Elecraft KAT500 Owners Manual



ELECRAFT

KAT500 AUTOMATIC ANTENNA

TUNER

OWNER’S MANUAL

Revision C4, October 6, 2014

Copyright © 2014, Elecraft, Inc.

All Rights Reserved

Contents

Introduction ............................................................................................................................................... 1

Quick Start ................................................................................................................................................ 1

Customer Service and Support ................................................................................................................. 1

Technical Assistance ....................................................................................................................................... 1

Repair / Alignment Service ............................................................................................................................. 1

Specifications ............................................................................................................................................ 2

Setup ......................................................................................................................................................... 3

Elecraft K3 Transceiver and KPA500 Amplifier ................................................................................................ 3

Placement ........................................................................................................................................................ 3

Firmware ......................................................................................................................................................... 3

Cabling ............................................................................................................................................................ 3

Icom Transceivers with AH-4 ATU Interface ..................................................................................................... 8

Cabling ............................................................................................................................................................ 8

Other Transceiver and Amplifier or Stand-Alone Transceiver ......................................................................... 11

Operation ................................................................................................................................................ 14

Front Panel Controls and Indicators .................................................................................................................. 14

Key Line Hot Switching .................................................................................................................................... 15

Tune Operation and Memories .......................................................................................................................... 16

Tune Operation ............................................................................................................................................. 16

Memories ...................................................................................................................................................... 16

Bandswitching ................................................................................................................................................... 17

Elecraft K3 and KPA500 Amplifier Combination ........................................................................................ 17

Non-Elecraft Amplifiers ............................................................................................................................... 17

Operating Tips ................................................................................................................................................... 18

Rapid QSY After Antenna Change: .............................................................................................................. 18

Automatic Bypass on Selected Bands: .......................................................................................................... 18

Fault Conditions ................................................................................................................................................ 19

Utility Program ....................................................................................................................................... 20

KAT500 Configuration ..................................................................................................................................... 20

Amplifier Key Interrupt Power ..................................................................................................................... 20

Antennas........................................................................................................................................................ 20

VSWR Thresholds ........................................................................................................................................ 21

Erase Memories ............................................................................................................................................. 21

Saving Configuration .................................................................................................................................... 21

Reset to Factory Default ............................................................................................................................... 21

Updating Firmware ........................................................................................................................................... 21

Forcing a Firmware Load ...................................................................................................................... 22

Kit Assembly Procedure ......................................................................................................................... 23

Preventing Electrostatic Discharge Damage ..................................................................................................... 23

Tools Required .................................................................................................................................................. 23

Assembly Procedure .......................................................................................................................................... 24

Appendix A Parts List ............................................................................................................................ 42

KAT500 Cable Set ............................................................................................................................................ 42

KAT500 Circuit Board ...................................................................................................................................... 42

KAT500 Core Assembly – E850561 ................................................................................................................ 43

Wrapped Covers E850565 ............................................................................................................................ 43

Wrapped Panels E850564 ............................................................................................................................. 43

Miscellaneous Bag E850562 ......................................................................................................................... 44

Ant 1 SO-239 Assembly E850553 ................................................................................................................ 46

Ant 2 SO-239 Assembly E850560 ................................................................................................................ 46

Ant 3 SO-239 Assembly E850559 ................................................................................................................ 46

XMTR SO-239 Assembly E850554 ............................................................................................................. 47

Elecraft manuals with color images may be downloaded from

www.elecraft.com

.

Introduction

The KAT500 Automatic Antenna Tuner is designed to be closely integrated with the Elecraft K3
transceiver and the Elecraft KPA500 amplifier although it may be easily used with other transceivers and
amplifiers. Features include:

 Automatic band switching, covering the spectrum from 1.8 through 54 MHz.
 Automatic antenna switching to connect one of three antennas according to the band selected.
 L and C settings for lowest SWR are stored in memory for extremely rapid frequency and band

changes.

 Robust self-protection circuits that guard against damage from switching high-power RF or trying

to match loads outside of its tuning range.

 Static bleed resistor built in to avoid damage from normal static buildup on antennas.
 Low profile enclosure that matches the footprint of the KPA500 and K3, allowing the KAT500 to

be placed on top or under either unit (the KAT500 is designed to support the weight of the
KPA500).

