AGN2104H to the left of K1 following the same procedure ELECRAFT LJ Turn the board face up so that KX1 is in the upper left corner LJ Locate the pins for K1 in the upper right quadrant Install C56 68 between pins 2 and 3 of K1 as shown in Figure 13 There are no solder pads for C56 Cut the two relay pins and solder the capacitor leads directly to the pads for the relay pins Be sure the capacitor does not exceed 5 16 7 9 mm in height above the board C56 IS SOLDERED DIRECTLY TO PINS 2 AND 3 OF RELAY 1 THA ND Note There are a A of COMPONENTS shown in this picture that you have not installed yet Figure 13 Installing Capacitor C56 ELECRAFT LJ Install electrolytic capacitor C53 10 uF 35 V between diode D4 and capacitor C21 in the lower right corner of the board as follows Insert the capacitor with the longer lead through the square pad with the symbol printed next to it Check to ensure the strip and minus sign on the capacitor is on the side opposite the sign on the board Solder one lead and be sure the capacitor is firmly against the board Measure the height above the board and confirm that it is less than 5 16 7 9 mm If necessary re
109. stal Tin the top of the crystal nearest the lead with a small amount of solder Keep the soldering time to 3 seconds or less to avoid overheating the crystal Allow the crystal to cool if you need to apply heat more than once It often helps to tin the case more quickly if you lightly scrape the metal with a knife or a screwdriver blade first Bend the ground lead so it lies flat against the top of the crystal where it is tinned and solder it to the top of the metal case Install white LED D1 as follows Locate flat side on DI s flange Position D1 over the outline in the lower left corner of the board with the flat side of the flange toward the corner of the board Bend the leads so that when they are inserted through the solder pads D1 rests against the board as shown in Figure 9 Note This LED is provided to illuminate your note pad or log while operating in the dark The slight downward angle will help direct the light down onto the table top Check to ensure that the flat side of the flange is toward the corner of the board D1 will not work if it is installed backwards Solder and trim both leads ELECRAFT FLAT ON FLANGE MUST FACE TOWARD THE CORNER OF THE BOARD Figure 9 Installing LED D1 Turn bottom face up with the outline for J1 in the upper right corner LJ Position J1 DC power connector on the board so the three tabs on the bottom of the jack fit through the slotted solder pads
110. t corner LJ Install electrolytic capacitor C7 220 uF 25 v at the center of the board near resistor R28 Be sure to observe the proper polarity as you did above Save one of the clipped leads to use in the following steps 21 LJ Turn the board over so the top face is up and test fit the low profile crystal in the space provided for X1 near the bottom edge below the socket for U1 The crystal may be installed either way Note The holes in the solder pads for X1 may be larger than necessary to fit the leads This is normal It is to accommodate different styles of leads on the crystals supplied with some kits Zi Do NOT use more solder than necessary on the leads for X1 Too much solder will wick through the holes and may cause a short to the case of X1 underneath the crystal The short is impossible to see or correct without removing the crystal Spread 1 5 leads as necessary to hold crystal against the board and solder one lead Do not hold your iron on the lead more than 2 or 3 seconds maximum Too much heat will ruin the crystal Check to ensure that X1 is sitting directly against board If necessary reheat the soldered lead while pressing down on the crystal L Solder the second lead to X1 and trim the leads flush 22 LJ Use a discarded component lead to ground the case of the crystal as follows Solder one end of the lead in the ground hole near the edge of the board to on the left side of the cry
111. the normal display S Meter and Voltmeter Displays DISP function holding BAND RIT together selects one of three display modes On power up frequency display mode will be in effect Hold to select S meter mode which will flash a 6 segment bar graph across the upper portion of the display The display may then go blank or show 1 or more segments since the S meter has not been calibrated The SIG menu entry is used for this purpose it is described later LJ Hold BAND RIT together again to select voltmeter mode You should see BAT battery flash briefly on the LED Your approximate power supply or battery voltage will then be displayed and will flash slowly LJ Return to frequency display mode by holding RIT again nor normal will flash briefly before the frequency is displayed ELECRAFT Keyer LJ Plug a keyer paddle into the key jack J3 The paddle must have a stereo 2 circuit plug If you don t have a keyer paddle you can still test the DOT and DASH lines by unscrewing the shell from the supplied stereo plug and inserting it in the KEY PADDLE jack Use a clip lead or a screwdriver to short the tip or ring terminals to the ground terminal to trigger dots or dashes MENU and rotate the VFO knob to locate INP menu entry CW input device selection Hold to see the parameter Turning the VFO knob selects HND hand key o
