ELECRAFT K3 User manual

ELECRAFT®K3
HIGH-PERFORMANCE 160 –6METER
TRANSCEIVER
KXV3 INTERFACE OPTION
INSTALLATION INSTRUCTIONS
Rev B, October 30, 2007
Copyright © 2007, Elecraft, Inc.
All Rights Reserved

2
Contents
Introduction...............................................................................................................................................3
Customer Service and Support............................................................................................................................3
Technical Assistance.......................................................................................................................................3
Repair / Alignment Service.............................................................................................................................3
Preventing Electrostatic Discharge Damage ............................................................................................4
How ESD Damage Occurs..................................................................................................................................4
Preventing ESD Damage..................................................................................................................................... 4
Preparing for Installation..........................................................................................................................5
Tools Required....................................................................................................................................................5
Parts Included......................................................................................................................................................6
Installation Procedure...............................................................................................................................7

3
Introduction
The KXV3 Interface provides a separate receive antenna input and output, inputs and outputs for use with an
external transverter, and a buffered i.f. output. Complete details for using the KXV3 are included in the K3
Owner’s manual. This manual covers the installation of the KXV3 Interface option in your K3 transceiver.
Only a few basic hand tools are needed (see page 5) to perform the installation. No soldering or wiring is
required.
Customer Service and Support
Technical Assistance
You can send e-mail to [email protected] 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-
662-8345. 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 turn around 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.
Elecraft 1-Year Limited Warranty
This warranty is effective as of the date of first consumer purchase. 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.
What is covered: During the first year after date of purchase (or if shipped from factory, date product is shipped to
customer), 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 us
for warranty repair, we 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.

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Preventing Electrostatic Discharge Damage
There is no climate or work location where the components of your K3 are safe from Electrostatic Discharge
(ESD) unless you take specific steps to prevent such damage. Many of the components in your K3 can be
damaged by static discharges of only a few volts: far too little for you to notice. It is those low-voltage but
destructive discharges that easily happen anywhere and under virtually any environmental conditions.
ESD damage may not be apparent at first. The damaged components may not fail completely. Instead, the
damage may result in below-normal performance for an extended period of time before you experience a total
failure.
How ESD Damage Occurs
Whenever an object containing a static charge touches a circuit in your K3, current will rush into the circuit until
the components reach the same voltage as the source of the static charge. If the voltage or current that passes
through a component during that brief period exceeds its normal operating specifications, it may be damaged or
destroyed.
Preventing ESD Damage
ESD damage cannot occur if there is no voltage difference between the components in your K3 and any object
that touches them. That is how anti-static packaging works. Anti-static bags allow the static charge to flow over
their surface, so that any part of the bag that touches the components inside are all at the same potential at all
times. Anti-static foam keeps the leads of sensitive components at the same potential.
At your work bench, avoiding a dangerous voltage is achieved most easily by tying everything together and
connecting them to a common mains safety ground. This includes your K3, individual boards or other sensitive
components as well as everything they may touch at the work table.
Inexpensive static dissipating work mats are readily-available that will steadily and safely drain off any charges
built up on parts or circuit boards placed on them. They are supplied with a lead that connects the mat to the
common workbench ground. Also, metal cabinets on test equipment used on the bench should be tied together
and connected to the common ground.
Most importantly, you must have a way of continuously draining off any static charges that occur on your body.
Such charges are easy to create, even while sitting quietly at the work bench. Moving your feet on the floor,
shifting position in your chair or even moving your arms so that clothing rubs against itself can produce
destructive static charges. You can discharge yourself by touching an unpainted metal ground, but that will last
only until you move in a way that produces a new static charge. The safest technique is to wear a grounded wrist
strap with a series 1-megohm resistor that continuously drains off any charges. Such wrist straps are readily-
available and inexpensive.
WARNING
DO NOT attach a ground directly to yourself without a current-limiting resistor as this poses
a serious shock hazard. A wrist strap must include a 1-megohm resistor to limit the current
flow. If you choose to touch an unpainted, metal ground to discharge yourself, do it only
when you are not touching any live circuits with your other hand or any part of your body.
We strongly recommend you take the following anti-static precautions (listed in order of importance) to avoid
trouble:
•Leave ESD-sensitive parts in their anti-static packaging until you install them. The packaging may be a
special plastic bag or the component’s leads may be inserted in conductive foam. Parts which are
especially ESD-sensitive are identified in the parts list and in the assembly procedures.

