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KRC2
User Manual
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User Manual
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Elecraft KRC2 User Manual

Elecraft • www.elecraft.com • 831-662-8345
ELE C R A F T KR C 2
BA N D D E C O D E R a n d C O N T R O L L E R
Assembly and Operating Instructions
For firmware Version 1.5 and later
Revision C, May 1, 2008. Copyright © 2004-2008, Elecraft; All Rights Reserved
Introduction
Individual driver outputs can be wire-ORed. However, the KRC2 also provides a PC-based command interface, allowing the user to configure the unit. New firmware can even be downloaded via the Internet.
Additional features are available when the KRC2 is used with our K2, K2/100, K3 and K3/100 transceivers. The ACC menu entry can be used to directly control the KRC2's accessory outputs. Four buttons on the top of the KRC2 can be used as "hot keys" for instant access to CW message buffers, fast switching of the RXANT jack, or other functions.
Specifications
Outputs 32 (16 sink, 16 source) Output Driver Ratings 500 mA max, 50 V max (sink and source) Analog Inputs 0-5 V (1 input), 0-10 V (2 inputs) Band Decode Formats Elecraft, Icom, Yaesu, Kenwood
1
Internal Current Drain Approx. 20 mA (excludes output driver current) Size 5.5" (L) x 3.5" (D) x 1.5" (H) (14 x 11.4 x 4 cm)
i
Caution: Some parts in this kit can be damaged by static discharge. Before handling any
transistors or ICs, put on an anti-static wrist strap, or touch a grounded, unpainted metal surface.
1
Refer to our web site for a complete listing of compatible formats and transceivers.
2
Table of Contents
Specifications
....................................................
1
Parts Inventory
..................................................
2
Firmware Requirements
....................................
5
Assembly
...........................................................
5
Case Assembly
................................................
14
KRC2 Test Procedure
.....................................
15
KRC2 Final Assembly
....................................
16
K2 to KRC2 Control Cable Assembly
...........
16
Using the KRC2
..............................................
18
KRC2 Jumper Configuration
..........................
20
KRC2 Power Connections
...............................
25
Connecting the KRC2’s Drivers
.....................
25
Connecting other Elecraft Peripherals
............
25
KRC2 PC Connections
....................................
25
Using the KRC2 with non-Elecraft Radios
....
26
Troubleshooting
...............................................
27
DC Voltage Chart
............................................
28
Circuit Details
..................................................
29
PCB Layout
......................................................
31
Customer Service Information
........................
34
3
Parts Inventory
The table below lists all parts in the kit. Typical markings on capacitors, as well as resistor
and RF choke color codes, are shown in parentheses.
Ref.
Description
Part No.
Qty
C1, C2
Capacitor, 33 pF ("33" or "330")
E530064
2
C3 - C6, C8-C11
Capacitor, .001 µF (“102”), 0.2" lead spacing
E530001
8
C7
Capacitor, .001 µF (“102”), 0.1" lead spacing
E530129
1
C16, C17, C21-C24, C28-C59
Capacitor, .01 µF ("103"), 0.1" lead spacing
E530019
39
C12
Capacitor, electrolytic, 220 µF
E530062
1
C13, C14, C20, C26, C27
Capacitor, .1 µF ("104"), 0.2" lead spacing
E530011
5
C15
Capacitor, electrolytic, 10 µF
E530045
1
C18
Capacitor, 120 pF ("121")
E530077
1
C19
Capacitor, 56 pF ("56" or "560")
