KBT2 Manual
Contents
1. l l 7 Black oS Figure 3 Connecting and Testing the Battery CAUTION Never connect the negative lead of the battery to the top cover speaker or other hardware since this may defeat the reverse polarity protection mechanism O Turn the K2 off and remove any power supply or battery connected to the DC power jack J3 O Use a DMM digital multimeter on a 20 or 30 volts DC scale to verify that the battery connector is wired as shown in Figure 3 In the next step you ll plug the battery connector into P3 on the RF board Be prepared to remove the connector immediately if you see or smell smoke or if battery wiring becomes hot to the touch The 2 5 resettable fuse F1 and shunt diode D12 protect the transceiver and battery in the event that you plug in the battery connector backwards When the fuse is in the tripped state high resistance a current of about 100 mA will continue to flow through the fuse until you disconnect the battery and plug it in correctly DO NOT INTENTIONALLY CAUSE A SHORT OR REVERSE POLARITY CONDITION TO TEST THE FUSE Plug the battery connector into P3 O Set the K2 s internal voltmeter switch S1 on the control board to the 12 V position O Turn on the K2 If power does not come on you may have plugged the battery connector in backwards tripping the resettable fuse on the RF board The fuse will be warm to the touch if it has been tripped Unplug the battery connect2. 4 40 hex nut Foam pad 050 5 0 13 6 2 15 cm O Identify all of the components in the kit using the parts list below If anything is missing or damaged contact Elecraft Qty 1 2 1 30 cm 2 60 cm 4 4 10 cm 2 2 2 2 2 1 O Turn the K2 off and disconnect any power supply or battery connected to the DC power jack J3 Remove the six screws identified in Figure 1 from the K2 top cover then remove the cover itself Note that screws 3 and 4 are removed from the side panels leaving two 2 D fasteners attached to the top cover Figure 1 U Disconnect the speaker There are two extra screws nuts and lock washers in the top cover between the speaker and the rear panel Remove these now They will be used to secure the battery bracket U Remove the bottom cover Install and solder the 2 pin male header at P3 as shown by its outline on the right hand edge of the RF board P3 must be oriented so that its plastic polarizing tab is towards the front panel O If you have a field test version of the K2 revision XC you ll need to install the self resetting fuse and shunt diode A separate instruction sheet has been provided for this modification Battery Bracket K2 Top Cover Figure 2 Refer to Figure 2 for the following steps O Lay the top cover upside down with the rear panel facing away
3. 7 5 19 cm RED 12 30 5 cm U Strip 1 2 12 mm of insulation from each end of the above wires Refer to Figure 3 for the following steps Wrap the leads of the 6 2 ohm resistor around the leads of the SB530 diode as shown in Figure 3 Detail B The resistor should be positioned as close to the diode as possible to insure that the heatshrink tubing will fit over the assembly in a later step The resistor s leads should be just long enough to wrap around the diode leads O Verify that the banded end of the diode is positioned away from the resistor before proceeding O Wrap and solder one end of the 3 7 5 cm red wire to the anode of the diode at the right end of the diode resistor assembly as shown in Detail B Clean up any protruding wire strands that might tear the heatshrink tubing O Solder the other end of this wire to a FAST ON terminal Flow solder into the cylindrical part of the FAST ON avoiding the plastic insulator Do not connect the diode resistor assembly to the battery terminal at this time U Wrap and solder one end of the 7 5 19 cm red wire to the cathode of the diode banded end When working with a heat gun or other source of heat in the following steps be sure to stay well away from the battery flammable liquids etc The diode resistor assembly should NOT be attached to the battery at this point in the installation O Slip a 2 length of heatshrink tubing over the diode r
4. 250 mA tapering off to about 30 mA as the battery comes up to full voltage This eliminates the need for a current limited power supply for charging You can remove the diode and resistor if you plan to use a two step lead acid battery charge controller Faster recharging is possible in this case CAUTION If you connect an external battery or a power supply of other than 14 0 V to the K2 you must disable the internal battery using the battery on off switch Otherwise the external battery or low voltage supply will charge the internal battery to an inadequate voltage greatly reducing the internal battery s life Keep the battery connected to the charging operating power supply whenever possible and recharge it immediately when you return from field operation Up to 16 hours may be needed to bring the battery up to full capacity depending on the depth of discharge Storing the battery in an uncharged state will quickly reduce its life due to sulfation Self discharge shelf life is only about one year at room temperature Temperature Extremes The life of a lead acid battery will be much shorter if the battery is stored or operated at high temperatures For example the self discharge shelf life will be cut about in half if the battery is stored at 35 C 95 F versus 20 C 68 F Do not use the battery if the ambient temperature is below 10 C 14 F or above 50 C 122 F If the ambient temperature is above 33 C 90 F
