ELECRAFT KXV3 User manual

ELECRAFT®K3

HIGH-PERFORMANCE 160 –6METER

TRANSCEIVER

KXV3 INTERFACE OPTION

INSTALLATION INSTRUCTIONS

Rev C, June 24, 2008

Contents

Introduction............................................................................................................................................... 3

Customer Service and Support............................................................................................................................ 3

Technical Assistance....................................................................................................................................... 3

Repair / Alignment Service............................................................................................................................. 3

Preventing Electrostatic Discharge Damage ............................................................................................ 4

How ESD Damage Occurs.................................................................................................................................. 4

Preventing ESD Damage..................................................................................................................................... 4

Preparing for Installation .......................................................................................................................... 5

Tools Required .................................................................................................................................................... 5

Parts Included...................................................................................................................................................... 6

Installation Procedure ............................................................................................................................... 6

Removing the Top Cover .................................................................................................................................... 6

Removing the KRX3 Subreceiver Module ......................................................................................................... 7

Removing the Bottom Covers and KIO3 Board ................................................................................................ 8

Installing the KXV3 Board ............................................................................................................................... 10

Reinstalling the KIO3 Board............................................................................................................................. 13

Reinstalling the KRX3 Subreceiver Module..................................................................................................... 14

Replacing the Top Cover .................................................................................................................................. 15

Enabling the KXV3 Module................................................................................................................... 15

Introduction

The KXV3 Interface provides a separate receive antenna input and output, inputs and outputs for use with an

external transverter, and a buffered i.f. output. Complete details for using the KXV3 are included in the K3

Owner’s manual. This manual covers the installation of the KXV3 Interface option in your K3 transceiver.

Only a few basic hand tools are needed (see page 5) to perform the installation. No soldering or wiring is

required.

Customer Service and Support

Technical Assistance

You can send e-mail to [email protected] and we will respond quickly - typically the same day Monday

through Friday. Telephone assistance is available from 9 A.M. to 5 P.M. Pacific time (weekdays only) at 831-

662-8345. 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 (We want to make sure everyone succeeds!)

If necessary, you may return your Elecraft product to us for repair or alignment. (Note: We offer unlimited email

and phone support to get your kit running, 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 turn around 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. 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.

What is covered: During the first year after date of purchase (or if shipped from factory, date product is shipped to

customer), Elecraft will replace defective or missing parts free of charge (post-paid). We will also correct any

malfunction to kits or assembled units caused by defective parts and materials. 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. Alaska, Hawaii and outside U.S. and Canada actual return shipping cost paid by

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, or builder modifications; or any performance

malfunctions involving non-Elecraft accessory equipment. The use of acid-core solder, water-soluble flux solder, or

any corrosive or conductive flux or solvent will void this warranty in its entirety. Also not covered is reimbursement

for loss of use, inconvenience, customer assembly or alignment time, or cost of unauthorized service.

Limitation of incidental or consequential damages: This warranty does not extend to non-Elecraft equipment or

components used in conjunction with our products. 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.

Preventing Electrostatic Discharge Damage

There is no climate or work location where the components of your K3 are safe from Electrostatic Discharge

(ESD) unless you take specific steps to prevent such damage. Many of the components in your K3 can be

damaged by static discharges of only a few volts: far too little for you to notice. It is those low-voltage but

destructive discharges that easily happen anywhere and under virtually any environmental conditions.

ESD damage may not be apparent at first. The damaged components may not fail completely. Instead, the

damage may result in below-normal performance for an extended period of time before you experience a total

failure.

How ESD Damage Occurs

Whenever an object containing a static charge touches a circuit in your K3, current will rush into the circuit until

the components reach the same voltage as the source of the static charge. If the voltage or current that passes

through a component during that brief period exceeds its normal operating specifications, it may be damaged or

destroyed.

Preventing ESD Damage

ESD damage cannot occur if there is no voltage difference between the components in your K3 and any object

that touches them. That is how anti-static packaging works. Anti-static bags allow the static charge to flow over

their surface, so that any part of the bag that touches the components inside are all at the same potential at all

times. Anti-static foam keeps the leads of sensitive components at the same potential.

