UTR-KPA500Amateur Radio Linear Amplifier

ELECRAFT  KPA500 500-W ATT AMPLIFIER OWNER’S MANUAL Draft, March 3, 2011 Copyright © 2011, Elecraft, Inc. All Rights Reserved 2 Contents Key to Symbols and Text Styles............................................................................................................... 3 Installation ................................................................................................................................................ 4 Operation .................................................................................................................................................. 7 Power On ..................................................................................................................................................... 7 Band Switching ............................................................................................................................................ 8 Transmitting ................................................................................................................................................. 8 Monitoring ................................................................................................................................................... 9 Fault Conditions ..........................................................................................................................................10 Menu ...........................................................................................................................................................11 Firmware Updates................................................................................................................................... 12 Specifications.......................................................................................................................................... 13 Customer Service and Support ............................................................................................................... 14 Theory of Operation ............................................................................................................................... 15 3 Key to Symbols Abbreviations and Text Styles Important – read carefully Operating tip T E M P Tap switch function (labeled above a switch) P K H O L D Hold switch function (labeled below a switch; hold for 1/2 sec. to activate) LED Light Emitting Diode LCD Liquid Crystal Display 4 Installation The following text uses braces to refer to numbered elements in the front- and rear-panel illustrations below. For example, {1} refers to 1 , the RF OUTPUT connector. Figure 1. KPA 500 Rear Panel Mains Voltage Settings CAUTION! Do not connect mains power to your KPA500 or attempt to turn it on before setting the fuse block switch and internal jumpers to match your supply voltage as described below; otherwise you may do extensive damage to your amplifier. 1. Check to ensure the fuse block {4} is set for either 120 VAC or 240 VAC to match your mains voltage. The current voltage setting is shown in the red window. If needed, change the fuse block setting as follows: • Open the door covering the fuse block and then carefully pry the red fuse block out of the holder as shown below: • Install the proper fuses in the block. Use 12A fuses for 115V and 6A fuses for 230V. • Replace the fuse block so that the correct mains voltage appears in the window in the cover. 5 2. Set the internal transformer tap for the specific voltage within the 120 or 240 VAC ranges as follows: • Remove the 14 screws securing the KPA500 top cover as shown below. Do not remove the screw indicated. It is part of the safety interlock switch mechanism. Lift the top cover off. • Three taps are provided via red, green and yellow wires. Choose the tap according to the actual mains voltage at the outlet you plan to use for the KPA500. If you cannot measure your mains voltage, use the yellow tap. 115V Nominal Mains TAP 230V Nominal Mains 95V to 105V GREEN 190V to 210V 106V to 115V RED 211V to 230V 115V to 125V YELLOW 231V to 250V • Be sure to place the unused taps side-by-side on the terminals at the back panel as shown. Do not leave them floating loose inside the unit. • Replace the top cover before proceeding. An interlock switch prevents operating the amplifier with the top cover removed. 6 3. Test the power supply voltage output as follows: • Connect the mains supply cable to {15} on the rear panel and plug the cable into the mains outlet. (At this point this may be the only cable connected to the rear panel.) • Position the rear-panel power switch to On (I). • Tap the front panel O N switch. The LCD should light. • Tap the H V switch ({3} on Figure 2) and note the voltage displayed on the LCD. It must be between 65 and 80 volts. If it is outside of this range, immediately tap the O N switch to turn the KPA500 off, and position the rear panel power switch to Off (O). Open the top cover again and select a different transformer tap. If the voltage was too low, select a tap further up the list in the above table. If the voltage was too high, select a tap further down the table. NOTE: If the red FAULT LED lights when you tap the O N switch, that indicates the power supply voltage is above the upper limit. Use a power transformer tap lower on the above table and retry the test. Cabling 1. Connect your station ground to the GND thumbscrew {10}. A good station ground is important for safety and to minimize local radio frequency interference (RFI). 2. Attach the RF INPUT {11} to the output of your driving transceiver or transmitter using a 50 ohm coaxial cable with an PL-259 male connector on the KPA500 end. The driving transmitter must supply up to 40 watts for full output from the KPA500. 3. Attach the RF OUTPUT {1} to a suitable load with an SWR of less than 1.5:1. A dummy load is strongly recommended for initial testing. 4. Connect the PA KEY {8} to the driving transmitter Key Output. This line must be grounded to t…

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1 97.317 (a) 3 Compliance If power input in the restricted frequency range between 26MHz and 28 MHz is detected, the amplifier automatically disables operation. The display shows “INVALID” and no power gain occurs. Toggling the OPER/STBY switch will not resume operation. Reset is accomplished only after the input frequency counter detects that input drive power is no longer in the restricted frequency range. The frequency counter is an integral part of amplifier operation: if the counter is disabled or shows an invalid count, amplification ceases within milliseconds. The frequency counting system is integrated onto the printed circuit board and the control microprocessor. A great deal of technical knowledge and assembly skill would be required to redesign the amplifier to disable this restricted-band lockout without rendering the amplifier useless.