If you purchased your KAT500 as a kit, turn to page 23 for assembly instructions.

Quick Start

To quickly set up and get started with your KAT500 Automatic Antenna Tuner, turn to page 3 to hook up
the unit and page 14 for operating instructions.

Customer Service and Support

Technical Assistance

You can send e-mail to [e-mail] 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 831-763-4211. 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 (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 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

.

1

Elecraft's 1-Year Limited Warranty

This warranty is effective as of the date of first consumer purchase (or if shipped from factory, date product is
shipped to customer). 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 to
Elecraft at time of order to insure 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 Elecraft for warranty repair, Elecraft will 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.

Specifications

Frequency Range
Supply Voltage and

Current
Weight
Size

Typical Matching
Range and Power
Limits

Autotune Power Range

1.8 to 54 MHz, continuous.

11 to 15 VDC, 1.0 A max (200 mA typical).

4.6 lbs (2.1 kg).

Enclosure only, 1.5 x 10.8 x 10.0 in., HWD (3.8 x 27.4 x 25.4 cm). With projections, 1.75
x 10.8 x 11.8 in. (4.4 x 28.4 x 30.0 cm). The projections are the bottom feet and the cable

connectors on the rear.

3 — 30 MHz 600 W into 5 Ω to 500 Ω (10:1 SWR).

1000 W into 16 Ω to 150 Ω (3:1 SWR).

1.8 — 2 MHz 600 W into 10 Ω to 500 Ω (5:1 Low Impedance, 10:1 High Impedance
SWR).

30 — 60 MHz 500 W into 5:1 SWR (10 Ω to 250 Ω).

Matching specified to a 1.0:1 to 1.6:1 output SWR. Power rating is ICAS (Intermittent
Commercial and Amateur Service: equal time on and off, 5 mi n. , max. at full power.)

7 W —100 W.

For better matching accuracy, tune with >20 W.

2

Setup

To provide maximum flexibility and the most convenient operation with your existing equipment, there
are several ways you can connect the KAT500 to your station.

The following cabling diagrams show how to use the KAT500 with any transceiver and amplifier in the
20 to 1,000 watt output range. Choose the one that fits your station needs:

 Elecraft K3 transceiver and KPA500 amplifier.
 Icom transceiver and amplifier equipped with the Icom AH-4 ATU interface.
 Other transceiver and any amplifier.

NOTE: Although the KAT500 works equally well with either a transceiver or a

stand-alone transmitter, transceiver is used throughout this manual for simplicity.

Three cables are supplied with your KAT500:

 Computer interface cable, either the KXUSB (USB port) or KXSER (serial port) cable

chosen when you ordered your KAT500. The KXSER cable may be in a bag marked
E850369.

 Power cable.
 Key Line cable with RCA type male connectors.

Elecraft K3 Transceiver and KPA500 Amplifier

Placement

The KAT500 may be placed under or above either the Elecraft K3 transceiver or the KPA500 amplifier.
The KAT500 can easily handle the weight of the KPA500 amplifier.

Although the KAT500's feet do not provide the full clearance recommended in the KPA500 Owner’s
manual, they provide adequate clearance for cooling air to enter the KPA500 for typical operation with
low duty-cycle modes (e.g. CW or voice SSB). Operation at higher duty-cycles (e.g. contesting, RTTY,
etc.) will cause the amplifier temperature to increase, resulting in higher speed cooling fan operation. For
those cases we recommend placing the KAT500 underneath or alongside the KPA500.

Firmware

We strongly recommend that you update your K3 and KPA500 with the latest firmware available from

www.elecraft.com

not be necessary in every case, but it will help avoid the possibility of some functions not working as
expected.

Cabling

The Elecraft K3 and KPA500 amplifier normally use the E850463 Aux interface cable that communicates
band selection and other information between the K3 and KPA500. The KAT500 can be included in the
E850463 Aux interface path and use the data to switch to the correct band along with the K3 and
KPA500. Although not strictly required, the E850463 Aux cable provides the best integration of the
KAT500, KPA500 and K3 equipment.

. Details about how to do this are in your K3 and KPA500 Owner’s manuals. This may

3

In addition to the supplied cables, you will need two E850463 Aux cables. Normally you will have one
already connected between your K3 and KPA500, so you may need one additional cable. This is the same
cable included in the KPAK3AUX cable set. You can purchase the cable from Elecraft (order E850463)
or, you can construct your own cable using male and female DB-15 connectors wired as follows.