5. from you O Install the battery cutoff switch in the top cover The switch terminals should be oriented to the right as shown in Figure 2 corresponding to the INT BATTERY ON label on the rear panel O Secure the switch with two 4 40 x 3 8 9 5 mm pan head Phillips machine screws black 4 lock washers and 4 40 nuts Before tightening the hardware align the switch slide with its hole in the panel O Remove the two rear most 3 8 9 5 mm screws lock washers and 4 40 nuts from the speaker The lock washers and nuts will be used in a later step Insert 1 4 6 mm screws into the two holes and through the fibre washers O Two hex male female standoffs are used to secure the front edge of the battery bracket Figure 2 Detail A Install the hex standoffs onto the two 1 4 6 mm speaker screws installed in the previous step O Place the battery in the position shown inside the top cover The terminal must be to the left O Lay the 2 x 6 5x15 cm foam pad on top of the battery O Install the battery bracket over the battery and foam pad securing it with the two 4 40 screws four 4 40 nuts and 4 lock washers removed in a previous step Do not over tighten the hardware since this may warp the top cover or strip the threads of the standoffs The battery bracket should be seated flat on the cover at all four points Cut the following lengths of insulated wire BLACK 7 18 cm __ RED 3 7 5 cm RED
6. ELECRAFT KBT2 INTERNAL BATTERY OPTION Installation and Operating Instructions Revision A July 19 1999 Copyright 1999 Elecraft All Rights Reserved Introduction The KBT2 rechargeable battery option allows convenient operation of the Elecraft K2 transceiver during power outages or in the field without the need to connect an external battery The 2 9 amp hour battery can handle the K2 s full 10 12 W maximum power output although QRP levels 5 W or less will provide greater battery life When a suitable power supply is connected to the K2 14 0 V the battery can be recharged whether the rig is in use or turned off The internal battery kit includes a recessed battery disable switch This switch must be set to the OFF position whenever an external battery is used as well as when the K2 is transported For protection from shorts or polarity reversal of the internal battery the K2 includes a self resetting fuse and shunt diode Conservatively rated components and gold plated connectors are used to insure reliable operation under field conditions To provide physical stability the battery is held firmly in place in the top cover of the K2 by a custom 060 aluminum bracket Specifications Battery Type PowerSonic PS 1229 2 9 AH sealed rechargeable lead acid Dimensions 7 01 x 1 34 x 2 52 inches 178 x 34 x 64 mm Life gt 5 years standby float service with occasional full discharge Temp range 10 to 50 C 14 to 122 F Ch
7. arging Requirements Voltage 13 8 14 2 VDC measured at K2 s DC power jack J3 Time 12 16 hours typ depending on discharge condition Operating time Receive only gt 20 hours receive current 150 mA or less Transceive 6 12 hours typ 150 mA receive 5 W transmit transmit duty cycle 20 Weight 2 5 Ibs 1 1 kg including battery bracket and all components Battery not included in model KBT2 X Installation CAUTION The battery is supplied charged To prevent shorts during assembly cover the terminal of the battery with tape immediately after removing it from the shipping box Part Number Source PS 1229 PowerSonic 100077 Elecraft V701 13 SS 05 Q C K WM5224 Digikey WM2111 Digikey WM2305 Digikey SB530CT ND Digikey P6 2W 2BK ND Digikey A0907 Digikey C2040B Digikey C2040R Digikey 37101 Digikey 67014 Digikey 8714K Digikey Olander Olander Olander Olander Elecraft Description 2 9 AH rechargeable battery K2 internal battery bracket SPST power slide switch 2 pin male header 0 156 4 mm gold 2 pin female housing 0 156 4 mm gold crimp pin gold shottky diode 5 A Resistor 6 2 ohm 2 W 5 FASTON terminal 20 AWG stranded wire black 20 AWG stranded wire red 3 8 cm cable tie Heat shrink tubing 0 25 6 4 mm OD 0 25 6 4 mm 4 40 thd hex M F standoff 4 40 x 3 8 9 5 mm machine screw black 4 40 x 1 4 6 mm machine screw black 4 internal tooth lock washer
