ELECRAFT KAT100 Manuel utilisateur

Elecraft

KAT100

Automatic Antenna Tuner

Revision D, February 13, 2015

KAT100-1 shown above. See page 3 for photo of full-height version (KAT100-2).

Table of Contents

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

Parts Inventory...........................................................................................................................................................................................................4

RF Board Assembly .................................................................................................................................................................................................8

Front Panel Board Assembly................................................................................................................................................................................18

Final Assembly........................................................................................................................................................................................................19

Alignment and Test ................................................................................................................................................................................................ 7

Using the KAT100...................................................................................................................................................................................................31

Troubleshooting......................................................................................................................................................................................................34

Specifications..........................................................................................................................................................................................................36

Circuit Details..........................................................................................................................................................................................................37

Schematic ............................................................................................................................................................................................. APPENDIX A

Parts Placement Drawing..................................................................................................................................................................APPENDIX B

Introduction

The KAT100 automatic antenna tuner (ATU) is designed for use ith

the Elecraft K2/100 transceiver, as ell as the basic K2. It can match

loads ith SWRs in excess of 10:1, and can easily handle 150 atts of

transmit po er. Ten front-panel LEDs provide an accurate, real-time

SWR indication during transmit. The KAT100 also includes two

antenna jacks–the equivalent of t o auto-tuners connected to the rig.

Because of its tight integration ith the K2, the KAT100 offers many

advantages over generic external auto-tuners:

• Automatic po er reduction to 2 or 20 atts (in lo - and high-

po er modes) hen the K2's T U N E s itch is pressed; auto-tune is

possible ith as little as 0.2 atts in lo -po er mode

• Direct display of po er, SWR, and other data on the K2 LCD

• ATU can be configured using the K2 menu

• K2's POWER control setting indicated by t o LEDs

• K2's A N T 1 / 2 s itch selection indicated by t o LEDs

• L/C settings stored in EEPROM for both antennas on all bands

• SWR LEDs can use bar or dot mode (set by G R P H menu entry)

• All LEDs have t o brightness levels (set by L C D menu entry)

The ATU comes in t o enclosure styles, both of hich match the K2:

• The KAT100-1, sho n on the cover of this manual, is housed in a

lo -profile cabinet, intended to be placed beneath the K2. T o

anti-slip brackets are provided, so the K2 ill remain in position

even if the KAT100-1 is tilted up. (Also see Tilt-Stand Options

at right).

• The KAT100-2, sho n in the photo at right, is intended for side-

by-side arrangement ith the K2. It includes front and rear panels

that match our K2-sized EC2 enclosure kit. (The EC2 is sold

separately.) The EC2 cabinet provides plenty of room in the top

cover for your o n accessories.

Both KAT100 types are covered in this man al.

Tilt-Stand Options

T o different matching tilt stands are available, one for each KAT100

type. The E T S 2 is our standard, full-height tilt stand (2.5"), and is

recommended for use ith the KAT100-2. The E T S 1 5 is identical to

the ETS2 but is only 1.5" tall. It's ideal for use ith the lo -profile

KAT100-1, providing the optimum vie ing angle during operation.

Pre-Wound Toroids Available

The toroids in the KAT100 kit are not difficult to ind, and detailed

instructions are provided (beginning on page 13).

If you prefer not to ind the toroids yourself, you can obtain a full set

of pre- ound toroids ( ith leads stripped and tinned) from an Elecraft-

qualified source. Ordering information is at .elecraft.com.

You do not need to send your cores or wire to the winding service. You

can keep your set for replace ents or for use in your own projects.

KAT100-2

Parts Inventory

You should do a complete inventory, and if you find anything missing, contact Elecraft.

Leave painted panels rapped until they are needed during assembly. This ill protect the finish.

Items s pplied only with the KAT100-1 (with low-profile enclos re).

Pict re Ref. Designator(s) QTY Description Part #

MISC 1 KAT100-1 Front Panel E100138

MISC 1 KAT100-1 Rear Panel E100139

MISC 2 KAT100-1 Side Panel E100140

MISC 1 KAT100-1 Top Cover E100146

MISC 1 KAT100-1 Bottom Cover (note: includes holes for optional feet/tilt-stand) E100147

The items below are in a small bag labeled "Misc., KAT100-1" (p/n E850132)

HDWR 28 Scre , 4-40 x 3/16" Panhead Phillips, black (includes several spares) E700015

HDWR 8 2-D Fastener E100078

MISC 4 Rubber foot, self-adhesive E700024

MISC 2 Anti-slide bracket E100150

Items s pplied only with the KAT100-2 (for se with an EC2 enclos re).

