KIO2 Manual
Contents
1. O Turn the K2 off and unplug the AUX2 board from the Control board O Turn the K2 back on and tap DISPLAY again The current drain should now be 0 00 0 02A lower than it was with the KIO2 connected If the difference is much more than this you may have a short somewhere on the KIO2 or the AUX2 board or an error in the Control board modifications O Turn the K2 off and disconnect the computer from the KIO2 connector 14 ATU J8 AUX2 PCB Figure 9 KIO2 installation in top cover see text 15 KIO2 Installation Figure 9 previous page shows where the KIO2 board will be installed in the K2 s top cover The KIO2 s female D connector will be mounted in the hole labeled AUX I O on the rear panel The ATU s control cable will plug into the AUX2 board if applicable There is no need to remove the battery or ATU O Place the top cover upside down on a cloth or other soft surface to protect the finish O Disconnect the KIO2 AUX2 assembly from the K2 O Position the KIO2 module as shown in Figure 9 The side of the board with the crystal X1 should be facing up the side with the cable connections faces down If you have the module placed correctly the female connector will be aligned with the trapezoid shaped AUX I O panel hole Note The module may be a very tight fit if you have the battery installed O Secure the KIO2 module using the hex male female standoffs Do not use washers of any kind as they will p2. O Attach a backshell two halves to one of the D connectors as shown in Figure 8 Use the provided cable clamp to hold the cable in the proper position then secure the clamp with two small screws The two jackscrews must be retained in position by the shells when the two halves are joined Secure the backshell halves with the provided hardware Once this is completed attach a backshell to the other D connector JACK SCREW CLONE BACK SHELL Figure 8 13 Serial Interface Test O Make sure the KIO2 board is hanging outside the K2 and is not shorting to the cabinet tools etc O Connect the serial cable to the K2 and the computer If your computer has a 25 pin serial connector you ll need a 9 pin to 25 pin adapter Secure the cable at the computer using the jackscrews Tighten them just enough to hold the connector in place O Turn on the K2 and computer O Tap MENU then tap DISPLAY to gain access to the secondary menu Secondary menu entries are described in the K2 Revision 2 Firmware manual O Locate the PORT menu entry using the BAND and BAND switches To edit the parameter hold gt us then change it from OFF to ON using BAND BAND Tap MENU twice to exit O For initial test purposes you can use your logging or control program to verify that basic operations such as band or mode change are working See Software Configuration page
3. This will make wiring easier O As shown in Figure 7 pins 7 and 8 of the female connector can be wired together using a discarded component lead to provide RTS CTS loop back Some application software requires this hardware handshaking between the computer and K2 We recommend that you make this connection unless you re sure that your application software does not need it Some programs use these lines for other functions such as CW keying of the transceiver If you have an existing computer control installation check the present connector wiring to see if RTS CTS loop back can be omitted O Clip the bare shield wire off at the PC end of the cable only The shield wire will be connected only at the K2 end RTS Request to send CTS Clear to send 12 O Solder the RED GREEN and BLACK wires of the PC end of the cable the end with no shield wire to the female connector Refer to Figure 7 LJ Remove the female connector from the vise and insert the male connector Keep this connector in the orientation shown below U Solder the BARE shield RED GREEN and BLACK wires to the male connector as shown U Remove the male connector from the vise PC END K2 END FEMALE MALE BARE RTS CTS LOOPBACK SEE TEXT BLK Figure 7 O Locate the connector housings backshells Open the bags and remove all hardware Each backshell consists of two plastic halves two long jackscrews a small cable clamp and associated hardware
4. 18 for application set up information Ifa K2 compatible application program is not available you can test the serial interface using a terminal program such as Hyperterminal as follows 1 Run the terminal program Set it up for communication at 4800 baud with 2 stop bits 1 will also work 8 data bits and no parity Turn off hardware handshaking RTS CTS It s also helpful to turn on local echo and line feed so you can see what you re sending to the K2 2 Tap MENU and locate the PORT menu entry as you did earlier Hold to enter edit mode 3 Tap DISPLAY to send a test message from the K2 to the computer The string FA000xxxxxxxx should be seen in the terminal program window where xxxxxxxx is the present VFO A frequency in Hz The first x will be 0 if VFO A is set to a frequency below 10 MHz 4 Tap MENU twice to exit the menu 5 At the computer keyboard type SW01 the semicolon is required This should cause the K2 to switch to the next higher band Note You cannot backspace and correct errors since each character is sent immediately to the K2 Commands with incorrect characters will be ignored If the K2 did not transmit and or receive data as described above or did not work properly with an application program refer to Troubleshooting Current Drain Test U Tap DISPLAY and check current drain with the KIO2 installed For example E13 8 0 22 indicates 0 22A Your reading A