IMPORTANT

Do not use standard VGA cables. The E850463 Aux cables are wired differently.

Table 1. E850463 Aux Cable Wiring.

CONNECTOR PINS SIGNAL

2 2 AUXBUS
3 3 BAND 1
5 5 GND

9 9 BAND 2
10 10 PTT (or KEY)
11 11 Inhibit
12 12 GND
13 13 BAND0
14 14 BAND3
15 15 ALC (Normally not used. See your KPA500 Owner’s Manual)

The basic E850463 Aux cabling setup is shown in Figure 1. If your station setup requires that other
equipment (e.g. SteppIR controller) have access to the key line to inhibit the amplifier, use the cabling
described in Figure 2.

50-ohm coaxial RF cables with PL-259 connectors.

 Be sure you select the antenna output on the K3 that connects to the KPA500.
 The KAT500 allows up to three antenna connections, selected from the front panel (See

Operation, page 14).

Two wire power cable with a female 2.1 mm coaxial connector.

 Connect to the station 11 to 15 VDC power supply with the white striped lead to the positive

terminal.

Computer interface cable.

 Not required, but used for controlling the KAT500 from a personal computer, customizing

the KAT500’s operation or for updating firmware (see Utility Program on page 20).

E850463 Aux interface cables with male and female connectors.
 Do not use common VGA cables; they are not wired correctly for this use. You can order

E850463 from Elecraft or you can make your own (See E850463 Aux Cable Wiring, above).

4

Figure 1. Cabling Diagram: Elecraft K3, KPA500 and KAT500 Using E850463 Aux Interface Cables.

5

Figure 2. Cabling Diagram: Elecraft K3, KPA500 and KAT500 Using E850463 Aux Interface Cables

with Separate Key Line.

6

Key Line Cables

 The Key Line (sometimes called a PTT line) controls the amplifier, enabling it for normal

transmission and inhibiting it when necessary to protect the amplifier other equipment. The
key line consists of a two conductor (center wire and shield) cable and connects to the
Elecraft equipment using RCA-type male connectors.

 The K3 transceiver grounds the Key line to enable the KPA500 amplifier. Opening this line

anywhere between the K3 and the KPA500 will inhibit the amplifier. If you have an external
device that must control the key line, such as a SteppIR controller, you may insert it series

with the key line in either place indicated with the
the external device.

 If you need additional cables, you can make your own or order additional cables from

Elecraft (part number E100416). The Elecraft cables use RG59 coaxial cable for optimum
shielding against incidental RF pickup.

IMPORTANT

When using a separate Key Line cable, you must:

1. Interrupt the key line in the E850463 Aux cable as described

in note

2. Use a separate key line cable between the transceiver and

between the KAT500 and between the KAT500 and the
amplifier. You cannot use an E850463 Aux cable in one
location and a separate key line cable in the other.

below.

using connectors that match those on

Key Line Interrupter

 The E850463 Aux cable includes the key line that inhibits the amplifier when needed to

protect other equipment. This circuit must be broken when using an external key line cable or
the key line in the E850463 Aux cable will bypass the external cable and the external
equipment will not be able o inhibit the amplifier. If you purchased the Elecraft Aux cable as
part of the KPAK3AUX cable set, you received with it a small device called the Key Line
Interrupter that opens the key line. The key line is cut inside the Inhibiter so you do not need
to modify your E850463 Aux cable in any way. If you only purchased the E850463 Aux
cables you can order a key line interrupter separately. Order E850462 from

[e-mail]

 If using a homemade cable, you can cut the circuit at pin 10 (see Table 1. E850463 Aux Cable

Wiring. on page 4)

7

Icom Transceivers with AH-4 ATU Interface

Icom transceivers equipped with the interface connector for the Icom AH-4 ATU can operate the
KAT500 through the AH-4 interface.

Icom transceivers not equipped with the AH-4 interface can use the KAT500 as described under Other
Transceiver and Amplifier or Stand-Alone Transceiver on page 11.

Cabling

Cables with the proper connectors is required wired as follows.

Table 2. Icom AH-4 Interface Cable Wiring.