Pict re Ref. Designator(s) QTY Description Part #

MISC 1 KAT100-2 Front Panel, EC2-compatible E100142

MISC 1 KAT100-2 Rear Panel, EC2-compatible E100143

The items below are in a small bag labeled "Misc., KAT100-2" (p/n E850136)

P3, P6 2 Connector, 2 pin male, 0.156"spacing (Aux 12V In and Aux RF Out) E620012

P 4 1 Connector, 10 pin (5x2) male, 0.1" spacing (Aux Control) E620040

Items in the KAT100 main parts bag (E850094), s pplied with both KAT100-1 and -2. Color codes and markings are sho n in parentheses.

Reference designators from 101 up refer to Front Panel components. Refer to Appendix A of the K2 o ner's manual for more parts photos.

Some components in this kit can be damaged by static discharge. Before handling diodes, transistors, and ICs, to ch a

gro nded, npainted metal s rface, or se a wrist strap gro nded thro gh a 1 megohm resistor.

Pict re Ref. Designator(s) QTY Description Part #

C1 1 Ca

acitor, 12

F, 2000V ceramic

(

3 KV ca

s ma

be substituted for an

2KV

)

E530107

C2 1 Capacitor, 22 pF 2000V ceramic E530108

C3 1 Capacitor, 39 pF 2000V ceramic E530109

C4 1 Capacitor, 82 pF 2000V ceramic E530110

C5,C6A,C6B,C7A-7D 7 Capacitor, 150 pF 2000V ceramic ("151") E530111

C8 1 Capacitor, 1200 pF, 1600V polypropylene film ("122") E530112

C32 1 Capacitor, 100 pF, 200V ("101") E530034

C33-36,C47 5 Capacitor, .001 µF, 50 V ("102") E530001

C37,C38,C39,C45,

C46 C50,C51,

7 Capacitor, .01 µF, 50 V ("103") E530009

C44,C49,C101,C102,

C56

5 Capacitor, .047 µF, 50V ("473") E530025

C9-30,C40,C41,C43,

C48,C52-55,C57-60

34 Capacitor, 0.1 µF, 50V ("104") E530020

C42 1 Capacitor, 10 µF, 35 V electrolytic E530045

C31 1 Capacitor, 5-30 pF trimmer E540001

D1,D2 2 Diode, 1N5711 (small glass body) E560004

D3,D4 2 Diode, 1N5817 (large black body) E560008

D110,D111,D112 3 Rectangular LED, Red (long lead is anode -- see text) E570007

D101,D103,D104,

D105,D106,D113

6 Rectangular LED, Green E570008

D102,D107,D108,

D109,D114

5 Rectangular LED, Yello E570009

E1 1 Scre terminal, right-angle PCB mount E700012

J1 1 Connector, DC barrel jack, 2.1mm, right-angle PCB mount E620026

J2 1 Connector, BNC, right-angle PCB mount, ith finishing nut and asher E850134

J3 1 Connector, DB9-F (female), right-angle PCB mount E620058

J4,J5,J6 3 Connector, SO239 E620064

J7 0 Connector, 6-pin female, 0.1" (not supplied; for future use) N/A

J101 1 Connector, 12-pin female, 0.1" spacing, PCB mount E620008

K1-K18 18 Relay, SPDT, 10A rating E640012

L1,L2,L3,L4 4 Toroidal inductor on T80-0 core (bro n, 0.8" dia.); see text E680020

L5,L6,L7,L8 4 Toroidal inductor on T94-2 core (red, 0.94" dia.); see text E680018

P1,P2 0 Connector, 2 pin male, 0.1" spacing (not supplied; for future use) N/A

P 5 1 Connector, 12 pin male, 0.1" spacing, right-angle mount E620065

Q1 1 Transistor, PNP, modified TO-92 package, Zetex ZTX789A

Note: Q1's labeling may be hard to read. The part number should be marked

on the silver-colored side.