112. the pause between messages during auto repeat can be programmed using the RPT menu entry 0 255 sec Long delays are useful for beacons Keyer Test Mode To play back messages without transmitting use keyer test mode In this mode you ll see 0 on the LED during message play rather than the transmit bargraph To turn keyer test mode on off locate the PL Y menu entry then tap the VFO knob You ll see 0 and nor on alternate taps ELECRAFT Receive Mode Selection CW LSB USB The KX1 provides three receive modes CW nor or normal LSB and USB Hold MENU RIT to select the desired mode In CW nor receive mode LSB is used on 40 meters and USB is used on 30 and 20 meters In this mode a CW offset is introduced on receive which means that you must match received signal pitch to your sidetone pitch to determine a station s carrier frequency CW mode also provides a 1 kHz fast VFO tuning rate compatible with ham band tuning LSB and USB receive modes have no receive CW offset so the VFO will show a station s carrier frequency when a voice signal is tuned in properly SSB or when a carrier is zero beated AM or CW The required CW offset is instead introduced on transmit These modes also provide a 5 kHz fast VFO tuning rate useful for tuning SWL band segments Cross mode CW SSB operation Cross mode contacts can be made in all three of the 1 5 receive modes without the need to use RIT When
113. to 4 10 2 cm in length and strip the insulation off of 1 4 6 mm at the end LJ Position the second holder on the bottom cover oriented as shown and start a screw in the hole nearest the edge of the cover closest to the bottom in Figure 25 Do not tighten this screw yet Leave it loose enough so that the other side of the holder can be lifted up off of the cover far enough to slip wires underneath ELECRAFT LJ Slip the three wires shown in Figure 25 under the edge of the holder as follows Position the red wire so it goes under the holder and around the nub at the corner Position the two black wires so the screw will prevent their being pulled out from under the holder Be sure the wires lie flat and do not cross over each other under the holder LJ Insert the remaining screw in the holder and tighten both screws LJ Wiggle all three wires running under the left battery holder to be sure they are not being pinched You should be able to move the free end of the black wire and see it move where it emerges from under the holder without interfering with the other wires If necessary loosen or remove the top screw and adjust the wires so each one lies flat under the holder Tighten both screws when you are done LJ Cut a 1 2 5 cm length of the black shrink tubing supplied and place it over the end of the red wire on the right hand battery holder LJ Twist the ends of the red wire from the right holder and the black wire fr
114. ulators used in the KX1 U7 and U9 respectively are low dropout types which may oscillate if their bypass capacitors are defective or are of the wrong value If you see high AC voltage at any of the points indicated above verify that electrolytic capacitors C7 C10 and C38 are installed in the correct orientation and that their leads are properly soldered If they are you may be seeing a false AC voltage indication due to noise or probe leakage re test using a different DMM ELECRAFT The Tap Hold Rule Each of the push button switches on the front panel has two functions one activated by a TAP short press and the other activated by a HOLD long press about 1 2 second The upper label on each switch shows the TAP function white lettering and the lower label shows the HOLD function yellow lettering To highlight this in the text we use two different typographical styles to identify switches and 018851 Accessing the Configuration Menu LJ Tap MENU to enter the KX1 s configuration menu You should see LED on the display which is the first menu entry display brightness setting and timeout period Try rotating the VFO knob which scrolls through all 16 menu entries LJ Use the knob to return to the LED menu entry Then hold to change the LED parameter The display will change to L followed by a number from 0 to 6 Tap BAND RIT to change display brightness Settings of 2 or 3
115. ulling open the bottom cover PLACE SERIAL NUMBER HERE Figure 28 Installing Serial Number Label ELECRAFT LJ Components on the bottom of the board must have an overall height of no more than about 1 8 3 mm above the PC board in the area shown below See Figure 29 Fold down or re solder components if necessary Also trim any long component leads which were not trimmed earlier COMPONENTS IN THIS AREA MUST NOT EXCEED 1 8 3MM ABOVE BOARD TO AVOID STRIKING BATTERIES Figure 29 Checking Component Clearance LJ Set the chassis top cover and circuit boards next to the bottom cover as shown in Figure 29 and attach battery connector J5 to plug P1 on the main circuit board 61 A When you install the bottom cover in the next step be sure not to pinch the battery cable under the nearby long standoff Fit the bottom cover place secure it with two 4 40 black knurled thumbscrews This completes assembly of your 1 Transceiver You should have a number of washers screws and other hardware left over These items have been provided as spares Please read the Operation section which follows and try each of the KX1 s features If you re new to be sure to read the QRP Operating Tips section page 70 AN If you have purchased 1 internal options do not install them until becoming familiar with basic KX1 operation Options can be installed any order All KX1 opti