MOLEX CONNECTOR TO

ICOM TRANSCEIVER

Pin 1 Key Tip NC
Pin 2 Start Ring NC
Pin 3 +12 VDC NC Center
Pin 4 Ground Shield Outer Shell

SIGNAL

T-R-S CONNECTOR

TO KAT500

NOTES:

 Molex Connector: Pin 1 is at the triangular end of the connector.
 T-R-S is tip, ring and shield on a 3.5mm “stereo” plug. NC = No connection.
 Power Connector is a 2.1mm barrel type connector. NC = No connection.

Table 3. Icom Key Line Cable Wiring.

DIN CONNECTOR TO
ICOM TRANSCEIVER

Pin 3 HSEND Tip NC
Pin 2 Ground Shell NC

SIGNAL

RCA TYPE

CONNECTOR TO

KAT 500

NOTES:

POWER CONNECTOR

TO KAT500

POWER CONNECTOR

TO KAT500

 The DIN connector varies with the model of Icom transceiver. See your owner’s manual for

the specific connector required.

8

Connect the equipment as described in Figure 3 and the associated notes.

50-ohm coaxial RF cables with PL-259 connectors.
 Be sure your transceiver is configured to deliver power to the antenna output that connects to

the KPA500.

 The KAT500 allows up to three antenna connections, selected from the front panel (See

Operation, page 14).

AH-4 Interface Cable.

 Wire the cable as shown in Table 2, Icom AH-4 Interface Cable Wiring, above.
 The Interface Cable includes the Key Line (sometimes called a PTT line) which controls the

amplifier, enabling it for normal transmission and inhibiting it when necessary to protect
other equipment.

 The transceiver grounds the Key line to enable the KPA500 amplifier. Opening this line

anywhere between the transceiver and the KPA500 will inhibit the amplifier.

Key Line Cables

 The Key Line (sometimes called a PTT line) controls the amplifier, enabling it for normal

transmission and inhibiting it when necessary to protect the amplifier other equipment.

 The key line between the KPA500 and the KAT500 consists of a two conductor (center wire

and shield) cable and connects to the Elecraft equipment using RCA-type male connectors.

 The key line between the KAT500 and the Icom transceiver must be wired as shown in

Table 3. Icom Key Line Cable Wiring.

External Device Controlling the Key Line.

 If you have an external device that must control the key line, you may insert it series with the

key line an either place indicated with the
external device.

Computer interface cable.

 Not required, but used for controlling the KAT500 from a personal computer, customizing

the KAT500’s operation or for updating firmware (see Utility Program on page 20).

using the appropriate connectors to match the

9

Figure 3. Cabling Diagram: Icom Transceiver with AH-4 Tuner Interface.

10

Other Transceiver and Amplifier or Stand-Alone Transceiver

The KAT500 works well with any H.F. transceiver covering 1.8 through 54 MHz and amplifier delivering

up to 1,000 watts output (see Specifications, page 2). If you have an Elecraft K3 transceiver and KPA500

amplifier you can connect them to the KAT500 as shown here. However, for best integration of the K3
equipment, we recommend that you use the E850463 Aux interface cable as shown on page 3 and
Figure 1.

The basic cabling requirements for a transceiver and amplifier combination are shown in Figure 4.
Figure 5 shows the basic cabling for a stand-alone transceiver. Refer to the following notes for details of
the connections.

50-ohm coaxial RF cables with PL-259 connectors.
 The KAT500 allows up to three antenna connections, selected from the front panel (See

Operation, page 14).

Two wire power cable with a female 2.1 mm coaxial connector.

 Connect to the station 11 to 15 VDC power supply with the white striped lead to the positive

terminal.

Computer interface cable.

 Not required, but used for controlling the KAT500 from a personal computer, customizing

the KAT500’s operation or for updating firmware (see Utility Program on page 20).

Key Line Cables

 The Key Line (sometimes called a PTT line) controls the amplifier, enabling it for normal

transmission and inhibiting it when necessary to protect other equipment. The key line
consists of a two conductor (center wire and shield) cable and connects to the KPA500 using
RCA-type male connectors. You’ll need to equip your cables with whatever connector types
are used on the transceiver and amplifier.

 If you have an external device that must control the key line, you may insert it series with the

key line an either place indicated with the
external device.

using the appropriate connectors to match the

11

Figure 4. General Cabling for Transceiver and Amplifier.

12