5
•Wear a conductive wrist strap with a series 1-megohm resistor. If you do not have a wrist strap, touch a
ground briefly before touching any sensitive parts to discharge your body. Do this frequently while you
are working. You can collect a destructive static charge on your body just sitting at the work bench. DO
NOT attach a ground directly to yourself as this poses a serious shock hazard.
•Use a grounded anti-static mat on your work bench.
•If you choose to use a soldering iron to work on your K3 for any reason, be sure your iron has an ESD-
safe grounded tip tied to the same common ground used by your mat or wrist strap.
Preparing for Installation
Tools Required
1. #0 and #1 size Phillips screwdrivers. To avoid damaging screws and nuts, a power screwdriver is not
recommended. Use the screwdriver that best fits the screw in each step.
2. Wrench to remove jack screw nuts on the K3 back panel. 3/16” nut driver recommended.
3. Small diagonal cutters.
4. Small needle-nose pliers or tweezers to position small parts.
5. Soft cloth or clean, soft static dissipating pad to lay cabinet panels on to avoid scratching.
The following tools are strongly recommended:
1. ESD wrist strap.
2. Static dissipating work pad.

6
Parts Included
The following parts should be included in your kit. Check to ensure you have them all. If any parts are damaged
or missing, contact Elecraft for replacements (see Customer Service and Support, page 3).
ILLUSTRATION DESCRIPTION QTY.
ELECRAFT
PART NO.
XV3 Printed Circuit Board Assembly
ESD Sensitive. 1 E850244
XV3 Connector Panel 1 E100224SS
KXV3 TMP Cable Assembly 1 E850292
Screw, 4-40, 1/2” (13 mm) 2 E700030
Lockwasher, 4-40, inside tooth 2 E700010
Nut, 4-40 2 E700011

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Installation Procedure
SPECIAL NOTE FOR K3 KIT BUILDERS: If you were directed here by the K3 Kit
Assembly Manual to install your KXV3 Module, inventory the parts in this kit then begin installation at
the step indicated on page 9.
Disconnect power and all cables from your K3.
Remove the nine screws to free the top cover as shown in Figure 1. After the cover is open, lift it gently to
reach the speaker wire connector. Unplug the speaker then set the top cover aside in a safe place.
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REMOVE 9 SCREWS
HOLDING TOP COVER. TO OPEN COVER, PRESS HERE TO TILT FRONT EDGE UP OR PLACE UNIT
ON ITS SIDE FEET, THEN TIP FARTHER SO THE TOP COVER SWINGS OPEN.
Figure 1. Removing K3 Top Cover.
CAUTION: Touch an unpainted metal ground or wear a grounded wrist strap
before touching components or circuit boards inside the K3. See Preventing ESD Damage on
page 4 for more information.

8
Remove the four jack screw nuts with their lock washers and the two black pan head screws from the KIO3
rear panel as shown in Figure 2.
REM
O
VE THE F
O
UR JA
C
K
SC
REW NUT
S
AND LOCK WASHERS
REMOVE
4-40 SCREW
REMOVE
4-40 SCRE
W
SPACE RESERVED
FOR KXV3 MODULE
Figure 2. Removing KIO3 Panel.
With the back cover of the KIO3 removed, remove the upper Remote I/O daughter board holding the
RS232 and ACC connectors as shown in Figure 3. Only the upper daughter board need to be removed. The
lower Audio I/O interface board may be left in place.
CAUTION: The Remote I/O daughter board is ESD sensitive. Put it in a safe place until you
reinstall it.
ESD SENSITIVE!
USE A THIN KNIFE OR
BLADE SCREWDRIVE
R
TO PRY THE BOARDS
APART TO SEPARATE
THE CONNECTOR.
DO NOT PULL ON THE
CONNECTOR SHELLS.
THE SHELLS MAY
COME OFF OF THE
CONNECTORS.
Figure 3. Removing the KIO3 Remote I/O Daughter Board.
Tilt the top of the KIO3 Main board toward the front panel gently so the standoff at the top clears the lip on
the rear panel, then use the standoff at the top to lift up on the board while rocking it from side to side to unplug
the connector.
CAUTION: The KIO3 Main board is ESD sensitive. Put it in a safe place until you reinstall it.

