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E L E C R A F T K 1 T R A N S C E I V E R

1. While listening with headphones test the keyer paddle to verify that both dot and dash are working If you use a dual lever keyer paddle you may wish to use the menu slAB entry to select iambic mode A or B page 55 Relays Filter Board and Attenuator Turn off the K1 Plug in the Filter board assembly The connectors on the Filter board must be fully inserted into J6 7 and 8 on the RF board Turn the K1 on The LCD should show E42 You may also hear one or more relays switching Tap BAND twice quickly to change to the next band Tap BAND two or more times quickly to return to 7 0 MHz Test the attenuator relay and the yellow LED by holding Hold again to turn the attenuator off 38 VFO Alignment Turn the K1 off and disconnect the power supply Two different capacitors are supplied for setting the approximate VFO range C2 68 pF disc and C2A 120 pF polystyrene 68 pF provides a range of about 80 kHz 120 pF provides a range of about 150 kHz Other values can also be used builder supplied Based on your VFO range selection page 12 install the appropriate capacitor at C2 Save the other for possible future use If you use the 68 pF disc cap pre form the leads to match the pad spacing for C2 wind L1 on a T50 6 toroid core yellow 1 2 12 mm diameter Use 24 inches 61 cm of red enamel wire Wind 33 turns on L1 leaving the
2. APPENDIX G ELECRAFT 1 Introduction The is a versatile low power CW transceiver that covers two or four builder selected HF bands It provides 5 watts or more of power output excellent receiver sensitivity and selectivity and many useful operating features including instant band selection receive and transmit incremental tuning RIT XIT digital display configuration menu and multiple crystal filter bandwidths With receive mode current drain of about 55 mA built in keyer and a stable low frequency VFO the K1 is ideal for portable operation It s also one of the smallest multi band HF transceivers available smaller than many single band rigs And when used with the optional wide range tilt stand KTS1 the is truly trail friendly The tilt stand comes with long arms for ground mounting see below as well as shorter arms for desk top use Like our all band K2 transceiver the K1 uses modular construction allowing it to adapt to your operating needs The Filter board covers either two KFL1 2 or four KFL1 4 bands and a different Filter board can be swapped in at any time There are two plug in options including a noise blanker KNB1 and automatic antenna tuner There s also an internal AA cell battery option KBT1 These options can be installed easily at any time The K1 s modular assembly will also appeal to first time builders The kit requires almost no point to poin
3. Hold to turn on the sidetone and edit the pitch parameter The pitch can be varied from 400 to 800 Hz using and WPM Select the desired pitch then tap MENU to end parameter edit and return to STP Tap M ENU again to return to the normal display in this case E42 because of the missing VFO signal Voltmeter On power up the LCD shows the operating frequency with 100 Hz resolution Holding once selects S meter mode Holding again selects voltmeter mode You should see BAT flash briefly on the LCD then your approximate power supply or battery voltage which will continue to flash slowly Return to the operating frequency display by holding again You should see E42 as explained previously 37 Keyer Note If you don t have a keyer paddle you can still test the DOT and DASH lines by using test clips to touch them to ground Plug a keyer paddle into the key jack J3 The plug must be stereo 2 circuit A stereo plug is supplied with the kit Tap MENU and locate the INP menu entry CW input device selection Hold 8 to see the parameter which defaults to Hn d hand key or external keyer Use WPM W P N to select either PDn or PDr paddle normal or paddle reverse Then tap MENU twice to return to the VFO display Select the keyer speed using WPM and WPM If you tap these switches quickly the speed will jump 2 WPM at a time
4. CATHODE COUNT PINS STARTING AT GREEN ANODE PIN 1 AND GOING COUNTER CLOCKWISE 8 PIN DIP SHOWN ORANGE ANODE ANODE special Symbols Elecraft K1 Schematic Key E bottom of PC board W Burdick Rev Date Sht E Swartz A 9 4 00 1 of 1 Appendix B lt VFOPOT 36 2G 2F 2A 2B 1G DS1 1 G i G 1 G LCD el 1 1 8 D pp D D Pushbutton Switches 3E 3D 3C 3DP 2E 2D 2C 2DP 1E 1D 1C 1B First label corresponds to switch TAP second label corresponds to switch HOLD s 1 WPM R14 DISPLAY FILTER L L R15 C 1K M MENU WPM OFFSET S2 55 6A LD lt EDIT ATTEN RF SMTR gt L O 5 i SR ANN PF1 REC RP1 a 1K gt D A Converter EEPROM U2 er ET MAX518 24LC04 R16 6A U1 PIC16C77 e XFIL TONE ZR78L06C R12 U5A 2 7K 100K LM358 M DVM ATTN Ey lt 95 Q gt N 2 4124 D Counter Amp OFFSET gt Pa 15 M eb S cw 10K ds lt RF SMTR Offset me Elecraft K1 Front Panel Board 187575117 11511112 8502881252552 Byw Burdick Pe Owe R5 AF Gai V E Swartz E 1 15 02 1 of 1 10K ain J1 1 Appendix XFIL TONE 100K 6A Q3 Attenuator Receive Mixer C24 2N4124
5. axial leads like a resistor Note the kit also includes a 120 pF polystyrene 120J Install C11 in the VFO area of the board near J6 Limit soldering time to 2 3 seconds 28 Install the resistor networks listed below checking the part numbers carefully before installation Orient the black dot or bar on each network towards pin 1 of its component outline RP3 47 k 10 pins 10A3473G 103C104 or 770103473 RP1 100 k 8 pins 8A3104G 83C104 or 77083104 RP2 100 k 8 pins 8A3104G 83C104 or 77083104 RP6 27 6 pins 6A3273G 63C273 or 77063273 RP4 3 9 6 pins 6A3392G 63C392 or 77063392 RP5 3 9 6 pins 6A3392G 63C392 or 77063392 LJ Install a 33 uH RF choke ORG ORG BLK at near the front edge of the board Orange bands may appear to be brown Install a 100 uH RF choke BRN BLK BRN at RFCA in the transmit area of the board The ceramic trimmer capacitors C13 and C20 have one side that 1s flattened This side must be oriented towards the flattened side of the component outline Install C20 near the front edge of the board and C13 in the back left corner Sort the diodes into groups for identification purposes You should have two types of small glass bodied diodes 1N5711 and The 1N4753 zener diode may also be glass is larger 1 4148 If necessary use a magnifying glass to read the labels AN Diodes with long axi
6. Internal Keyer To use a keyer paddle use the menu to set INP to PDn or PDr normal or reverse paddle With PDn selected the tip contact on the stereo key jack is DOT and ring the middle contact is DASH PDr is the reverse Keyer Setup Keyer Speed Use the WPM and WPM switches to select the desired CW speed The display will show the speed in WPM Tapping either switch quickly two or more times will cause the speed to jump in 2 WPM increments Iambic Mode Selection If you use a keyer paddle with two mechanically independent levers you can use iambic keying meaning that both the DOT and DASH paddles can be pressed at the same time to generate a repeating DOT DASH or DASH DOT pattern With practice this can improve sending efficiency The IAB menu entry allows you to select from two Iambic modes A or B If you re not sure which to use select mode A the default which has more forgiving timing characteristics Mode A is similar to mode A of the Curtis keyer IC mode B is similar to Super CMOS Keyer III mode B Keyer Test Mode At times you may want to disable the transmitter completely so that you can practice recording messages or just sending code with the keyer The K1 has a built in Keyer Test mode for this To activate keyer test mode first select the OUT menu entry and hold to display the power output level Next hold The power output parameter will change to P 0 indicating that the transmi
7. that will eliminate possible confusion during assembly LJ Open the bag of components for band 1 only setting the band 2 components aside for now AN The leads on small capacitors may be pre formed so that the capacitor sits slightly above the board when inserted this will not affect performance The leads are also somewhat fragile Install the capacitors for band 1 using the reference designators and values from the appropriate columns in the parts list For example if band 1 15 40 meters install 390 pF capacitors at Cl and C5 then 330 pF capacitors at C2 and C4 etc Double check each capacitor value as it is installed Do not solder yet LJ Solder all of the band capacitors ELECRAFT At this point you ll need to choose whether to set up the VFO for 80 kHz or 150 kHz coverage approx The smaller range covers the most used portion of every band provides smoother tuning and is strongly recommended if you plan to upgrade to the four band module KFL1 4 which has narrower band pass filters Record your VFO range selection here for reference _ 80 kHz 150 kHz Note Two different crystals are supplied for 30 meters corresponding to two different lower band edges Which one to use depends on your selected VFO range see below In the following steps you ll select one of the two crystals when applicable VFO Range Band Edge 80 kHz 18 100 10 100 30 Meters
8. 150 kHz 18 000 10 000 If band 1 is 30 meters select the appropriate crystal using the table above Save the other crystal for possible future use Install the band 1 crystal at X1 on the filter board to the right of X2 bending the leads to hold it in place Make sure the crystal 15 seated correctly then solder Use a minimum amount of solder to avoid a short under the can Move the strips of paper or labels that you used earlier so that they cover the band 1 reference designators column and all of the components columns except the column associated with band 2 Open the components bag for band 2 Install the band 2 capacitors using the reference designators and values from the appropriate columns as before Example if band 2 1s 20 meters you ll install 180 pF capacitors at C6 and C10 etc Locate the band 2 crystal and verify that it is the correct frequency If band 2 is 30 meters select one of the two crystals supplied see table above Install it at X2 and solder ELECRAFT LJ Cut two 3 4 19 mm bare wires use component leads LJ Referring to Figure 4 1 insert bare wires into the grounding holes provided near X1 and X2 Fold each wire over the top of the crystal and solder it on top Keep soldering time below 5 seconds at a time if it takes longer your iron may not be hot enough or your iron tip may not be making good contact with th
9. To access the operating frequency calibration display locate CAL in the menu then hold You ll see OPF briefly then the operating frequency will be shown with the 100 Hz digit flashing If you see E42 the VFO is not functioning WPM WPM until the displayed frequency matches the frequency of the known signal In the case of the internally generated signal tap WP M or WPM until the display reads 99 7 Tap MENU twice to return to the normal display Tap BAND twice quickly to switch to band 2 Repeat the calibration procedure on this band If you have a 4 band Filter board installed repeat the procedure for bands 3 and 4 AN You can calibrate the dial on transmit rather than receive if desired after completing Alignment and Test Part II In this case you ll need either a frequency counter or a calibrated ham band receiver to verify the actual transmit frequency You ll then use the CAL menu entry as described above to check and adjust the operating frequency after each transmission 4 AGC Automatic Gain Control and S Meter Test Turn the K1 on and connect an antenna or signal generator S meter display mode provides a bar graph to indicate approximate received signal strength To select this mode hold BTE You should see a brief bar graph test pattern then the display may go blank or show one or more bars Tune in a strong signal A
10. 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 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 10 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 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 A number of sugge
11. 6 RF Board Part I In Part L the VFO TUN TI d LJ Locate the RF board and orient it as shown in Figure 6 1 This En oscillator and receiver illustration shows the major areas of the board Receiver and VFO vice circuits occupy the front half transmitter and T R switch stages use Open bag labeled RF and sort components into groups the rear half The Filter board plugs into J6 J7 and 8 Observe anti static precautions when handling transistors and ICs gas Ta cre Figure 6 2 shows the bottom side Four 2 D fasteners will be attached to the RF board at the indicated locations to secure it to the chassis panels T R Switch and Transmitter 2 D Fastener Receiver Figure 6 1 Figure 6 2 26 Locate a 2 D fastener and hold it vertically Figure 6 3a Looking at a side with two holes note that the holes are offset from the center The PC board outlines for the 2 D fasteners have a matching offset which will aid in installing them in the next step Holes offset from center a Q b l l Tel Figure 6 3 Install 2 D fasteners at the four locations indicated in Figure 6 2 on the bottom of the RF board Secure each fastener from the top side of the board with 3 16 4 8 mm pan head screws and 4 split lock washers Figure 6 3b Make sure that the 2 D fasteners line up with the edges of the PC board and do not hang over If the
12. ELECRAFT Position 20 pin male right angle connector on bottom of the RF board Figure 6 5 but do not solder yet Review Figure 3 3 for correct placement The short ends of the bent pins are inserted into the holes and the long ends are parallel to the board Top of board Front edge Figure 6 5 Solder just the two end pins of P1 Make sure that the front panel assembly can be plugged into P1 as shown in Figure 3 3 Then unplug the front panel assembly Look closely at 1 to make sure that its plastic support 15 pressed down as far as it will go and that the pins are parallel to the board If not re heat the soldered ends while pressing it into place Once it 1s seated properly solder the remaining pins AN In the steps that follow you ll be installing larger groups of components When working from a long list install all of the items on one line before moving on to the next Arrows appear in the list to remind you of this order In general assembly proceeds from left to right across the board Note All components mounted in the T R switch and transmitter areas must be kept as low profile as possible since the Filter board will be plugged in directly above 27 Install the resistors listed below R23 is at the left front edge __ R23 1 5 Q BRN GRN GOLD R7 680 BLUE GRAY BRN R21 2 7 k RED VIO RED R13 2 2 M RED RED GRN R2 100 BRN BLK YEL R16
13. ELECRAFT KI TRANSCEIVER TEM UP ATTN WPM BAND 2 ELECRAFT _ OWNERS MANUAL ELECRAFT Multiband 011 CW Transceiver T ELECRAPI Owner s Manual Revision F January 24 2002 Copyright 2002 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 1 ux 3 D JSBECIRICATIONS u ce ICD M M LN MM D DL E EDAM IE 5 3 PREPARATION FOR ASSEMBLY et eine 6 45 BOARD DLL uyanan 11 5 FRONT PANEG BOARD lll DM ead 17 6 PL BOXRE PART ae EE 25 7 ALIGNMENT AND TEST PART 36 8 RF BOARD u u uuu usnu tere ee ee 42 9 ALIGNMENT AND TEST PART 46 10 FINAL 125 0212 RR 4 11 OPE 111 2 ce A LI nee ee 50 12 lt uu nn ce 58 PARTS LM ML LE APPENDIX Tes 2 P Wa eM APPENDIX B BLOCK DIAGRAM 7 APPENDIX PHOTOGRAPHS 0 APPENDIX D TROUBLESHOOTING uuu un cr APPENDIX E PARTS PLACEMENT 0811186 APPENDIX F
14. Make sure VFO knob is rotated fully counter clockwise If the frequency shown is now higher than 3 100 7 squeeze the turns of L1 bunch them more closely together to lower the frequency You can squeeze the turns by hand or use the tuning tool Watch the frequency display as you adjust the turns If the frequency shown is lower than 3 090 MHz spread the turns of L1 out This raises the VFO frequency If the frequency cannot be raised to at least 3 090 by spreading the turns out you may need to remove one turn from L1 the non grounded end Note The final VFO frequency should be between 3 090 MHz and 3 100 MHz to make sure that the low end of each band is covered Once turns on L1 have been correctly adjusted tighten nylon screw so that the L1 s turns are held firmly in place This may shift the indicated frequency slightly ELECRAFT Band Assignments To see the correct display when you tap BAND you ll need to specify which bands are covered by your Filter board If you re still in the CAL menu entry tap MENU to exit Locate the B1 menu entry note that the b actually appears in lower case If B2 B3 or B4 is shown tap BAND to change it to B1 To check the present assignment for band 1 the lowest frequency band hold The default is 7 0 MHz Use or WPM to specify band 1 AN On 30 meters you have a choice of two band edges 10
15. N nf 0 T d 2 RFC3 C15 ee ef P10 TID 018 gt 5 12V 8 D9 1 NOT GND S D 790 n TR2 C72 C18 R21 lt 3 lt D c C74 C73 4 ji t Q C 2617 aa m id K1 RF Rev C10 2001 ELECHAFT CUT MONO Rev E 2001 ELECRAFT 85 SOCKET R9 US Bis lO K1 FIL2 Rev D lt gt 025 lt BENI iB SINE E C24 C C26 S QL Ilo 5 D m U F cal 2 C23 bs HB gt lt gt 7 9 K3 08 fe s CD N z 50 110 L X2 0 L ELECRAFT K QUICK REFERENCE Tap once to show band tap twice to change bands LCD LEDs Hold to select display RX VFO freq or S meter RIT XIT GREEN ORANGE mode normal S meter TX bargraph 1 bar per watt YELLOW or BAT supply voltage Hold both for TUNE during TUNE can change power w WPM BAND Jap for WPM up Hold for FL1 2 3 DISPLAY MENU Tap for WPM down Hold for ATTN on off to play message 1 or 2 hold to record message 1 or 2 when prompted with 1 2 during message play tap 1 or 2 for single play hold 1 or 2 for auto repeat Tap for RIT on off hold for on off PFn normally XIT see MENU VFO MENU Tap to enter menu hold to edit use W
16. metal flat washer fiber washer Figure 10 2 ELECRAFT Cut a 5 13 cm length of two conductor speaker cable Remove 1 4 6 mm of insulation from the wires at both ends Solder crimp pins to the two wires at one end Figure 10 3 Copper wire Pin side Hous Crimp pin Figure 10 3 AN When you insert the crimp pins into the housing in the next step they should snap into place Each pin has a small tab on the back that latches into a hole in the housing when inserted Insert the copper wire into the pin 1 position of a two pin housing as shown Insert the other wire into the pin 2 position Connect the other end of this cable to the speaker terminals The copper wire should be connected to the lug marked on the speaker Solder both wires If there are any missing chassis screws in bottom cover side panels or front panel install them now 49 Plug internal speaker cable into P2 RF board The connector is keyed and can only be plugged in one way AN When you install the top cover in the next step route the speaker cable along the right side of the cabinet away from the pins of the microcontroller front panel UI The speaker wire could pick up signals from the microcontroller causing receiver interference Place the top cover onto the chassis Secure the top cover using tw
17. Driver Key Keyer Paddle install a jumper at RFC8 R29 27 Rag 12V R30 J3 33 0 3 30 7 BUF RFC8 Transmit Mixer Osc C53 220uF lt gt C29 C28 Buffer 12v_2 gt 59 T EGER 001 001 DASH DOT O O U9 LT1252 C14 001 C15 i lt PREMIX 6 R35 1N4007 RP5 V7 120 3 9K C58 R11 N N L 01 82 Transmit Attenuator 20K C16 Rp4 1 L 014 2N4124 6R_2 D 4 915 MHz Elecraft K1 RF Board RFC2 50 By W Burdick Rev Date Sht 330 1 8K V 0 Transmit signal tracing points see text Appendix Premix Band Pass Filters RF Band Pass Filters C2 Band 1 C4 C1 L See Note 2 12 Band 1 L C1 C5 2 9 C11 3 1 L2 8 d 5 RF IN Band 1 Band 2 PREMIX ATTN RY AGC OFF 112 3 4 5 6 7 8 L IBID To RF J6 To RF J7 Notes 1 J1 and J2 are supplied with the KAT1 option Antenna Tuner If the KAT1 is not installed J2 pins 2 and 10 must be connected using a jumper see text 2 See Parts List for values of all band specific components 3 K1 K3 are latching relays and are shown in the RESET position Pins 5 and 6 of relays are not connected internally but may be used as tie points for other circuitry on the PC board 4 This schematic is for the 2 band Filter board Refer to KFL1 4 manual for 4 band Filter baord schematic C14 3 C15 2 L6 3 O 4 7 4 C7 Band 2 CIT Band 2 cig C8 C18 C6