5. 3 LS Toroidal inductor FT23 43 core dark gray see text E680004 1 Ql Transistor J310 E580012 1 RI Resistor 3 9 k 1 4 watt 5 ORG WHT RED E500009 1 R2 Resistor 47 ohms 1 4 watt 5 YEL VIO BLK E500019 1 Ul IC MAX1406CPE alt LT1039CN16 E600036 1 U2 IC voltage regulator 78L05 E600029 1 XI Crystal low profile 16 289 MHz S162 or similar label E660014 1 Components on the AUX2 PC board C2 Capacitor 01 uF 103 E530019 1 Cl Capacitor 0 1 uF 104 E530020 1 Jl Conn 10 pin total dual row female 0 1 spacing E620045 1 J2 Connector not used wires will be soldered at this location 0 Ll RF choke subminiature 15 uH BRN GRN BLK E690012 1 PI Conn 10 pin total dual row male 0 1 spacing E620040 1 Hardware and Miscellaneous MISC KIO2 PC board E100125 1 MISC AUX2 PC board E100126 1 MISC 9 pin female D connector DB9F E620048 1 MISC 9 pin male D connector DB9M E620049 1 MISC DB9 backshell assembly w hardware E620050 2 MISC 8 conductor shielded cable E760014 2 ft MISC 4 conductor shielded cable E760009 10 ft HDWR Hex standoff male fem 4 40 x 3 16 qty incl 1 spare E700052 3 HDWR Nut 4 40 brass qty includes spare E700051 3 MISC Enamel wire 26 Thermaleze RED E760002 2 ft MISC Hookup wire green E760008 1 ft MISC Cable ties 3 inch 7 6 cm E980002 3 Firmware Requirements To use the KIO2 you ll need main microcontroller firmware revision 2 01 or later the main microcontroll
6. as an antenna drape the wire near the KIO2 If you still can t find the signal proceed with the DC voltage checks Strong noise signals heard on one or more bands This could indicate that the KIO2 s 8 wire cable or another option cable is laying directly on top of the K2 s RF board Remove the top cover and re dress the cables using cable ties It may actually be easier to remove the right side panel for this purpose since you can see exactly how all of the cables are positioned with the top cover in place Weak noise signals heard on quiet bands It s nearly impossible to eliminate all computer related noise However you may be able to eliminate some weak computer modulated signals heard on quiet bands This involves disabling the KIO2 s on board 16 29 MHz crystal oscillator If you disable the oscillator the supply voltage for the KIO2 is then derived from the computer s RxD signal at pin 3 of J1 on the KIO2 board This will not work in all cases since some computers don t provide an adequate voltage level on the RxD line To disabled the oscillator remove R2 on the KIO2 47 ohms Do before and after tests on the suspected noise signal to verify that this eliminates it Then test the KIO2 with the software application to make sure it still functions correctly Do this with each computer to be used with the K2 22 DC Voltage Chart These measurements were made with a 14 V power supply R2 installed and no computer or other e
7. side has 5 pads matching J1 s 5 pin row Each solder cup pin should be lined up as closely as possible with the center of its pad Do not solder yet Figure 2 Note If you have a padded vise with wide jaws such as a PC board vise you can use it to hold J1 firmly against the edge of the PC board O Make sure J1 is perpendicular to the board before soldering Solder just one pin to its corresponding pad using a minimum of solder O Re check the position of J1 It must be pushed all the way on and should be perpendicular to the board Then solder the remaining pins of both rows O Install D1 1N4148 on the bottom side of the board pre forming the leads to fit the given location The cathode end of the diode which has a band or the widest band must be oriented towards the banded end of the component outline Solder D1 using a soldering time of about 1 2 seconds per lead O Trim D1 s leads as short as possible on the top side of the board after soldering O Install D2 D3 and D4 in the same manner as D1 Note D2 s banded end faces the opposite direction of the other three diodes O Install C14 56 pF located near the ELECRAFT label It must be seated as far down onto the PC board as it can go with no lead length exposed between the capacitor body and the board Small capacitors are fragile Do not pull on the leads and keep soldering time to about 1 2 seconds per lead O Install electrolytic capacitor C8 Orient the capac
8. step O Temporarily make a single knot in the middle of the 8 conductor cable It should look like a pretzel with a diameter of about 1 2 5 cm The knot will apply tension to keep the wires from slipping out O Choose any one of the eight insulated wires Carefully remove 3 16 5 mm of insulation from one end Avoid nicking the stranded copper wires with the stripping tool O Tightly twist the exposed strands of this wire together then tin the strands using a very small amount of solder Use just enough to keep the wires from coming unraveled Any more than this may make the wire impossible to insert into the hole provided on the PC board O Test the wire you just prepared to see if it will fit into one of the holes provided on the KIO2 board at J2 If it does not fit you either did not twist the strands together cleanly or you applied too much solder O Strip 3 16 5 mm of insulation from each remaining insulated wire at both ends of the cable O Twist and tin the strands of each wire as you did above O Twist and tin the strands of the bare wire As with the other wires use a minimum of solder U Untie the knot in the cable O If a small vise is available clamp the KIO2 board into it in the orientation shown in Figure 4 Otherwise you can lay the board on your work bench Be careful not to damage crystal X1 or other components when clamping the board into a vise Zi CAUTION Before proceeding make sure you have the KIO2 boar
9. the top side O If J1 is not flush with the board re heat the soldered pin while pushing down on the connector O Solder the remaining pins of J1 O On the top side install P1 10 pin male connector Make sure it is flush with the board then solder KIO2 to AUX2 Cable Assembly O Locate the 8 conductor shielded cable This cable will be used to connect the KIO2 board to the AUX2 board as shown in Figure 4 Refer to this illustration during the next several assembly steps KIO2 PCB BLUE ORANGE BARE RED BLK WHITE BLK 8 CONDUCTOR BLUE GREEN CABLE 9 23 cm ORANGE BARE BLACK RED BLK RED WHITE BLK WHITE Figure 4 O Cut a 9 23 cm length of the 8 conductor cable Note 2 feet 60 cm of the 8 conductor is supplied The extra cable can be used to make a replacement if the original becomes damaged O Carefully remove 3 4 2 cm of the outer gray jacket from the cable To avoid nicking the individual conductors proceed slowly using a sharp tool to cut around the circumference of the jacket It is OK to cut through the foil shield which will be discarded O Peel off and discard the thin foil shield surrounding the individual wires Zi In the steps that follow you ll be removing insulation from all wires in the cable If you attempt to hold the individual wires with long nose pliers during stripping you may damage their insulation or pull the wires out of the jacket An alternative method is given in the following