At your work bench, avoiding a dangerous voltage is achieved most easily by tying everything together and

connecting them to a common mains safety ground. This includes your K3, individual boards or other sensitive

components as well as everything they may touch at the work table.

Inexpensive static dissipating work mats are readily-available that will steadily and safely drain off any charges

built up on parts or circuit boards placed on them. They are supplied with a lead that connects the mat to the

common workbench ground. Also, metal cabinets on test equipment used on the bench should be tied together

and connected to the common ground.

Most importantly, you must have a way of continuously draining off any static charges that occur on your body.

Such charges are easy to create, even while sitting quietly at the work bench. Moving your feet on the floor,

shifting position in your chair or even moving your arms so that clothing rubs against itself can produce

destructive static charges. You can discharge yourself by touching an unpainted metal ground, but that will last

only until you move in a way that produces a new static charge. The safest technique is to wear a grounded wrist

strap with a series 1-megohm resistor that continuously drains off any charges. Such wrist straps are readily-

available and inexpensive.

WARNING

DO NOT attach a ground directly to yourself without a current-limiting resistor as this poses

a serious shock hazard. A wrist strap must include a 1-megohm resistor to limit the current

flow. If you choose to touch an unpainted, metal ground to discharge yourself, do it only

when you are not touching any live circuits with your other hand or any part of your body.

We strongly recommend you take the following anti-static precautions (listed in order of importance) to avoid

trouble:

•Leave ESD-sensitive parts in their anti-static packaging until you install them. The packaging may be a

special plastic bag or the component’s leads may be inserted in conductive foam. Parts which are

especially ESD-sensitive are identified in the parts list and in the assembly procedures.

•Wear a conductive wrist strap with a series 1-megohm resistor. If you do not have a wrist strap, touch a

ground briefly before touching any sensitive parts to discharge your body. Do this frequently while you

are working. You can collect a destructive static charge on your body just sitting at the work bench. DO

NOT attach a ground directly to yourself as this poses a serious shock hazard.

•Use a grounded anti-static mat on your work bench.

•If you choose to use a soldering iron to work on your K3 for any reason, be sure your iron has an ESD-

safe grounded tip tied to the same common ground used by your mat or wrist strap.

Preparing for Installation

Tools Required

1. #0 and #1 size Phillips screwdrivers. To avoid damaging screws and nuts, a power screwdriver is not

recommended. Use the screwdriver that best fits the screw in each step.

2. Wrench to remove jack screw nuts on the K3 back panel. 3/16” nut driver recommended.

3. Small diagonal cutters.

4. Small needle-nose pliers or tweezers to position small parts.

5. Soft cloth or clean, soft static dissipating pad to lay cabinet panels on to avoid scratching.

The following tools are strongly recommended:

1. ESD wrist strap.

2. Static dissipating work pad.

Parts Included

The following parts should be included in your kit. Check to ensure you have them all. If any parts are damaged

or missing, contact Elecraft for replacements (see Customer Service and Support, page 3).

ILLUSTRATION DESCRIPTION QTY.

ELECRAFT

PART NO.

XV3 Printed Circuit Board Assembly

ESD Sensitive. 1 E850244

XV3 Connector Panel 1 E100224SS

KXV3 TMP Cable Assembly 1 E850292

Screw, 4-40, 1/2” (13 mm) 2 E700030

Lockwasher, 4-40, inside tooth 2 E700010

Nut, 4-40 2 E700011

Installation Procedure

SPECIAL NOTE FOR K3 KIT BUILDERS: If you were directed here by the K3 Kit

Assembly Manual to install your KXV3 Module, inventory the parts in this kit against the list under Parts

Included on page 6 then begin installation at the step indicated on page 10.

Removing the Top Cover

Disconnect power and all cables from your K3.

Remove the nine screws to free the top cover as shown in Figure 1. After the cover is open, lift it gently to

reach the speaker wire connector. Unplug the speaker then set the top cover aside in a safe place.

Whenever you remove screws from a panel, if one screw seems too tight to loosen

without damaging it, first loosen the other screws then try again. Sometimes one screw

binds in its hole when the other screws are tightened.

Figure 1. Removing K3 Top Cover.

CAUTION: Touch an unpainted metal ground or wear a grounded wrist strap

before touching components or circuit boards inside the K3. See Preventing ESD Damage on

page 4 for more information.