18. large hole in the board you ll find three pads for 5 leads labeled 1 2 and 3 Referring to Figure 5 9 insert the potentiometer s wires into their corresponding holes Do not solder yet AN Caution If the leads of R1 are not connected to the correct pads the potentiometer is very likely to be damaged Re check the connections then solder R1 s leads on the top side of the board Avoid touching nearby parts with the iron ELECRAFT Install caps on switches S1 through S6 S3 s cap 15 square while the others are rectangular as shown in Figure 5 10 The caps are installed by pressing them onto the switch plungers Figure 5 10 AN The LCD s glass surface is protected by a very thin nearly invisible piece of protective film In the following step be very careful to remove only the thin film not the LCD s glass top Do not use any type of metallic tool Hold the Front Panel PC board assembly under a strong light so that you can see the surface of the LCD glass clearly Using a fingernail rub one corner of the LCD s glass top to loosen the protective film then peel it off Locate the front panel chassis piece Place it on a soft cloth to protect the finish and labeling Some holes in the front panel are masked on the inside surface during painting If masking tape usually green in color is still present you ll need to remove it To remove masking tape Use a blunt instrument such as a ball point pe
19. 2 2 7K 237000 01 R23 6A 1 59 OFFSET DH RFC6 HE E PD 1 D1 C30 100uH 0 1 1N4148 047 V y N 6R AUX 2 dg g TT REE me cO YY YYYY J UU c36 01 iL po ise S T 1 2 3 4 5 7 10 11 12 13 14 15 16 17 18 0 Elecraft K1 RF Board J2 v v V V V V V V V V V V V V V V P1 By i Rev Date Sht C72 C69 W Burdick Swart G 1 5 02 1 of 2 Ext Speaker Int Speaker Appendix B 6R AUX gt C45 01 RFC4 144007 49 100HH 011 012 E 01 C75 RFC7 p 0 100uH i K1 ATTN Relay E 10 1N4007 2 1 1 J8 To FIL P3 R27 1 8K L2 47uH 1N4007 R24 D 12 3 4 7 8 2 7K J7 lt 2 5 48 To FIL P2 D9 TOORN C46 7 01 1 4007 0 1 1 Q4 ZVN4424A RF SMTR 1N5711 Io T R Switch 9 a dud 0 100K 01 2260 6T gt 1 RF Det BEGG EN e T Source RCV RF SS 0 1 xL RF Output Detector y C50 C78 047 78 is supplied with ar le f the KAT1 ATU is installed jumper P3 pins 2 3 D5 27 EB the 80 band kit If not P3 pi D19 jumper P3 pins 1 2 01 1N4753 TR1 36V s TR2 DRV C1 150 3 D14 R33 1N4007 470 L xb R31 R32 x Q7 N 33 33 NZ 2SC1969 p R28 i 27 820 RFC8 is supplied with the Q6 N 80 m band kit If 80 m is not used Wa 2SC2166
20. 5 1 16 1 5 mm above the board You can use the switch spacing tool a toothpick or short length of insulated hookup wire to Identify all of the 4 40 screws and sort them into groups maintain the proper spacing while soldering Install a 3 16 4 8 mm diameter x 1 4 6 4 mm long round Verify the orientation of DI s flat side then solder standoff on the top of the board Figure 5 6 The hole for this standoff 1s just below the large hole Use two 4 split lock washers LJ Install and solder D2 using the same method and a 1 4 6 mm pan head screw not black anodized as shown Insert the lock washers between the standoff and PC board ELECRAFT Inspect solder side of Ul s socket on top side of board Make sure all pins are soldered with no cold solder joints Using a DMM check every pair of adjacent pads on U1 on the top side of the board pins 1 20 and 21 40 The resistance between pads should be over 1000 ohms 1 k in all cases and may read infinite on your DMM often indicated by a flashing display A Before handling U1 in the next step touch an unpainted grounded metal surface Straighten the pins of the microcontroller U1 You can hold the IC body at the ends as you re form each row of pins into its socket with the notched end oriented Insert towards the pin 1 end of the component outline Look at both rows of pins on U1 closely If any pins are b
21. 75 VIO GRN BLK R17 120 BRN RED BRN 18 75 VIO GRN BLK R14 2 7 RED VIO RED 1 8 BRN GRAY RED These resistors start on the left edge of the board near 16 __ R19 39 ORG WHT ORG __ R20 20 RED BLK ORG R9 2 7 RED VIO RED R26 1 8 BRN GRAY RED __ R34 100 BRN BLK YEL the back right edge near 18 The following capacitors are all of disc or monolithic type Start with C26 which is on the left edge close to J6 Note C65 22 pF may be labeled 220J see top of page 9 26 39 39 _ C27 39 39 _ C42 220 221 C41 047 473 C30 047 473 C40 01 103 C25 01 103 C7 39 39 C4 01 103 C6 01 103 7 C69 220 221 C72 01 103 18 01 103 7 C74 01 103 7 C73 0 1 104 C64 01 103 7 C68 0 1 104 7 17 01 103 C32 047 473 C70 0 1 104 C75 01 103 C61 047 473 7 66 01 103 C39 220 221 C36 01 103 C71 0 1 104 7 C63 330 331 C24 047 473 C21 01 103 37 01 103 C24 0 1 104 __ C23 01 103 7 C65 22 22 2205 7 C19 001 102 7 C22 001 102 7 C38 220 221 C28 and _ C29 001 102 back left corner of the board __ 49 and C48 01 103 back right corner __ C45 01 103 near J4 which is on the back edge 1200 pF polystyrene capacitor C11 labeled 12004 has
22. RF board Adjust C20 for approximately the desired signal pitch Fine BFO Alignment Using the Sidetone Pitch Select your desired sidetone pitch using STP menu entry Many CW operators use 500 600 Hz or lower Exit the menu Tune a strong signal adjusting the VFO slowly until the signal strength is centered in the filter as you did above Turn on sidetone again using STP menu entry Adjust C20 so that pitch of received signal matches your sidetone pitch This is best done with both the received signal and sidetone at about the same amplitude The received signal will seem to disappear under or merge with the sidetone when the pitch is closely matched Tap MENU twice to return to normal operation ELECRAFT Operating Frequency Calibration The operating frequency display may be off by up to 10 kHz until calibrated due mostly to variations In the crystals on the Filter board Accuracy of 100 Hz can be obtained Note The approximate lower band edges in MHz are as follows 3 50 7 00 10 00 or 10 10 selected earlier 14 00 18 05 21 00 Select the lower frequency band using BAND Also select the narrowest filter FL 3 by holding 5 Tune in a signal at a known frequency centering the signal in the crystal filter passband Use a signal from a known accurate signal generator or check the signal s frequency using a second receiver
23. any rough surface rock dirt etc and tilt the display upwards to the ideal viewing angle It also keeps antenna and power connections away from the ground and provides a mounting point for a keyer paddle Refer to our web site for information on custom paddles Noise Blanker KNBI KNBI is effective in reducing pulse type noise such as that from power poles or automobile ignition systems Automatic Antenna Tuner KATI If the internal automatic antenna tuner is installed you can connect coax fed or random length wire antennas directly to the An inexpensive home made balun can be used with balanced lines In most cases the tuner will allow you to match one antenna on all bands Once you ve tuned up an antenna the tuner s L and C settings will be recalled instantly when the band is changed Internal Battery KBTI The KBT1 includes an 8 AA cell socket and a replacement top cover with a quick access battery door Any cell type may be used 58 12 Circuit Details While reading this section refer to the Block Diagram Appendix B and schematics Appendix C Overview The is a compact high efficiency CW transceiver capable of operating over a wide range of frequencies The two or four bands of operation are determined by a single plug in filter module allowing the builder to swap in a different set of bands if desired The firmware will recognize whether a two or four band board is install
24. cm 10 25 cm 9 22 cm 18 000 MHz x1 X2 11 500 MHz 15 000 MHz p n E660007 22 000 MHz 26 050 MHz 29 000 MHz p n E66001 1 p n E660008 or 18 100 MHz p n 660004 p n E660012 p n E660005 p n E660010 Value 1 E530068 E530049 E530005 2 or 2 2 E530047 E530008 E530002 Capacitor 2 7 3 or 3 3 E530065 E530042 E530035 Part Numbers 4 7 or 5 E530048 E530050 E530054 10 E530006 E530043 E530003 22 E530017 E530051 E530073 56 E530015 E530004 68 E530007 E530052 82 E530038 E530053 100 E530034 E530018 120 E530041 E530072 Appendix A K1 Misc Bag Parts List PICTURE Designators Description Part Number QTY ad 4 int tooth lockwasher 3 Spares 700010 10 iw 4 split lockwasher 4 Spares E700004 16 HW o6 screw 1 8 stainless steel fillister head 2 spares E700023 6 4 40 nut Steel zinc 2 spares E700011 9 4 40 screw 1 4 Panhead phillips steel zinc 700005 4 40 screw 3 8 Panhead phillips steel zinc 700036 1 4 40 screw 3 16 Panhead phillips black 5 spares E700015 25 4 40 screw 5 16 Flathead phillips undercut BLK 2 spares E700027 7 4 40 screw 3 16 Flathead phillips undercut BLK 3 spares 700025 16 4 40 standoff round 1 4 long x 3 16 for FP board 700026 1 4 40 male female standoff hex 7 16 long x 3 16 dia RAF 4504 440 A for Filter board Shoulder washer nylon black for PA transistor Q7 self adhesive rubber foot Digikey SJ5518 0 ND 700024 LCD
25. connected to the ground jumper near J7 The measurements on P1 the 20 pin right angle connector should be taken from the bottom side of the board 30 AN Electrolytic capacitors are mounted vertically so their PC board outlines are circular The lead must be installed in the hole marked with a symbol The lead is usually longer than lead and the lead 1s identified by a black stripe Figure 6 6 Figure 6 6 Install the electrolytic capacitors listed below They must be seated as close to the PC board as possible to avoid interfering with option modules that you may install later Note The 10 uF capacitors are of the low profile type so they may be smaller than the 2 2 uF capacitors __ C33 C59 C35 10 uF see note above __ C54 31 300 C67 2 2 uF __ C9 0 and 53 220 8 volt regulator US LM2930T 8 is a TO 220 package device with 3 leads see photo in parts list Mount U5 vertically at the back edge of the PC board Figure 6 7 Only the wide part of the leads should be above the board The hole in tab of U5 will not be used for mounting so positioning is not critical Figure 6 7 ELECRAFT DC Voltage Checks Set power switch S1 to its OFF position with the plunger out extended toward the back Connect a 12 to 14 V DC power supply battery to 14 If your power source does not already have a plug that mates with J4 use t
26. connector Once 1 is in right position solder the remaining pins Do not trim the leads Install P2 and P3 in same manner as Before soldering verify that each connector is flat against the board and not tilted 15 Cut a 1 25 mm length of insulated hookup wire Strip about 1 8 3 mm of insulation off of each end Install this wire between pins 2 and 10 of J2 in the upper right hand corner of the board Figure 4 5 The pins on J2 are counted from left to right and top to bottom as shown Figure 4 5 A Before handling U1 in the next step touch an unpainted grounded metal surface Straighten the leads of U1 PIC16C620 as shown in Figure 4 6 The two rows of pins must be straight and parallel to each other to establish the proper pin spacing To straighten the pins rest one entire row of pins against a hard flat surface Press down gently on the other row of pins and rock the IC forward to bend the pins into position as shown below Flared Straight Figure 4 6 16 Insert U1 into its socket with the notched or dimpled end of the IC aligned with the notched end of the PC board outline Figure 4 7 shows an 8 pin IC U1 is similar but has 18 pins Press Ul down into the socket as far as it will go Pin 1 Dimple Pin Figure 4 7 Note IC pins are counted by going around the IC counter clockwise from pin 1 Examine Ul closely If any pins are
27. d lt U2 14 dB U1 5 20 3 SA602 RD a 4 20 FT37 43 PENES L 2 3 10 uH 20 C22 01 1 2 2 ROVRF gt 2 4 2 5 A lt PD1 R14 15 149 7 MIU E R16 i Co C65 22 75 Noise Blanker C22 must be removed when Crystal Filter 2 2uF 10 the noise blanker is installed C63 Premix m 330 4 915 MHz T 6R AUX EB 01 R1 AGC 1 2VDC no signal 33 uH 1 8K 2 RP6 OFF 27K Low Dropout Product Det BFO g 1 6V Reg 8V Regulator Use 120 pF at C2 for 150 kHz range da D U5 8V 5 AGC oe Qi 2 78106 y LM2930T 8 RP2 es G 27009 VFOPOT 100K D2 S 6B gt OUT IN OUT IN lt 12 2 1 5711 N RP2 SD NOT USED ae a sa Ds RF SMTR C41 N EH OR 7 10 2 2UF 4 VFO 047 RP3 1SV149 E J9 S Q8 U7 To Rev Mixer via W1 i E s J309 D p SA602 Premix R5 01 8 8 25 PIK SZ 1 C7 1200 la 6T 4 4 uH 39 RP2 220 2 7 g 100K 2 me a C25 no signal 3 R2 C54 N VY D17 1200 286 91 7 L 4 1N4148 UT 100K 7 C73 4 209 lt gt 100 70 2 2uF R21 0 1 10 7 1 23 4 5 e 0 1 U3 27K T C10 3 080 MHz when RF XX 000 MHz J6 Do LM386N 1 LM380N 8 2 930 MHz when RF XX 150 MHz Q9 C4 To FIL P1 Q10 G1 G2 C18 73 L 01 2N3906 01 Re BYPASS 2201 S C32 G C64
28. 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 Any 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 2 Specifications Measurements were made using a 14 V supply and 50 ohm load Transmitter General Power output Size H x W x D Cabinet 2 2 x 5 2 x 5 6 5 6 x 13 x 14 cm Overall 2 4 5 2 x 7 1 6 x 13 x 18 cm Weight 1 4 Ibs 0 6 kg excluding options Sidetone pitch Supply voltage 8 5 to 15 VDC f Internal keyer Current drain Receive 55 mA typ no signal Transmit 700 900 mA typ 5 W 14 VDC Receiver Bands covered MHz 3 5 7 0 10 1 14 0 18 05 21 0 151 2 or 4 selected bands per module Sensitivity Frequency control Electronically tuned 3 MHz VFO LF approx 80 or 150 kHz range selected during assembly Selectivity VFO drift 200 Hz per hour after 5 minute warm up at 25 Audio output RIT XIT range Approx 3 kHz Int speaker Display 3 digit LCD w bargraph modes Headphones or ext speaker The RIT XIT range can be easily modified se
29. first step on the next page Visual Inspection You should also cross off all the remaining steps on page 21 3 Page 30 right column above the title DC Voltage Checks write Install RFCS First see page 31 right column 7 assembly step A jumper is actually installed in place of RFC8 as explained in the assembly step This jumper must be installed before the DC voltage checks on page 30 can be made 4 Page 45 right column Uninstalled Components C78 which is mentioned here is supplied with the 80 meter band kit If you build a 2 band Filter board that includes 80 meters you should install C78 at this time 10 uF electrolytic C78 is on the bottom of the board near the PA and 12V labels Bend the leads of the capacitor down at a 90 degree angle with the lead oriented as indicated by the component outline Make sure C78 15 folded flat against the board before soldering 5 Page 48 right column second assembly step Your kit includes a 3 x 3 inch piece of speaker grille cloth Trim the grille cloth so that it is the same size as the speaker frame Then cut just enough material off each corner of the grille cloth so that it fits between the fibre washers mentioned in this step Keep the grille cloth in place as you secure the speaker 6 Appendix A RF Board Parts List Page 6 The filter and BFO crystals X1 X6 are now matched at 4 9136 MHz and are labeled ECS V4 9136 S or similar 7 Appendix A Per Ban
30. from Elecraft but can still be used if you obtain the necessary components On 30 meters you have a choice of two different band edges corresponding to your selected VFO range see page 12 Hold SERES to select either 10 0 or 10 1 MHz 53 Operating Frequency Calibration and VFO Test CAL This menu entry is used to calibrate the operating frequency display or to align the VFO VFO test and alignment is covered in detail on page 38 To calibrate the operating frequency Switch to the band to be calibrated and tune in a signal at a known frequency Then select CAL in the menu and hold You ll see OPF briefly then the operating frequency will be displayed to 100 Hz The last digit flashes as a reminder that you re in calibration mode Use WPM and to set the reading to match the known frequency Note Each band must be set independently since they use different crystals on the Filter board To check the range of the VFO After holding 21 0 to switch to OSC The display will then show you the MHz and kHz portion of the VFO frequency alternating about once per second Turn the VFO pot all the way in both directions to check the range Holding SEES again will switch back to OPF operating frequency calibration display S Meter Calibration SIG To check the S meter zero setting use to switch to S meter mode make sure the attenuator 1s OFF and disconnect the antenna With no signal the S
31. 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 Initial Tests AN If any test or alignment step fails refer to the Troubleshooting section Appendix E To improve the visibility of the LCD during testing you should prop up the front edge with a non conductive object small box book etc Note Do not attach the KTSI tilt stand at this time With the bottom cover removed it could cause a short Set AF GAIN fully counter clockwise minimum volume Make sure the K1 is turned OFF power switch S1 out Plug your power supply or battery into J4 on the rear panel ELECRAFT LED Test AN When you turn the K1 on the next step watch for the LED test You should see the ATTN yellow LED turn on briefly followed by the RIT XIT dual color LED green then orange Turn on power to the If you see or smell smoke or a component feels hot to the touch disconnect the power source immediately Locate the source of trouble before proceeding If you did not see the LED test refer to Troubleshooting LCD and Error Codes You should now see E27 on the LCD This is an error cod
32. gain seems to be too low you may have an assembly error in the transmit stages or T R switch Remove the Filter board and re check the orientation of all diodes transistors and ICs Also look for shorts on both the top and bottom of the board in the transmitter area Also see Troubleshooting Switch to the voltmeter display to make sure that the battery or power supply voltage is not being pulled down when 15 turned on Hold once to select S meter mode and second time to select voltmeter mode Preparation for Transmit Alignment Turn the K1 off Secure the Filter board to its three standoffs using 3 16 4 8 mm pan head screws and 4 split lock washers Connect 50 ohm dummy load at antenna jack The dummy load should be rated at 5 watts or higher Connect a key or keyer paddle Turn the K1 on Tap MENU and locate the OUT entry power output level Hold EDITI then use WPM and WPM to set power to 2 0 watts ELECRAFT Band 1 Alignment If a 4 band Filter board is in use refer to the KFL1 4 manual page 19 All filters are shared between receiver and transmitter so transmit alignment should already be close However it s important to re peak the filters on transmit An analog wattmeter ham band receiver or the K1 s built in digital wattmeter can be used Switch to lower frequency band using BAND Set the VFO to approxim
33. menu parameter select next crystal filter FL1 3 5 WPM decrement keyer speed or menu parameter ATTN attenuator on off MSG play CW message 2 to repeat hold or REC record CW message 1 or 2 MSG cancels record Fast Tap If you tap WPM or two or more times quickly the keyer speed will change by two WPM at a time In the OUT menu entry fast tapping will change the power in 0 5 watt steps 52 Using the Menu To access the menu tap MENU Scroll menu entries by tapping WPM ELECRAFT Hold to display a menu entry s parameter which can then be changed by tapping Tap MENU to return to scrolling Another tap of MENU will return you to normal operation If a parameter appears as the associated option is not installed Edit Shortcut If the menu entry you want is the last one you accessed you can jump directly into edit mode by holding After editing exit by holding once more Note The AGC and NB parameters are not are not saved On power up AGC 15 ON and NB is OFF All menu entries are listed below They are arranged so that the ones used most often are at the beginning and end of the list allowing you to get to them quickly by scrolling forwards or backwards The FLx Bx CAL and SIG entries are described under Calibration Functions OUT STL STP T R RPT INP IAB
34. position Secure the right side panel to the RF board using two 3 16 4 8 mm flat head screws Solder and trim the leads of Q7 on the bottom of the board Using ohmmeter a low resistance scale check for a short from Q7 s tab to ground The tab is connected to the collector lead The metal hardware used to hold Q7 to the side panel may show low resistance to ground but the tab should be floating gt 1 LJ Install 8 pin ICs U8 SA602 and U9 LT1252 Orient the ICs as indicated by their component outlines AN Toroidal transformers T3 and T4 must be wound exactly as described in the following steps Recall that transformer windings are identified by numbered pairs of leads which correspond to the numbered PC board pads ELECRAFT wound on an FT37 43 core dark gray the smaller of 18 13 the two cores remaining Start with the 1 2 winding which uses 12 turns of red enamel wire 9 22 cm See Figure 8 4 3 GRN Figure 8 4 T3 s 24 winding uses 4 turns of green enamel wire 6 16 cm The turns of the 3 4 winding must be tightly interlaced with the 1 2 winding as shown in Figure 8 4 Strip and tin T3 s leads Install T3 flat against PC board to the right of Pull the leads taut on the bottom side before soldering ELECRAFT AN T4 uses a bi filar winding which means that two wires are wound on the core together The wires for the two windin