E530015
1
C25, C60
Capacitor, .1µF (“104”), 0.1" lead spacing
E530020
2
D6-D10
Diode, 1N4148
E560002
5
D2-D5
Diode, 1N4007
E560001
4
DS1
LED, green, rectangular
E570008
1J1PC-Mount Connector, DB9 Female
E620058
1J2PC-Mount Connector, DB9 Male
E620068
1
J3
Connector, DC barrel power 2.1mm
E620026
1
J4-J13
Connector, screw terminal
E700079
10
L1-L3
Inductor, 100 µH mini (brn-blk-brn)
E690013
3
L4
Inductor, 15 µH mini (brn-grn-blk)
E690012
1
Q1
Transistor, J310 JFET
E580012
1R1Resistor, 47 k, 1/4 watt, 5% (yel-vio-org)
E500067
1
R2, R6-R8, R10, R11
Resistor, 10 k, 1/4 watt, 5% (brn-blk-org)
E500015
6
R3
Resistor, 1 k, 1/4 watt, 5% (brn-blk-red)
E500013
1R4Resistor, 470 ohms, 1/4 watt, 5% (yel-vio-brn)
E500003
1R9Resistor, 100 ohms, 1/4 watt, 5% (brn-blk-brn)
E500010
1
R12
Resistor, 4.7 k, 1/4 watt, 5% (yel-vio-red)
E500047
1
R13
Resistor, 47 ohms, 1/4 watt, 5% (yel-vio-blk)
E500019
1
R14
Resistor, 4.7 k, 1/8 watt (yel-vio-red)
1
RP1
Resistor network, 390 ohms, 4 resistors, 8 pins (391)
E510021
1
RP2
Resistor network, 47 k, 7 resistors, 8 pins (473)
E510022
1
S1- S4
Momentary push button switch
E640005
4
S5
Miniature slide switch, DPDT
E640009
1
4
U1
IC, programmed microcontroller, PIC16F877A-I/P
E610013
1
U2
IC, MAX1406 or LT1039
E600036
1U3IC, voltage regulator, 5V, 78L05
E600029
1
U4, U5
IC, UCN5891A
E600049
2
U6, U7
IC, TPIC6595
E600048
2X1Crystal, 4.0 MHz
E660006
1
X2
Crystal, 16.2 MHz (S162ECSL)
E660014
1
HDWR
2-D Fasteners
E100078
2
HDWR
1/4 x 3/16” round threaded standoff
E700026
1
HDWR
4-40x3/16” flat head Philips machine screw, black oxide
E700025
5
HDWR
4-40x3/16” pan head Philips machine screw, black oxide
E700015
3
HDWR
#4 internal-tooth lock washer
E700010
3
HDWR
#4 Standoff, hex male-female (for DB9 connectors)
E700078
4
MISC
Jumper, 2-pin shorting (for W1-23)
E620055
23
MISC
KRC2 Printed Circuit board
E100163
1
MISC
IC socket (for U1), 40 pins
E620017
1
MISC
Keycap, rectangular, black for pushbuttons
E980000
4
MISC
Rubber foot, self-adhesive
E700024
4
MISC
Connector, dual-row 16-pin male header
E620010
3
MISC
Cable Tie, 3-inch
E980002
2
MISC
8-conductor shielded cable
E760014
2 ft
MISC
9-pin female “D” connector (DB9F)
E620048
1
MISC
9-pin male “D” connector (DB9M)
E620049
1
MISC
DB9 backshell assembly
E620050
2
MISC
Case Top Shell
E100166
1
MISC
Case Bottom Shell
E100167
1
MISC
2.1mm DC Barrel plug
E620032
1
MISC
KRC2 Manual
E740047
1
The following ICs are packed on a piece of black foam for their protection:
E580012 J310 E610013 programmed PIC16F877A microcontroller chip E600036 MAX1406 E600049 UCN5891A E600048 TPIC6595 E620017 40 pin socket
5
Firmware Requirements
To use the KRC2 with a K2 or K2/100 transceiver, you will need K2 main microcontroller firmware revision 2.01 or later and either the KIO2 or KPA100 options.
Note: The main K2 microcontroller is U6 on the K2 Control board. To check your firmware revision, hold any K2 pushbutton when powering up the K2. When you release the pushbutton, the revision will be shown on the LCD (left side).
Assembly
i
A fine-point, temperature-controlled soldering iron (700-800 degrees F maximum) is required to assemble the printed circuit board. A higher-wattage iron or one with a wide tip may damage components, pads, or traces. We also recommend the use of a Panavise (or equivalent bench vise) and an illuminated magnifying glass to facilitate PCB and connector assembly. Additionally, flush-cut wire cutters are recommended for steps where component leads must be cut close to the circuit board.
i
To avoid soldering conflicts, install components only in the order described below.