10. to supportO elecraft com and we will respond quickly typically the same day Monday through Friday If you need replacement parts send an e mail to parts Oelecraft com Telephone assistance is available from 9 A M to 5 P M Pacific time weekdays only at 831 763 4211 Please use e mail rather than calling when possible since this gives us a written record of the details of your problem and allows us to handle a larger number of requests each day Repair Alignment Service If necessary you may return your Elecraft product to us for repair or alignment Note We offer unlimited email and phone support so please try that route first as we can usually help you find the problem quickly IMPORTANT You must contact Elecraft before mailing your product to obtain authorization for the return what address to ship it to and current information on repair fees and turnaround times Frequently we can determine the cause of your problem and save you the trouble of shipping it back to us Our repair location is different from our factory location in Aptos We will give you the address to ship your kit to at the time of repair authorization Packages shipped to Aptos without authorization will incur an additional shipping charge for reshipment from Aptos to our repair depot Elecraft 1 Year Limited Warranty This warranty is effective as of the date of first consumer purchase or if shipped from the factory the date the product is shipped to the cust
11. BT2 12V connector was to be replaced with a different type of connector If your KBT2 s 12V connector is the same type used for the KAT2 RF connector you should use paint nail polish tape or labels of some type to make the two connectors easy to tell apart For example you could dab red model paint onto both the male and female KBT2 12V connectors Zi Touch a grounded unpainted metal surface before handling the Control board in the following steps O Remove the screws that hold the Control board to the Front Panel board If you have the KAF2 audio filter installed 1t must be unplugged first after removing the screw on the left side O Extract the Control board using the long handled Allen wrench see page 40 of the K2 manual O If you received the revision 2 01 or later K2 firmware as an upgrade and have not yet installed it you should do so now Follow the steps in the K2 Revision 2 Firmware manual O Locate 2 pin connector PS in the upper left hand corner of the Control board near switch S1 top side of the board Trim 0 1 2 5 mm off both pins of PS This will prevent shorts to the AUX2 board O Locate the Control board revision letter at the bottom right hand corner near P3 top side of the board If your Control board is rev A or XC used during K2 field test only you will need to modify it If your board is rev B or later skip the next four steps Figure 5 shows the bottom side of the Control board where most of t
12. Connector P1 should be at left and the pads for J2 should be at right A connector will not be used at J2 As before the wires will be soldered into position here O Insert the wires of the free end of the cable into the holes of J2 on the AUX2 board Figure 4 Insert the wires in the same order as you did on the KIO2 board BLUE pin 1 GREEN 2 ORANGE 3 BARE 5 BLACK 6 RED BLACK 7 RED 8 WHITE BLACK 9 WHITE 10 O Turn the AUX2 board over Carefully solder and trim the wires Note The wires must be trimmed as close to the bottom of the AUX2 board as possible This will prevent shorting to the voltmeter connector on theK2 Control board O Once all wires are soldered check for and correct any cold solder joints or solder bridges K2 Control Board Preparation O Make sure the K2 s power is turned OFF If the battery is installed put its switch in the OFF position O Remove the 6 top cover screws shown on page 77 of the Rev C K2 manual Figure 7 6 Carefully lift off the top cover and set it to the right being careful not to short the battery terminals to the case if applicable Disconnect the speaker and all top cover option connectors A If you have both the KBT2 internal battery and KAT2 ATU options installed you should make sure that their 2 pin connectors are visually distinguished in some manner Otherwise you might reverse them during re assembly damaging one or more components As of this writing the K
13. ELECRAFT KIO2 AUX I O MODULE Assembly and Operating Instructions Revision C June 6 2012 Copyright 2012 Elecraft All Rights Reserved Introduction The KIO2 option allows the K2 to be remote controlled by a computer It also provides a number of useful signals for interfacing the K2 to other equipment With the KIO2 option and a small lap top computer the K2 becomes a highly integrated field contesting or DXpedition station Many transceivers with serial interfaces provide only logic level TTL signals so that connection to a computer requires an external RS 232 converter In contrast the KIO2 provides true RS 232 signal levels It also adds very little to the K2 s receive mode current drain RS 232 interfaces are often significant sources of RFI radio frequency interference which can degrade receiver performance This is because most RS 232 driver circuits use a 20 200 kHz square wave RC oscillator to generate the negative DC voltage needed for signal drivers To minimize RFI the KIO2 s serial interface provides an HF crystal oscillator operating well outside of any ham band to generate the negative driver voltage In addition to the serial interface the KIO2 includes an AuxBus output and 12 VDC for use with small external accessories as well as signals for controlling an external power amplifier All signals are RF filtered Shielded cable and all connectors needed for connection to the computer are provided in the kit S