35. resistance If you cannot find a peak for L1 and L2 set them to about the mid point of their range for now and go on to the next step Peak the two band 1 RF inductors L5 and L6 If no signals are heard while peaking either L1 L2 or L5 L6 use a transmitter to generate a stronger signal or scramble the settings and try again Re peak L1 and L2 then L5 and L6 until no further improvement is noted Once all four inductors have been peaked received signals and noise should be quite strong Tap twice quickly to select band 2 switch to an appropriate antenna for this band if available and set the VFO for the mid point of the band ELECRAFT While listening to noise or a weak signal peak the band 2 Premix inductors L3 and L4 Peak the two band 2 RF inductors L7 and 1 8 Re peak L3 and L4 then L7 and L8 until no further improvement is noted Coarse BFO Alignment The K1 three crystal filter bandwidths are selected by holding the switch Hold until you see FL3 on the LCD Note FL1 2 and 3 are pre set to bandwidths of about 800 400 and 250 Hz They can be set up differently using FL x page 53 Tune in a moderately strong signal Adjust the VFO slowly to find the pitch where the signal is strongest At this point the signal will be centered in the crystal filter Locate the BFO trimmer C20 near the front edge of the
36. the menu parameter will flash AF if tones are enabled and NOR if disabled ELECRAFT Calibration Functions The FLx Bx CAL and SIG menu entries are typically used during initial test and setup of the Bx and CAL are also used whenever you plug in a different Filter module to allow the K1 to display the correct frequencies Crystal Filter Bandwidth Selection FLx The K1 provides three crystal filter bandwidths FL1 2 and 3 which are selected using during normal operation By default the filters are set to about 800 400 and 250 Hz You can change these settings using the FLx menu entry To modify the bandwidth for a particular filter enter the menu and scroll to FLx where x is 1 2 or 3 Use to change the menu entry to the desired filter Hold then tap to select one of the available bandwidths in Hz The bandwidth settings are approximate The BFO is not programmable One setting of C20 on the RF board is used for all filters see page 40 Band Assignment Bx This menu entry is used to tell the K1 firmware what bands your Filter board covers allowing AND switch and VFO to display the correct frequencies You should set up B1and B2 as well as 3 and B4 if applicable then do VFO calibration using CAL The Bx parameter can be set to any band from 1 8 to 28 0 MHz corresponding to the components on the Filter board Some of these bands may not available
37. the K1 plug in together using board to board connectors which eliminates nearly all hand wiring Gold plated contacts are used on these connectors for reliability and corrosion resistance Figure 3 3 shows a side view of the PC boards and board to board connectors As can be seen in the drawing the Front Panel board has a connector J1 which mates with right angle connector P1 on the RF board The Filter board has three connectors 1 2 and P3 which mate with J6 J7 and J8 on the RF board These multi pin connectors are difficult to remove once soldered in place Refer to Figure 3 3 during assembly to make sure you have each connector placed correctly before soldering If you install a multi pin connector incorrectly clip all of the pins at the body of the device first remove all of the pins individually and call us to request a new connector You may damage pads and traces by trying to remove such components intact Front Panel Filter Board P1 P2 77 18 RF Board Figure 3 3 K1 2 2 band version and K1 4 4 band version This manual covers all aspects of assembly for the two band K1 model K1 2 If you purchased a four band K1 model K1 4 you ll use the KFL1 4 assembly manual during assembly and alignment of the Filter board You ll find instructions specific to the 4 band module at all appropriate places in this Owner s manual ELECRAFT Unpacking and Inventory The markings on RF chokes reflec
38. the bottom cover Install a very short jumper from the point labeled DRV to ground This allows measurement of all low level transmit stages 5 Turn on the and switch to the desired band Set the power level to 3 watts using the OUT menu entry 6 Connect the RF probe s ground clip to the ground jumper on the bottom of the RF board near the center Connect the RF probe s output to the DMM and set the DMM for DC volts 2 or 3 V scale s In the remaining steps touch the RF probe tip to the indicated points and enter TUNE mode to take a reading Hold WPM WPM together to activate TUNE Cancel TUNE after each reading by tapping any other switch Note Do not key the transmitter for more than about 10 seconds at a time 7 PRE premix Expected 04 09 V DC Actual 8 ATTN TX attenuator Expected 02 05 V Actual 9 OSC TX 4 915 MHz Expected 01 04 V Actual 10 MIX TX mixer Expected 0 1 0 2 V Actual 11 BUF TX buffer Expected 1 5 2 0 V Actual 12 TRI first TX T R Expected 0 5 1 0 V Actual 13 BPF band pass filter Expected 0 5 1 0 V Actual 14 TR2 second TX T R Expected 0 5 1 0 V Actual I 15 receive signal shunt Expected lt 01 V Actual 16 Remove the short from DRV to ground Set DMM scale to 20 or 30 V 17 DRV driver Expected 0 9 1 6 V Actual 18 PA power amp Expected 10 15 V Actual 19 ANT low pass filter Expected
39. the level needed to stay at about 2 watts 47 Band 2 Alignment Switch to band 2 and set the VFO to about mid band Put the K1 into TUNE mode and adjust L3 L4 L7 and L8 for maximum output refer to Figure 7 2 if necessary Verify that the K1 is transmitting at the intended frequency S watt Test Set power output to 5 0 watts using the OUT menu entry Enter TUNE mode briefly The wattmeter should display approximately 5 watts Test 5 watt output on both bands Transmit Offset Adjustment Locate the offset test switch S2 on the bottom of the RF board Place it in the TEST position You should hear a tone in the headphones its pitch 1s equal to the transmit offset If you don t hear a tone try rotating C13 back left corner near the key jack Using the menu locate STP sidetone pitch and go into edit mode to turn on the sidetone You should now hear two tones the sidetone and the transmit offset tone If the sidetone 15 very weak or very strong compared to the transmit offset tone use the STL menu entry to adjust the sidetone volume Note The receiver is muted in STL edit mode so you ll have to return to STP after making any change to the sidetone setting Adjust C13 so that the transmit offset pitch is as close as possible to your selected sidetone pitch The two will seem to merge when the pitches are matched LJ Exit the menu an
40. the tools supplied you will need these standard tools Temperature controlled soldering iron 700 800 F 370 430 C Fine point soldering iron tip approx 05 spade type Small diameter IC grade solder see Solder Recommendations Desoldering tools wick solder sucker etc Needle nose pliers Small point diagonal cutters preferably flush cutting Small Phillips and flat blade screwdrivers DMM digital multimeter do not use an analog VOM Magnifying glass 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 Soldering and Desoldering Use adequate ventilation when soldering and 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 04 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 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
41. using a minimum amount of solder Limit soldering time to 2 or 3 seconds per pin Do not bend or trim the leads LJ Turn the board back over and verify that all of the relays are in the correct orientation and are seated flat on the board To check the orientation refer to the Filter board drawing in Appendix F at the bottom of the page LJ Solder all of the remaining relay pins Do not bend or trim the leads 12 LJ Install the capacitors listed below The list shows the capacitance value followed by the labeling in parentheses After installing each capacitor bend the leads outward at about a 45 degree angle to hold it in place until 11 15 soldered and trimmed __ C29 001 102 __ C30 001 102 __ C27 047 473 LJ Place a bookmark at this page and another at the Per Band Components table in Appendix A LJ Locate the two bags of per band components which are labeled by band e g 40m K1B40 40 meters Under Reference Designators in the Per Band Components table there are Band 1 and Band 2 columns Fill in the blanks at the top with your two bands e g 40 and 20 The lower frequency band should be designated as Band 1 Using strips of paper or labels with a light adhesive such as post its temporarily cover the band 2 reference designators column Similarly cover all of the components columns except the column associated with band 1 This is a very important step
42. 0 or 10 1 depending on your VFO range selection from page 12 The appropriate band edge is set by holding Tap MENU to return to the B1 display then tap BAND to switch to B2 Hold again to show the band 2 assignment Use and WPM to specify band 2 If band 2 is 30 meters select the band edge using DISPLAY In the same manner specify band 3 and band 4 if applicable four band module only see KFL1 4 manual page 16 Tap MENU twice to exit the menu To re check the band assignments tap BAND The current band will be displayed in MHz followed by a 3 digit display 1 kHz resolution followed by the normal frequency display to 100 Hz For example if the band 15 40 meters and the VFO 15 set to 7025 3 kHz tapping BAND will show 7 then 025 and finally 25 3 Tapping BAND twice quickly switches to the other band 39 Receiver Alignment This section applies only to the two band Filter board If you have a four band Filter board installed refer to the KFL1 4 manual page 17 Set the BFO trimmer C20 so that its adjustment slot 15 parallel to the nearby crystal C20 is located near the front edge of the RF board The final setting of C20 will be determined later If the present band is not band 1 the lower frequency band tap BAND twice quickly to select it Make sure that the attenuator yellow LED is off Plug i
43. 10 12 V Actual 20 Disconnect the RF probe The last measurement is DC volts not RF 21 RFD RF output detector Expected 1 7 2 0 V Actual DC Voltage Table NOTES Measurements listed for FIL U1 apply only to the two band Filter board for 4 band Filter board voltages refer to the KFL1 4 manual Measurements were made with a 50 ohm dummy load connected and a supply voltage of 14 V 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 made with the Filter board removed Reference designators are prefixed with the board identifier FP front panel board RF board FIL filter board Ref i Ref i Ref Pin 2 band RF U2 10 3 0 I 6 6 0 60 r 5 123 30 2 14 17 53 13 2 3 5 6 0 4 8 6 0 13 6 22 6 jJ 4 SE 15 30 jJ 48 1 6 oo 18 6 0 8 6 0 7 5 4 2 1222 39 SS El l ft s 23 6 0 URS COM jJ 32 160 gt EMEN 7 3 8 33 39 3 0 BO ee 6 8 0 APPENDIX F PARTS PLACEMENT DRAWINGS including 2 band Filter board AUX 12 45 12V B 00 eso
44. 2 V or higher is recommended The components are not critical and can vary 2096 with little variation in performance Nearly any NPN RF transistor will work in the circuit Crystal X1 should be chosen for the band in use The potentiometer can be any small trimmer or panel mount unit but should not wire wound nian X1 see text 2N2222A 2N3904 etc 50 or 1000 non inductive Figure 2 Receiver and VFO Signal Tracing In the following steps you ll use an RF probe DMM and a signal source to find the stage where the received signal is getting lost or attenuated You can then use voltage tables and resistance checks to find the bad component or connection Space is provided at each step to record your measurements which can vary as much as 25 in most cases and still be acceptable Test points and components are on the RF board unless otherwise indicated l Connect the RF probe s output to your DMM s DC input jacks Select a 2 or 3 V DC range 2 The DMM should read close to 0 000 V DC and the reading should increase when you touch the RF probe tip with your finger 3 Turn on and switch to the desired band Use the menu to turn AGC OFF Set AF GAIN to minimum 4 Connect the RF probe s ground clip to the ground jumper near the VFO inductor L1 The probe tip will be touched to the points indicated in the following steps 5 WFO U7 pin 1 U7 is near the left edge of the RF board Expected DMM ind
45. 3 4 shows how to read the four Blue 6 x 1M color bands on 5 resistors For example a 1 500 ohm 1 5 k 5 Violet 7 resistor has color bands BROWN GREEN RED and GOLD Gray 8 1 resistors are similar but use five bands three significant digits a White 9 multiplier and tolerance The first four bands a 1 5 1 Silver resistor are BROWN GREEN BLACK BROWN The multiplier Gold value is rather than 2 in the this case because of the third significant digit 120 resistors have color bands that are sometimes hard to distinguish clearly use an ohmmeter to identify them Figure 3 4 ELECRAFT Identifying Capacitors 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 uF 1 1s equal to 1 000 000 pF Tools The following specialized tools are supplied with the K1 050 1 3 mm and 5 64 2 mm Allen wrenches Double ended plastic alignment tool In addition to
46. 37 inches 9 4 mm The suffix 6 refers to a specific mix of iron powder which uses a particular color in this case yellow Later in assembly you ll encounter ferrite cores for example type FT50 43 In this part number identifies the core as ferrite and 50 is the size 0 50 12 5 mm The suffix 43 identifies the type of ferrite used although all ferrite cores are dark gray in color All ferrite cores used in the are of the 43 type 14 AN In the following steps you ll install toroidal inductors L9 L12 type T37 6 cores They must be wound as indicated in the instructions or the transceiver will not operate correctly Use only the number of turns specified It is not necessary to attempt to precisely match the inductances specified in the parts list Find the component outline for L9 on the Filter board Compare this component outline to Figure 4 3 which shows two views of a typical toroidal inductor L9 will be mounted vertically as shown at the right side of the drawing with one wire exiting at the core s upper left and the other at the lower right There are pads on the PC board in these two locations Using the Per Band Components parts table Band 1 determine the number of turns and wire length for L9 and L10 To wind L9 cut the specified length of 26 red enamel coated wire then sew the long end of the wire through the core Each pass through the core counts as one turn The finished w
47. 40009 E620055 E980023 E 00035 E 00021 4 0 00022 1 1 1 RF Per Band Components 2 Band Filter Board only Refer to KFL1 4 manual for 4 band Filter board parts list Note All Inductors in table below are wound with 26 red enamel wire on T37 6 cores Elecraft p n E680013 All capacitors are NPO disc or monolithic 5 0 2 lead spacing Values are in pF Some small valued capacitors may use or other lettter rather than a decimal point e g 2R7 Ref Designators Components Qty meters 40 meters 30 meters 20 meters 17 meters 15 meters 3 5 MHz 7 0 MHz 10 0 MHz 14 0 MHz 18 0 MHz 21 0 MHz C1 C5 C6 C10 470 471 390 391 220 221 180 181 100 101 100 101 C2 C4 C9 1200 122 330 331 180 181 120 121 68 C8 10 1 C11 C15 C16 C20 5600 562 2200 222 1800 182 1000 102 680 681 470 A71 C12 C14 C17 C19 2700 272 560 561 270 271 120 121 82 56 C13 C18 82 2 7 3 0r3 3 20 2 2 2 or 2 2 C21 C23 C24 C26 1200 122 470 471 330 331 220 221 180 181 150 151 C22 C25 2200 222 820 821 560 561 390 391 330 331 270 271 2 5 uH 1 40 uH 1 0 uH 0 8 uH 0 6 uH 0 5 uH L9 L10 L11 L12 28 turns 21 turns 18 turns 15 turns 13 turns 12 turns 20 51 cm 14 36 cm 12 30 cm 11 28
48. 7 1 000 MHz crystal HC 49 standard height E660006 Misc ront Panel PC board E100093 Misc 40 pin DIP socket for U1 E620017 4 SWITCH SPACING TOOL Misc switch spacing tool made from PCB material E980033 1 nylon washer 0 75 O D 0 385 I D Keystone 3227 Misc Keycap rectangular black E980000 5 Misc Keycap square black E980009 1 Misc 700019 1 OJ GW O H Page 3 Front Panel Appendix A K1 RF Board Parts List PICTURE Designators Description Part Number QTY C14 C15 C16 C19 C22 C28 C29 C51 001 UF monolithic label 102 E530001 8 C4 C6 C17 C18 C21 C23 C25 C36 C37 C40 C43 C44 C45 C47 C48 C49 C58 C60 C64 C66 C72 C74 C75 C76 1 01 UF monolithic label 103 E530009 24 C24 C30 C32 C41 C50 C56 C57 C61 047 uF monolithic label 473 E530025 C34 C46 C52 C55 C68 C70 C71 C73 0 1 uF monolithic label 104 E530011 C3 10 pF NPO mono or disc 5 label 10 E530006 C65 22 pF NPO mono or disc 5 label 22 E530017 C7 C26 C27 39 pF NPO mono or disc 5 label 39 E530036 0 C2 68 pF NPO mono or disc 5 label 68 E530007 C8 82 pF NPO mono or disc 5 label 82 E530038 C1 150 pF NPO mono or disc 5 label 151 E530049 C38 C39 C42 C69 220 pF NPO mono or disc 5 label 221 E530042 C62 C63 330 pF NPO mono or disc 5 label 331 E530043 IN I la ja la 9 O
49. AGC power output level 0 1 7 0 watts hold SIDES to select P 0 for keyer msg test sidetone level volume 0 31 sidetone pitch 400 to 800 Hz in 10 Hz steps can also be used to SPOT since RX is not muted transmit receive QSK delay 0 to 900 ms 50 ms recommended for casual operation CW message repeat interval 0 to 255 seconds CW input device selection Hnd hand key or external keying device PDn internal keyer paddles normal PDr internal keyer paddles reversed iambic mode A or B AGC ON or OFF no S meter if OFF LED FLx Bx CAL SIG NB ATU PFn Tones only available on the RIT XIT and ATTN switches they are useful when you have the LEDs turned off When you hold DISPLAY RIT XIT ATTN LEDs ON or OFF hold to turn switch audio tones on off crystal filter bandwidth 200 850 Hz hold 988 to select FL1 2 3 then tap WPM to set bandwidth band assignments in MHz 1 8 to 28 0 tap BAND to select B1 through B4 on 30 m hold to select 10 0 or 10 1 operating frequency cal OPF per band hold to select OSC for VFO test S meter zero set Lxx where xx 30 70 hold for scale Hx where x 2 6 noise blanker mode OFF HI LO automatic antenna tuner mode see manual programmable function PFn assignment sets up switch as a shortcut to a selected menu entry Set to NOR normal to use XIT
50. C10 C16 C20 L3 L4 L7 L8 Ooo 6A xi X2 RY 9 8 7 To ATU P2 To RF J8 P3 J2 Note 1 PA Low Pass Filters Band 1 L10 K2B Controller C27 U1 047 PIC16C620A 71 D C24 C25 C26 sl 5 E To ATU P1 Elecraft K1 2 Band Filter Board By w Burdick Rev Date Sht E Swartz 1 5 02 1 of 1 Appendix B POWER LOW PASS AMP PASS FILTERS 5W FILTERS i 4 915 MHz pee AGC PROD A F RCV RCV 1 CRYSTAL pan ATTEN MIXER FILTER DETECTOR PREAMP 4 915 MHZ 11 915 12 065 MHz 40 m zs AF AMP BFO BAND 4 915 MHz PASS FILTERS Y 15 000 MHz 40 m VFO 3 085 2 935 PREMIX 5 MCU DISPLAY KEY AND Common Transmit Receive On Filter CONTROLS PC Board Appendix K1 BLOCK DIAGRAM L J W Burdick E Swartz Rev A 8 16 00 Appendix D K1 Assembly Photographs Completed K1 with top cover and side panels removed Front Panel and 2 band Filter board shown Plugged into the RF board Front Panel RF board with assembly bottom cover Attached headphone jack 15 visible at left 2 Band Filter Board Appendix E Troubleshooting General Troubleshooting 00 19 Troubleshooting Steps General Trouble shootin g Procedure 00 Unit appears to be Make sure your power supply is connected completely dead when turned on and not plugged in backwards Look for your problem in the Trou
51. C2A alternate for C2 120 pF polystyrene axial leads 5 label 120J E530070 3300 pF polystyrene axial leads 5 label 3300 530071 C31 C54 C67 2 2 UF electrolytic 25V E530023 1200 pF polystyrene axial leads 5 label 1200J E530069 3 Electrolytic capacitor supplied with 80 m band kit 2 band module only 0 3 3 C33 C35 C59 10 uF electrolytic 35V low profile Digikey P922 ND E530045 C9 C10 C53 220 uF electrolytic 25V Digikey P6240 ND E530046 Page 1 Appendix A PICTURE K1 RF Board Parts List Designators Description Part Number QTY Ceramic trimmer capacitor 8 50pF E530000 2 SB530 Shottky diode 5A very large plastic pkg black alternate 1N5821 E560003 1 MV209 560006 1 15 149 TO 92 pkg m NO 0 NO O 560005 4 E620005 3 E620005 0 2 1 mm DC barrel connector BNC jack E620020 1 2 Appendix A PICTURE K1 RF Board Parts List Designators Description Keyer Jack threaded bushing Stereo vertical mount CUI Stack p n SJ 373 J9 J10 2 pin pads only coax soldered to connections see text Latching Relay 5V in plastic tube L T50 6 Toroid yellow approx 4 41 33 turns FT37 43 Toroid gray 16 turns FT37 43 Toroid GRAY 4 20 receiver mixer input FT37 43 Toroid GRAY 5 20 product detector input J3 Headphone jack non threaded Stereo with switch J2 horizon
