Specifications

l Page 5 Kaval Telecom Inc. - Company Secret DCD000000003
• PROCESS
• Inspection and Preparation
• Housing Kit.
Inspect housing parts for hazardous burrs, loose metal chips and clean and deburr as required. If machining
oil residue exists, clean with Varsol.
Install Top Cover to Wall Extrusion using 16 #2-56 flat head machine screws.
• PCB
Inspect PCB for missing or improperly installed SMD parts.
Using a file or Dremel tool, chamfer two corners of PCB closest to RF connectors approximately 0.100” to
eliminate interference with weld fillets in housing.
• Divider Wall Subassembly
Install two divider walls to center divider wall using 4 #2-56 x 3/8” thread cutting screws. Be mindful of
correct orientation of grooves and notched in walls to ensure they conform to PCB ground locations and allow
clearance for components.
Install EMI gasket material to grooves in underside of divider wall assembly. Cut gasket to length so that it
is only installed where divider wall meets exposed ground on top of PCB or where divider walls contact metal
housing. Be careful that stray embedded wires do not possibly contact any active traces on PCB. Gasket
bits should be tack-glued to divider assembly with sparing use of cyanoacrylate glue. (Loctite type 401
recommended).
• Hookup Wire.
Cut hookup wire to 1.5” length. Use different colour wires for each connection (resistor color coding
corresponding to pin number on D connector is recommended)
Strip one end (PCB) to a length of 0.080”, other end (D-connector) to 0.150”.
• Regulator Leads
Trim voltage regulator leads to a length of 0.200”
• Installation of Leaded Components
Install fuse clips into PCB. It may be helpful to install a fuse into the clips before clip insertion into PCB to assure
correct alignment.
Install hookup wires to location P1. Refer to Interconnect Diagram for connection details.
Using flush cutters, trim fuse clip and wire leads flush with PCB. Length of protrusion below PCB cannot exceed
0.030” or short circuits may occur.
• Installation of PCB into Housing
Install PCB assemblies into housing. 8 pcs #4-40 x 5/16” thread forming screws are used to fasten down each
booster PCB. Screws go through top plate and into heatsink. Note that one screw hole in PCB is not used. This is
normal.
Be sure that one PCB of each band split is installed. One should have an 881 MHz dielectric filter (F1), the other
must be an 836 MHz part.
• Installation of Bolted Components
Apply heatsink grease (a.k.a. Synthetic Gorilla Snot) to regulator and power module tabs.
Note: Be sure to stir compound thoroughly before using. Apply a minimal amount. Excess compound actually
reduces thermal conductivity. Objective is to eliminate air voids between device tab and heatsink. Avoid getting this
material on clothing. There is no known way of removing it from fabrics.
Install voltage regulators and RF power modules to heatsink using 6 pcs. #6-32 x 5/16 thread forming screws.
Solder all connections of installed parts just installed.
Install filtered 9 pin D connector from outside of housing. Fasten it down using two hex jack screws with single
lockwashers (252900-00). Note: Jack screw kits will have excess parts that are unused.
Solder interconnect wires to D connector in accordance with sketch.
• Installation of Divider Wall Assembly
Install divider wall assembly into housing and fasten with 8 pcs #2-56 x 3/8 thread cutting screws. It is helpful to
clamp divider assembly down with a clamp or toggle press to ensure gaskets are compressed and holes line up.
Inspect divider wall areas of PCB to ensure no components short to wall. Realign components as needed.
NOTE: This step can be done after bias test if divider walls are not available, but these steps must be repeated
after wall installation in such case.