8. esistor assembly as shown in Detail B Position the tubing so that it completely covers all exposed wiring at either end CJ Shrink the tubing using a heat gun If a heat gun is not available you may use a cigarette lighter or match Remember to stay clear of the battery O Position the diode resistor assembly between the battery and speaker as shown in Figure 3 O Solder the free end of the 7 5 19 cm red wire to the right hand terminal of the battery switch O Solder one end of the 12 30 5 cm red wire to the left hand terminal of the battery switch U Solder one end of the 7 18 cm black wire to a FAST ON terminal Do not connect the black wire to the battery terminal yet O Solder the free end of the black wire to a female crimp terminal O Solder the free end of the 12 30 5 cm red wire to a female crimp terminal O Insert the wires with the crimp terminals into the female connector housing battery connector as shown at the left side of Figure 3 Verify that the black wire is on the left with the plastic nubs on the housing facing down 1 Connect the FAST ON terminal on the black wire to the terminal of the battery Connect the FAST ON terminal at the end of the diode resistor assembly to the terminal of the battery O Use cable ties to secure the red and black wires at approximately the locations shown in Figure 3 T NES 1 2 Red
9. ge reading is starting to dip below 10 V on transmit you should reduce power output and recharge the battery as soon as possible The K2 uses a low dropout 8 V regulator and will operate down to 8 5 V if necessary but discharging the battery below 10 V will reduce battery life When operating in the field we recommend setting a fairly low current limit level using the CAL CUR calibration function This is available only with firmware revision 1 02 and up When the current limit is reached when transmitting you ll see a HI CUR warning the LCD and power will be scaled back as needed Often this happens when your antenna changes impedance due to wind etc or if you change bands and forget to re tune your antenna tuner The current limiting feature will prevent excess drain until you figure out what happened Charging You can recharge the battery and operate the K2 from the same power supply simultaneously Even if the K2 power switch is in the OFF position the battery continues to charge as long as the power supply is turned on For charging purposes the power supply must be set for 14 0 V 0 2 V as measured at the transceiver s DC input jack 13 7 0 2 V as indicated by the K2 s internal voltmeter which includes the drop across D10 Voltages slightly lower or higher than this can be used but battery life may be reduced The 6 2 ohm resistor supplied with the battery limits charge current to a safe level typically
10. keep the K2 out of direct sunlight since the temperature inside the cabinet can be much higher If you frequently recharge the battery at other than room temperature you ll need a temperature compensated power supply or charger 14 0 V can be used from about 10 to 35 C 50 to 95 F A higher charge voltage is required at lower temperatures and lower voltage is needed at higher temperatures Consult Elecraft if you have special charging temperature requirements Shipping the K2 With the Internal Battery Installed Anytime the K2 is transported with the battery installed be sure that the battery disable switch is in the OFF position This will prevent power up of the transceiver in the event that the on off switch is inadvertently depressed Before shipping the K2 by any method consult the shipper to be sure that they can safely accommodate battery powered equipment 10 1 Notes Elecraft www elecraftcom 831 662 8345
11. or and review the instructions above before continuing O Tap the DISPLAY button on the front panel The voltage E should be around 12 V if your battery is charged The reading will be about 0 2 V lower than the battery voltage itself due to the drop across the diode in series with the battery The current i should be between 100 and 250 mA depending on your menu settings 1 Plug in your power supply charger at 13 The voltage shown on the K2 display should now read between 13 6 and 14 0 V which is the acceptable range of charging voltages for the internal battery The reading will be about 0 2 V lower than the power supply voltage itself due to the drop across the K2 s reverse polarity protection diode D10 U Re install the top and bottom covers Figure 1 Using The Internal Battery Operating Considerations With a full charge the 2 9 AH battery will power the K2 receiver continuously for over 20 hours at 150 mA see the K2 manual for current reduction strategies Transceive mode operating time at 5 W CW is about 6 to 12 hours depending on how well the antenna is matched whether you re mostly listening or calling CQ etc To extend operating time use the lowest practical transmit power If you use 5 W or less exclusively you can wind T4 differently to further reduce transmit current drain refer to the K2 manual You should check battery voltage often using the K2 s built in digital voltage meter If the volta
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