52. L U1 did not respond to messages from the main processor MCU FP UI Turn power OFF and back ON if you hear some relays switching the IOC may be OK and the problem is likely to be with the AuxBus 29 If you do not hear any relays switching on power up your IOC FIL UI may be defective Inspect FIL U1 to see if you have installed it backwards or if any pins are bent With power ON check all voltages associated with U1 You should see 6V at pins 1 and 14 See DC voltage table If you saw the message E28 the I O controller FIL U1 sent an incorrect response to the MCU FP U1 This may indicate a firmware incompatibility Try removing each option board If voltage at pin 13 of the IOC FIL UIL the auxBus line may be shorted Try tapping the BAND switch quickly while watching pin 13 It should drop below 6V briefly if the MCU is sending a message to the IOC Check the AuxBus signal at the MCU pin 8 FP U1 The voltage should drop below 6V briefly when the band is changed If you E30 E31 or E32 on the LCD one of the EEPROM tests has failed CW memories cannot be used Parameters will be set to defaults and band 1 will be selected Verify that the Filter board 1s plugged in Check all voltages on the EEPROM FP U3 Inspect FP U3 and surrounding traces Make sure FP R16 is installed If a menu parameter is out of range or can t be modified EEPROM may need to be reinitialized See page 57 for instructio
53. LiteOn LTL 4253 Digikey 160 1133 E570001 1 Diode not used at present 0 3 character 7 segment LCD V L Electronics p n VI 321 DP RC S 12 E600015 1 20 pin x 1 female socket E620025 1 2N4124 transistor TO 92 plastic E580006 1 2 7000 transistor TO 92 plastic E580002 1 1 Front Panel Appendix A K1 Front Panel Board Parts List PICTURE Designators Description Part Number QTY R1 100 k 10 turn potentiometer 520007 1 R2 R3 10 k potentiometer linear taper E520005 R7 3 92 k 1 4W 1 color code org wht red brown E500031 R12 R16 2 7 1 AW 596 color code red violet red E500005 R9 R10 R11 R19 100 k 1 4W 5 color code brown black yellow E500006 82 uH miniature RF choke Mouser 434 22 820 RFC1 RFC2 color code gray red black E690003 2 t 1 SIP resistor pack 8 pins 4 resistors 49 RP1 p n 77083102 alt 8A3102G L83C102 etc R4 10 k 1 4W 5 color code brown black orange E500015 gt gt gt E510006 1 Page 2 Front Panel Appendix A K1 Front Panel Board Parts List PICTURE Designators Description Part Number QTY Switch push button E640005 6 PIC16C77MCU programmed 40 pins E610005 1 MAX518BCPA Dual D A converter 8 pins Alt MAX518ACPA E600013 1 24LCO4B P EEPROM 8 pins alternate 24 WC04P E600021 1 LM358 8 pins E600010 1 ZR78L06C Voltage regulator 6V 2 5 Zetex TO 92 plastic 3 pins E60001
54. PM to scroll menu or modify parameters POWER OUTPUT 0 1 7 0 W IAB IAMBIC MODE or B Operating freq cal OPF per band hold DISPLAY to select P 0 hold DISPLAY for VFO display OSC On or Off SIDETONE VOLUME LEVEL 0 31 S METER ZERO SET Lxx xx 30 70 LED RIT XIT ATTN LEDs On or Off hold DISPLAY for scale H x x 2 6 SIDETONE PITCH Hz or SPOT FLx XTAL FILTER BW 200 900 Hz NOISE BLANKER Off NB1 NB2 QSK DELAY 0 900 ms hold XFIL to select FL 1 2 3 then tap WPM to set bandwidth AUTO TUNER mode see ATU manual AUTOREPEAT DELAY 0 255 sec BAND ASSIGNMENT MHz PROGRAMMABLE FUNCTION KEYING DEVICE Hnd PDn PDr tap BAND to select B1 or B2 30m shortcut to selected menu entry or hold DISPLAY to select 10 0 10 1 set to NOR normal to use as XIT KI MANUAL ERRATA October 26 2005 rev F 5 READ THIS AND MAKE THE INDICTATED CHANGES BEFORE YOU BEGIN ASSEMBLY OF YOUR 1 1 Page 16 bottom of the page If you re building a 2 band Filter board that includes 80 meters you ll have a 10 uF electrolytic capacitor left over at this point This will be installed on the RF board at C78 in a later step 2 Page 21 left column after fifth step If you have purchased and are going to install our K1 LCD Backlight Kit into your unbuilt K1 you need to add the following text At this point refer to the instruction set for adding the K1 LCD Backlight Once installation is completed continue with the
55. TIN Attenuator yellow Note The LEDs can be disabled using the LED menu entry This can save up to about 20 mA of receive mode current drain VFO The VFO covers about 80 or 150 kHz of each CW band as selected during assembly The approximate lower band edges in MHz are 3 50 7 00 10 00 or 10 10 14 00 18 05 and 21 00 Potentiometers AF GAIN Sets the receive audio output level It also affects the sidetone volume in conjunction with the STL menu entry Note The gain setting for headphones will be lower than for the speaker OFFSET Adjusts the offset when RIT or is turned on The range is about 3 kHz The range 15 set by RF C7 51 Switch Functions a switch to access its upper function a switch for 1 2 second to access its lower function All functions are listed below The 1 and 2 labels near WPM and WPM correspond to CW message buffers 1 and 2 see MSG and below The label near these switches is a reminder that TUNE mode 15 activated by holding both and WP M simultaneously see page 54 TAP and Switch Functions BAND show present band freq tap twice to change bands ISPLAY select display mode normal S meter or battery enter the menu see Menu edit current menu parameter E turn RIT on or off A turn XIT on or off or select PFn see Menu WPM increment keyer speed or
56. ad appears to be an island in a small pool of solder chances are it is not making good contact Wind and install 110 in same manner as 19 using same number of turns Install L10 vertically to the right of L9 Wind and install L11 and L12 Use the Per Band Components table Band 2 to look up the wire length and number of turns AN Do not use adhesives or fixatives of any kind to secure L9 L12 to the PC board They will be adequately held to the board by their leads alone ELECRAFT A The connectors to be installed in the following steps must be positioned correctly to avoid intermittent or unreliable operation Before attempting to install multi pin connectors review the information on page 7 Install an 8 pin male connector plug at P1 but do not solder yet Figure 4 4 shows as viewed from the left end of the Filter board The plastic part of the connector must be on the bottom side of the board with the long end of the pins pointed down The short pins are inserted into the board Figure 4 4 Solder just one of the middle pins of P1 on the top side Note multi pin connectors have plastic bodies that can melt if too much heat is applied causing the pins to be mis positioned Limit soldering time for each pin to 2 to 3 seconds Examine placement of P1 closely If it is tilted is not flat against the board re heat the solder while pressing down on the
57. al leads such as the types mentioned above must be installed with the banded end cathode oriented towards the banded end of their component outlines If a diode has more than one band the widest band indicates the cathode end LJ Install 1N4148 diodes at D17 and D1 observing the proper orientation as explained above Do not solder yet D17 and are both near RP2 in the VFO area LJ Install 1N5711 diodes at D2 and D15 but do not solder yet D2 is in the VFO area D15 is in the back right corner near J8 LJ Re check the orientation of the diodes then solder ELECRAFT Identify the two types of black axial lead diodes 1N4007 and SB530 The 1N4007 is the smaller of the two Install the SB530 diode at D16 near the back edge of the board Install 1N4007 diodes at D11 and D10 to left of D16 Install 1N4007 diode at 05 near J7 The varactor diodes have a small plastic package like a TO 92 transistor but with only two leads Sort the varactor diodes into two types MV209 quantity 1 and 1SV149 quantity 4 Install the varactor diodes listed below The flat side of each diode must match the flat side of its PC board outline Bend the leads slightly on the bottom to hold the diodes in place __ D4 MV209 in the VFO area Note The 1SV149 diodes may have a third lead in the center cut off near the body Mount them slightly above the board to a
58. along the front edge The label R1 appears just left of the resistor s outline LJ Install a 100 ohm 5 resistor brown black brown at with its first color band brown toward the left Make sure it is seated flat on the board then bend the leads outward at about a 45 degree angle to hold it in place Solder R1 on the bottom of the board Trim the leads as close as possible to the solder joints A Components may be soldered one at a time or in groups Leads can be trimmed either before or after soldering 11 LJ Install an 18 pin IC socket at with the notched end of the socket oriented towards the K1 FIL2 label Bend two leads of socket outward slightly to hold it in place while soldering U1 itself will be installed in a later step A In the following steps you ll install three relays K1 K3 Relay pins must not be bent even after placement on the PC board as this may cause unreliable mechanical operation LJ Place relays K1 K3 on the top side of the board One end of each relay has a heavy line printed across the top to indicate the pin 1 end This end must be matched with the same end of the relay s PC board outline Do not solder the relays yet LJ When all three relays have been placed on the board lay a flat object such as a book or piece of cardboard on top of the relays to keep them in place then flip the board over LJ Solder only two pins at opposite corners on each relay
59. an hear the signal from your test generator peaked in the crystal filter Since AGC is turned off the signal may be extremely loud and will probably be clipping distorted at the AF output Crystal filter U2 pin 1 Expected 30 50 V Actual the signal using the VFO as needed Disconnect the RF probe from the DMM Set up the DMM to read AC volts 20 or 30 meter range Connect lead of the DMM to one of the ground test points using an alligator clip The lead will be touched to the points indicated in the following steps Product detector saturated output U2 pin 4 Expected 40 80 V AC rms Actual Re peak the signal using the VFO as needed AF preamp U3 pin 5 Expected 2 4 V Actual AF amp U4 pin 6 Output voltage should vary from 0 to ont 4or 5 V as the AF GAIN control is varied Re peak Transmitter Signal Tracing In the following steps an RF probe is used to determine where the transmitted signal is getting lost or attenuated These checks are made from the bottom side of the RF board so that the Filter board can be left plugged in Each transmit test point is clearly labeled with a small arrow pointing to the appropriate PC board pad You ll want to refer to the transmitter schematic K1 RF Board sheet 2 as you perform the measurements Do the VFO and receiver signal tracing first to check VFO premix signals Connect a dummy load to the antenna jack Turn the K1 upside down and remove
60. ately the middle of the desired band Refer Figure 7 2 to identify band 1 inductors AN The K1 can be placed in TUNE mode by holding the and WPM switches together During TUNE the power in watts will be shown on the LCD e g P2 0 Hitting the key or pressing any switch except WPM and WPM will cancel TUNE Put K1 into TUNE mode Using alignment tool adjust L1 L2 L5 and L6 for maximum output f the output jumps up to well above 2 watts exit TUNE mode then re enter it again If necessary repeat adjustment of filters two or three times to be sure that you have the inductors peaked correctly If output is lt 2 w or 15 not stable see Troubleshooting If possible verify that the K1 is transmitting on correct frequency using an external ham band receiver Connect a short length of wire to the receiver s antenna jack Do not connect the directly to the receiver Key the and locate the signal To make sure that the filters are peaked at the correct frequency vary each inductor a small amount while observing the receiver s S meter The transmitter s ALC automatic level control attempts to set the power you specify ALC is activated for 1 2 seconds when you enter TUNE mode After that it is open loop allowing you to adjust the filters If the power jumps re starting TUNE mode will activate the ALC again reducing the drive back down to
61. bent remove the IC and straighten them To remove UI from its socket pry it up gently on each end using a small flat blade screwdriver Locate the blank white area near U1 This area is provided for labeling the Filter board with the two bands covered e g 40 20 Use an indelible marker dry transfers or an adhesive label Uninstalled Components All component locations on the Filter board should now be filled except and 12 which are provided for the automatic antenna tuner The option should be installed only after the basic K1 kit has been completed and tested At that time the jumper you installed between pins 2 and 10 of J2 will be removed ELECRAFT Visual Inspection Using the parts placement drawings in Appendix F re check the orientation of the relays K2 and UI A About 90 of all problems with kits are caused by poorly soldered component leads Such problems can be avoided by doing a careful inspection of the board preferably with a magnifying glass Examine the bottom of the PC board closely for cold solder joints solder bridges and unsoldered components Resistance Checks Make the measurements listed below touching the meter s and leads to the indicated points Measurements at relay K3 must be made on the bottom side Relay pins are numbered like ICs with pin 1 identified by its round pad The Filter board schema
62. bleshooting Tables power switch is turned Check fuses examine cables for open short Closely examine PC boards for poor solder joints and incorrect broken or display Check resistance to ground on 12V 8V and missing components audio possible 6V lines check for RF Q7 tab short Follow the step by step receiver and transmitter Signal Tracing smoke hot t front panel and filter boards are procedures at the end of this section components etc plugged in with connectors fully seated Check voltages using the DC Voltage Table at the end of this section E oe T and 8V regulated power supplies Check the MCU FP U1 26 Error Messages 01 LCD or LED control circuits 24 problem If you see a message such as E30 on the LCD look up the corresponding 02 BAT LO 2 voltage may be P 9 V Recharge entry in the Troubleshooting Tables Error messages can usually be cleared by displayed pressing any switch However the cause of the message should be investigated 03 No audio See Receiver troubleshooting table 60 before continuing to operate the transceiver 04 Switches or Front panel board may not be plugged in potentiometers do not Check the MCU 26 function correctly or Check all regulated supply voltages 20 Troubleshooting Tables are intermittent Check switches and related components 21 There are five troubleshooting tables listed below Within each table ex
63. cessive on receive component that s warm to the touch 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 drops when K is on Battery not fully charged observe If in doubt start with the General Troubleshooting table Some problem identifiers have corresponding error messages see above displayed frequency General Troubleshooting 00 19 instability VFO and Premixer 40 59 is pending Resetting to Factory Defaults page 57 Receiver 60 79 10 EEPROM was You may see one time on power up or Transmitter and Keyer 80 99 just initialized if you install a new version of the firmware parameters are set to defaults Note Components are identified by their PC board and reference designator 15 END orP 0is END TX out of range see specifications For example FP U1 means U1 on the Front Panel board displayed keydown 0 TX disabled via OUT menu entry Display and Control Circuits 20 39 Troubleshooting Steps 20 Regulated DC input voltage must be gt 8 5V voltage s incorrect Remove all option boards and re check f 6V is too low lt 5 7V go to 22 If 8V is too low lt 7 5V go to 23 21 General problem Check switch resistance open closed check with switches or R14 R15 and potentiometers Check resistance of potentiometers check related connections to FP J1 22 6A or 6B Remove
64. controls and describes each of the menu entries Connections Power Supply You can use any 9 15 V DC power supply current drain is about 0 5 1 on transmit A mating DC power connector is provided with the kit Use an in line 2A fuse when operating from a battery or power supply that does not include its own fuse Low Battery warnings If your battery or power supply voltage drops below about 9 V you ll see a brief BAT LO message flashed on the LCD once every 5 minutes approx This voltage level was chosen to be compatible with an 8 cell NiMH or NiCd battery back Other battery types may have a different end of life voltage check the voltage using BAT display mode often 12 V gel cell batteries must be recharged at 10 5 11 0 V Headphones or External Speaker The front panel headphone jack can accommodate either headphones or an external speaker with an impedance of 8 ohms or higher A stereo plug or mono stereo adapter is required unless you modify the RF board see 2 step on page 31 ELECRAFT Keying Device Any type of hand key bug or external keyer can be plugged into the KEY jack or you can connect a paddle and use the K1 s built in memory keyer In all cases you must use a stereo plug with the keying device a suitable plug is provided with the kit It is also possible to connect both a keyer paddle and another keying device at the same time see Keying Device Selection page 55 Antenna Any well
65. ctly installed solder the remaining pins Do not use an excessive amount of solder Locate the Switch Spacing Tool made of PC board material Position push button switch 51 on top side of board as shown in Figure 5 2 using the switch spacing tool to set the switch height Make sure all four legs of the switch are centered in their holes then gently push the switch until it is resting flush against the switch spacing tool Caution switch pins are fragile Do not solder yet Figure 5 2 18 Top of board 1 16 v Figure 5 3 Figure 5 3 shows a side view of a switch that 1s properly mounted spacing tool not shown The leads of the switches will just be visible on the bottom of the board Proper switch height is important for maintaining an even appearance Once 51 is seated correctly solder the leads on the bottom side of the board Leave the spacing tool in place while soldering Install S3 once again using the switch spacing tool to adjust the switch height When soldering 53 be careful not to contact the plastic body of J1 with the soldering iron Install switches 52 54 S5 and 56 using the same technique Note Switch caps will be installed later Install these parts top side of board Solder them on the bottom side using a minimum of solder __ R8 22 RED RED BLK __ C4 047 uF 473 Trim the leads of R8 and C4 as close to the boa
66. d Components for 2 Band Filter board The 80 meter band kit only K1B80 includes a 10 uF electrolytic capacitor for installation at C78 on the RF board 8 Resistor taping order The resistors in the K1 kit are supplied in assembly order attached to strips of tape However due to recent changes in the kit some of the resistors may be supplied loose rather than on tape Be sure to check the color codes of all resistors during assembly to make sure you re installing the right ones
67. d set S2 back to the OPER position If necessary use the CAL menu entry to calibrate the operating frequency on transmit see page 41 This completes transmitter alignment 48 10 Final Assembly Remove any masking tape from the top and bottom covers Use the technique described on page 23 Remove and save the hardware supplied with the antenna and key jacks LJ The components on the bottom of the board must have an overall height of no more than about 0 2 5 mm above the PC board Fold down or re solder components if necessary LJ Install the bottom cover by sliding it over the rear panel controls Secure it to the rest of the assembly using six 3 16 4 8 mm pan head screws LJ Install the hardware supplied with the antenna and key jacks Be careful not to strip the plastic threads on the antenna jack Figure 10 1 ELECRAFT LJ Set the top cover upside down in front of you with the back edge facing away Place the speaker over its holes with the lugs to the eft Figure 10 1 Secure the speaker to the top cover using four 5 16 8 mm flat head screws 4 fiber washers black 4 metal flat washers 4 internal tooth lock washers and 4 40 nuts Figure 10 2 The fiber washers go between the speaker and the top cover Do not over tighten the nuts as this can flex the speaker frame causing damage to the speaker and or distorted audio lockwasher