9
Remove the blank panel covering the space for the KXV3 module (see Figure 2). This panel will not be
replaced.
Turn the K3 upside down and remove the bottom covers (see Figure 4).
SEE NOTE
SEE NOTE
SEE NOTE
NOTE:
THESE THREE SCREWS
A
RE 1/4" (6.4 mm) LONG
AND HAVE INSIDE TOOTH
LOCK WASHERS UNDER
THE SCREW HEADS.
ALL THE OTHER SCREWS
A
RE 3/16" (4.8 mm) LONG
AND HAVE NO LOCK
WASHERS.
REMOVE ALL THE
SCREWS INDICATED
AND LIFT THE
BOTTOM COVERS
OFF.
Figure 4. Removing the Bottom Covers.
SPECIAL NOTE TO KIT BUILDERS: If you were directed here to install your KXV3
module as part of the overall kit assembly, begin with the following step.
Cut jumpers W1 and W2 on the RF board (the large board filling the bottom of the chassis). These jumpers
are located under where you just removed the KIO3 boards (see Figure 5). Take care to identify the correct
jumpers. Do not cut nearby jumpers W20 or W21! It is not necessary or desirable to unsolder the jumpers.
Simply cut them with your diagonal cutters, taking care not to lose the bits of the jumper wire inside the K3, but
be sure to cut the ends short. No more than 1/8” (3 mm) of jumper should be left at each solder pad to avoid the
possibility of its shorting to a nearby circuit.
ESD SENSITIVE!
REAR PANEL
KEY AND PADDLE JA
C
K
S
CUT JUMPERS
W1 AND W2
Figure 5. Locating Jumpers W1 and W2.

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Inspect the white connector at the end of the TMP cable. The side nearest the connector holes must be
smooth and flat. Use your diagonal cutters or a hobby knife to cut away any bumps or ridges (see Figure 6 ).
TRIM AWAY ANY RID
G
E
S
OR BUMPS TO PROVIDE
A FLAT, SMOOTH SURFACE
Figure 6. Preparing TMP Cable for Installation.
CAUTION: The KXV3 board is ESD sensitive. Wear a grounded wrist strap or touch an unpainted
metal ground before handling it.
Remove the KXV3 board assembly from its packaging. If the black panel is mounted on the assembly,
remove it. Set the screws and washers aside to be installed later.
Fit the TMP coaxial connector onto J87 on the KXV3 board assembly (see Figure 7).
Thread the square connector on the TMP cable through the gap between Q3 and the side of the RF board,
then plug the KXV3 board assembly into J66 on the RF board with the four BNC connectors facing out through
the rear panel (see Figure 7). The pins will just clear the top of J66 when the BNC connectors are up against the
top of the opening in the rear panel.
PLUG COAXIAL
CONNECTOR
INTO J87
ROUTE CABLE
TO UNDERSIDE
OF RF BOARD
INSERT PIN
S
ONLY PART
WAY INTO
J66
CABLE PASSES
BETWEEN EDGE
OF BOARD AND
KIO3 BOARD
Figure 7. Mounting KXV3 Board.
Push the connector pins into J66 only as far as needed so the holes in the KXV3 connector bushings are
aligned with the holes in the back panel as shown. These connectors do not fully mate and the bushings hold the
board away from the rear panel. .

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As you install components and reassemble your K3, be sure all the screws are in place
and secure, but do not over tighten them. Failure to tighten all screws may result in poor
shielding of sensitive components, resulting in possible noise or birdies in the receiver as well
as other difficult-to-trace problems.
Mount the KXV3 rear panel over the BNC connectors using two 4-40 1/2” (13mm) black pan head screws
through the corner holes with #4 inside tooth lock washers and 4-32 nuts on the inside as shown in Figure 8. Do
not fully tighten the nuts yet.
Figure 8. Mounting Hardware.
Adjust the depth the KXV3 board connector mates J66 on the RF board so the KXV3 connector panel is
parallel with the back panel. The pins on the KXV3 board connector do not go all the way into J66 as shown in
Figure 9.
ESD SENSITIVE!
TYPICAL CONNECTO
R
POSITION WHEN
INSTALLATION
COMPLETE
Figure 9. Typical Connector Fit.
Tighten the screws and nuts holding the KXV3 to the back panel that you installed earlier (See Figure 8) .

