K2 up-to-date assembly sequence?

[Etienne Ali]

Hi! I'm about to build a K2 with options and upgrades, with the intent to
build an up-to-date K2 as if it just got ordered from Elecraft.
The updated K2 manual rev. F on the official website introduces changes not
covered by the upgrade documents I have (C88 and
K2ExtremelyStrongSignalMod.pdf for example).
 
I wonder what is the safest, easiest, most efficient way to go about
building my kit and options.
My goal is to do things right the first time, avoid risky rework, and have
on hand precise official instructions.
 
Which documentation should I follow to acheive my goal?
What is the recommended module assembly sequence?
 
Here is some details on what I have on hand.
K2 kit S/N 3801 bought october 2003, and some upgrades bought recently :

RF board rev. B
Front Panel board rev. B
Control board rev. B
PLL stability thermistor upgrade kit.
MCU firmware 2.03D and 2.04p
K2IOC firmware rev. 1.07 and 1.09.

options bought october 2003, and some upgrades bought recently:


KIO2 board rev B with AUX2 board rev B.
KAT2 control board rev. C, with firmware rev 1.06 and 1.07
KDSP2 versions 3.0 and 3.1 with DSP module 3.8 on board rev. C
KNB2 board rev. E with firmware rev 1.02

Documentation hardcopies shipped with kits from Elecraft:

Owner's manual rev. E, feb 16, 2003
manual errata rev. E-4, june 4, 2003
PLL upgrade instructions (thermistor board) rev. B, april 25, 2003
revision 2.03 firmware, inst. and ref. manual, rev. E, feb 27, 2003
revision 2.04 firmware, inst. and ref. manual, rev. H, feb 3, 2004
keying modification instr., rev. A, feb. 3, 2004
KAT2 antenna tuner, ass. and oper. instr., rev. D, march 22, 2001

KAT2 antenna tuner, manual errata D-1
KIO2 aux I/O module, ass. and oper. instr., rev. B, july 16, 2001
KIO2 manual errata, rev. B-1, march 6, 2002
KSB2 SSB adapter, ass. and oper. instr., rev. C, may 2, 2000

KSB2 manual errata, rev. C-5, aug. 7, 2003
KDSP2 internal DSP and real-time clock, ass. and oper. instr., rev. A-1.
june, 2003

KDSP2 manual errata, rev. A-2 for manual rev. A-1, feb. 4, 2004
KNB2 noise blanker, ass. and oper. instr., rev. D, aug 20, 2002
KBT2 internal battery, inst. and oper. instr., rev. A, july 19, 1999
MH2 microphone, ass. and oper. instr., rev. B, feb. 13, 2003

 
Note: This must be an FAQ that the answer varies with individuals and
evolves as Elecraft and builders come with mods that become official. I just
wished there were a system where you type in your serial number, kits you
have with their revision numbers, and that system offers you the possible
upgrades and the recommended assembly sequence.
 
Thanks for your guidance,
 
Etienne Ali,
VA2SSS
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[Don Wilhelm-2]

For those wanting to build a post 3000 SN K2 to the latest level without
going through the interim steps of building as instructed FIRST and THEN
adding the changes to bring it up to level...
You already have a Rev E manual - go to the Elecraft website and download
the REV F manual and print pages 20, 49, 52, 54, 56 and page 110.  You may
want to print the schematics and parts list too, but not mandatory.

If you don't have the keying waveshape mod instructions already, download
that too and print page 3.

Now make the following modifications to your Rev E manual:

1) Following page 19 - add the sheet from page 3 of the keying waveshape mod
(do only the 1st instruction step from the mod page - the rest of the steps
are covered on the Rev F manual page) and insert page 20 from the Rev F
manual. (this is the major part of the keying waveshape change)
2) Page 47 of the Rev E manual Last step of the 2nd column, delete RP3 and
replace it with the steps on page 49 from the Rev F manual. (this adds the
thermistor board for the PLL stability mod).
3) Page 49 of the Rev E manual (last step) - delete this step and do the
steps shown on page 52 from the Rev F manual - NOTE the trace indicated in
step 1 will NOT be cut on your RF board, so make this cut.  (This adds C88,
RFC15 and C91).
4) Page 54 of the Rev E manual next to the last component - change D36 from
a 1N4007 to a 5082-3081 (fragile glass diode) - this completes the keying
waveshape change.
5) Replace page 56 of the Rev E manual with the contents of page 59 from the
Rev F manual (this adds the strong signal handling changes).
6) - optional - Replace page 110 of the Rev E manual with the contents of
page 113 from the Rev F manual.
7) - optional - Replace the parts list and the schematic pages of the Rev E
manual with the parts list and schematic information from the Rev F manual.

Now you have the instructions to build a K2 to the latest level - Happy
Building.
In addition to the K2 kit you have in hand, you will need parts from the PLL
temperature stability mod kit, the keying waveshape mod kit, a 68 pf
capacitor for C88, a 100uH minature choke for RFC15, a .001 capacitor for
C91 and 2 - 1N4148 diodes for D40 and D41.

You should compare the Rev E manual with the Rev F manual and verify for
yourself that I have not missed anything.  All I can say is that I have gone
through these steps for a customer with an unbuilt 37xx SN K2 and everything
performed as advertized.

The firmware levels needed to support these changes are MCU 2.04p or above
and IOC 1.09 and above.

Of course, another way to approach it (the safe way) is to build to the Rev
E manual with the errata that was shipped with your kit and then apply the
changes after it is built according to the instructions for each change.  In
either case you will end up with a current level K2.  Other than the 2 trace
cuts that are being made at the factory, the boards are the same.

73,
Don W3FPR


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