Removing the KRX3 Subreceiver Module

If your K3 is equipped with the optional KRX3 Subreceiver, you must remove the subreceiver module to install

the KXV3. The KRX3 subreceiver module is the “L” shaped metal enclosure (see Figure 2). Remove the

subreceiver module as follows:

Remove the chassis stiffener bar that runs across the top of the K3 chassis and is attached to the side panels.

If the KPA3 is installed, the stiffener will be attached to the KPA3 shield by two screws. These screws may have

nuts and lock washers or they may thread into permanently-attached PEM nuts on the stiffener bar.

Remove the two 1-1/2” (38 mm) screws and lock washers shown in Figure 2. These screws extend all the

way through the KRX3 module and secure it to standoffs mounted on the main RF board that fills the bottom of

the K3.

Figure 2. Removing the KRX3 Module.

In the following steps you will handle small TMP coaxial connectors. These are friction-

fit connectors shown in Figure 3. Handle the connectors by the grips as shown. Do not pull

on the coaxial cable.

Figure 3. TMP Cable Connectors.

Hold the KRX3 module by the two brass knurled nuts on the top, and lift it straight up to gain access to the

small TMP coaxial connectors plugged into the module. There are two along the front. There may be one at the

back as well, depending upon the options installed. As you lift the KRX3 module, it will unplug from two small

interface circuit boards. One is at the front and the other is at the rear. These small boards may come out with

the module or they may remain attached to the K3 main RF board.

Unplug the TMP coaxial cables leading to the KRX3 module, then lift the module free and set it aside.

Locate the two small interface circuit boards (see TBD and TBD), remove them and put them in a safe

place.

Removing the Bottom Covers and KIO3 Board

Remove the four jack screw nuts with their lock washers and the two black pan head screws from the KIO3

rear panel as shown in Figure 4.

Figure 4. Removing KIO3 Panel.

With the back cover of the KIO3 removed, remove the upper Remote I/O daughter board holding the

RS232 and ACC connectors as shown in Figure 5. Only the upper daughter board need to be removed. The

lower Audio I/O interface board may be left in place.

CAUTION: The Remote I/O daughter board is ESD sensitive. Put it in a safe place until you

reinstall it.

Figure 5. Removing the KIO3 Remote I/O Daughter Board.

Tilt the top of the KIO3 Main board toward the front panel gently so the standoff at the top clears the lip on

the rear panel, then use the standoff at the top to lift up on the board while rocking it from side to side to unplug

the connector.

CAUTION: The KIO3 Main board is ESD sensitive. Put it in a safe place until you reinstall it.

Remove the blank panel covering the space for the KXV3 module (see Figure 4). This panel will not be

replaced.

Turn the K3 upside down and remove the bottom covers (see Figure 6).

Figure 6. Removing the Bottom Covers.

Installing the KXV3 Board

SPECIAL NOTE TO KIT BUILDERS: If you were directed here to install your KXV3

module as part of the overall kit assembly, begin with the following step.

Cut jumpers W1 and W2 on the RF board (the large board filling the bottom of the chassis). These jumpers

are located under where you just removed the KIO3 boards (see Figure 7). Take care to identify the correct

jumpers. Do not cut nearby jumpers W20 or W21! It is not necessary or desirable to unsolder the jumpers.

Simply cut them with your diagonal cutters, taking care not to lose the bits of the jumper wire inside the K3, but

be sure to cut the ends short. No more than 1/8” (3 mm) of jumper should be left at each solder pad to avoid the

possibility of its shorting to a nearby circuit.

Figure 7. Locating Jumpers W1 and W2.

Inspect the white connector at the end of the TMP cable. The side nearest the connector holes must be

smooth and flat. Use your diagonal cutters or a hobby knife to cut away any bumps or ridges (see Figure 8 ).

Figure 8. Preparing TMP Cable for Installation.

CAUTION: The KXV3 board is ESD sensitive. Wear a grounded wrist strap or touch an unpainted

metal ground before handling it.

Remove the KXV3 board assembly from its packaging. If the black panel is mounted on the assembly,

remove it. Set the screws and washers aside to be installed later.

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