Rework Eliminators™ Companion Guide Rework-Free Assembly Instructions for use with the rev. F Elecraft® K2 Manual Version 8 / Revision C 6 June 2012 Our method is not an official Elecraft ® mod! Ken Kaplan, WB2ART – Oakdale, NY Gary Hvizdak, KI4GGX – Melbourne, FL Elecraft is a registered trademark of Elecraft, Inc. Rework Eliminator, Rework Eliminators, and unpcbs are trademarks of Ken Kaplan and Gary Hvizdak. Copyright © 2005 – 2012 by Ken Kaplan and Gary Hvizdak, all rights reserved.
Revision History Date(s) Version Revision(s) 6 JUN 2012 8 C • Updated the price in Appendix A (footnote 5). Changes 5 JUN 2012 8 B • Minor wordsmithing (mostly) plus a “product name” correction. 5 JUN 2012 8 A • Updated prices and “pruned” this revision history. 3 JUN 2012 7 Z • Updated logo, revision, release date, prices, and copyright notice. 16 SEP 2010 7 Y • Updated preface, Scott King, AH6KL (SK). 6 FEB 2010 7 X • Minor tweaks to page 1.
Preface and Acknowledgements My investigation into the possibility of a rework-free K2 build began in December 2004 after I completed a High Reliability Soldering course at the local junior college. This was before Ken’s first Reflector post about his prototype UN-PCB headers, so I started by designing some un-modules using perf-board. In doing so, I noticed an error in the original KE1L article’s description of an UN-KNB2 header.
- 1 - Introduction This guide describes a rework-free assembly method for the Elecraft® K2. It incorporates un-module option bypass headers and 46 option supplied K2 parts which include electrical components, connectors, miscellaneous wire, and mounting hardware. Our instructions seamlessly combine initial K2 assembly with the changes that must be made prior to installing the options. The result is an “Option Ready” K2 for which the later installation of the options is dramatically simplified.
- 2 - How to Use This Guide 1. Based on which options you are initially getting with your K2 and which options you want to build it “Option Ready” to accept, review Appendix A to determine which (if any) of our Duplicate K2 PCB Parts Kits will be required. 2. Visit www.unpcbs.com and order our option bypass Headers Kit, plus whichever of our K2 PCB Parts Kits you determined will be required. 3.
- 3 - Not included in an “Option Ready” K2. This image of #5048 shows three items which are not part of an “Option Ready” K2: 1) Ken’s custom brass plate; 2) the “option supplied” hex spacer which is very easy to install; and 3) RF-J5 (Aux AF) which provides fixed level audio for digital modes. Although adding J5 requires some disassembly and additional soldering, it’s not part of an “Option Ready” K2 because it doesn’t relate to the installation of an existing Elecraft® option.
- 4 - Rework-Free Assembly Summary # Option(s) PCB DELETED STEPS 17 KAF2 & KDSP2 CTRL Do not install R18 & R19 28 KSB2 FP - 48 KNB2 RF 50 50 51 51 K60XV KSB2 K60XV KNB2 RF RF RF RF 51 KSB2 RF 56 56 K60XV K160RX RF RF 57 K160RX RF K60XV KSB2 KNB2 K60XV K160RX K60XV KSB2 KNB2 K160RX KAT2 71 KPA100 KBT2 RF RF RF RF RF RF RF RF RF 71 RF 57 59 59 59 59 60 71 71 71 K60XV RF K2 manual page numbers ADDED STEPS Install J1 & J2 (on top) Insta
- 5 - Rework-Free K2 Manual Annotations KAT2 KBT2 KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple 1. The color code above is used on the previous page and all following pages, to indicate for which option(s) an annotation applies. If you never intend to install some options, this coding makes it easy to select for which options you want your K2 to be “Option Ready”. Please only attempt this if you are certain how the assembly procedure changes relate to the options.
- 6 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 Δ Be sure that the following electrolytic caps – and any other tall parts on the right side of the CTRL board – are seated flush and standing perfectly vertical. This will ensure adequate clearance between them and the KAF2 or KDSP2.
- 7 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple Δ Do not install jumper wires R18 and R19 on the back of the board. Instead, install connectors J1 and J2 on the front as follows. [ ] Install a 5-pin female jack* on the top / component side at J1. It must be seated flush on the board and be standing perpendicular to it.