E580019

Q2,Q3 2 Transistor, MOSFET, TO-92 package, 2N7000 E580002

Q101,Q102 2 Transistor, NPN, TO-92 package, PN2222 E580001

R5,R101-R114 15 Resistor, 120 ohms, 1/4W, 5% (brn-red-brn) E500022

R2 1 Resistor, 200 ohms, 1W, 5% (red-blk-brn) E500074

R115 1 Resistor, 220 ohms, 1/4W, 5% (red-red-brn) E500002

R116 1 Resistor, 470 ohms, 1/4W, 5% (yel-vio-brn) E500003

R11 1 Resistor, 680 ohm, 1/2 W, 5% (blue-gray-brn) E500085

K2 CTRL-R12 1 Resistor, 820 ohm, 1/4 W, 5% (gray-red-brn) E500001

R1,R8,R9 3 Resistor, 3.3K, 1/4W, 5% (org-org-red) E500017

R12,R16,R17,R18 4 Resistor, 10K, 1/4W, 5% (brn-blk-org) E500015

R3,R4 2 Potentiometer, 100K trimmer ("104") E520001

R6,R7,R13 3 Resistor, 8.45K, 1/4W, 1% (gray-yel-grn-brn) E500071

R15 0 Resistor (not supplied; for future use) N/A

RFC1 1 RF choke, 15µH (brn-grn-blk) NOTE: may be in bag with toroid cores E690012

RFC2 1 Toroidal inductor on FT37-43 core (gray, 0.37" dia.); see text E680003

RP1 1 Resistor pack, 3.9K, 4 individual resistors, 8 pins E510000

T 1 1 Transformer on FT50-43 toroidal core; see text E680008

U1 1 IC, Programmed microcontroller for KAT100, PIC16F877 or PIC16F877A E610012

U2,U3,U4,

U101,U102

5 IC, octal driver, TPIC6B595 E600032

U5 1 IC, op-amp, LM358 E600010

U6 1 IC, high-current op-amp, EL5146C E600041

U7 0 IC, EEPROM, 25LC320 (not supplied; reserved for future use) E600009

U8 1 IC, 5V regulator, TO-220 package, 78M05 or 7805 E600024

W1-W7 0 Wire jumper (leave open except as specified in text) N/A

Z1 1 Ceramic resonator, 4.0MHz, 0.2% tolerance (orange, ith 3 leads) E660001

HDWR 2 L-bracket, front panel retainer, 4-40 threaded E700073

HDWR 14 Scre , 4-40 x 3/16" Panhead Phil, black (2 spares) E700015

HDWR 15 Scre , 4-40 x 5/16" Panhead Phil, zinc plated (2 spares) E700077

HDWR 1 Thumb scre , 6-32 x 1/2", ith black plastic knob E700070

HDWR 1 Nut, 6-32 E700069

HDWR 2 Flat asher, #6 E700067

HDWR 24 Split lock asher, #4 (2 spares) E700004

HDWR 15 Nut, 4-40 (2 spares) E700011

HDWR 3 Solder lug E700062

HDWR 2 Standoff, hex male-female (for DB9 connector, J3) E700078

MISC 1 Connector, 2.1 mm mating plug for J1 (DC barrel jack) E620032

MISC 1 Connector, 9-pin, DB9M (male), solder cup terminals (for control cable) E620049

MISC 3 ft. Cable, 4-conductor shielded E760009

MISC 1 DB9 backshell and hard are (for control cable) E620050

MISC 1 40-pin socket for U1 E620017

MISC 1 ft. Hookup ire, #20, black insulation E760006

MISC 1 ft. Hookup ire, #20, red insulation E760007

MISC 4 ft. #26 enamel ire for T1 and RFC2, red E760002

MISC 2 ft. #26 enamel ire for T1, green E760004

MISC 20 ft. #20 enamel ire for L1-L8, red E760022

MISC 10 Cable ties (for L1-L8; 2 spares) E980002

MISC 1 Sand paper E850090

MISC 1 KAT100 RF PC Board E100144

MISC 1 KAT100 Front Panel PC Board (may be rapped ith one of the panels) E100145

RF Board Assembly

Place the KAT100 RF PC board in front of you, ith the bottom

side up and the front edge facing you as sho n in the Parts

Placement Dra ing, Appendix B.

On the bottom of the board, along both edges, you'll find six

locations for 2-D fasteners. These are used to secure the RF board to

the chassis panels. In the next fe steps, just fo r 2-D fasteners ill be

attached, and the remaining t o locations ill not be used. Which four

locations to use depends on hether you're building a KAT100-1 or

KAT100-2:

KAT100-1: Use the t o 2-D locations near the front edge, and the

t o near the back edge.