Double-check all values before soldering, since removing parts from double-sided printed circuit boards can be difficult.
i
The leads on small capacitors can be fragile. When handling capacitors in the
following steps, do not pull on the leads or bend them excessively.
Locate the KRC2 PCB and identify the top and bottom sides. The side of the board with outlines of ICs U4-U7 and most other components is the top; the side with the "KRC2" label is the bottom. If an assembly step does not specify top or bottom, the component should be installed on the top side.
Install the two 0.1-µF (104) capacitors with 0.1" (2.5 mm) lead spacing on the top side of the board:
__C25, __C60
Solder C25 and C60. Trim the leads of C25 as short as possible, using flush-cutters if available. If the leads are not kept very short, they will interfere with installation of J5 on the bottom side of the board.
6
On the top side of the board, install the 0.01 µF (103) capacitors with 0.1" (2.5 mm) lead spacing listed below, beginning with C28 in the upper center of the board and proceeding in a line to the end of the board. After installing each capacitor, bend the leads outward to hold it in place. The capacitors line up so that you can solder them in one step after inserting them into the circuit board. You may solder the components in smaller groups if desired.
Note: When multiple items appear on one line in a component list such as the one below, complete all items on one line before moving on to the next, as indicated by the small arrow. (In other words, install C28 first, then C29, C30 and C31, then go to the second line.)
__C28, __C29, __C30, __C31, __C32, __C33, __C34, __C35, __C24, __C23, __C22, __C21, __C44, __C45, __C46, __C47, __C48, __C49, __C50, __C51
Solder the fixed capacitors. After soldering the leads of the capacitors, be sure to flush trim the leads so that terminals J6, J8, J10 and J12 will seat properly on the bottom side of the PCB when they are installed later in these instructions.
On the top side of the board, install the small 0.01 µF (103) capacitors with 0.1" (2.5 mm) lead spacing listed below, beginning with C36 in the upper right of the board and proceeding to the end of the board. After installing each capacitor, bend the leads outward to hold it in place.
__C36, __C37, __C38, __C39, __C40, __C41, __C42, __C43, __C52, __C53, __C54, __C55, __C56, __C57, __C58, __C59
Solder the small fixed capacitors. After soldering the leads of the capacitors, be sure to flush trim the leads so that terminals J7, J9, J11 and J13 will seat properly on the bottom side of the PCB when they are installed later in these instructions.
Install the three remaining small 0.01 µF (103) capacitors with 0.1” (2.5mm) lead spacing listed below on the top side of the PCB:
__C7, __C16, __C17
Solder the small fixed capacitors.
Note: For all remaining assembly steps, you should solder then trim component leads after installing each group of components unless otherwise instructed. Leads can be trimmed before or after soldering, but trim them as short as possible.
7
Install the two 33pF ceramic disk capacitors on the top side of the PCB. Note that the lead spacing for C1 and C2 may be too wide for the holes in the PC board. If so, use a pair of needle­nose pliers to crush the ceramic ‘flash’ which covers the leads up close to the body of the capacitor and then re-bend the leads so they fit the available holes and scrape away the crushed flash debris.
__C1, __C2
Install the following 0.1µF (104) capacitors with 0.2” (5.0mm) lead spacing on the top side of the PCB:
__C13, __C14, __C20, __C26, __C27
Install the following 0.001µF (102) capacitors with 0.2” (5.0mm) lead spacing on the top side of the PCB:
__C3, __C4, __C5, __C6
Install the following miniature inductors on the bottom side of the circuit board. The components should be mounted vertically, with one end resting on the pc board and the lead of the other end bent down into the corresponding solder pad. You should also alternate the orientation of the RF chokes, with L1 and L3 mounted towards the left and L2 mounted to the right. Then solder and trim the leads.