116. ust the AF GAIN control until you hear some background noise If you do not hear any noise refer to Troubleshooting LJ If the present band is not 14 MHz 20 m tap twice quickly to select it LJ Set the VFO to about 14100 kHz Tap BAND if necessary to verify that you re in the right 100 kHz segment Connect appropriate antenna for 20 meter band At minimum connect approximately 15 30 feet 5 to 9 meters of any type of wire to the center conductor of J7 In general the longer and higher the antenna the more signal strength that will be available during receiver alignment A Receiver alignment will be easiest if you use a controlled signal i e from a ham band transmitter signal generator or noise generator In all cases use a signal that is weak enough to not activate the KX1 s AGC otherwise it will be much more difficult to find the correct settings for the trimmer capacitors If you use a transmitter be sure to connect it to a dummy load and operate it at low power 46 LJ Locate a small flat blade screwdriver or tuning tool for use in adjusting the trimmer capacitors Test the tip of the tool to make sure it will through the access holes and can turn the trimmers If the handle is not insulated wrap the end with tape to prevent your hand capacitance from affecting the adjustment Zi The trimmer access holes on the revision B and B1 KX1 PC boards are plated through and grounde
117. w hole Just above capacitor Test Point Resistance 01 Pins 1 3 4 and 20 gt 1k Ul pins 8 and 19 lt 5 ohms U1 all other pins gt 10k lt 5 ohms gt 10k U3 all other pins D2 or D3 cathode banded end 51 D2 or D3 cathode 51 Off gt gt 10 ELECRAFT Alignment and Test Part I In this section you ll become familiar with basic KX1 operation while testing the control and display functions Zi Microcontroller U1 is extremely static sensitive Wear a wrist strap or ground yourself before handling U1 LJ Remove microcontroller U1 from its conductive foam packing and inspect the pins The two rows of pins must be straight and parallel to each other to establish the proper pin spacing for insertion into the socket If necessary straighten the pins as shown in Figure 5 L Identify the end of the IC where Pin 1 is located It will have a notch a dimple or both at this end see Figure 11 Zi When U1 is pressed into its socket you must be careful to avoid jamming its pins Make sure all the pins are lined up with the associated holes before pressing down on the IC Watch the pins on both rows as you press down to be sure each pin goes straight down into its socket hole and does not bend in under the IC or outward alongside the socket Realign each pin individually with its socket hole if necessary LJ Insert microcontroller U1 in its socket with pin 1 or the notched end lin
118. wice to make sure that the battery or power supply voltage is not being pulled down when the is turned on If it is it could indicate a short incorrect component somewhere in the transmit stages ELECRAFT LJ Repeat the receiver alignment steps page 45 This is necessary because some components added in Assembly Part III may affect the tuning of the receiver s band pass filters A If receiver gain seems to be too low after re alignment you may have an assembly error in the transmit stages low pass filter or T R limiter Q7 Turn the KX1 off remove the top cover and re check the orientation of all diodes transistors and ICs Look for shorts on both the top and bottom of the board in the transmitter area Also see Troubleshooting Turn the KX1 off Connect 50 ohm dummy load to antenna jack along with a wattmeter if available The dummy load should be rated at 5 watts or higher Connect key or paddle Set 4 fully clockwise Turn ELECRAFT A TUNE mode key down is activated by pressing the MENU and switches together Tapping any switch or the keyer paddle will cancel TUNE During TUNE the display will show tun If the ATU option is installed the display will instead show both power output in watts and SWR Refer to the KXAT1 manual for details 20 Meter Transmit Test Switch to
119. ycap square blue 6 mm Zi Handle with care ESD Sensitive UI IC MCU 16 876 E600075 Pre installed on board IC DDS AD9834 SMD ELECRAFT E640015 E640016 E640017 E610017 E600076 ELECRAFT Zi Handle with care U3 IC TC4427 dual driver E600077 ESD Sensitive U5 U6 IC NE602 or NE612 mixer E600006 7 Pre installed on board TPS76427 2 7V 5 SMD 6600078 A Handle with care Ug IC 78L05 5 V regulator E600029 ESD Sensitive IC 77L06 Low dropout 6 V regulator E600079 Crystals 4 9136 MHz matched set of 4 using p n E660000 E850162 Crystal 3 995 MHz low profile HC49 US E660020 Encoder 80 Counts w PB switch E640018 Pre Installed on Board Oscillator module 50 MHz SMD E660021 9 ELECRAFT HDWR Shoulder washer E700001 MISC Battery holder 3 AA cells E980071 HDWR Screw 2 56 x 1 8 Panhead Phillips black E700084 2 spares HDWR Standoff 4 40 x 5 16 long 3 16 dia hex 2 E700083 Male Female HDWR Standoff 4 40 x 3 16 long 3 16 dia hex E700068 HDWR Standoff 4 40 x 3 4 long 3 16 dia hex E700085 HDWR Split lock washer 4 2 spares Re E700004 HDWR 4 40 x 5 16 thumbscrew black oxide 700050 HDWR m x 1 4 undercut flat head Phillips black 700082 ELECRAFT A10 amp HDWR Screw 4 40 x 3 16 pan head Phillips black E700015 MISC Rubber foot self adhesive 700024 MISC top cover E100172

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