14. If you use scanning mode don t set it up to scan multiple bands since this could cause excessive K2 relay wear especially if unattended K2REMOTE K2VOICE See descriptions on page 20 Log EQF Rig EQF A modified rig file for these programs that better supports the K2 s RTTY and RTTY reverse modes can be found on our web site MixW Ver 2 02 and later includes K2 support may be listed under Kenwood NA Run the CONFIG program Select F4 Serial Port Setup On the desired port set baud to 4800 and set device to XCVRI Select F5 Equipment Configuration Set XCVR 1 to KENWOODI Run NA Go to the Equipment Control Panel and check Radio 1 RCP570 T R Log TS 570 emulation some controls not applicable to the K2 Since the K2 supports only a subset of TS570 commands the program will time out on the others and can take up to 30 seconds to turn on the radio display on start up Don t use SEND button hangs the computer Ver 6 63 includes Elecraft K2 as a radio type For older versions in the configuration file cfg set RADIO ONE TYPE TS570 Also add SHIFT KEY ENABLE TRUE to use the right and left SHIFT keys to change the receive frequency when RIT is on Hitting both shift keys simultaneously resets the RIT to zero TRX Manager RTS CTS loop back required at computer end pin 7 to pin 8 WriteLog Check the Poll box and select No for Comm PTT YPLOG Specify 2 w
15. d in the orientation shown J2 s label and outline should be to the left and the DB9 connector should be to the right A connector will not be used for J2 the wires will be soldered in place O The RED and RED BLK wires in the cable as well as the WHITE and WHITE BLK wires may be confused during assembly because the black stripes on the RED BLK and WHITE BLK wires are not very prominent To avoid confusing the striped and non striped wires separate out the striped wires only and mark them with a heavy black dot using a felt pen O Using long nose pliers insert the wires of one end of the cable into the holes of J2 on the top side of the KIO2 board Figure 4 Insert the wires in this order BLUE pin 1 round pad GREEN 2 ORANGE 3 BARE 5 BLACK 6 RED BLACK 7 RED 8 WHITE BLACK 9 WHITE 10 Be sure to match the wire colors to their associated pads as shown Note that the dual row connectors have their pins numbered left to right and top to bottom which is different from IC pin numbering O Turn the KIO2 board over Bend the wires slightly so they won t fall out Solder the wires about 1 2 seconds per wire excessive heat could damage the insulation Trim off excess lead length O When all wires are soldered examine the solder joints carefully All joints should be clean and shiny with no solder bridges O Clamp the AUX2 PC board into a vise or place it on the work bench using the exact orientation shown in Figure 4
16. e PORT menu entry in the K2 is set to ON Your software may require the CTS RTS loopback shown in Figure 7 Also some PC programs work only under DOS or require extra serial port configuration steps Check our web site for further information about your software or PC No characters are echoed when typing using Hyperterminal There is a bug in some versions of Hyperterminal that prevents local character echo even if the appropriate box is checked A link to a corrected version or patch may be available on our web site Missing sidetone The Control board modification which was made to improve RS 232 interface performance changes the source of the sidetone to pin 4 of U8 The original sidetone source pin 25 of U6 becomes the serial transmit pin The K2 needs to be configured to recognize the new sidetone source as explained on page 11 If the sidetone still can t be heard re check all Control board modification steps No supply voltage at U1 8 The KIO2 s crystal oscillator may not be running This oscillator operates at about 16 29 MHz Most K2 s can tune to this frequency where you can hear the KIO2 s signal First switch to the 17 meter band 18 MHz Next tune the VFO to the KIO2 s oscillator frequency the signal should be loud and stable If you can t find the signal it may be because your K2 s VFO cannot tune this low in frequency Try looking for the KIO2 oscillator signal using a general coverage receiver with a short length of wire
17. er is U6 on the K2 Control board If you received new firmware as an upgrade you can install 1t now or at the point indicated in this manual page 10 To check your firmware revision hold any switch when powering up the K2 When you release the switch the revision will be shown on the LCD KIO2 PC Board Assembly Zi A fine point temperature controlled soldering iron 700 800 degrees F maximum is required to assemble the PC boards A higher wattage iron or one with a wide tip may damage components pads or traces We also recommended the use of a Panavise or equivalent bench vise and an illuminated magnifying glass to facilitate PCB and connector assembly A Install components only in the order described below Double check all values before soldering since removing parts from double sided PC boards can be difficult O There are three 9 pin D connectors type DB9F supplied with the kit two female and one male The two types both have solder cup terminations on one side On the other side the male connectors have pins while the females have sockets Locate one of the female connectors for use at J1 on the KIO2 board O Locate two male female hex standoffs and two brass nuts Temporarily insert the standoffs through J1 from the socket side and secure them hand tight only with the brass nuts as shown in Figure 1 A SOLDER Figure 1 O Clamp Jl into a padded vise with the brass nuts facing up An alternative is to temporarily at
18. gnal from the K2 and or for powering low current external peripherals Total load current should be kept under 50 mA continuous 80 mA peak to avoid damage to L1 on the AUX2 board A 150 Q or larger series current limiting resistor should be used Bypass capacitors in external equipment must be placed on the far end of the limiting resistor 1 e not on the K2 end 9 8 V Receive 8 V on receive 0 V on transmit approx current limited to 2 mA This signal is intended for use sequencing external amplifiers A new firmware feature allows the 8 V receive line to remain low during the entire T R delay to reduce CW mode relay switching See the K2 Rev 2 Firmware manual for further details 21 Troubleshooting If your symptoms are not covered below check the orientation of all components connectors and wiring look for cold solder joints and check all DC voltages see DC Voltage Chart Band changes take longer than before This is completely normal and has nothing to do with the KIO2 The new K2 firmware revision 2 01 or later suppresses relay switching during rapid band changes The receiver will come alive about 1 2 second after the last tap of BAND orBAND No KIO2 to computer data communication Usually this is caused by a broken or poorly soldered I O connection or by incorrect setup of the computer program Verify the baud rate 4800 and related settings at the computer and make sure th