KAT100-2: Use the t o 2-D locations near the front edge, and the

t o located about t o-thirds of the ay back. (The 2-D fasteners are

supplied ith the EC2 enclosure kit, not the KAT100-2.)

Locate a 2-D fastener and hold it vertically (Figure 1a). Looking

at a side ith t o holes, note that the holes are offset from the center.

The PC board outlines for the 2-D fasteners have a matching offset,

hich ill aid in installing them in the next step.

Holes offset

from center

(a) (b)

Fig re 1

Install 2-D fasteners at the four locations identified earlier, on the

botto of the RF board. Secure each fastener from the top side of the

board ith 3/16" (4.8 mm) pan-head scre s (black) and #4 split lock

ashers (Figure 1b).

Make sure the 2-D fasteners line up ith the edges of the PC

board and do not hang over. If they hang over or do not match their

component outlines, they are installed back ards.

The leads on small capacitors are fragile. Do not p ll on

the leads or bend them excessively.

Sort all capacitors into groups by physical appearance (size, color,

and lead spacing). Within these groups, sort them by capacitance

value.

Locate the component outline for capacitor C55, on the top side

of the board near the front edge.

Install a 0.1-µF capacitor (labeled "104") at C55. Keep the lead

length as short as possible. (If the leads are pre-formed, the capacitor

may sit slightly above the board.)

Bend C55's leads out ard on the opposite side of the board to

keep it from falling out or shifting position. Then solder the capacitor

and trim the leads.

Note: Components may be soldered one at a time or in groups. Leads

can be trimmed either before or after soldering. After soldering, trim

leads to about 1/16" [1.5 mm] or less in length.

If yo r solder joints are not clean and shiny, yo r iron

may not be hot eno gh, or yo may be sing the wrong type of

solder. These "cold" solder joints will likely res lt in poor

performance, reliability problems, or component fail re. Yo

may wish to cons lt o r web site for additional soldering

instr ctions and tool recommendations.

In the steps that follo , you'll be installing groups of

components. When orking from a long list, install all of the items on

one line before moving on to the next. Arro s (⇒) appear in the list

to remind you of this order. In general, assembly proceeds from left to

right and front to back across the board.

Install the capacitors listed belo . Start ith C29, hich is to the

left of C55, near relay K16. Check each capacitor's labeling

caref lly (shown in parentheses).

__ C29, 0.1 (104) ⇒__ C26, 0.1 (104) ⇒__ C25, 0.1 (104)

__ C24, 0.1 (104) __ C23, 0.1 (104) __ C22, 0.1 (104)

__ C21, 0.1 (104) __ C20, 0.1 (104) __ C19, 0.1 (104)

__ C60, 0.1 (104)

__ C51, .01 (103) __ C50, .01 (103) __ C39, .01 (103)

__ C40, 0.1 (104) __ C38, .01 (103) __ C46, .01 (103)

__ C37, .01 (103) __ C48, 0.1 (104) __ C43, 0.1 (104)

__ C9, 0.1 (104) __ C18, 0.1 (104) __ C17, 0.1 (104)

__ C16, 0.1 (104) __ C15, 0.1 (104) __ C14, 0.1 (104)

__ C13, 0.1 (104) __ C12, 0.1 (104) __ C11, 0.1 (104)

__ C10, 0.1 (104) __ C52, 0.1 (104) __ C53, 0.1 (104)

__ C45, .01 (103) __ C54, 0.1 (104) __ C36, .001 (102)

__ C35, .001 (102) __ C41, 0.1 (104) __ C58, 0.1 (104)

__ C44, .047 (473) __ C49, .047 (473) __ C56, .047 (473)

__ C57, 0.1 (104) __ C47, .001 (102) __ C59, 0.1 (104)

__ C33, .001 (102) __ C34, .001 (102)

__ C32, 100 pF, 200V (101)

__ C28, 0.1 (104) __ C30, 0.1 (104)

__ C27, 0.1 (104) Near K17, middle of board

Install the high-voltage capacitors listed belo .

Note: Save a fe of the clipped leads from these capacitors for use as

ground jumpers in later steps.