68. diodes Since the transmitter circuits run from a different regulator and since the VFO 15 also well buffered from the transmitter there is virtually no VFO frequency shift or chirp on key down over the full power output range 0 1 7 watts Second temperature compensation techniques are used in the VFO itself including careful selection of capacitor types The inductor used has a low temperature coefficient and its turns are adjusted to select the desired range which eliminates drift prone trimmer capacitors 60 Q9 isolates the VFO from noise pickup on the frequency counter line US and U6 double regulate the VFO supply voltage for improved stability Since U5 is low dropout 8 volt regulator K1 s supply voltage can drop to as low as about 8 5 V without affecting the VFO frequency U6 is a 6 0 volt regulator with a very tight tolerance of 2 5 Premixer U7 mixes the VFO with one of the crystals on the Filter board Receiver Sheet 1 UI is a double balanced receive mixer which provides an excellent noise figure at low current drain If input levels are too high an attenuator can be switched in via 1 RFC9 across K1 suppresses attenuator on off switching noise that might otherwise be audible Emitter follower Q3 provides some power gain while providing a low driving impedance for the crystal filter X1 X4 The crystal filter has variable bandwidth by virtue of varactor diodes D6 D8 T2 steps up the crystal filt
69. e which occurs when the K1 self test finds that the Filter board is not plugged in Error codes are listed and described in the Troubleshooting tables AN If the LCD is blank it may indicate that one or more switches are closed Check for shorts on all switch lines any switch to clear error code You should then see E42 which indicates that the self test found the VFO signal missing This is correct since the VFO inductor RF L1 has not yet been installed When the VFO is functioning normally you ll see the operating frequency displayed ELECRAFT Sidetone Generator and Audio Amplifier Plug in a pair of stereo headphones and rotate the AF GAIN control clockwise to about 9 or 10 o clock Tap MENU The first menu entry will be displayed OUT transmit power output Tap to select the next menu entry STL sidetone volume Lower case t is used The Sidetone can be activated by editing the STL menu parameter Hold to show the parameter and turn on 6 sidetone You can then use WPM and WPM to vary the sidetone level from 0 31 Select a comfortable level then tap MENU to turn off the sidetone and return to the STL display Note STL is used to set the sidetone volume level in relation to normal received audio However the AF GAIN control sets the overall headphone or speaker volume Select the sidetone pitch menu entry STP using by tapping
70. e E500042 100 k SIP resistor pack 8 pins 4 resistors p n 8A3104G alt 77083104 L83C104 etc 3 9 k SIP resistor pack 6 pins 3 resistors p n 6A3392G alt 77063392 L63C392 etc 27 k SIP resistor pack 6 pins 3 resistors p n 6A3273G alt 77063273 L63C273 etc 47 k SIP resistor pack 10 pins 5 resistors p n 10A3473G alt 770103473 L103C473 etc LM2930T 8 8 volt regulator TO 220 package Page 5 E600018 2 O I IN 2 2 RF Appendix A K1 RF Board Parts List PICTURE Designators U1 U2 U7 U8 Wt Jumper RG174 coax From J9 to J10 see text U6 1 X1 X6 MISC MISC Description LM380N 8 8 pin DIP AF amplifier Part Number QTY E600019 LM386N 1 8 pin DIP AF amplifier E600022 LT1252 8 pin DIP VFO Buffer TX Buffer E600020 SA602AN 8 pin DIP TX Mixer Prod Detector Alt SA NE612AN E600006 6 volt reg 2 5 92 package 3 pins W 4 9152MHz Crystal 4 91 20 or 4 91 0195 Filler BFO Xtals Parallel mode matched HC 49 DPDT Power Switch Miniature DPDT slide switch 2 pin shorting jumper for use at P3 RF detector select Keycap rectangular for S1 p n TAC BLK 4 washer nylon Washer nylon 0 375 diameter For VFO inductor 4 32 nut nylon nut nylon For VFO inductor 4 32 screw nylon x 1 2 screw pan head nylon For VFO inductor Page 6 E600017 E6
71. e crystal can Solder and trim the wires on the bottom of the board X2 Xl ofO Figure 4 1 LJ Install the ceramic resonator Z1 to the right of U1 The ceramic resonator looks like a capacitor with three pins and can be oriented in either direction Limit soldering time to 2 or 3 seconds on each pin to avoid altering the oscillation frequency n Locate the eight 1 uH slug tuned inductors and make sure they are all be labeled T1050 LJ Install the inductors at L1 through L8 pressing each one down as far as it will go They have five pins plus ground tabs and can only be installed on the board one way Solder the inductors 13 At left and right ends of board you ll find two short jumper locations each labeled with a ground symbol Use component leads to make 3 4 19 mm U shaped wires for each jumper Figure 4 2 Solder the jumpers on the bottom of the board with the top of the U shape approx 1 4 6 mm above the board side P UP Figure 4 2 Identifying Toroid Cores Several toroidal inductors are used in the K1 including four on the Filter board It is important to use the correct type of core This can be determined from the color and size The cores used on the Filter board are type T37 6 The T identifies an iron powder core The number following the 7 specifies the outside diameter in hundredths of an inch in this case 0
72. e installed in the following steps is referred to as W1 in the RF board parts list Cut a 2 6 67 mm length of RG 174 coax cable Using sharp tool remove about 3 8 9 mm of the coax jacket from each end Be careful not to nick the braid Figure 6 14 Separate the braid shield from the center conductor at both ends Figure 6 14 Clip off about half the strands of the braid close to the jacket then twist the remaining braid into a fine bundle Remove a small amount of insulation from the center conductor Use long nose pliers to hold the center conductor while stripping it or you may pull it out of the coax jacket On the bottom of the RF board you ll find the component outlines for two 2 pin connectors J9 and J10 Install the coax cable on the bottom of the board between these two points The center conductor should be inserted into pin 1 of each connector square pad and the braid into pin 2 round pad Do not solder yet Make sure that the coax braid is not touching any adjacent pads at either end and that the coax is not covering the nearby screw mounting hole Solder the coax on the bottom side of the board Trim the leads on the top side if there 1s excess lead length 36 7 Alignment and Test Part I In this section you ll become familiar with K1 operation while testing control circuits and aligning the VFO and receiver The Tap Hold Rule Each of the push button switches on the
73. e page 55 0 5 watts or higher spurious and harmonic content 40 dB 5 W 2 1 or better SWR recommended will survive high SWR operation 400 800 Hz in 10 Hz steps 8 50 WPM Iambic modes A and B 2 message buffers auto repeat Approx 0 2 uV for 10 dB S N N 4 915 MHZ single conversion 4 pole variable bandwidth crystal filter approx 200 800 Hz watt peak into 8 ohm load 8 ohms high efficiency 8 ohms or higher stereo plug mono optional see page 31 second assembly step 3 Preparation for Assembly Overview of the K1 The K1 uses modular design for ease of assembly and troubleshooting The chassis is made up of five pieces Figure 3 1 any of which can be removed individually The RF power amplifier transistor uses the right side panel as a heat sink so there 15 no separate heat sink element Each side panel includes a 10 32 threaded PEM nut as a mounting point for the KTSI tilt stand Top Cover Bottom Cover Right side panel not shown Figure 3 1 ELECRAFT There are three printed circuit boards PCBs as shown in Figure 3 2 Front Panel board Filter board and RF board These boards plug in together with no wiring as explained in the next section options such as the KNBI noise blanker also plug in directly Appendix D shows photographs of each completed PC board assembly Front Panel Figure 3 2 ELECRAFT Board to board Connectors The circuit boards in
74. eceive frequency XIT works similarly to RIT except that the transmit frequency 1s varied with the offset control For example suppose a DX station says to call up First turn on RIT and use the OFFSET control to find a clear spot above the DX station s frequency Then turn on XIT by holding gt The XIT LED orange will turn on If you need to determine the transmit frequency when using XIT briefly turn on RIT then switch back to OFFSET Range The range of the OFFSET control is determined by the value of C7 in the VFO area of the RF board A larger or smaller value of C7 will increase or decrease the OFFSET range respectively Keying Device Selection A single connector in the back is provided for your keyer paddle hand key keyer or computer You must use a stereo 2 circuit plug even if you use only a hand key or external keyer This should not affect the use of the keying device with other equipment since the middle contact on the plug often called the ring contact 1s only used with keyer paddles Hand key or External Keying Device To use a hand key external keyer computer or external keying device set INP to Hnd using the menu You can key the K1 externally at up to 70 WPM Note The K1 s message memories can only be programmed using a directly connected keyer paddle If you have assigned PFn switch to another function using the PFn menu entry you cannot use XIT 55
75. ed The filter module includes the band pass filters and crystals for the Kl s pre mix conversion scheme in which a low frequency 3 MHz VFO is subtracted from a high frequency crystal oscillator to produce a pre mixed injection frequency for the transmit and receive mixers Because of the VFO s low operating frequency stability is excellent An analog VFO is used resulting in a lower noise floor than most synthesized transceivers The filter board also has RF band pass and low pass filters for each band 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 good CW selectivity with a 4 pole crystal filter The use of active mixers keeps current consumption low compatible with portable operation There are three stages of transmitter amplification Maximum power output from the final stage class C is about 5 to 7 watts depending on the band and supply voltage The T R circuitry 1s all ELECRAFT solid state no relays resulting in smooth fast QSK A low power microcontroller MCU on the front panel board is used to control the transceiver and handle user interface elements such as the display and switches A second smaller microcontroller the I O controller IOC acts as a driver for the filter and attenuator relays The IOC is controlled by the main MCU v
76. en adjust VFO until received signal pitch matches sidetone pitch The received signal may seem to disappear when the pitch is exactly matched You can assign STP to the rogrammable function switch if you don t use XIT see above will then activate spot signal AGC Control Some operators prefer to turn AGC off and use manual gain control under certain weak signal conditions To turn AGC off use the AGC menu entry The attenuator may help with strong signals Checking the Firmware Revision Hold any switch on power up to display the revision e g 108 Resetting to Factory Defaults requires rev 108 or higher Reset to defaults takes two steps Step 1 Hold BAND and MENU together on power up releasing the switches after the LED test You should see E09 Step 2 Turn power off and back on again you should see E10 You ll then need to re do VFO calibration etc 57 Options Four and Two Band Filter Modules 1 4 2 The KFL1 4 and KFL1 2 options provide additional bands of your choice allowing you to select the best combination of bands for home use field trips or specific operating events The KFL1 4 includes 40 30 20 and either 17 or 15 meters Wide Range Tilt Stand KTSI When hiking or camping you may find that there s no table or other smooth surface on which to operate a transceiver The KTSI solves this problem by allowing you to rest the K1 on nearly
77. en solder and trim 1 GRN 3 RED 2 GRN L 4 gt r 2 GRN 3 RED s a b T2 Figure 6 8 T2 is wound on the same core type as 1 Start with the winding which uses 20 turns of red enamel wire 13 33 cm 3 4 The 1 2 winding uses 5 turns of green enamel wire 6 16 cm Strip and tin T2 s leads Install T2 flat against the board to the right of U2 Pull the leads taut then solder Using your DMM check for continuity between the pads of L2 If the DMM doesn t indicate a short lt 5 ohms you may not have fully removed the insulation from one or both leads Since the insulation can be heat stripped you can usually improve the electrical connection by re heating each lead for 4 to 5 seconds LJ similarly check T1 s two windings 1 2 and 3 4 for continuity Then check T2 s windings AN Toroidal inductor L1 VFO will not be installed until the VFO is aligned in Alignment and Test Part I page 36 ELECRAFT top side of RF board locate hole identified as A in Figure 6 9 The label 51 appears near the hole Figure 6 9 Install a 7 16 11 mm hex male female standoff top of the board at location A as shown Use an internal tooth lock washer and 4 40 nut on the bottom Do not over tighten the hardware the standoff threads can be easily strip
78. ent carefully remove the IC by prying at both ends using a small flat blade screwdriver Straighten the pins using long nose pliers Locate the black neoprene LCD spacer MISC bag which is 1 2 x 1 2 square and 3 16 thick 12 x 12 x 5 mm Remove the adhesive backing from one side and position the spacer as shown in Figure 5 7 It must be mounted flat against the PC board centered between the two rows of pins on UI s socket Spacer Figure 5 7 21 AN Caution the LCD DS1 and its pins are fragile Remove the LCD from its packing materials being careful not to bend the pins As shown in Figure 5 8 the pin 1 end of the LCD glass has a very slight bump along with a break in the black border This end will be oriented towards the pin 1 end of DS1 s component outline 24 13 AAAA Bump gt 1 12 51 Figure 5 8 Remove the adhesive backing from top side of the LCD spacer Install the LCD at DS1 oriented as shown above Make sure that all 24 pins are inserted into their holes then press down gently on the LCD to secure it to the LCD spacer s adhesive surface The LCD pins may not extend all the way through the holes The surface of the LCD must be parallel to the PC board Once LCD 1s positioned correctly solder all pins 22 Visual Inspection Using the parts placement drawings in Appendix F re check the or
79. er output to match the 1500 ohm input impedance of the product detector BFO U2 The BFO is mixed with the I F to produce an audio signal U3 amplifies the audio signal enough to drive the audio derived AGC detector D2 R21 and C18 remove high frequency hiss D2 is DC biased just below the level needed to turn on darlington transistor Q2 When a signal is present Q2 will turn on in proportion to the signal amplitude pulling the AGC line down from its nominal 1 2 V to as low as 0 6 V The AGC line is connected to the input bias pins of both U1 and U2 so that the gain of both mixers is reduced as signal strength increases R1 limits the gain reduction at Ul so most of the AGC action is due to U2 which minimizes the chance of front end overload when AGC 15 activated Only signals in the passband of the crystal filter can cause AGC in any case so the AGC line stays at about 1 2 V most of the time Q10 and 11 are shunt and series mute devices respectively Both are required due to the large amount of audio gain the receiver ELECRAFT U4 amplifies the received audio signal and sidetone to headphone or speaker level The AF GAIN control is located on the front panel but is electrically connected between 11 and U4 at the AF1 and AF2 points In receive mode the AGC signal is routed onto the RF SMTR line which is then sampled by an A to D input on the MCU UI front panel QI is used to connect or disconnect
80. es may be wrong type small or shifted Check all capacitors in VFO esp C2 and low high See Alignment and Test Part I Receiver 60 79 Troubleshooting Steps 60 Low or no audio If you hear normal audio output on one band output from receiver but not all bands see 62 or general receiver Make sure you have headphones or speaker gain problem connected turn AF GAIN clockwise Check the key jack for a short to ground Make sure the attenuator 1s turned off Re peak the band pass filters Check for ground shorts in the LPF and BPF Turn the AF GAIN to maximum If you don t hear any hiss at the receiver output troubleshoot the AF amplifier 65 Check the 8V regulated supply voltage and troubleshoot if necessary 20 Try using signal tracing see procedure later in this section 62 Signalloss only Re doalignment on affected band one band Check the band pass low pass filters and crystal for this band Check functioning of the associated relays change bands then measure relay leads that should be open or shorted for that band 65 AF amplifier not Use the STL menu entry to set a sidetone working level of 31 If you hear a strong tone the A F amplifier RF U4 is probably working and the problem 15 likely to be with the preamp RF U3 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 volta
81. f both DOT and DASH are open the voltage at RA3 will be about 6 V If both are closed the voltage will be 0 V If only one paddle is closed an intermediate voltage results either 2 V or 4 V See RF board sheet 2 Q21 defeats the RIT XIT offset when its gate voltage is at 6 V since its low drain source resistance forces a fixed 3 V to appear at the wiper of the offset pot R3 U2 and U3 are controlled by the SDA data and SCL clock lines using the industry standard I2C protocol U2 is a dual output D to A converter that controls the power level and generates audio tones When tones are not being generated the tone output 1s used to set the crystal filter bandwidth U3 is a 512 byte EEPROM which stores all operating parameters and CW messages VFO pot RI is physically part of the front panel assembly but its wiper voltage 0 6 V is routed to the RF board via 11 R19 located between the wiper and the high end of the pot improves tuning linearity Filter Board Note This section applies to the 2 band filter module KFL1 2 For details on the four band module refer to the KFL1 4 manual L1 L4 and associated capacitors form two band pass filters one for the premix signal on each band There are also crystals for each band X1 X2 For example on 40 m 7 000 MHz the premixer U7 RF board mixes a 3 085 MHz signal from the VFO with a 15 000 MHz crystal oscillator to obtain a difference signal at 11 915 MHz There
82. f necessarily 86 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 RF chokes in series with the paddle connections Seek a better antenna match Improve your ground system if you have RF problems add two or more radials cut to 1 4 wavelength at the affected frequency Signal Tracing You can solve nearly all problems yourself by signal tracing using an RF probe and signal source such as the ones shown here RF Probe The RF probe shown in Figure 1 converts RF signals to DC so they can be measured using a DMM C1 R1 COAX E1 01uF 4 7Mohm 12 36 30 90 cm J1 probe tip 2 ground Figure 1 The probe E1 should be no longer than 3 see ARRL Handbook for ideas and you should not touch the tip while taking measurements Use an alligator clip at E2 with a 4 13 cm lead Note With this RF probe DC voltage readings on your DMM will be approximately equal to the signal voltage in Vrms root mean square However the error in the reading 1s quite significant for small signals typ 50 at 50 mVrms The signal tracing procedures take this error into account Crystal Oscillator The simple crystal oscillator shown in Figure 2 can be used in lieu of a commercial signal generator It will run on voltages as low as 8 V but 1
83. ges in the receiver Inspect the amp and preamp circuits 70 AGC or S meter Make sure the attenuator is off not working Check voltages on RF U1 U2 Q1 Q2 D2 Transmitter and Keyer 80 99 Troubleshooting Steps 80 General Transmitter problem 86 Power output 15 low or zero 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 Try signal tracing Check power output when using a 50Q dummy load if the output is correct on a dummy load but not when using an antenna your antenna 15 probably not matched Check all component values in the RF detector you may have two resistors swapped R36 R37 or the wrong detector diode D15 should be 1N5711 You may have a short in the LPF or BPF also check relays 25 Examine T3 and T4 these must be wound as indicated in part II of the RF board assembly Look for toroid leads that are not completely stripped or are soldered poorly Check all DC voltages in the transmitter RF board Q5 Q6 Q7 U8 U9 If drive is lacking R35 RF board TX attenuator can be made larger at the expense of power setting resolution Make an RF probe and signal trace through the transmitter to fi