19. he KIO2 and a computer Some pins on the KIO2 provide special signals not intended for use with an RS 232 interface and you could damage the K2 KIO2 or the computer if these lines are used incorrectly You must assemble your own K2 to computer cable as explained below O Locate the 4 conductor cable The cable can be cut to a shorter length 1f desired but it will work equally well at its full length 15 3 m If a longer cable is needed contact Elecraft Any cable substituted for the supplied type must be shielded to minimize noise pickup O Remove 1 2 12 mm of the jacket from the cable Be very careful not to nick the individual wires O Peel back and cut away the foil shield LU The white wire will not be used for serial communications but should be saved as a spare For now fold the white wire against the cable jacket at both ends and secure it with small strips of tape O Strip off 3 16 5 mm of insulation from each insulated wire O Twist the strands of each wire tightly together then tin the ends using a minimum of solder O Locate the DB9F female and DB9M male D connectors Arrange them as shown in Figure 7 with the female connector on the left and the solder cups facing up O Each connector has a 5 pin row and a 4 pin row Make sure the 5 pin rows are facing each other Figure 7 shows how the two connectors will be wired in the following steps O Clamp the DB9F female connector into a padded vise if available
20. he modifications will be made One trace will be cut on the top side of the board Cut trace on top side Jumper 4 ERE EEE 40 Q5 U6 I i 1 I NERE RE LEE EREEREEED MARISA Bottom view of Control board Figure 5 O The trace between Q5 gate and U6 pin 25 must be cut as shown above This trace is located on the top side of the Control board Once you have located the trace use a sharp tool such as an X acto knife to make two small cuts near the location marked with an X Press down with the tip don t draw the knife across the trace since you may slip cutting adjacent pads or traces Next pry up and remove the small segment between the cuts Examine the trace closely to make sure the cut segment is completely removed O Cut a 3 4 19 mm length of the supplied green insulated hookup wire and remove 1 8 3 mm of insulation from each end Solder this jumper on the bottom of the board between Q5 gate and U8 pin 4 as shown above Make sure the jumper doesn t contact adjacent pads or component pins O Solder a 001 uF capacitor 102 across P4 pins 1 and 5 Listed as Ctxd in the parts list O Prepare a 4 10 cm jumper using the green hookup wire Solder 1t between U6 pin 25 and P4 pin 1 on the bottom side of the board pin 1 is the round pad Make sure the jumper doesn t touch adjacent pins 10 Initial Tests O Re install the Control board and plug in the KAF2 module if applicable O Plug
21. ic jacks is required for keying the K2 In SSB mode the computer sends the K2 TX and RX commands which the K2 responds to by turning PTT on and off internally In CW mode the computer sends typed characters to the K2 using a KY command and the K2 converts the characters to dots and dashes internally This method of keying is supported by only a few remote control applications including RCP570 and Elecraft s K2REMOTE program For details on the TX RX and KY commands refer to the KIO2 Programmer s Reference Case 2 above is by far the most common Connection diagrams showing how to use serial or parallel port control lines are usually provided in the program s user manual In the case of a serial port control line you can use the spare wire white in the 4 conductor cable for CW or PTT keying You ll need to connect this wire to the specified control line at the PC end At the K2 end a simple level converter using an NPN transistor will be required usually diagrammed in your program s user manual The white wire must then be brought out from the connector at the K2 end and routed to a 1 8 inch stereo plug for the key jack You can optionally use two diodes or two transistors to take advantage of the K2 s auto detect feature allowing both the computer and a keyer paddle to be connected to the K2 s key jack at the same time Additional information on this topic can be found on our web site 20 Connecting Other Equipment to
22. ire mode RxD TxD no handshaking The program may send the K2 FL filter selection commands which are not supported These issues are likely to be resolved once full K2 support is added by the program s developer 19 Using the K2REMOTE and K2VOICE Programs K2REMOTE provides flexible remote control of the K2 even over the Internet using TCP IP K2VOICE is a voice feedback program for the K2 which make the K2 fully usable by hams who are unable to see the normal K2 controls and displays Both of these programs were developed by Elecraft for use with the KIO2 You can download the programs and associated documentation from our web site CW Keying and PTT There are three basic ways to key the K2 when using a computer 1 Directly connected microphone hand key paddle etc This is the simplest method and may be preferred if you don t plan to use the computer to generate CQs and contest exchanges etc 2 Serial or parallel port control line keying Most programs support this method In SSB mode the computer turns a selected control line on to activate PTT In CW mode the computer generates the dots and dashes turning the selected control line on and off in response The control line s used which may be at RS 232 or TTL CMOS levels must be level shifted for connection to the K2 key and or mic jacks 3 Virtual keying using computer commands sent to the KIO2 s serial port In this case no connection to the key or m