__L1 100µH Inductor, (brn-blk-brn) __L2 100µH Inductor, (brn-blk-brn) __L3 100µH Inductor, (brn-blk-brn)
Install L4, a 15µH miniature inductor (brn-grn-blk) on the top side of the PCB.
Install C18, a 120pF (121) capacitor, with 0.1” (2.5mm) lead-spacing on the top side of the PCB.
Install C19, a 56pF (560) capacitor, with 0.1” (2.5mm) lead-spacing on the top side of the PCB.
Install the following 0.001µF (102) capacitors with 0.2” (5.0mm) lead spacing on the top side of the PCB:
__C8, __C9, __C10, __C11
8
Install the following resistors on the top side of the circuit board. Be sure to use the 4.7k 1/4 watt resistor at R12. The smaller 1/8 watt resistor will be used later.
__R1 47k, (yel-vio-org) __R3 1k, (brn-blk-red) __R4 470 ohms, (yel-vio-brn) __R6 10K (brn-blk-org) __R7 10K, (brn-blk-org) __R8 10K, (brn-blk-org) __R9 100 ohms, (brn-blk-brn) __R10 10K, (brn-blk-org) __R12 4.7K, 1/4 watt (yel-vio-red) __R13 47 ohms, (yel-vio-blk)
Install two 1N4007 diodes D4 and D5 on the top side of the board. Make sure the cathode (banded end) of the diodes follow the same orientation as that silk-screened on the PCB then solder and trim the leads. D5 must be flush-trimmed on the bottom side in order not to interfere with J5. Be sure to save these cut leads for later use as ground jumpers.
__D4, __D5
Install the following 1N4148 diodes on the top side of the board. Make sure the cathode (banded end) of each diode follows the same orientation as that silk-screened on the PCB, then solder and trim the leads.
__D6, __D7, __D8, __D9, __D10
i
Before handling ICs and transistors, touch an unpainted, grounded metal surface.
Install voltage regulator U3 (78L05C) on the top side of the board as indicated by its outline. The voltage regulator has a 3-pin TO-92 package, like a transistor. The installed height of the regulator must be no more than 3/8" (9 mm). Use a minimum of soldering time (1-2 seconds per lead).
Locate the four pushbutton switches. One of these will now be installed on the top side of the board. Insert the switch into its mounting holes at S1, spreading the legs slightly so they will properly engage the holes. Press the switch down until it is fully seated on the bends in its leads. When the switch is fully seated, there will be a slight gap between the switch body and PCB. This is normal. Solder the switch onto the circuit board from the bottom side.
9
Note: The pin 1 end of ICs can be identified by a notch or dimple as shown in Figure 1. This end must be oriented toward the notched end of the component outline.
Pin 1
Notch
Pin 1
Dimple
Figure 1
Install the following ICs on the top side of the board. Orient the notched or dimpled end toward the notched end of their PCB outline (pin 1 end, to the left). Double-check the orientation before soldering. Be sure to flush-trim the leads of each IC after soldering so as not to interfere with cables on the bottom side of the board.
__U4 UCN5891A __U5 UCN5891A __U6 TPIC6595 __U7 TPIC6595
Install the rectangular Green LED at DS1 on the top side of the board. Spacing the LED about 1/8” (3 mm) above the board will nicely align the top of the LED with the case top. The dot marked on the PCB next to DS1 indicates the placement for the longest lead of the LED.
Visual Inspection: Using a magnifying glass, examine the entire board for unsoldered pins, solder bridges, broken leads, or backward diodes or ICs. Reheat any suspect joints This simple check could save you hours of troubleshooting later.
The following components will be installed on the bottom side of the circuit board. Turn over the circuit board to install the components.
Install 1N4007 diodes at D2 and D3 on the bottom side of the PCB. Make sure the cathode (banded end) of the diode matches the silk-screened outline on the PCB.
__D2, __D3
Install a 4.7k, 1/8 watt (yel-vio-red) resistor at D1 on the bottom side of the PCB. The resistor replaces a small diode that was previously used in this position.