- 8 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 [ ] Install a Rework Eliminator™ UN-KAF2/UN-KDSP2 un-module option bypass header at CTRL-J1 / J2. KNB2 K160RX K60XV KSB2 Multiple [ ] Remove the UN-KAF2/UN-KDSP2 header from the CTRL board to reduce the possibility of damaging it. It will be re-installed again in a later step for phase I alignment and test.
- 9 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple [ ] Skip ahead to the section entitled SSB Components at the top of page 28 and install all of these KSB2 (or Rework Eliminator™ KSB2 Parts kit) supplied parts now! This includes the installation and configuration of P1.
- 10 - The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KAT2 KBT2 KPA100 KAF2 KDSP2 SSB Components [ ] Install the KSB2 option or Rework Eliminator™ KSB2 Parts kit supplied Front Panel components* on the front/top of the board near the cutout for the headphone jack. __ C4 – C8** (.01 μF) __ Q3 (2N3906) __ RP3 (10K, 8 pins) __ R13 (68.
- 11 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple [ ] Install a Rework Eliminator™ UN-KAF2/UN-KDSP2 un-module option bypass header at CTRL-J1 / J2.
- 12 - The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KAT2 KBT2 KPA100 KAF2 KDSP2 KNB2 K160RX K60XV REW•RK-FREE K2 ASSEMBLY KSB2 Multiple [ ] Remove the UN-KAF2/UN-KDSP2 header from the CTRL board.* See notes 1, 2, & 3 * It will be re-installed in a later step for phase II alignment and test. 1) Do not install anything at R90. 2) Instead of the original R89, install W89 (i.e. just a bare jumper wire).
- 13 - The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KAT2 KBT2 KPA100 KAF2 KDSP2 KNB2 K160RX K60XV REW•RK-FREE K2 ASSEMBLY KSB2 Multiple __ D19* __ D20* * D19 and D20 are provided with the Elecraft® K60XV option, or the Rework Eliminator™ K60XV Parts kit. * Older rev. ‘A’ RF boards (supplied with pre-S/N 3000 K2s) do not have mounting locations for these diodes. If you are assembling an older K2 (with a “rev.
- 14 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple Δ Do not install W5, the Noise Blanker option bypass jumper. See note 1 Δ Do not install W2 and W3, the SSB Crystal Filter option bypass jumpers.
- 15 - The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KAT2 KBT2 KPA100 KAF2 KDSP2 KNB2 Δ K160RX REW•RK-FREE K2 ASSEMBLY K60XV KSB2 Do not install W6*. Δ Do not install W1, the Receive Antenna option bypass jumper. * W6 is the Transverter I/O option bypass jumper.
- 16 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 __ C75, 470 (471)* The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 __ C13, 1200 (122)* KDSP2 KNB2 K160RX K60XV KSB2 Multiple __ C14, 1200 (122)* (continued) * These three caps are provided with the Elecraft® K160RX or the Rework Eliminator™ K160RX Parts kit. C75 is on the left edge of the board near K13. C13 and C14 are in the band-pass filter, near L3 and L4.
- 17 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple [ ] Install RF-J9 through RF-J15 per notes 1 through 4 below, right. [ ] Skip ahead to the section entitled Option Module Standoffs at the top of page 71, and install just the KNB2 standoff now! [ ] Install option bypass headers at CTRL-J1 & J2, and RF-J9 through RF-J15.
- 18 - The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KAT2 KBT2 KPA100 KAF2 KDSP2 KNB2 K160RX K60XV REW•RK-FREE K2 ASSEMBLY KSB2 Multiple [ ] Change the Extended VFO Range (D19) Secondary Menu to Y*. * This informs the firmware that you installed a 120 pF cap at RF-C71 (instead of the original 82 pF) and installed RF-D19 and D20, as described on pages 50 and 51.
- 19 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple [ ] If some of the above VCO control voltage readings are < 1.0 V, or some of them are > 7.5 V, you may be able to shift the entire set of readings so that they are all within the 1.0 to 7.5 V range.