84. gs will be twisted together see Figure 8 5 Y CT mt GRN 2 3 GRN RED Figure 8 5 Cut two 8 20 cm lengths of enamel wire one red and one green Twist the wires together over their entire length The wires should cross over each other approximately every 1 2 1 cm LJ Wind the twisted wires onto the 1 2 12 7 mm dia ferrite core FT50 43 dark gray using 5 turns and covering about 85 of the core Figure 8 5 shows how the winding should look Separate T4 s leads as shown In Figure 8 5 Strip and tin the leads Be careful not to let the red and green wires short together LJ Install T4 flat against the PC board as indicated by its outline Using your DMM on a low resistance scale measure continuity between the 1 and 2 pads of T3 If you get a reading over 5 ohms re strip the affected lead s Similarly check the 3 4 winding of T3 Then check T4 s 1 3 and 2 4 windings 45 If you plan to operate the K1 on 80 meters and your K1 RF board is revision D or earlier you may need to make a minor modification to the PC board Please refer to the errata sheet included with the K1B80 80 m Band Kit Uninstalled Components Make sure that all component locations on the RF board have been filled except for two which 15 supplied with the noise blanker option kit 1 and C78 which may be supplied with the 80 m band kit for the 2 band Fil
85. he leads to the correct length __ R3 825 1 GRAY RED GRN BRN __ R15 10 ohms 5 BRN BLK BLK __ 5 _ R6 2 7 RED VIO RED __ R27 1 8 k BRN GRY RED __ 012 1N4007 black body __ RFC6 and 100 uH BRN BLK BRN __ C5 3300 pF polystyrene 3300J __ C12 1200 pF polystyrene 12007 see note above LJ Install C8 82 pF on the bottom of the board near P1 Before soldering fold it down against the board towards the back On top and bottom sides of board near J7 you ll find short jumpers Install U shaped wires at both locations Locate the DC power switch S1 Install S1 near the back of the board with the plunger facing the back edge Make sure S1 is pressed firmly onto the board and that it is not tilted 29 Push the black keycap onto S1 s plunger until it snaps Install the DC input jack J4 at the back edge The 3 leads on the jack must be lined up with the slot shaped holes in the component outline If the holes are a tight fit press firmly until the connector snaps into position flat against the board Visual Inspection Verify correct orientation banded end of each diode installed so far using the parts placement drawing Appendix F Examine both sides of the PC board closely for solder bridges cold solder joints or unsoldered components Resistance Checks Make the resistance checks listed below with your DMM s lead
86. he supplied mating plug and prepare a suitable power cable The center lead of the plug is positive Turn on 51 If you see or smell smoke or a component feels hot to the touch disconnect the power source immediately Locate the source of trouble before proceeding Using your DC voltage setting make the DC voltage checks listed below The lead of your DMM should be connected to one of the ground jumpers AN Be careful not to short adjacent pins of ICs with the DMM probe use only a fine point probe Test Point DC Voltage pin 15 5 8 0 2 P1 pin 16 supply 0 3 V 3 8 4 2 7 6 8 7 ELECRAFT Turn the K1 off and disconnect the power supply Install the headphone jack J2 on the small board extension near the front left corner The pins on J2 are not very long so they will be nearly flush with the bottom of the board Solder the pin closest to the front edge first ground then verify that the jack is seated flat on its plastic nubs before soldering the other pins Mono Headphones If you plan to use only a mono plug at J2 cut the trace marked cut mono on the bottom of the board under J2 You ll lose the sound on one side of stereo headphones Install the key jack J3 at the back left corner Before soldering make sure that the jack 1s aligned with its PC board outline Install the antenna jack J5 BNC in the back right corner Solder one of the
87. hiny finish not black Z4 internal tooth lock washer and 4 40 nut The screw should be inserted from the bottom side Figure 8 1 Verify the part number on Q6 28C2166 or C2166 then solder Trim the pins on the bottom Remove the right side panel if it is still attached 43 Identify the hole in right side panel where thermal insulator will be placed Figure 8 2 If the edge of the hole is not completely smooth use a large drill bit to de burr the hole by hand Follow with a small amount of light sanding of the indicated area LJ Attach a self adhesive thermal pad to the side panel at the location shown in Figure 8 2 The hole in the thermal pad must be aligned precisely with the hole in the panel The pad must be straight not tilted or skewed either direction Thermal insulator Figure 8 2 Attach Q7 to the right side panel using the hardware shown in Figure 8 3 a 5 16 8 mm x 4 40 flat head screw shoulder washer black plastic 4 internal tooth lock washer and 4 40 nut The small diameter part of the shoulder washer must be inserted into the hole in Q7 s tab Do not over tighten the hardware mq Figure 8 3 44 Bend the center lead of Q7 slightly away from the side panel forming it as shown in Figure 8 3 Hold the right side panel up to the right edge of the RF board Insert Q7 s leads into their pads while guiding the panel into
88. ia a one line network auxBus Option microcontrollers 1 e on the noise blanker and antenna tuner also communicate via the auxBus Front Panel Board Microcontroller MCU U1 is used to control all functions and doubles as the driver for the LCD DS1 U1 runs at just below 4 MHz The crystal X1 is intentionally kept under 4 MHz by using large oscillator capacitors so that any internally generated band edge signals will be below the bottom edge of the band The LCD segments are driven with 50 duty cycle square waves to ensure that the average DC voltage on each segment is 0 volts The LCD backplane pin 24 is also driven by a low frequency square wave To turn on a segment it must be driven 180 degrees out of phase with the backplane In phase segments remain off The MCU has a number of miscellaneous functions It reads the states of the switches S1 S6 by periodically making the associated LCD drive lines into inputs The VFO signal is amplified by 1 then counted at MCU pin 6 RA4 Pin 3 is made an A to D analog to digital input to read the battery voltage or an output to turn the ATTN LED on or off Pin 4 RA2 drives to 6 V or 0 V to turn on the RIT or XIT LEDs respectively both part of D1 by ELECRAFT virtue of an intermediate voltage supplied by op amp USA To turn both elements of D1 off pin 4 1s made an input The states of the DOT and DASH lines are sampled on analog input RA3 pin 5 I
89. ication 02 04 V DC Actual 6 Premix crystal U7 pin 7 Expected 04 25 V Actual 11 12 13 14 15 16 Wwe 18 19 20 21 22 23 Premixer U7 pin 4 or 5 whichever is greater Expected 04 25 V Actual Premix band Pas filter FIL P1 pin 6 FIL P1 is an 8 pin connector on the Filter board near the crystals Pin 6 is the third pin from the right end Expected 04 15 V Actual Note the expected voltage takes into account the de tuning effect of the RF probe The signal level would be higher if the filter was re tuned to compensate for it BFO U2 pin 7 Expected 015 100 V Actual Connect a signal generator or test oscillator to the antenna jack Set the signal level to about 0 14 Vrms as indicated by the RF probe with the probe tip on pin 8 of FIL P3 right hand end of the 8 pin connector on the Filter board near the antenna jack Low pass filter FIL P3 pin 1 Expected 12 16 V Actual T R switch FIL P2 pin 8 P2 is the front center 8 pin connector on the Filter board Expected 07 12 V Actual RF band pass filter FIL P2 pin 1 Expected 06 13 V Actual Attenuator and T1 U1 pin 1 Expected 40 70 V Actual Receive mixer U1 pin 4 Expected 50 80 V Actual Post mixer amp R14 right end Expected 50 80 V Actual Connect a pair of headphones or a speaker and adjust the AF GAIN so that you can just hear some background noise Tune the VFO until you c
90. ientation of the LEDs D1 and D2 LCD DS1 and all ICs Examine both sides of the PC board closely for solder bridges cold solder joints or unsoldered components Resistance Checks Set both potentiometers to their mid points The resistance measurements shown below can all be made from the top side of the board The lead of your DMM should be connected to the ground jumper at the left side of the board Front Panel Final Assembly Cut three 1 25 32 mm lengths of hookup wire Remove 1 4 mm of insulation from both ends of each wire 6 Locate the 10 turn potentiometer R1 Look closely at Figure 5 9 which shows the positions of the three lugs The lugs may be labeled 1 2 and 3 or 5 CW and CCW 10 turn potentiometer labeling can be confusing so use the drawing to identify the lugs Your potentiometer may be either of the two types shown ELECRAFT Type 1 Type 2 Figure 5 9 Attach prepared wires to the three lugs Each wire should wrapped around its lug leaving the other end free Do not solder yet RI s plastic body can be damaged if you apply too much heat to the lugs Solder the three lugs limiting soldering time to about two seconds each Insert R1 through large round hole in Front Panel board rotating it into approximately the position indicated above Make sure that none of the lugs are touching the PC board Near
91. inding should look similar to Figure 4 3 but with the number of turns indicated in the parts list Figure 4 3 shows 14 turns m Remove insulation Figure 4 3 ELECRAFT Verify that the turns of L9 are not bunched together They should be evenly spaced and should occupy about 80 90 of the core Stripping Toroid Leads The enamel wire supplied with the kit can be heat stripped One way to do this is to place a small amount of solder a blob on the end of your soldering iron then insert the wire into the hot solder If the iron is hot enough you should see the insulation vaporize after 3 to 6 seconds Another possibility is to burn the insulation off by heating it with a small butane lighter for a few seconds then use fine grain sandpaper to remove the enamel residue Avoid scraping insulation off with a razor blade as this may nick the wire Strip the leads of L9 as explained above You should 6 the enamel from the leads up to about 1 8 3 mm from the core Figure 4 3 195 leads The solder should appear clean and shiny If it looks dull or is not adhering very well to the bare lead there is probably some insulation remaining Remove it as described above Install L9 vertically as shown by its component outline Pull the leads taut on the bottom of the board Solder the leads of L9 When soldering make sure that the solder binds well to the leads If the le
92. into non 50 ohm loads the power display may not be accurate TUNE Mode To put the transmitter into TUNE mode key down press WPM and WPM switches simultaneously At 5 watts the display would show P5 0 It is normal for this number to vary over as much as several tenths of a watt While in TUNE mode you can change power output using and Keyer Test Mode It is possible to completely disable the transmitter to do keyer or message buffer testing page 55 QSK Delay and Sidetone The QSK delay is set with the T R menu entry Sidetone volume and pitch are set using the STL and STP menu entries respectively Transmit Offset The transmit offset should be matched to your selected sidetone pitch using C13 on the RF board This is normally accomplished during alignment page 47 Transmit Frequency Limits Some countries require transmit to be disabled outside of specified amateur bands Your K1 may include such limits encoded in firmware In this case if you key the transmitter with the VFO set outside the usable range you ll see End on the LCD ELECRAFT RIT and XIT RIT receive incremental tuning can be used to fine tune the pitch of a received signal without affecting your transmit frequency This is most often used when a station calls you off frequency To turn on RIT tap The RIT LED green will turn on and the LCD s decimal point will flash slowly You can then use the OFFSET control to vary the r
93. is also a sum frequency 18 085 MHz which is rejected by the band pass filter The 11 915 MHz signal is routed to the RF board at 1 pin 6 59 L5 L and associated capacitors form two RF bandpass filters one for each band T R switching circuits on the RF board place these filters in either the receive or transmit path L9 L12 and associated capacitors form the two low pass filters All filters and the two crystals are switched by latching relays K1 K3 Microcontroller U1 pulses the relay coils bidirectionally to switch them on or off The reset condition of each relay selects band 1 Latching relays are only energized when switched between set and reset so they consume no power during normal operation Board VFO Sheet 1 Q8 15 used in a varactor tuned Colpitts VFO The VFO tunes backward For example its frequency 15 about 3 080 MHz when the operating frequency is 7 000 MHz and 2 930 MHz when the operating frequency is 7 150 MHz This is due to the fact that the VFO 1s subtracted from the crystal oscillator in the premixer U7 The use of varactor diodes electronic tuning results in a compromise between circuit complexity tuning range and stability While VFO drift can never be eliminated entirely steps were taken to minimize it First the VFO supply voltage is double regulated explained in the next paragraph This improves stability by guaranteeing a very stable voltage reference for the varactor
94. large ground mounting pins first If J5 then appears to be tilted or twisted reheat this ground pin while pushing J5 down onto the board Once it is seated properly solder the remaining pins L The internal speaker connector P2 is a 2 pin connector with a locking tab Orient P2 as shown by its PC board outline near the front right corner of the board with the locking tab facing the front P2 must be seated flat against the board before soldering Install crystal X5 near the front edge of the board Make sure it is flat against the board and not tilted before soldering The leads can be bent to hold it in place Install X6 near the back left corner Install X1 X4 at the front right corner Ground cases of all six crystals using near by ground pads Use discarded component leads as before Limit soldering time to 4 5 seconds to avoid overheating the crystals 31 Install R39 1 8 k BRN GRAY RED on the bottom of the board near crystal X6 In the back right corner of the board near the antenna jack install a 3 pin male connector The long end of P3 s pins 75 face up Install the two pin shorting jumper across pins 1 and 2 of P3 the two terminals closest to J5 On the bottom of the board install R4 5 6 k GRN BLUE RED Locate miniature slide switch 52 Install 52 on the bottom of the board with the switch pressed down onto the b
95. matched unbalanced usually coax fed antenna can be used with the K1 With non resonant antennas or balanced feedlines a suitable balun and or antenna tuner will be required If you have the automatic antenna tuner option installed you can connect a wide range of random length or non resonant antennas directly to the K1 and use them on one or more bands Power setting accuracy with internal RF detector Power readings using KI s built in RF detector D15 are only accurate when the SWR is low If you use a poorly matched load you should check your power output with an external wattmeter In some cases a high SWR load can result in excessive current drain Power setting accuracy with KATI If you have the KATI installed power output display will be much more accurate under all SWR conditions since the tuner provides its own calibrated SWR bridge wattmeter ELECRAFT Controls and Display LCD The 3 digit LCD liquid crystal display shows the operating frequency or relative signal strength S meter on receive power output on transmit menu parameters and status information Decimal Point The decimal point is flashed when RIT or XIT is enabled This acts as a reminder that RIT or XIT is on Error Messages If a problem is detected on power up or during normal operation the display may show E42 or a similar message If this happens see Troubleshooting LEDs RIT XIT dual color RIT green or XIT orange A
96. mers and T4 not yet installed The remaining diodes to be installed are all type 1N4007 585 is on the left side of the board near 16 D18 D14 __ 013 9 Install a 100 uH RF choke BRN BLK BRN at RFC3 located near 51 Install 22 uH RF chokes RED RED BLK at RFC2 and RFCS Refer to Figure 5 4 page 19 when installing these transistors __ Q5 J309 near J6 __ 14 2N4124 back left corner Install 150 pF 15177 on the bottom of the board Before soldering fold C1 down towards the pads of R31 and R32 but make sure it isn t touching these pads CI s overall height should be more than 0 15 4 mm above the bottom of the board ELECRAFT AN TO 220 package transistors Q6 and Q7 look identical but are different types Locate the 28C1969 labeled C1969 Q7 and set it aside The 28C2166 transistor Q6 C2166 will be installed first Attach a self adhesive thermal pad to the PC board top of the component outline for Q6 The hole in the thermal pad must be aligned precisely with Q6 s mounting hole on the board Prepare the leads of Q6 as shown below bending them downwards to match their pads To avoid stressing the leads use smooth bends rolling them over a small screwdriver blade or forming them using long nose pliers Use smooth bend not 90 Figure 8 1 Secure Q6 to the board using a 4 40 x 3 8 9 5 mm pan head screw s
97. meter should indicate 0 bars or the first bar may just be flickering on If not you can use the SIG menu entry to change the LXx parameter After each change to L xx hold to exit the menu and return to the S meter display to see the effect on the S meter reading To check the S meter full scale setting re connect the antenna and tune in a very strong signal If the S meter s reading appears to be too low or too high for the given signal strength use the SIG menu entry to change the Hx parameter To get to the Hx parameter hold while Lxx parameter is displayed Reducing the Hx parameter value will increase the S meter reading 54 Basic K1 Operation Self Test A number of tests are done at power up If you see an error message such as E42 refer to Troubleshooting Band and Frequency Display When you turn on the or tap B AND the current band and operating frequency will be displayed For example if the last band used was 40 meters and the VFO was set to 7025 3 kHz the LCD would show 7 then 025 and finally 25 3 Changing Bands To change bands tap BAND quickly two or more times Receiver Setup Display Mode Holding alternates between three receive mode displays frequency default S meter and voltmeter For normal operation use frequency or S meter mode In S meter mode the frequency is re displayed automatically whenever the VFO is moved AF GAIN Adjust the AF GAIN control f
98. n If the antenna tuner is installed SWR bridge wattmeter output takes over from D15 via pin 5 of J8 Appendix A PICTURE K1 Packing Box Parts List Designators Misc 1 2 4 5 Bag Misc Bag Wire Bag Filter Board Bag Per Band Components Bag Front Panel Board Bag RF Board HW in envelope Revised 11 30 2000 Description RF PC board E100094 Additional Filter board components for two selected K1B80 K1B40 bands 2 band 1 kit only K1B30 K1B20 Elecraft order numbers shown at right K1B17 K1B15 Components for Front panel PC board E850021 Components for RF PC board E850020 Thermal insulator TO220 for Q6 Q7 RF BOARD E700002 Page 1 1 1 1 Part Number QTY Box Appendix A PICTURE K1 Packing Box Parts List Revised 11 30 2000 Designators Description Part Number QTY Misc in envelope Acrylic display bezel for LCD Front Panel E100108 1 Mise in envelope SP1 KN1 Large knob 1 25 dia 0 25 shaft Rogan RB 67 3 M E980021 1 KN2 KN3 Small knob 0 5 diam 6mm shaft E980016 2 Page 2 Box Appendix A K1 Front Panel Board Parts List PICTURE Designators Description Part Number QTY C1 C2 82 pF NPO disc label 82 E530038 2 01 uF monolithic label 103 E530009 2 047 UF monolithic label 473 E530025 1 LED dual orange green LiteOn LTL 298WJ Digikey 160 1037 E570000 1 LED yellow