C:\Projects\KPA400\Mechanical\KPA 500 BACK PANEL_SILK_REV A.pcb (Silkscreen & pads)

C:\Projects\KPA400\Mechanical\KPA 500 BACK PANEL_SILK_REV A.pcb (Silkscreen & pads)

KPA500 PC Board Photos Power Amplifier Board Low Pass Filter Front Panel & Control I/O Board Power Supply Power Rectifier Board Power Amplifier (front) Power Amplifier (heat sink side) Low Pass Filter PC Board (front) Low Pass Filter (rear) Front Panel & Control (front) Front Panel & Control (rear) I/O Board (front) I/O Board (rear) Power Supply (front) Power Supply (rear) Power Rectifier Board (front) Power Rectifier Board (rear)

1 ELECRAFT  KPA500 500-W ATT AMPLIFIER OPERATIONAL DESCRIPTION 2 Theory of Operation When the KPA500 is in Operating (OPER) mode, RF is routed by the Transmit-Receive (TR) switch to the Power Amplifier (PA) module where it is amplified by a pair of VRF2933 FETs. The PA module output is routed to the Low Pass Filter (LPF) bank input. The LPF bank provides filters for each frequency band. The frequency of the incoming signal is monitored and the appropriate filter is automatically switched into the signal path. The filter also may be selected by band data provided by the transceiver or by front panel switches on the KPA500. However, the automatic selection based on the incoming signal frequency overrides either of those inputs to ensure the correct bandpass filter is always in the signal path. If power input in the restricted frequency range between 26MHz and 28 MHz is detected, the amplifier automatically disables operation. The display shows “INVALID” and no power gain occurs. Toggling the OPER/STBY switch will not resume operation. Reset is accomplished only after the input frequency counter detects that input drive power is no longer in the restricted frequency range. The frequency counter is an integral part of amplifier operation: if the counter is disabled or shows an invalid count, amplification ceases within milliseconds. The output of the LPF bank is routed to the RF Output via the TR Switch. During receive or when the KPA500 is in Standby (STBY), the TR switch routes the RF Input directly to the RF Output, bypassing both the PA Module and the Low Pass Filter Bank. The MCU in the Display and Control module monitors and makes critical measurements of a number of operating conditions including two levels of fault conditions that automatically alter the operation of the KPA500: 1. If an undesirable, but not critical, fault conditions occurs, a 3 dB attenuator is switched in line with the PA input and the red FAULT LED is blinked at a 1 Hz rate to alert the operator. An example of such a fault is overdriving the KPA500 input. When the fault is corrected, such as reducing the driving power, the 3 dB attenuator is switched out automatically and FAULT light stops blinking. 2. If a critical fault occurs, the amplifier is automatically switched to STANDBY, passing the RF drive directly through to the RF Output. The red FAULT LED is lighted continuously and the fault conditions are displayed on the front panel. 3

Tune Up Procedure The KPA500 is a fixed-tune amplifier. It requires no operator adjustments once set up as described in the Operator’s Manual.