23. itor s positive lead towards the mark near the component outline C8 must be fully seated on the board before soldering L install R1 3 9 k ORG WHT RED and R2 47 ohms YEL VIO BLK O Install crystal X1 Make sure it is flat against the board before soldering Use a minimum of solder O Locate the ground pad near X1 identified by a small arrow between X1 s leads on the top side of the board Insert a discarded component lead through this pad then fold 1t over the top of X1 Solder this lead at the ground pad then solder it to the crystal can Avoid overheating the crystal U Install the capacitors listed below on the top side of the board When soldering be very careful not to touch adjacent components _ C1 C2 001 pF 102 C3 C4 C5 C6 C7 C9 Cll C13 01 uF 103 __C10 120 pF 120 or 121 C12 CIS 0 1 uF 104 L install the RF chokes listed below These miniature RF chokes are very fragile Do not pull on the leads and keep soldering time to a minimum __L1 15 pH BRN GRN BLK __L2 __L3 _ LA 100 uH BRN BLK BRN Zi Touch a grounded unpainted metal surface before handling ICs or transistors L install U1 MAX1406CPE or LT1039CN16 The notched or dimpled end of the IC must be aligned with the notched end of the component outline pin 1 can be identified by the round pad on the PC board There is no need to trim the leads of U1 L install Q1 4310 and U2 78L05 but do not solder yet O Verif
24. omer It covers both our kits and fully assembled products For kits before requesting warranty service you should fully complete the assembly carefully following all instructions in the manual Who is covered This warranty covers the original owner of the Elecraft product as disclosed to Elecraft at the time of order Elecraft products transferred by the purchaser to a third party either by sale gift or other method who is not disclosed to Elecraft at the time of original order are not covered by this warranty If the Elecraft product is being bought indirectly for a third party the third party s name and address must be provided at time of order to ensure warranty coverage What is covered During the first year after date of purchase Elecraft will replace defective or missing parts free of charge post paid We will also correct any malfunction to kits or assembled units caused by defective parts and materials Purchaser pays inbound shipping to us for warranty repair we pay shipping to return the repaired equipment to you by UPS ground service or equivalent to the continental USA and Canada For Alaska Hawaii and other destinations outside the U S and Canada actual return shipping cost is paid by the owner What is not covered This warranty does not cover correction of kit assembly errors It also does not cover misalignment repair of damage caused by misuse negligence battery leakage or corrosion or builder modifications or any pe
25. p cover Be very careful not to short the battery terminals to the chassis O Plug in the speaker connector U Plug the AUX2 board assembly into the K2 Control board Make sure the AUX2 board is oriented as shown in Figure 6 A Review the comments at the bottom of page 9 regarding the ATU and battery connectors Plugging them in at the wrong locations on the RF board can damage one or more components O If you have an ATU KAT2 plug its RF cable into the K2 RF board connector labeled AUX RF O If you have an internal battery KBT2 plug its cable into the K2 RF board connector labeled AUX 12V O Place the top cover onto the K2 carefully adjusting the positions of cables as needed Re install the top cover hardware six screws O If a battery is installed set its slide switch to the ON position if required This completes assembly and installation of the KIO2 17 Computer Control Using the KIO2 Computer Antenna and Noise Considerations Desktop computers and their peripherals especially monitors and networking equipment can generate spurious signals over wide portions of the HF spectrum If your antenna is fed with coax you may not hear any computer generated noise at all However if you use an end fed random wire antenna that s connected directly to the transceiver or use unshielded feedline twin lead ladder line etc you ll almost surely hear birdies or hash on some bands when the computer is on Even if the com
26. pecifications RS 232 Interface Data Rate and format 4800 baud 8 data bits no parity 2 stop bits Handshaking None ESD protection 15 kV signal lines RF filtered and shielded Current Drain 5 to 10 mA typ Size KIO2 PC board 1 5 L x 1 5 D x 0 5 A 3 8 x 3 8 x 12 cm Zi Caution Some components in this kit can be damaged by static discharge Before handling any transistors or integrated circuits always put on an anti static wrist strap or touch any grounded unpainted metal surface Elecraft www elecraftcom 831 763 4211 Parts Inventory O The table below lists all parts in the kit Refer to the K2 manual parts lists for parts photographs Ref Description Part No Qty Components on the KIO2 PC board C14 Capacitor 56 pF 56 or 560 E530076 1 C10 Capacitor 120 pF 121 or 120 E530077 1 CI C2 Ctxd Capacitor 001 uF 102 Ctxd used on Control Board E530074 3 C3 C7 C9 C11 C13 Capacitor 01 uF 103 E530019 8 C12 C15 Capacitor 0 1 uF 104 E530020 2 C8 Capacitor 10 uF low profile electrolytic E530045 1 D1 D4 Diode 1N4148 E560002 4 Y 9 pin female D connector DB9F E620048 1 y Connector not used wires will be soldered at this location 0 Ll RF choke subminiature 15 uH BRN GRN BLK E690012 1 L2 L3 L4 RF choke subminiature 100 uH BRN BLK BRN E690013