99. n 1 should be labeled 77083102 83C102 or 8A3102G If the labeling differs verify the resistance You should measure about 1 0 k between each pair of adjacent pins Install RP1 on the bottom side of the board The end with a dot or bar should be oriented towards pin 1 of the PCB outline When soldering RP1 keep the iron tip away from 54 and 55 Install and solder the two 82 RF chokes and RFC2 GRAY RED BLK ELECRAFT A Before handling ICs and transistors in the following steps touch an unpainted grounded metal surface Locate transistor Q1 type 2N4124 which has a small 2 46 TO 92 package Q1 and other TO 92 devices may have either of the two shapes shown in Figure 5 4 The right hand illustration shows a modified TO 92 package which may be labeled on either the front or back side The large flat side of each device will be aligned with the flat side of its component outline Figure 5 4 Install 1 the bottom side of board to the right of large hole Align as shown above The transistor should be mounted about 1 8 3 mm above the board don t force it down too far or you may break the leads Bend the leads outward slightly to hold QI in place then solder and trim the leads 19 Locate U4 a 78L06 voltage regulator which has a TO 92 package similar to Install U4 below the large hole A Touch an unpainted g
100. n a pair of headphones or an external speaker and adjust the AF GAIN control until you hear some background noise If you do not hear any background noise refer to Troubleshooting Set the VFO to about the mid point of the present band 7 050 MHz on 40 meters 10 125 MHz 30 meters etc Tap BAND if necessary to verify that you re in the right 100 kHz band segment Connect an appropriate antenna for band 1 At minimum connect approximately 20 30 feet 6 to 9 meters of any type of wire to the center conductor of J5 In general the longer and higher the antenna the more signal strength that will be available during receiver alignment AN Receiver alignment will be easiest if you use a ham band transmitter or signal generator to create a very strong signal that can be located with the K1 If you use a transmitter be sure to connect it to a dummy load and operate it at low power 40 Band Pass Filter Alignment On the Filter board there are premix filters and RF filters for each band as shown in Figure 7 2 Each filter has two slug tuned inductors These filters will be peaked in the following steps Premix RF Figure 7 2 LJ Locate the plastic tuning tool The smaller end of the tool will be used to adjust the slug tuned inductors LJ while listening to atmospheric noise or a CW signal peak the two band 1 Premix inductors L1 and L2 Do not continue to turn the slug if it has bottomed out Stop when you feel
101. n to push on the tape through a hole until the tape begins to lift away Peel the tape off using a sharp tool if necessary Be careful not to scratch the outer surface of the panel 23 After removing any masking tape turn front panel face up with the Elecraft logo at the top Position the clear plastic LCD bezel over the large LCD opening then secure 1 with four 2 56 screws stainless steel as shown in Figure 5 11 Tighten the 2 56 screws only the amount needed to hold the bezel to the front panel Over tightening may crack the bezel or strip the threaded holes in the panel 2 56 Screw 4 LCD Bezel Figure 5 11 Remove all hardware from the shaft of the 10 turn potentiometer R1 It will be re attached in a later step Locate the 0 75 19 mm diameter nylon washer Place this washer over 1 5 threaded bushing 24 Insert the Front Panel PC board assembly into the front panel Figure 5 12 The push button switch caps should protrude slightly Figure 5 12 The 1 4 6 4 mm standoff on the PC board should now be visible through the countersunk panel hole just below Secure the panel to the standoff with a 3 16 4 8 mm flat head screw AN Caution The 10 turn potentiometer may have a plastic bushing In the following step do not over tighten the nut or you may strip the threads Use the nut and lock washer supplied with to secure it to the f
102. nd where signal is lost see probe and procedure later in this section Check for any components getting hot Check for RF Q7 s tab shorted to the right side panel ground 88 Power output fluctuates 90 Output power drops to zero suddenly 92 Current drain too high on transmit 95 Keyer Problem If you stay in key down TUNE mode for several seconds it 1s 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 Make sure none of the diodes in the T R switch circuits are in backwards If the transmitter 1s unstable oscillating even when connected to a 50 Q load you may have an incorrect component value or a toroid winding error 86 If you have transmit power set too high for your battery or power supply the supply voltage may drop so low on transmit that it resets the MCU FP U1 or the I O controller FIL U1 Reduce power 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 i
103. ng components in the remaining assembly steps unplug the Front Panel assembly and remove the side panels LJ Install the following capacitors starting with C3 which is in the back left corner of the RF board 10 10 gt C62 330 331 C56 047 473 7 15 001 102 7 C58 01 103 7 C51 001 102 7 C14 001 102 7 16 001 102 C60 01 103 7 76 01 103 7 C57 047 473 C47 01 103 44 01 103 7 C46 0 1 104 C50 047 473 C55 0 1 104 C52 0 1 104 C43 01 103 Install the following 5 resistors starting with R35 on the left side of the board near J6 2 R35 120 BRN RED BRN _ RI0 470 YEL VIO BRN 82 GRAY RED BLK R22 33 ORG ORG BLK R12 820 GRAY RED BRN R24 2 7 k RED VIO RED R38 270 RED VIO BRN R28 820 GRAY RED BRN R29 270 RED VIO BRN 7 R30 3 3 ORG ORG GOLD R33 470 YEL VIO BRN R25 100 k BRN BLK YEL R31 33 ORG ORG BLK R32 33 ORG ORG BLK ELECRAFT On the bottom of the board near the antenna jack install a k 1 resistor at R36 BRN GRN BLK BRN and a 226 ohm 1 50 resistor at R37 RED RED BLU BLK 1 AN Be sure to check the orientation of the banded end of each diode in the following steps Install the 36 volt zener diode D19 type 1N4753 which has a large glass or silver colored body D19 is on the right side of the board between transfor
104. ng side of the panel Use one 3 16 4 8 mm flat head screw to hold each 2 D fastener to the side panel Figure 6 11 The two unused holes on each fastener must be offset away from the side panel as shown Holes offset away from panel Figure 6 11 ELECRAFT Attach the side panels to the RF board using two 3 16 4 8 mm flat head screws per side panel The side panels are attached using the 2 D fasteners that are already in place on the RF board Figure 6 12 shows the approximate location of the two screws used to secure the right side panel Figure 6 12 ELECRAFT With the assembly upside down or resting on one side plug the front panel assembly into the RF board Figure 6 13 Connector J1 on the bottom of the front panel PC board mates with on 6 bottom of the RF board indicated by an arrow below Figure 6 13 Secure the front panel to the side panels and RF board using two flat head and two pan head 3 16 4 8 mm screws Flat head screws are used on the top and pan head on the bottom You may need to adjust the 2 D fasteners slightly then re tighten all hardware 35 AN The switches should now be accessible and the headphone jack should be even with the front panel Also the LEDs above the VFO knob should be visible If any of these controls are not properly situated you may not have the Front Panel fully plugged into the RF board Note The coaxial jumper to b
105. ns VFO and Premixer 40 59 Troubleshooting Steps 40 General VFO Note Some VFO drift will always be present problem frequency jumps or drifts due to aging of components and heating or cooling of the cabinet The VFO will drift more if you used the larger range C2 120 pF Use CAL menu entry to check actual VFO frequency hold to show the operating frequency calibration display then switch to OSC using sure supply voltage 15 above 8 5V If you used solder with water soluble flux clean the board with hot water and a Q tip sure L1 leads are properly stripped Check crystals on Filter board Check actual VFO range 40 Measure voltage on anode of RF D3 VFO main varactor diode while tuning VFO pot Measure voltage on anode of RF D4 offset varactor diode while tuning the OFFSET pot Varactors may be installed backwards 42 VFO inductor not Ifyou see E42 the VFO signal is either installed or VFO not missing or is too low in amplitude to be oscillating counted by MCU FP U1 Check all VFO components Check the counter amplifier and related components 1 R11 R12 Use signal tracing to determine where the VFO signal is getting lost 41 Can t tune VFO or RIT XIT offset 45 VFO tunes the VFO pot 1 CCW and CW leads may wrong way be reversed 46 VFO or RIT XIT Check actual VFO range 40 range is too large too Varactor diod
106. nty 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 instructions 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 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
107. nytime you are actually moving the VFO the S meter bargraph will be replaced with the frequency display Once the signal 1s tune in the AGC should be activated as indicated by an increase S meter reading The S meter zero point and scale can be adjusted page 53 AGC can also be turned off if necessary page 57 Note Since the K1 uses audio derived AGC the initial code element from a very strong station may be heard at louder volume This 1s due to the time it takes for the AGC detector capacitor to charge up If this 1s objectionable the attenuator can be used Turning on the attenuator adds one bar to the S meter reading to roughly compensate for the loss in signal strength Receive Current Drain Test Optional Typical current drain for the K1 in receive mode is approximately 55 mA with all LEDs off If the current drain 15 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 K1 and the power supply Turn the K1 on and note the current mA This completes receiver alignment Each bar corresponds to roughly two S units so that 4 or 5 bars indicates about an S 9 signal 42 6 Board Part II In this section you ll install the transmitter components LJ Turn off the K1 and disconnect the power supply LJ Unplug the Filter board and set it aside AN If you have difficulty installi
108. o pan head and two flat head 3 16 4 8 mm screws Four self adhesive feet are supplied for the bottom cover Install one at each corner approximately 1 4 6 mm from edges Attach the self adhesive serial number label to the rear panel of the bottom cover in the space provided Write the serial number on the inside cover of your manual If you have the KTS1 wide range tilt stand you should configure it for desk top use using the short arms and attach it to at this time Refer to instructions This completes assembly of your 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 K1 s features If you re new to QRP be sure to read the QRP Operating Tips page 56 AN If you have purchased internal options we recommend that you do not install them until becoming familiar with basic K1 operation Once you re ready to build option kits the suggested order of assembly is KFL1 2 KFL1 4 KNB1 KBT1 All K1 options are described on page 57 50 11 Operation This section explains how to set up and operate the K1 We suggest you read the first few pages as an overview then follow the tutorial which starts on page 54 Basic K1 Operation There s also a Quick Reference Appendix G which shows the locations of front panel
109. oard as far as it will go If it isn t pressed all the way down the actuator might hit the bottom panel Limit soldering time on each of S2 s pins to 2 seconds to avoid melting the plastic body Set S2 s actuator to the OPER operate position Locate the component outline for RFC8 on the bottom of the RF board in the transmitter area Install a short wire jumper at RFC8 formed from a component lead or solid hookup wire Note an RF choke may be supplied with the 80 meter band kit 2 band Filter board only for use at RFC8 This RF choke can be installed at any time and will have no effect on K1 alignment or testing on any band Its function is to improve stability on 80 meters when the K1 is used with poorly matched loads or an ATU Locate the component outline for RF choke RFC9 on the bottom of the board between the pins of relay K1 Flush trim the four pins of K1 closest to RFC9 Form the leads of RFC9 15 uH BRN GRN BLK to fit between the indicated pads Install RFC9 and position its leads so that they don t contact any adjacent pads of K1 Solder and trim RFC9 s leads from the top side of the board 32 Locate the dark gray ferrite toroid cores You should have four smaller cores type FT37 43 and one larger core FT50 43 The three inductors to be wound in the following steps L2 T1 and T2 all use the smaller ferrite cores AN Review the toroid winding and lead preparation inst
110. or comfortable headphone or speaker volume The sidetone volume can be set higher or lower in relation to receiver audio using the STL menu entry Crystal Filter Selection Filter FL1 usually the widest filter is selected on power up Holding cycles through the filters Use narrower filters to reduce interference from nearby stations Attenuator Holding switches in about 14 dB of attenuation This may be useful if extremely strong signals are causing receiver overload The receiver has sufficient sensitivity to allow the attenuator to be left in at all times if necessary If you turn the attenuator on when the display is in S meter mode an extra bar is added to the S meter display to compensate Note You can disable LEDs to save current using the LED menu entry ELECRAFT Transmitter Setup Display Mode During transmit the LCD normally shows a bargraph 1 bar per watt If you select supply voltage display mode sine BETTE the power supply or battery voltage will be shown flashing slowly In TUNE mode power is shown in watts see below SWR can be displayed if the KAT1 ATU 1s installed Setting Power Output Approximate power output can be set using the OUT menu entry 0 1 to 7 0 watts Anytime you change the power level or change bands you ll see power start out near zero then go up while you send the first few characters of CW This is due to the transmitter s ALC automatic level control Caution When working
111. ped Install 7 16 11 mm hex male female standoffs at the two locations identified as B in Figure 6 9 replacing the existing 3 16 pan head screws Do not use any lock washers Temporarily place the Filter board assembly top of three standoffs just installed If the standoffs are in the correct positions they will be visible through their holes in the Filter board 33 AN When working with the side panels in the following steps place a soft cloth on your work surface to protect the paint A clean anti static mat will also suffice Locate the two side panels and arrange them as shown in Figure 6 10 with the inside surfaces facing up The right side can be identified by the presence of an extra hole as shown The illustration also shows where 2 D fasteners will be installed as well as the areas which were masked during painting Left side inside surface 2 Fastener Masked area Z Right side Inside surface Extra hole Figure 6 10 Remove any masking tape from the panels using the same technique described on page 23 taking care not to scratch the outer surfaces 34 AN Flat head screws are more easily damaged than pan heads Do not use excessive force when tightening them Attach two 2 D fasteners to each side panel at the locations indicated in Figure 6 10 Make sure that the holes are countersunk if not you may be working with the wro
112. rd as possible so that they won t interfere with the 40 pin IC socket next step Install the 40 pin IC socket at on the bottom side of board The board is labeled SOCKET at this location Orient the socket s notched end to the left the pin 1 end To hold the socket in place bend pins and 21 outward slightly these two pins are diagonally opposite Solder only these two pins ELECRAFT If the socket does not appear to be seated flat on the PC board reheat these two pins while pressing on the socket If the leads of C4 hit the socket trim them closer to the board LJ solder the remaining pins of U1 UI itself will be installed in the socket in a later step Install and solder the following components When soldering components near the push button switches be careful not to touch the switches with the soldering iron Top side _ R4and 5 10 BRN BLK ORG 100 BRN BLK YEL Bottom side __ R6 12 7 1 BRN RED VIO RED 7 3 92 k 1 ORG WHT RED BRN R9 10 and _ R19 100 k BRN BLK YEL R13 470 YEL VIO BRN R12 2 7 RED VIO RED Rl4and 815 1 BRN BLK RED R16 2 7 RED VIO RED 5 C6 01 pF 103 Install capacitors and C2 82 pF near UI LJ Locate resistor network RP means resistor pack another name for resistor networks One end of has a dot indicating pi
113. ront panel It should be just tight enough to keep R1 from rotating Place the large knob on RI s shaft Push the knob on until it just touches the bushing If the knob does not spin freely move it out slightly If the shaft or knob appears to be tilted the large nylon washer may not be positioned correctly behind the panel ELECRAFT AN The Allen wrenches are located in a small bag with the MISCELLANEOUS items These wrenches may have been oiled during manufacturing Remove the wrenches and wipe off the oil if any then discard the bag Use larger Allen wrench 5 64 2 mm to tighten two set screws on the large knob Set the AF GAIN and RIT XIT potentiometers to midway in their rotation and place a small knob on each Do not push down hard on the knobs as this may damage the potentiometers Tighten each knob s two set screws using smaller Allen wrench 050 1 3 mm Align the pointers per panel labeling AN At this point in the assembly the push button switches may not all protrude an equal distance The switch height will become equalized once the front panel assembly is mated to the RF board in a later step AN When you rotate the VFO knob you may hear a faint sound produced by the wiper of the 10 turn potentiometer as it moves across its resistance element This is normal Uninstalled Components All component locations should now be filled 25 ELECRAFT
114. rounded metal surface before handling the 2N7000 transistor in the next two steps Locate the component outline for Q2 2N7000 on the top side of the board near the rectangular hole Q2 s outline has the three pins side by side not in a triangular pattern Pre form the leads of Q2 to match this hole pattern so that it can be mounted very close to the PC board with little excess lead length Install Q2 Make sure the top of Q2 s body is no more than 0 25 6 mm above the board when seated Solder Q2 Install the 8 pin ICs U2 518 03 24LC04 and U5 LM358 on the bottom side Orient the notched or dimpled end of each IC with the notched end of its component outline see Figure 4 7 Bend two leads outward slightly on the opposite side of the board to hold the devices in place but do not solder yet Turn to Appendix F parts placement drawings to verify that you have the ICs installed in the proper locations then solder Limit soldering time to 2 to 3 seconds on each lead top side of board at left end you ll find a short jumper location labeled with a ground symbol Install a 3 4 19 mm U shaped wire here as you did earlier on the Filter board AN The potentiometers to be installed in the next step can be damaged if you push on their plastic shafts When seating a potentiometer press down only on the metal frame Install the two 10 k potentiometers at R2 and R3 on the
115. ructions if necessary page 14 Wind L2 using 16 turns of red enamel wire 11 inches 28 cm L2 should appear similar to Figure 4 3 on page 14 the figure shows 14 turns rather than 16 Recall that each pass of the wire through the core counts as one turn Prepare L2 s leads as before page 14 Remove the insulation to within about 1 8 3 mm of the core then tin the leads Install L2 vertically at back edge of RF board between the on off switch 51 and the antenna jack 15 AN TI is a toroidal transformer with two numbered windings These numbers are printed next to each pad on the PC board TI s windings are 1 2 and 3 4 1 is wound on an FT37 43 ferrite core dark gray and has windings similar to those shown in Figure 6 8a Wind the 3 4 winding first using 20 turns of red enamel wire 13 33 cm This winding should occupy 80 to 90 of the core Note the drawing shows only 14 turns Wind the 1 2 winding on top of the 3 4 winding using 4 turns of green enamel wire 6 16 cm These turns should be wound tightly and will overlap the turns of the first winding The drawing shows the turns interleaved for clarity but this 1s not required Strip and tin all four of TI s leads carefully ELECRAFT Install flat against the board between U1 02 Insert the leads into its numbered holes as shown by the component outline Pull the leads taut on the bottom th