55 44 33 22 11 D D C C B B A A 5 - GND5- GND KEY INALC OUT03 - BAND 1 IN11 - INHIBIT12 - GND07 - ALARM OUT13 - BAND 0 IN08 - POWER ON|OFF IN02 - AUXBUS06 - BAND V (Icom)09 - BAND 2 IN01 - BAND V Ref (Icom)04 - NC05 - GND15 - ALC OUT10 - KEY IN (OPT)14 - BAND 3 IN 2 - RXD OUTDE-9S -> PC6 - NC8 - CTS1 - NC3 - TXD IN7 - RTS4 - NC9 - NC2 - RXD IN9 - NC6 - NC8 - CTS1 - NC3 - TXD OUT7 - RTS4 - NCDE-9P -> K3 Connector keyed at pin 8.Connector keyed at pin 18. 2009112401 C KPA500: I/O Board Elecraft, Inc. Copyright (C) 2009 - 2010.L JohnsonB 11 Friday, February 11, 2011 TitleSize Document Number Rev Date: Sheet of RX1RX2TX1TX2 SBYP FAN2FAN0 FAN3FAN160VEN ALC PWRONBANDV ALCKEYALRMBANDVRBANDVFAN0FAN1FAN2FAN360VENTX2TX1RX2RX1 XBAND2XBANDVXBAND3XBAND1XALRMXPWRONXINHIBIT XALC XALCXBAND0 SBYPFAN3AUX6FAN0FAN2 AUX560VENFAN1 BAND0 INHIBIT ALRM BANDVI PWRONFP BAND1 BAND2 BAND3 KEYALC RX2RX1TX2TX1 XKEY AUX7AUX3AUX1 AUX4AUX0AUX2 AUX1AUX3 AUX5AUX7 AUX0 AUX2 AUX6 AUX4 AUXBUS AUXBUS XBANDVR BANDVRALRM ALRM PWRON SBYP SBYP AUX7 BAND2BAND1BAND0 KEY INHIBIT PWRON BANDVRI BANDVRBANDV BAND3 +5D +5D +12D +5D +12D +5D -12D +5D -12D -12D+12D +5D +12D -12D +5D +5D +12D +12D +12D +5D C30 0.1 uF C21000 pF L7 100 uH L3 100 uH L12 100 uH C16 0.1 uF C23 1000 pF P2DE15P 1510 4 14 93 13 82 12 71 11 65 1617 C19 0.1 uF U274LVC1G34 2 4 53 1 P3DEBUG13579 2468 10 D3BAT54TW 132 456 P1 RS232 14181317121611151019202122 217859634 L19 100 uH R2 1M C11 0.1 uF L6 100 uH Q12N7002K 1 32 L11 100 uH C32 0.1 uF C51000 pF L8 100 uH C36 0.1 uF L2 100 uH D5BAT54 1 3 L4 100 uH C281000 pF +- U3BLM6032 56 7 84 L16 100 uH K1G6K-2P 3 24 6 75 18 R1 1K J1ARCJ-22XX 3 1 C25 1000pF C21 0.1 uF L13 100 uH C15 0.1 uF R9 10K P5FP13579111315171921232527293133353739 2468 10121416182022242628303234363840 C10 0.1 uF C141000 pF C31 0.1 uF L5 100 uH C41000 pF U1 LT1039ACN 12345678 9 10111213141516 V+ R1in T1out R2in T2out R3in T3out V- GNDT3inR3outT2inR2outT1inR1outVCC R8 1M C9 0.1 uF J1BRCJ-22XX 2 1 C31000 pF L10 100 uH D1BAT54TW 132 456 C20 0.1 uF R4100K L1 100 uH L15 100 uH L17 100 uH C17 0.1 uF C27 0.1 uF C29 0.1 uF C12 0.1 uF C60.1 uF C33 0.1 uF R10 1K C35 0.1 uF L9 100 uH R3 100K R6 1M C11000 pF L14 100 uH C8 0.1 uF L18 100 uH C24 1000 pF P4CONTROL13579 2468 10 C13 0.1 uF D2MMBD914 1 3 R5100K R7100R C220.1 uF C18 0.1 uF C70.1 uF C26 1000 pF D4BAT54 1 3 +- U3ALM6032 32 1 84 C34 0.1 uF 55 44 33 22 11 D D C C B B A A 2009110401 C KPA500: Front Panel Elecraft, Inc. Copyright (C) 2009 - 2010.L JohnsonB 19 Friday, February 11, 2011 TitleSize Document Number Rev Date: Sheet of Sheet 3CONDITIONING AN0 60V1 AN1AN2AN3AN4AN5 IPA1 VFWD VREF 60V2 IPA2 SAMPLE FRQIN FRQOUT SWITCHESSheet 9 SCANADC[0..2]PWRSW Sheet 5LED PWMBSCKRXCBMOSIFAULT Sheet 8RPIO AUX[7..0] TXD1 BYPRLY TXD2 ALARM EN60V RXD1RXD2 INHIBIT VREFICOM VBANDICOM KEYIN PWRSW BAND[3..0] FAN[3..0] ALC Sheet 4DISPLAY SCLSDAVLCDBKLTVCONTRAST Sheet 6RFIO1 PABYP 5T EN60V SER RCK 6Mn 5R SRCK 60VMON THS IPA FRQIN VFWD VREF RFDRV OVRDRV 270VMON Sheet 2ALC PWM1PWM2 VFWD nALCCS ALC