27. puter is not being used for communication with the K2 its RFI may be heard on quiet bands If computer generated noise is a problem at your QTH you may have to improve your ground system re orient your antenna s move the antenna s farther away or use coax feed When you re only using the computer to control the transceiver you may be able to turn off networking equipment and switching power supplies which are the worst offenders Some types of weak computer modulated noise heard on quiet bands can be reduced in amplitude by disabling the KIO2 s on board crystal oscillator The negative supply voltage is then derived from the computer s RxD signal This alternative is described in the Troubleshooting section Software Configuration The KIO2 is intended to be compatible with a wide range of existing PC based logging DXing remote control and contesting applications However we cannot guarantee 100 compatibility Some applications have been or will be modified by their developers to take advantage of the K2 s full command set In general software used with the K2 should be set up as follows Radio Type Elecraft K2 Interface 4800 baud 8 data bits no parity 2 stop bits 1 stop bit will also work Handshaking Set to None if this choice is provided No hardware handshaking is required Polling Many programs periodically poll the radio to see if the operator has manually adjusted any of the controls The K2 can respond ve
28. revent the serial I O cable from being fully inserted into the KIO2 connector Tighten the standoffs using pliers or a socket driver Avoid over tightening which may strip the standoff threads O If a battery KBT2 is installed route the 8 conductor cable around it as shown If an ATU KAT is installed position its RF cable as shown and make sure this cable is not shorting to the KIO2 board O If you have the antenna tuner installed plug its control cable into P1 on the AUX2 board as shown in Figure 10 Orient the ATU connector as shown with the green wire at the top Make sure the antenna tuner s connector is mated with all 10 pins of P1 on the AUX2 board GREEN WIRE Ak AUX2 PCB TO KAT2 i TOKIO2 Figure 10 LJ Use the provided cable ties to keep all option cables in place If any of the cables lay across the RF board once the top cover is re installed they could cause spurious signals in the receiver The best location for the cable ties depends on which options you have installed If you have a battery installed make sure that the KIO2 cable runs along the side of the battery just above the 2 D fastener Figure 9 You can bundle the KIO2 cable along with the red wires running to the battery on off switch 16 Zi Place the top cover to the right of the K2 on its right edge while plugging in cables in the following steps It may be helpful to place a 2 3 stack of books at the right side of the K2 as a support for the to
29. rformance malfunctions involving non Elecraft accessory equipment The use of acid core solder water soluble flux solder or any corrosive or conductive flux or solvent will void this warranty in its entirety Also not covered is reimbursement for loss of use inconvenience customer assembly or alignment time or cost of unauthorized service Limitation of incidental or consequential damages This warranty does not extend to non Elecraft equipment or components used in conjunction with our products 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 25
30. ry quickly to these requests but we recommend a setting of 1 3 seconds to minimize possible computer noise TX Polling Polling during transmit is allowed but we recommend turning it off Table 1 page 19 may provide further details about using your software with the K2 Check our web site for more up to date information Also available on the web is the Elecraft KIO2 Programmer s Reference which you can consult when writing your own K2 control programs 2 If your software does not list the K2 select the TS 570D or the closest equivalent 950 850 50 The K2 can recognize a large subset of TS 570 commands TS 570 is a trademark of the Kenwood Corporation 18 Table 1 Application software information Program K2 Configuration and Operating Notes CT DOS program requires a batch file to start up correctly for details see http www klea com hintkink htm In the batch file use the command COMTSRx Px B4800 N82 e g x 1 for COMI Set Radio 1 to TS950 if K2 is not in the list Optional change bands from the K2 manually the first time so CT can store the values for VFO A and VFO B for each band You can then change bands from the PC or K2 DX4WIN Use Kenwood generic radio type 4800 baud Default polling rate is 6000 msec with 6 retries but 1000 2000 msec is recommended Clicking on a DX spot may set the wrong mode due to the order in which the program sends the mode and band change commands
31. tach J1 to the K2 top cover in its intended location labeled AUX I O Either method will hold J1 firmly while soldering in the next step LJ Solder the brass nuts to the D connector J1 at the locations shown in Figure 1 B This is best accomplished by using the tip of your soldering iron to heat both the nut and flat portion of J1 at the same time If you cannot melt solder onto the brass nut after heating this junction for about 8 10 seconds use a larger iron Avoid overheating the connector which could melt the plastic surrounding the solder cups O Allow J1 and the brass nuts to cool then remove the assembly from the vise O Carefully remove the two hex standoffs The nuts should remain firmly attached to J1 Note If the nuts should become loose during later assembly steps they can be re attached with the KIO2 in place O Locate the larger of the two PC boards labeled KIO2 along one edge of the board This is the top side of the board Flip the board over so that the side with the ELECRAFT label is facing up Zi In the following step Jl may be a very tight fit onto the edge of the PC board Press it on firmly but be careful not to bend any of the solder cup pins O Press J1 with the nuts attached onto the notched edge of the KIO2 board as shown in Figure 2 There must be no gap between J1 s plastic body and the edge of the board The bottom side of the board has four pads corresponding to the row of 4 pins on J1 The other