- 20 - The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KAT2 KBT2 KPA100 KAF2 KDSP2 KNB2 K160RX K60XV REW•RK-FREE K2 ASSEMBLY KSB2 Multiple See note 1 1) In order to protect them from physical damage during subsequent assembly, temporarily remove all Rework Eliminator™ option bypass headers from both the RF and CTRL boards.
- 21 - The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KAT2 KBT2 KPA100 KAF2 KDSP2 KNB2 K160RX K60XV REW•RK-FREE K2 ASSEMBLY KSB2 Multiple [ ] Check off the components listed below, verifying that they are not installed. All of these components are on the top side of the board. Note: P6 and P3 will be installed on the next page. The remaining parts will not be installed.
- 22 - REW•RK-FREE K2 ASSEMBLY KAT2 KBT2 The K2 manual is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. KPA100 KAF2 KDSP2 KNB2 K160RX K60XV KSB2 Multiple Option Module Standoffs The three aluminum and the one nylon standoff and their associated hardware, are supplied with the individual Elecraft® options, and also with the corresponding Rework Eliminator™ K2 PCB parts kits.
- 23 - Appendix A – Required K2 PCB Parts The following table lists all of the parts – electrical components, connectors, miscellaneous wire, and mounting hardware – required to make current K2s “Option Ready” for each option. It also shows how to obtain these parts, either from Elecraft® options or from our parts kits.
- 24 - “Option Ready” Support for This Elecraft® Option 1 Requires Either of These Kits Elecraft® Rework Eliminator™ K60XV 5 K60XV K60XV Parts KSB2 KSB2 KSB2 Parts Which Supply These K2 PCB Parts Reference Designator(s) RF-C71 RF-D19, D20 RF-J13 RF-J15 RF-J9, J10 RF-J11 FP-Rbias FP-C4 – C8 FP-P1 FP-Q3 FP-R13 FP-RP3 - (Quantity) / Description 120 pF (2) MV209 8-pin SIP jack 3-pin SIP jack 9/16" Nylon standoff 2' RG174 coax 6" #24 Solid hookup wire 3" Heat-shrink tubing (2) 3-pin SIP jack 12-pin S
- 25 - Appendix B – Annotated K2 Schematics The schematics on the following six pages are annotated to depict the configuration of an “Option Ready” K2. Using the same color code as the previous two sections, these schematics show … • Which K2 parts are option supplied, and with which option or options they are provided. • The six option supplied parts that must replace original K2 parts. These are shown in bold blue font. • Which parts must be removed or preferably were never installed.
- 26 - The K2 schematics are the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission.
- 27 - The K2 schematics are the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. J1 & J2 supplied with KAF2 & KDSP2.
- 28 - The K2 schematics are the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. (NOTE 5) (NOTE 4) R29 supplied with all K2s since S/N 3000, and with the K60XV. (NOTE 2) D19 & D20 supplied with K60XV. C71 120 The K2’s original C71 is replaced with K60XV supplied 120 pF C71. C75 supplied with K160RX. P3 supplied with KBT2 & KPA100. NOTE 2: Pre-S/N 3000 K2s (those with the earlier rev. A RF board) don’t have mounting holes for D19 and D20.
- 29 - The K2 schematics are the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. J12 is supplied with the KNB2. The K2’s original R89 is replaced with W89, a zero ohm jumper wire. W89 0Ω 2.7 k The K2’s original R88 is replaced with KNB2 supplied 2.7 k R88. (NOTE 1) NOTE 1: J9, J10, and J11 are supplied with the KSB2. (NOTE 3) NOTE 3: C153 is 68 pF in current K2s.
- 30 - The K2 schematics are the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. J14 is supplied with the K160RX. ⌂ J15, J13, and the RG174 coax cable for jumpering V RFDET to J13-6, are supplied with the K60XV. V RFDET P6 supplied with KAT2 & KPA100. (NOTE 3) NOTE 3: C13 & C14 are supplied with the K160RX.
- 31 - The K2 schematics are the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission. All components shown on RF Sheet 4 are provided with the K2.
- 32 - Appendix C – Color-Coded K2 Un-Module Diagram The K2 schematic diagram is the intellectual property of Elecraft, Inc, copyright © 1999-2012, all rights reserved, used with permission.