MOSI SCK Sheet 7RFIO2 6Mn EN60V THS 5R 60VMON IPA 5T PABYP PGDPGCMOSISCKMISO MOSI SCK RCKB PWM5 AN5AN3AN2AN1AN0AN4 60V1IPA1VFWDVREF60V2IPA2 60V1IPA1VFWDVREF THS1FRQIN THS1 THS2PABYPEN60VBEN6M5R5TMOSIRFSCKRFRCKCRFRFDRVRXD1TXD1RXD2TXD2KEYININHIBITBYPRLYEN60VAALARMPWRSWALCBAND[3..0]FAN[3..0]AUX[7..0] THS2 EN60VA AVDD MCLRPGDPGC TXD1RXD1TXD2RXD2 AUX1AUX2AUX3AUX4AUX7AUX0 BAND1BAND0 BAND2BAND3 FAN3FAN2 FAN1 FAN0KEYININHIBITPWRSW VBANDICOMVREFICOM BANDV1BANDV0 BANDV0BANDV1MCLR RCKB PWM4 PWM5 SAMPLE EN60A MISO PIEZO FRQOUTPWM3 SCANADC[0..2] SCANADC0SCANADC1SCANADC2 RFDRV 5TPWM1 PABYPEN6M5R5TEN60VBALCVFWDPWM1PWM2MOSISCKnALCCS AN0AN3AN2AN5AN1AN4 PWRSW PWRSW FAULT FAULT EN6A EN6M EN60BBYRA PABYP EN60VB ALRMAPABA ALARMBYPRLY EN60AEN6APABAEN60BBYRARCKC SAMPLE60V2IPA2 PWM4SCLSDAPWM3 SDASCLALRMA AUX5AUX6 FRQOUTFRQIN BAND0BAND1BAND2BAND3KEYININHIBITAUX1AUX2AUX3AUX4AUX5AUX6AUX7AUX0 OVRDR OVRDRV OVRDR OVRDRV 270VMON 270VMON MOSISCK SCKRF SPIRFERCKC MOSIRFRCKCRF SPIRFE SDASCL MOSISCKRCKBMOSIRFSCKRFRCKCRF PWM1PWM2PWM3PWM4PWM5PIEZO AVDD 5R PWM2PIEZO VCC5 VCC5A VCC5 VCC5 VCC5 12VIN VCC5 VCC5 VCC5 VCC5 VLED VCC5 VCC VDD VSS VCC5 -12VRP12VRP12VINVCC5 VCC5 12VIN MTG10GND 1 R104 120R R97 120R + C15220 uF/16V R55 39K R79 10K U9B 74HC32 45 6 R53 39K TP17SCKRF TP4-12VRP TP21GND R102 120R R54 10K MTG8GND 1 C990.1 uF J1ICD-2 123456 C900.1 uF TP18MOSIRF C640.1 uF R63 10K TP7RCKB TP10SDA TP3PWM4 R9947K + C92 220 uF/16V R73 10K + C5220 uF/16V C880.1 uF R35 39K MTG4GND 1 U9C 74HC32 910 8 C930.1 uF R78 10K C950.1 uF TP1PWM3 TP13SCK TP12+12VTP9SCL TP8PIEZO R88 51R C810.1 uF C5415 pF PZ1BEEPER R98 10K R56 10K MTG9GND 1 R47 39K R101 10K U13 MAX6035 1 3 2 VI GND VO + C3220 uF/16V R100 10K R95 10K R68 330R + C6220 uF/16V R89 10K TP11PWM2 TP14MOSI TP6PWM5 R103 120R TP19VCC5 TP22GND C210.1 uF R87 51R MTG1GND 1 C5515 pF L9100 uH MTG5GND 1 U9D 74HC32 1213 11 D38BAT54 1 3 R96 10K R64 10K R48 39K U11 PIC18LF8722 123456789 10111213141516171819202122232425262728293031323334353637383940 41424344454647484950515253545556575859606162636465666768697071727374757677787980 RH2/A18RH3/A19RE1/WR/AD9 RE0/RD/AD8RG0/CCP3RG1/TX2/CK2RG2/RX2/DT2RG3/CCP4MCLRRG4/CCP5VSSVDDRF7/SSRF6/AN11RF5/AN10/CVrefRF4/AN9RF3/AN8RF2/AN7/C!OUTRH7/AN15RH6/AN14RH5/AN13RH4/AN12RF1/AN6/C2OUTRF0/AN5AVDDAVSSRA3/AN3/VREF+RA2/AN2/VREF-RA1/AN1RA0/AN0VSSVDDRA5/AN4/LVDINRA4/TOCKIRC1/T1OSI/CCP2RC0/T1OSO/T13CKIRC6/TX1/CK1RC7/RX1/DT1RJ4/BA0RJ5/CE RJ6/LB RJ7/UB RC2/CCP1 RC3/SCK/SCL RC4/SDI/SDA RC5/SDO RB7/KBI3/PGD VDD OSC1/CLKI OSC2/CLK0/RA6 VSS RB6/KBI2/PGC RB5/KBI1/PGM RB4/KBI0 RB3/INT3/CCP2 RB2/INT2RB1/INT1RB0/INT0 RJ3/WRH RJ2/WRL RJ1/OE RJ0/ALE RD7/PSP7/AD7RD6/PSP6/AD6RD5/PSP5/AD5RD4/PSP4/AD4RD3/PSP3/AD3RD2/PSP2/AD2RD1/PSP1/AD1 VSS VDD RD0/PSP0/AD0 RE7/CCP2/AD15 RE6/AD14RE5/AD13RE4/AD12RE3/AD11 RE2/CS/AD10 RH0/A16RH1/A17 R108 10K TP15PWM1 R107 10K TP16RCKCRF R74 10K TP20+12VRP TP5GND R94 51R U7ULN2803 12345678 10 9 1817161514131211 IN1IN2IN3IN4IN5IN6IN7IN8VCCGND OUT1OUT2OUT3OUT4OUT5OUT6OUT7OUT8 Y1 16 MHz C860.1 uF U9A 74HC32 12 3 55 44 33 …