32. than from the oscillator This voltage will vary depending on the K2 s serial I O transmit duty cycle as well as the quiescent voltage supplied by the computer on RxD If the on board oscillator is running R2 installed the negative supply voltage will be determined by either the RxD line or the detector output D2 D3 whichever is more negative 23 Di Ji L2 L4 100 pH 6T0 12V DI ce L D2 To PC C3 C6 01 uF nee 10uF T 1N4148 D1 D4 av Ac D3 1N4148 A_IY bu e li CT 01 an ot Se 8 23 lt gt gt gt tav Li 4225295258 D4 ci J310 D 6 se 15uH na o la 2 Ts Ta Ta Tz 1N4148 150 D s Y E E 4 G Lai E U1 ele a Zs Ss ct MAX1406 XI L Y 001 a _ Vos L5 16 289 MHz FT23 43 3 C11 ANN 8R WZ 01 RI C14 4 3 9K TT 56 WZ J1 BACK VIEW R2 47 12 3 4 5 J2 3 To CTRL Board 00000 0000 6 7 8 9 AUX2 BOARD ALL PINS OF P1 J1 AND J2 ARE CONNECTED IN PARALLEL EXCEPT FOR PIN 8 WHICH IS CONNECTED AS SHOWN P1 J1 J2 sv To ATU J8 To CTRL P4 To KIO2 J2 frane IN le a c15 gt lt gt ot iE u2 dE 0 1 gt gt Y Y gt gt OUT GND IN gt lt gt gt lt gt wF On bottom of PC board Elecraft KIO2 Aux I O Adapter By W Burdick E Swartz 24 Customer Service and Support Technical Assistance You can send e mail
33. the AUX2 board into the K2 Control board at P4 the Aux I O connector as shown in Figure 6 When the AUX2 board is correctly installed it will be about 0 1 2 5 mm below the top edge of the control board Do not proceed until the AUX2 board is correctly installed with all 10 pins mated _ CABLE TO KIO2 BOARD 0 s AUX2 BOARD J1 ON AUX2 BOARD PLUGGED INTO P4 U6 ON CONTROL BOARD K2 CONTROL BOARD Figure 6 O Lay the KIO2 board over to the right side of the K2 so that it cannot contact the chassis O Turn on the K2 If you see or smell smoke or if the K2 does not turn on turn power off and refer to Troubleshooting O The sidetone may not be working at this point due to the Control board modifications Tap MENU and locate the ST L sidetone volume menu entry then hold gt to edit the parameter Tap DISPLAY to change the sidetone source to U8 4 default is U6 25 Use headphones or speaker to verify that the sidetone can be heard Then tap MENU twice to return to the frequency display O Set up a voltmeter for DC volts Connect the lead of the meter to K2 ground Touch the lead to pin 8 of U1 on the KIO2 board You should see a negative voltage reading of between 6 and 12 VDC O Turn off the K2 but leave the KIO2 connected to the Control board 11 K2 to Computer Cable Assembly Zi CAUTION Do not use a pre assembled cable of any kind printer cable etc between t
34. the KIO2 The KIO2 s 9 pin connector provides a number of signals in addition to those needed for the RS 232 serial interface Table 2 Note Use pin 1 as the electrical ground for any external devices Pin 5 should only be used as the RS 232 ground return to the computer Table 2 KIO2 Signal Descriptions Jl Pin Signal Description Notes 1 Chassis Ground RF DC ground use pin 5 for RS 232 signal ground 2 TxD RS 232 data from K2 to computer RF filtered 3 RxD RS 232 data from computer to K2 RF filtered 4 ALC Automatic Level Control from an external amp to the SSB adapter Refer to our web site for related application notes 5 RS 232 Sig Ground RS 232 ground return for computer serial data RF filtered 6 AuxBus K2 configuration network RF filtered intended for use with external AuxBus compatible peripherals Connections made to this line must be shielded and total bypass capacitance should be between 001 and 005 uF Excessive capacitance may cause auxBus data transmission errors 7 RF Detect RF level feedback DC intended for use with external SWR bridges when a KAT 2 is not installed A low impedance lt 100 ohms DC signal driving this line will override the K2 s internal RF detector Refer to the KAT2 ATU schematic for an example Improper use of this line could result in incorrect K2 power settings high current etc 8 DC Supply Voltage This is intended as a power on si
35. xternal equipment connected to J1 on the KIO2 Negative voltages may vary by 3V or more without affecting performance Voltages marked with an asterisk may vary due to DMM probe loading effects Pin V Pin Vy Pin V Pin V Pin Vv Pin y Pin V Ji 1 0 Ul 1 14 U1 10 0 J2 1 5 0 J2 10 0 Q1 G 1 D3 A 4 1 2 8 U1 2 0 1 Ul 11 5 J2 2 5 5 Q1 S 0 D3 C 0 1 3 0 1 Ul 3 14 Ul 12 5 1 3 5 U2in 14 QI D 14 D4A 1 J1 4 45 Ul4 0 1 U1 13 4 5 J2 4 0 Out 5 D4 C 5 J1 5 0 Ul 5 8 Ul 14 0 2 5 0 DI A 9 J1 6 5 5 Ul 6 0 1 Ul 15 4 5 2 6 0 DI C 0 1 1 7 0 Ul 7 14 Ul 16 5 J2 7 4 5 D2 A 9 J1 8 14 Ul 8 9 J2 8 14 D2 C 4 J1 9 8 Ul 9 0 J2 9 8 Circuit Details Refer to the schematic diagram page 24 Ul is an RS 232 transceiver IC It converts the 5V logic level signals at pins 11 and 12 RX and TX data to RS 232 levels typically 5 to 12 VDC QI is a Colpitts oscillator that drives a negative going detector D2 D3 The negative voltage is filtered by C8 and supplied to U1 pin 8 as the transmit supply voltage Vss L2 L4 and C3 C6 provide pi net RF filtering The RS 232 signal ground J1 pin 5 is isolated from the chassis ground pin 1 to reduce noise pickup If the on board crystal oscillator is disabled by removing R2 the negative supply voltage U1 pin 8 is derived from the RxD line J1 pin 3 rather
36. y that Q1 and U2 are mounted in the correct locations then solder O Wind 12 turns of 26 red enamel wire 7 18 cm on the FT23 43 toroid core L5 as shown in Figure 3 Avoid scraping the wire against the core as you wind The turns should occupy 80 90 of the core Figure 3 O Trim the leads of L5 to about 1 2 long Remove all of the enamel coating to within about 1 16 1 8 of the core using a soldering iron to heat strip the thermaleze wire An alternative is to use sandpaper Tin the leads and make sure they appear clean and shiny O Install and solder the toroid vertically as indicated by L5 s component outline O On the top side of the board to the left of C7 you ll find a small arrow This arrow identifies a pad for use in grounding the case of J1 the DB9 connector Insert a discarded component lead into this hole from the top side of the board then solder it at this pad O Fold the free end of this ground lead over the top of the DB9 connector case keeping 1t well away from J1 s pins Solder the ground lead to the DB9 case Trim excess lead length on both sides of the board AUX2 PC Board Assembly O Locate the smaller PC board labeled AUX2 on the bottom side O On the top side of the board install the following components _ C1 0 1 uF 104 __C2 01 uF 103 __ El 15 uH BRN GRN BLK U On the bottom side install J1 a 10 pin female connector Make sure J1 is flush with the board then solder one pin only on
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