10
Install 10k, 1/4 watt resistors (brn-blk-org) at R2 and R11 on the bottom side of the PCB.
__R2, __R11
Install the 40-pin IC socket at U1 on the bottom side of the board. The notched end should be oriented toward the notched end of the PCB outline (pin 1 end, to the left). Solder just two corner pins. If the socket is not sitting completely flat against the PC board, reheat these two pins one at a time, pushing the socket down until it snaps into position. Then solder the remaining pins of the socket.
Install U2, (MAX1406CPE or LT1039CN16) on the bottom side of the PCB. Orient the notched or dimpled end toward the notched end of their PCB outline (pin 1 end, to the left). Double-check the orientation before soldering. There is no need to trim the leads of U2.
Install resistor network RP1, 390 ohms (391), 8 pins, on the bottom side of the PCB. This resistor network is symmetrical and can be installed in either orientation, but for consistency you should orient it with the pin 1 end (black dot) toward pin 1 of the PCB outline (round pad, also labeled "1").
Install resistor network RP2, 47k (473), 8 pins, on the bottom side of the PCB. This resistor network should be oriented with the pin 1 end (black dot) toward pin 1 of the PCB outline (round pad, also labeled "1").
Install low-profile crystal X2 on the bottom side of the PCB. This is a
short
16.289 MHz device. Make sure it is flat against the board before soldering. Use a minimum of solder so that it does not wick through and cause a short on the opposite side of the PCB..
Locate the ground pad near X2. Insert a discarded component lead through this pad, then fold it over the top of X2. Solder this lead at the ground pad, then solder it to the crystal can. Avoid overheating the crystal.
Install electrolytic capacitor C15 (10 µF) on the bottom side of the PCB. The (+) lead of C15 must be installed in the hole marked "+". The (+) lead is usually longer than the (-) lead. The (-) lead is identified by a stripe on the body of the capacitor.
Install transistor Q1 (J310) as indicated by its outline on the bottom side of the PCB. The installed height of the transistors must be no more than 3/8" (9 mm). The top of Q1 must be no higher than the top of C15. Use a minimum of soldering time (1-2 seconds per lead).
11
Install the subminiature DPDT slide switch S5 on the bottom side of the PCB. Make sure the switch is firmly seated against the board when soldering. After installing the switch, move its handle to the position closest to J2.
Install a 16-pin dual-row header at W1-W8 on the bottom side of the PCB. The short pins are inserted into the PCB. The header must be firmly seated against the board when soldering.
Install a 16-pin dual-row header at W12-W19 on the bottom side of the PCB. The short pins are inserted into the PCB. The header must be firmly seated against the board when soldering.
Locate the remaining 16-pin dual-row header. Cut the header into three pieces so that you have one 8-pin dual row header, a six-pin header and a 2-pin header. This is best done using diagonal cutters. Cut the header on the side, then bend the portion to be cut off away from the rest of the header. The two pieces should snap apart somewhat cleanly. Discard the 2-pin header.
Install the 8-pin dual-row header at W20-W23 on the bottom side of the PCB. The short pins are inserted into the PCB. The header must be firmly seated against the board when soldering.
Install the 6-pin dual-row header at W9-W11 on the bottom side of the PCB. The short pins are inserted into the PCB. The header must be firmly seated against the board when soldering.
Locate the shorting headers. Install 14 shorting headers on the dual-row headers W9-W19 and W21-W23 by plugging them onto the header pins. Do not install a jumper at W20 at this time.
Install electrolytic capacitor C12 (220 µF) on the bottom side of the PCB. The (+) lead of C10 must be installed in the hole marked "+". The (+) lead is usually longer than the (-) lead. The (-) lead is identified by a stripe on the body of the capacitor.
Install the DC barrel jack (J3) on the bottom side of the PCB.
Install J2, a male PC-mount DB9 connector on the bottom side of the PCB. This position is next to the side of the PCB. The connector will “snap” into the board as its mounting tabs “grab” the board. Be sure you have installed the MALE connector (with pins) before soldering the connector pins onto the board.
Figure 2
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