__ C1, 12 (12) ⇒__ C2, 22 (22) ⇒__ C3, 39 (39)

__ C4, 82 (82) __ C5, 150 (151) __ C6B, 150 (151)

__ C6A, 150 (151) __ C7D, 150 (151) __ C7C, 150 (151)

__ C7B, 150 (151) __ C7A, 150 (151)

__ C8, 1200 pF (122)

Install the electrolytic capacitor, C42 (10 µF), near the back-right

corner of the board. The (+) lead must be installed in the hole marked

ith a "+". The (+) lead is usually longer than the (–) lead, and the (–)

lead is identified by a black or hite stripe.

Install the 5 to 30 pF ceramic trimmer capacitor, C31, near the

back edge of the board. Orient the flat side of the trimmer as indicated.

Using a small flat-blade scre driver, set the trimmer to its

midpoint (scre driver slot perpendicular to the flat side).

Sort all of the resistors by value. The color bands on 1% resistors

( hich usually have a blue body) can be difficult to read, so you should

use a DMM (digital multimeter) to verify their values. Tape them to a

piece of paper ith the values labeled.

Install the resistors belo . Start ith R18, hich is at the front

edge of the board, near the microcontroller, U1 (the only 40-pin IC).

__ R18, 10k, 5% (brn-blk-org) ⇒__ R17, 10K, 5% (brn-blk-org)

__ R5, 120, 5% (brn-red-brn) __ R9, 3.3k, 5% (org-org-red)

__ R8, 3.3k, 5% (org-org-red)

__ R7, __ R6, and __ R13, 8.45k, 1% (gray-yel-grn-brn)

__ R16, 10k, 5% (brn-blk-org)

__ R11, 680, 5% (blue-gray-brn), 1/2-watt

__ R12, 10k, 5% (brn-blk-org) __ R1, 3.3k, 5% (org-org-red)

Install the 200-ohm, 1- att resistor (red-blk-brn) at R2, on the

bottom of the board. Make sure R2 is flat against the board before

soldering.

Install resistor net ork RP1 (3.9k). RP1 is located on the right

side of the board, near relay K9. The dotted (pin 1) end of RP1 should

be oriented to the left. (RP1 is symmetrical and can be reversed, but

this orientation ill help you visually identify the pin 1 end.)

Install trimmer potentiometers R3 and R4 (100 k, "104"), in the

back right corner of the board. The trimmers ill sit a small distance

above the PC board on the pin shoulders.

Set both trimmer potentiometers to their midpoints.

The subminiature RF choke to be installed in the step has very

fragile leads. Do not pull on them. Keep soldering time to a maximum

of 2 seconds.

Locate the miniature 15-µH RF choke, RFC1 (brn-grn-blk), hich

is the same bag as the toroidal cores. Install the choke in the back-

right corner of the board, near J3.

Check the resistance across RFC1 using the lo est resistance scale

of your DMM. This ill ensure that the choke as not damaged during

soldering. The reading should be under 5 ohms.

Install the ceramic resonator, Z1, near the microcontroller. Z1

looks like a capacitor ith three leads.

Near the "KAT100 RF" label in the front-left corner, you’ll find

a short jumper location, identified by a ground symbol ( ). Use a

discarded high-voltage capacitor lead to make a 3/4" (19 mm) U-

shaped ire for this jumper. Mount the jumper on the top side of the

board, ith the top of the U-shape approx. 1/4" (6 mm) above the

board. Solder it from the bottom side.

Install a similar jumper in the back-right corner, near relay K1.

Install diodes D1 and D2 (1N5711) near connector J3 at the back

edge of the board. Make sure the banded end of each diode is oriented

to ard the right as indicated by its component outline.

Install diodes D3 and D4 (1N5817), both located along the right

edge. Note that the banded ends of these diodes point in opposite

directions.

Before handling transistors in the next two steps, to ch

an npainted, gro nded metal s rface. Electrostatic discharge

can ca se transistors to become damaged or intermittent.

Using a magnifying glass if necessary, identify the three different

types of TO-92 package transistors (small black body, three leads).

They ill look like one of the t o types sho n in Figure 2.

ZTX

789A

(b)

(a)

Fig re 2

Locate the t o 2N7000 transistors. Install these at Q2 and Q3 as

sho n in Figure 2a. Q2 is near the center 2-D fastener on the right

edge, and Q3 is near the microcontroller, U1. The flat side of each

transistor should be aligned ith the flat side of its component outline.

Locate the ZTX789A transistor, hich is labeled on its smaller

flat side. Install Q1, located near D4. Orient the transistor as sho n in

Figure 2b.

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