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Conducted Emissions Test Results, Elecraft KPA500 Data measured 8 March 2011, Watsonville CA Equipment Used: HP-8595E Spectrum Analyzer, Serial number 3911AO4576 Bird Power Attenuator 8329-300, Serial Number 036 Elecraft K3, Serial number 3604 Yaesu FT-1000MP mkV, Serial Number 1E280376 Amplifier was operating at 500W output for each test on every band (including the 5.3 and 10.1 MHz power-restricted bands). The tests were repeated with the amplifier powered-ON but in Standby mode and again with the amplifier powered OFF. In no case were the conducted emissions higher than those shown for 500W of fundamental power output. 1.8 MHz Band Test Results 3.5 MHz Band Test Results 5.3 MHz Band Test Results 7 MHz Band Test Results 10.1 MHz Band Test Results For completeness, 10.1MHz data measured at the 200W US output limit 14 MHz Band Test Results 18 MHz Band Test Results 21 MHz Band Test Results 24.9 MHz Band Test Results 28 MHz Band Test Results 50 MHz Band Test Results

KPA500 IMD & Linearity Lowest band: 1.8MHz Mid band: 14MHz Highest band: 50MHz Test Date: 10 March 2011 Test Equipment used: HP-8595E Spectrum Analyzer Serial number 3911AO4576 Bird 500 W Dummy Load Elecraft K3 Transceiver, Serial Number 3604 Elecraft K 2-Tone Test Generator Yaesu FT-1000MP mkV Serial Number 1E280376 1.8MHz IMD/Linearity (input) 1.8MHz IMD/Linearity (output) 14 MHz IMD/Linearity (input) 14MHz IMD/Linearity (output) 50MHz IMD/Linearity (input) 50MHz IMD/Linearity (output)

KPA500 Gain Test 3/4/2011KPA500 S/N 003 Test Frequency (MHz)Input PowerOutput PowerGain, dB 1.812550013.01 1.992550013.01 3.512550013.01 3.992450013.19 5.36652950012.37 7.012350013.37 7.292750012.68 10.112750012.68 10.142750012.68 14.012650012.84 14.342650012.84 18.072650012.84 18.162650012.84 21.012550013.01 21.442550013.01 24.902550013.01 24.982550013.01 26.01550.00 27.00550.00 27.99550.00 28.012850012.52 29.693350011.80 50.013450011.67 53.992850012.52 Test Equipment: Elecraft K3 Serial Nr. 3792 , Bird 43 Wattmeter S/N 268821, Bird Dummy load

KPA500 Radiated Emissions Report KPA500 serial number 0000 was tested. Range test equipment: HP8546 spectrum analyzer, Chase 6141 bilog test antenna (receive side). Substitution test side: HP8468A Signal Generator, Chase 6112 bilog antenna. All spurious emissions were better than 20dB below the applicable limits except for one test point, listed below. FundamentalSpuriousEquivalent AmplitudeMargin to SpecificationNotes 52.000MHz104.0MHz-20.6dBm-17.6dBVertical polarization Unit under test with dummy loadUnit under test with dummy load Signal substitution signal generator and 6112 bilog antenna 6141 receive antenna on height-adjustable pole The KPA500 meets the provisions of Part 2.1053 and the limits of Part 97.317 and 97.307. The KPA500 was operated at its rated output of 500W into a non radiating load and tested for radiated spurious emissions per the test procedures of TIA-603- D section 2.2.12. Tests were performed at the Atlas Compliance 10m outdoor test range, FCC Measurement Facility Registration number 90452.