116. socketed ICs front panel board voltages too low filter board and options individually lt 5 7 Inspect the entire 6A or 6B path on the RF and Front Panel boards Check for regulator ICs installed backwards iftthe output lead of the affected regulator and measure the voltage this lead if the voltage is still too low replace the IC Lift other component leads on the 6V line as needed to find cause of excess loading 23 8V too low Use techniques given for 6V regulators lt 7 5V above 24 LCD or LED LCD in backwards or bent pin check for problem shorts to ground on each LCD pin MCU pin bent or broken FP U1 LEDs swapped or installed backwards Relays installed backwards or not soldered Check relay coil resistance pins 1 and 10 controller defective or backwards 27 26 Possible MCU Check all DC voltages on FP U1 problem Remove the Front Panel board and inspect UI Make sure it is not backwards has no bent pins and is seated firmly in its socket Check oscillator components X1 C2 Also see 33 if you suspect an error in a menu parameter etc 25 Relay Problem 27 Filter board not plugged in or I O controller FIL U1 communication problem 28 I O controller data error 29 AuxBus problem 30 EEPROM write read test 1 failed 31 EEPROM write read test 2 failed 32 EEPROM data error 33 Configuration data or menu problem If you saw the message E27 the I O controller FI
117. spacer 0 5 x 0 5 x 0 187 self adhesive both sides 700020 1 HW 4 flat washer steel zinc for speaker one spare 700044 HW 4 washer 047 thick fiber black for speaker lt L L a5 TI TI TI NI O O O O O O O O O N Page 1 Misc and Wire Appendix A K1 Misc Bag Parts List PICTURE Designators Description Part Number QTY 2 pin female conn Housing 0 1 spacing locking ramp SPK J1 for speaker E620021 1 ACC P1 2 1mm male conn mates with DC power jack E620032 1 Stereo 1 8 phone plug ACC P2 for key paddle computer or other keying device E620033 1 Female crimp pins for SPK J1 E620022 lt a Plastic tuning tool p n MARS 12 E980012 1 T Misc Allen wrench 5 64 long handled for large knob E980004 1 N Misc Allen wrench 05 short handled for small knobs E980008 1 Appendix A K1 Wire Bag Parts List QTY PICTURE Designators Description Part Number ft Misc 26 Red Enamel Wire for toroids 760002 14 Misc 4 Misc 1 Misc 1 Misc 0 9 Page 2 Misc and Wire Transistors Diodes 2N3906 25 2166 ZN4424 MPSA14 1SV149 2N7000 2N4124 J309 m m A T Anode Cathode Integrated Circuits LEDs PLASTIC DIP VOLTAGE REGULATORS D1 D2 DUAL INLINE PACKAGE 78L06 LM2930T BOTTOM VIEW BOTTOM VIEW NOTCH NOTCH IN
118. stions 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 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 wick on both the top and bottom pads when possible This helps get all of the solder out of the hole If 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 1s 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 in the assembly process is accompanied by a check box This symbol is used to alert you to important information A Do not skip any steps You may adversely affec
119. t both the performance and appearance of the kit by using the wrong assembly order Components Sometimes we refer to components by their PC board and reference designator For example FP Q1 refers to transistor Q1 on the Front Panel board A few components in the kit are mounted on the bottom of PC boards Component outline symbols are provided on the appropriate side of the board so it will always be clear which side a particular component goes on Bottom mounted parts are also identified on the schematics by this symbol Photographs Before beginning assembly you should review the photographs in Appendix D to get an idea of 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 ELECRAFT 4 Filter Board This section applies only to the two band Filter board If you have a four band refer to the assembly instructions in the KFL1 4 manual The Filter board determines the K1 s bands of operation A photograph of the completed board appears in Appendix D LJ Open the bag of components labeled FILTER BOARD and sort the parts into groups Identify components using the photographs in the Filter board parts list in Appendix A Locate the Filter printed circuit board PCB labeled K1 FIL2 on one side LJ With the top side of the PC board facing you notch at the lower right locate the position of resistor
120. t their value in microhenries using two significant digits a multiplier Example a choke Handling Integrated Circuits and Transistors with color bands RED VIOLET BLACK has value of 27 uH This kit uses integrated circuits ICs and transistors that can be damaged by electrostatic discharge ESD Problems caused by ESD can often be difficult to troubleshoot To avoid this Color Code Leave parts in their anti static packaging until you install them Use an anti static mat on your work bench Use a soldering iron with a grounded tip Tolerance Ground yourself using a wrist strap with 1 Mohm series resistor gold 5 At minimum touch an unpainted grounded metal surface silver 10 before handling ESD sensitive components Multiplier Inventory second Digit First Digit We recommend that you do a complete inventory using the parts lists in Appendix A Start with the K1 Packing Box Parts list Color Digit Multiplier which details the items you should find when you first open the box Additional parts lists are provided for components used in each Black 0 x 1 subassembly Component photographs are provided in most cases Brown 1 x 10 Red 2 x 100 Identifying Resistors and RF Chokes Orange 3 x 1K Yellow 4 x 10K Resistor and RF choke values and color bands are provided in the text However it s helpful to familiarize yourself with the color Green 9 x 100K code The color code chart Figure
121. t wiring unlike earlier designs that used wiring harnesses The K1 even provides its own built in test equipment including battery voltage monitor wattmeter and frequency counter The manual provides complete troubleshooting and signal tracing procedures and you ll find further support on our website www elecraft com We d like to thank you for choosing the K1 transceiver and hope it meets your expectations for operation both at home and in the field Wayne Burdick NOKR 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 the Elecraft e mail forum elecraft qth net Telephone assistance 15 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 kit 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 Warra
122. tal mount 1 1 33 uH RF choke soleniodal color code orange orange black NOTE orange bands may appear brown 100 uH RF choke soleniodal RFC3 RFC4 RFC6 color code brown black brown Page 3 Part Number QTY E680010 E680003 E680003 E680003 E680003 E680008 E690012 E690000 N Ie a e a a a a E690007 N NO 0 0 0 NO NO Co E690004 4 RF Appendix A K1 RF Board Parts List PICTURE Designators Description Part Number QTY 20 x 1 male RA 20 pin male right angle To Front Panel P1 J1 1 P2 2 pin male 0 1 conn with locking ramp for speaker 1 P3 3 pin male 0 1 conn RF detector select 1 Q6 2SC2166 driver E580007 1 E620029 Q7 25 1969 PA Power Amp 1 05 08 017 e 03 014 2 07 010 2 02 04 R37 226 O 1 4W 196 color code red red blue black 523 R30 RTS R22 R31 R32 R16 RIB 2 RTI RTT R35 2 R29 R38 270 1 AW 5 color code red violet brown 2 Page 4 Appendix A PICTURE K1 RF Board Parts List Designators R10 R33 R7 R12 R28 R1 R26 R27 R39 R5 R6 R9 R14 R21 R24 R4 R20 R19 R2 R25 R34 R13 Description Part Number QTY 470 1 4W 5 color code yellow violet brown E500003 1 8 1 4W 5 color code brown gray red E500004 5 6 k 1 AW 5 color code green blue red 500007 39 1 4W 5 color code orange white orang
123. ter board Visual Inspection Examine the bottom solder side of the RF board carefully for unsoldered pins solder bridges or cold solder joints Resistance Checks For the following measurements connect the lead of your DMM to a ground jumper When making measurements at J7 and J8 use a component lead or hookup wire as a probe tip 46 9 Alignment and Test Part II In this section you ll align and test the transmitter stages Make sure the Filter board is not installed Place the power switch 51 in the OFF position out LD DD D Turn on the K1 You should see E27 on the LCD due to the missing Filter board Tap any switch to clear the message Place the transmitter in TUNE mode key down by holding the and WPM switches simultaneously The display should show 0 1 watts even though actual power output is zero Make the following transmit mode DC voltage measurements Connect the lead of the DMM to a ground jumper Note The banded end of diodes 1s the cathode Attach the side panels then plug in the Front Panel assembly Connect a 12 to 14 V 1 power supply or battery to J4 ELECRAFT Turn off the K1 Plug in the Filter board Connect an antenna that is adequate for receiver testing Plug in a pair of stereo headphones or a speaker at J2 Turn on K1 and test receive performance If receiver
124. the AGC signal from the RF SMTR line Transmitter Sheet 2 To vary the power output JFET Q5 and PIN diode D18 control the amount of premix signal input to the transmit mixer U8 The DC control voltage at the drain of Q5 15 set by the MCU UI front panel ALC automatic level control is implemented in firmware During keying the ALC determines what DC voltage is needed to get to the requested power level as well as what voltage corresponds to zero output As you key the transmitter the control voltage alternates between these two levels so that that the keying waveform can be effectively shaped by R10 and C59 Video amplifier U9 buffers and amplifies the TX mixer output Q14 keeps U9 fully turned off during receive The low level transmit signal 15 passed through RF band pass filter on the Filter board via J7 D9 D13 form a fast high isolation T R switch that allows the appropriate RF band pass filter to be shared between receive and transmit On transmit the signal is routed through D9 to the driver transistor Q6 On receive D10 11 and 12 are turned on bypassing the transmit stages Q7 is the class C final amplifier It operates at a nominal collector impedance of 12 5 ohms which is stepped up to 50 ohms by T4 Q7 s output is filtered by one of the low pass filters on the Filter board with signals routed through J8 RF detector diode D15 samples some of the RF output voltage to provide a power output indicatio
125. thusiasts can be found at certain watering holes on each band listed below MHz An asterisk indicates European or alternative QRP frequencies 80 3 560 40 m 7 040 7 030 30 m 10 106 10 116 20 m 14 060 17 m 18 096 15 m 21 060 Calling and Listening Calling CQ with low power may be frustrating unless you have a good antenna Usually you ll 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 500 Hz and slower code speeds should be used when conditions are marginal Contests Both general interest and QRP only contests provide a great way to work new states or countries The K1 with its low current drain and compact size 1s particularly well suited to outdoor events such as Field Day and QRP To The Field ELECRAFT Advanced Operating Features Programmable Function Switch XIT PFn By default the switch turns XIT on and off Alternatively this switch can be set up as a direct edit shortcut to any menu entry To program the switch function enter the menu and scroll to then change the parameter to the desired menu entry Setting it to NOR normal assigns the switch to XIT Spotting The STP menu entry can be used to spot or match the pitch of received signals so that you ll be exactly on frequency when you transmit To spot a signal select the STP menu entry hold th
126. tic in Appendix B may help you troubleshoot any incorrect readings A The symbol gt means greater than and lt means less than Your DMM may indicate infinite resistance all digits flashing for readings that are listed as gt 100 k Do not use an analog VOM PI pin 1 Pl pin 3 ES 1 1 P2 pin 7 P2 pin 8 gt 100 k K3 pin 2 K3 pin 9 K3 pin 4 K3 pin 7 ELECRAFT 5 Front Panel Board The liquid crystal display LCD switches and other controls are located on the Front Panel board as well as the microcontroller See Appendix D for photos of the completed assembly Open the bag labeled FRONT PANEL and sort the parts into groups Observe anti static precautions with ICs and transistors Locate front panel PC board which is labeled K1 FP along one edge In the steps that follow we will refer to the side with the switches and LCD S1 S6 and DS1 as the top side Place the board in front of you with the bottom side up Locate the component outline for J1 below the large hole Install a 20 pin female connector receptacle at 11 as shown in Figure 5 1 Do not solder yet Top side lt Bottom with LCD side Figure 5 1 17 Solder one pin of J1 on top side near the middle of connector If J1 is not seated flat against the PC board or is tilted re heat the solder and press down on the connector Once you re sure that 11 is corre
127. top side of the board They must be pressed downward until the metal frame is fully contacting the PC board on both sides Do not use excessive heat when soldering ELECRAFT 20 Open bag labeled MISCELLANEOUS and empty contents into a shallow box or pan This will prevent loss of any of the small hardware while allowing you to locate items as needed Top Side A Five sizes of 4 40 screws are used All are black anodized except the 1 4 and 3 8 pan heads see Figure 5 5 The length of flat head screw 15 measured from the top of the head Pan head 1 4 6 mm Figure 5 6 Pan head 3 8 9 5 mm Install crystal X1 near Cl and C2 the bottom of board Pan head 3 16 4 8 mm Use a discarded component lead to make the grounding wire as shown in Figure 4 1 page 13 Locate LEDs D1 and D2 which are identical in size but have Flat head 3 16 4 8 mm different colored bodies D1 has a clear diffuse body while D2 has a yellow tint Near the point where the leads exit the body you ll find a flat side in the plastic which identifies the cathode lead Flat head 5 16 8 mm Install D1 clear diffuse body on the top side of the board with its flat side aligned with the flat side of the component outline This is the side nearest the square pad Position D1 about the right of X1 you ll find a ground pad for crystal can Figure 5
128. tter 15 disabled To restore the original power level setting hold MEIN again Note Turning power to the K1 off and back on cancels keyer test mode and restores the original power level 56 Recording and Playing Messages The K1 provides two CW message memories of 90 bytes each CW messages can only be recorded using a keyer paddle connected directly to the Kl s key jack Set INP to PDn or PDr Messages are stored in EEPROM so they won t be lost when power is turned off To Record a Message Hold 39 and when prompted with 1 2 tap either 1 2 The display will then show REC 90 indicating that 90 bytes of storage are available in this message 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 MSG If you do this before starting to send the original message contents will not be lost To Play a Message Tap MSG then select a message by tapping either 1 or 2 Message play be canceled at any time by hitting M SG again or by tapping the keyer paddle You can also change the keyer speed while messages are playing using W and W PP N as usual Keyer Test Mode To play back messages without transmitting use keyer test mode page 55 In this mode you ll see 0 on the LCD during message play rather than the transmit bargraph Using A
129. two leads about 1 2 12 mm long LJ Adjust the turns of L1 so that they are fairly evenly spaced and occupy about 90 of the core LJ Strip and tin the leads of L1 to within 1 8 3 mm of the core Review toroid lead preparation instructions page 14 LJ Secure L1 loosely to the PC board as indicated by its component outline near J6 As shown in Figure 7 1 use two nylon washers a 1 2 12 mm nylon screw and nylon 4 40 nut Figure 7 1 LJ Insert L1 s leads into their pads and solder Connect the power supply and turn on ELECRAFT VFO Range Test Tap MENU and locate CAL enable operating frequency calibration display OPF hold The 100 Hz digit should be flashing If you see E42 the VFO is not functioning To see the VFO frequency you ll use CAL s other display mode OSC To select this hold You ll seeOSC followed by the VFO frequency in MHz 1 digit then kHz 3 digits For example 3 012 MHz would be shown as 3 then 012 Make sure that the VFO frequency goes up as the VFO knob is rotated counter clockwise If not see Troubleshooting Rotate the VFO knob fully clockwise until it stops then note the frequency kHz Rotate 11 counter clockwise until it stops and note the frequency kHz Subtract the low reading from the high reading to obtain the VFO range about 80 or 150 kHz depending on the value of C2 VFO Range Adjustment
130. uto Repeat Either message memory can be auto repeated when played which 15 useful when calling CQ on a quiet band or during contests Sometimes a band will be open but will sound dead simply because no one is calling CQ at that moment This is a great time to let auto repeat do the work To use Auto Repeat Tap as usual but then hold either u or The message will then play back continuously until you tap M SG again or hit your key or paddle You ll see RPT on the display in between message transmissions ELECRAFT Setting the Auto Repeat Interval The length of the pause between messages during auto repeat can be programmed using the RPT menu entry 0 255 sec Long delays are useful for beacons Using RIT During Message Repeat You can use RIT if it is turned on to listen above and below your receive frequency between calls This 15 useful when stations call you off frequency QRP Operating Tips Antennas When you re using low power a good antenna and ground system can make a big difference In general antennas should be mounted as high off the ground as possible and resonant or multi element antennas will be the most effective An excellent choice for light weight multi band portable use is a long end fed wire used In conjunction with two or more ground radials and an antenna tuner There are many references on antennas available including the ARRL Antenna Handbook QRP Frequencies Low power en
131. void letting this lead short the two pads together __ D3 ISV149 D6 D7 _ D8 1SV149 in the VFO area right front corner AN TO 92 package may have either of the package types shown in Figure 5 4 page 19 Orient the large flat side of the package with the flat side of the component outline Verify the part numbers using magnifying glass if necessary Install the TO 92 package transistors listed below starting with Q9 in the VFO area Observe anti static precautions 09 2N3906 009 gt QlIl J309 010 2N7000 Q2 5 14 QI 2N7000 Q3 2N4124 ELECRAFT AN Transistor Q4 ZVN4424 is labeled on the back the side with smaller area which is different from most TO 92 devices The labeled side of Q4 must face the power switch 51 LJ Install Q4 ZVN4424A in the back right corner near S1 LJ Install U6 78L06 near the left edge of the VFO area LJ Install the 8 pin ICs listed below Orient the notched or dimpled end of each IC with the notched end of its component outline see Figure 4 7 Make sure the part numbers on the ICs match the numbers on the component outlines __ U4 LM380N 8 do not confuse with U3 check part numbers carefully __ 93 LM386N 1 U2 U7 and UI SA602AN alternates NE602 SA612 NE612 Install the following components bottom of board soldering them on the top side Note R3 is easier to solder on the bottom In this case pre trim t
132. y hang over or do not match their component outlines they are installed backwards Install relay K1 near center of board Make sure pin 1 end with the heavy line is oriented as indicated by K1 s component outline Do not bend or trim the relay leads ELECRAFT AN In the steps that follow you ll install the connectors that mate with the Filter and Front Panel boards These connectors must be installed properly to ensure reliable mechanical connection They are difficult to remove once installed so follow all instructions carefully Review Figure 3 3 before proceeding Install 8 pin female connector at 16 on top side of RF board It must be flush with the board and not tilted Figure 6 4 Solder just one pin near the center of J6 J6 Figure 6 4 If J6 does not appear to be completely flush with the board or it is tilted re heat the soldered pin and press down Do not solder the remaining pins yet Install J7 and J8 in same manner as J6 soldering just one pin in each case The Filter board can now be used to check for proper installation of the three 8 pin connectors Place the Filter board above the connectors do not plug it in Verify that all pins of 2 and 3 on the Filter board align with the corresponding holes of J6 7 and 8 on the RF board Remove the Filter board Solder all remaining pins of J6 7 and 8 on the bottom of the RF board

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