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Route the coaxial cable from the KXV3 board to connector P86 on the bottom of the RF board as shown in
Figure 10. Mate the connector to P86 as shown. If the connector does not appear to fit, check to make sure there
are no plastic ridges on the side toward the RF board (see Figure 6).
ESD SENSITIVE!
FROM K3XV
BOARD
P86 ON THE
RF BOARD
ORIENT CONNECTOR
AS SHOWN
Figure 10. Routing KXV3 Cable to P86.
SPECIAL NOTE TO KIT BUILDERS: If you were directed here to install your KXV3
module as part of the overall kit assembly, installation of the KXV3 module is complete. Return to the K3
Kit Assembly Manual where you left off.
Replace both bottom covers using the 4-40 black pan head screws you removed earlier. Note that three
locations take the 4-40 1/4” (6.4 mm) black pan head screws with lock washers as shown in Figure 4, while the
remainder are 4-40 3/16” (4.8 mm) screws . Be sure to replace these screws in the correct locations. Make sure
all the screws are secure, but do not over tighten them/
CAUTION!
Failure to replace the three 1/4” (6.4 mm) screws with their lock washers in the
locations shown in Figure 4 may destroy power transistors in your K3!

13
Check the KIO3 board and ensure the screws holding the two standoffs are tight. Also check to ensure the
connector on the Audio I/O daughter board is fully mated with J91 on the KIO3 Main board (see Figure 11).
BE SURE THE
CONNECTOR
S
ARE FULLY
MATED
Figure 11. Check KIO3 Audio I/O Board Mating.
Replace the KIO3 Main Board with the Audio I/O daughter board attached in the K3 as shown in Figure 12.
The Audio I/O board fits just over the KXV3 board assembly and the TMP cable passes through the space
between the edge of the KXV3 board and the KIO3 board. Ensure the KIO3 connectors are fully mated so the
standoffs line up with the holes in the rear panel.
BE SURE CONNECTORS
ARE ALIGNED WITH
ALL PINS ENGAGED
WHEN BOARD IS
FULLY SEATED
TILT BOARD JUST
ENOUGH FOR THE
STANDOFF TO CLEAR
THE LIP ON THE REAR
PANEL
KXV30 BOARD
ASSEMBLY
Figure 12. Installing KIO3 Main Board.
Install the KIO3 Digital I/O daughter board as shown in Figure 13. Be careful to support the KIO3 main
board as shown while pressing the daughter board in place.
ESD SENSITIVE!
SUPPORT THE KIO3
MAIN BOARD WHILE
PRESSING THE
DIGITAL I/O BOARD
IN PLACE.
BE SURE THE PINS ARE
PROPERLY ALIGNED AND
THE CONNECTORS ARE
FULLY MATED
Figure 13. Installing the KIO3 Digital I/O Board.

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Install the KIO3 rear panel as shown in Figure 14.
4-40 3/8" (9.5 mm) BLACK
PAN HEAD SCREW
(NO WASHER) IN
EACH CORNER
BE SURE AUDIO JACKS
ARE ALIGNED WITH
PANEL CUTOUTS
USE A 4-40 SPLIT
LOCK WASHER UNDER
EACH JACK SCREW NUT
(4 PLACES)
KXV3 INTERFACE OPTION
(IF INSTALLED)
Figure 14. Mounting the KIO3 Rear Panel.
Hold the top cover above the K3 and plug the speaker wire into P25 on the KIO3 board at the left rear of
the K3 as shown in Figure 15.
TO SPEAKE
R
ORIENT
CONNECTOR
AS SHOWN
KIO3 BOARD
IN BACK LEF
T
CORNER OF
CHASSIS
Figure 15. Connecting Speaker Cable.
Position the top cover on the K3. Note that the tab on the back center goes under the rear lip of the K3 rear
panel. Secure the top cover with the nine 4-40 3/16” (4.8 mm) black flat head screws you removed earlier.
REPLACE ALL THE SCREWS!
The K3's chassis has excellent rigidity despite its light weight. The screws that hold the top
cover in place are an important part of the structural design. Please be sure to replace all the
screws and verify they are tight whenever you replace the cover or other panels
Reconnect power and antenna (or dummy load) to your K3 and turn it on. Enable your KXV3 interface
using the CONFIG menu as described in the Owner’s Manual.
This completes the installation of the KXV3 interface in your K3 transceiver.