Kenwood TS-430S PLL Board.

After getting thru most of the alignment I’ve moved onto the PLL.  The board appeared to be in good shape visually but after doing the first initial checks at TP1 I realized there was a problem.  After carefully removing it I noticed a small gouge on the edge of the board which had broken trace connectivity.  I repaired that with a small bit of foil and solder.  I also realized that the caps had been replaced by the previous owner with larger volt caps which normally doesn’t cause an issue except the fit was too tight and smaller 10V caps are of preference on this board so they fit nicely.  I continued on after removing the caps and ordering parts from Mouser to replace the large 50V rated caps with the 10V.  So more waiting.

After replacing the caps and a complete the alignment the TS-430S now works at least as well as it did new.

Kenwood TS-430S Clicking on Transmit Problem TX

After doing some initial testing on the Kenwood TS-430S project cleaning up the IF board issues I had been getting 100 watts on some of the bands.  Suddenly last night during a test I noticed the radio would begin clicking and resetting.  After a bit of head scratching and doublechecking power going into the radio I finally traced it down.  The molex connector at the rear wasn’t making a good connection.  I used some needle nose pliers and some deoxit and solved the problem.  A quick fix to a problem is always good.

 

Kenwood TS-430S IF Board Repair

07/14/2011 – After removing the IF board from the TS-430 I could see some issues right off hand.  The top site of the board was realitivly clean although I noticed some excess thermal compound on the regulators which gave me a hint that this IF board had been repaired at some point.  Getting it out I could see lots of oxidation, burn traces at one of the regulators and at least one connect that had ripped the traces from the board.  Tonight I cleaned up much of the board tested all the diodes on the rear of the board, and repaired the 5V traces.   At this point the radio seems to work but I don’t have very good recieve and it still only transmits on some bands.  On the bands it does transmit on it does full output which is a good sign.  I’ll be working on the IF board for the next few days as its in bad shape on the rear side.

07/18/2011 – Well thus far, I have replaced the traces on the 5V regulator with jumpers as the eyelets were missing and that area of the board wasn’t in very good shape.  I also located a burnt or gouged trace which will need repair.  A missing eyelet was found on Connector 10 and I ended up glueing the connector to the board and replacing the trace with a wire.  After looking at the board from the top I’ve noticed several missing caps.  I expect someone has tried to repair this board and during checking cold solder joints they may of pushed the caps off the board without noticing.

07/19/2011 The gouged trace has been repaired.  Now the IF section seems to be working at least a stage or two away from the audio section.  I ended up with a TX issue which was a bad connection at the molex connector which slowed progress on the IF board issues.

 

 

 

 

Kenwood TS-430S Rebuild.

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07/13/2011 Most of my spare time for the next few months will be spend refurbishing a Kenwood TS-430S HF Radio.  At this point the unit doesn’t have any RX or TX so it should be a challenge to get everything back into working order.

07/13/2011 Considering the radio’s age I started with basically taking it apart to see if any visible damage could be seen.  My main goal is to ensure the PA is good and perform some modification to ensure it stays that way.

 

While I had the PA removed, I checked all the LFP relays cleaning and testing each one.  The best way I’ve found to do this is to use contact cleaner and a pieces from a paper bag. Looking at the PA it appears to be in good shape.  The first order of business was to remove all old solder with suction and wick.  I removed the rivets and replaced with Z wires to ensure a long lasting connections to the PA transistors.  One thing to make sure is to make sure the mica insulators are retained during removal.  I did a complete cleaning of the board and sink.  I replaced the aging thermo compound.  A big problem I found was the fan was not connected. After replacing the wire and testing the fan worked.  I know that I want to modify the turn on temp but I’ll do that later.  I tested the transistor connections to make sure no shorts and that everything was ok.  Next order of business was to ensure I had good connections on all the board connectors.  Deoxit was used and I discovered a connector that was not connected to the correct place on the IF board.  After getting it all back together I turned the unit on with all the settings in Alignment position.  Care was taken to make sure the CAR was on lowest setting.  I can now receive and on most bands I now see 95-100 watts of power to a dummy load.  RX doesn’t seem to be very sensitive as I can’t tune in anything. TX seems to work on some bands to the full power.  On other bands the radio seems to have a problem.  As increase of the CAR while TX it pulls the voltage down and the radio resets clicking the relays along with it.

I tore deep into the radio and started alignment.  The boards had some oxidation on them.  I’ve decided while I have it apart to go ahead and replace all oxidized “lytics” just to ensure once back together it’ll last another 15-30 years.   I normally don’t like digging deep into a non-working device always afraid of making it way much harder to troubleshoot existing problems. I’ve noted some questionable solder joints on all boards and did a tedious cleaning of the traces.  The speaker connector from the IF board to the lid was badly damaged.  I managed to replace it with a computer switch header lead which works nicely on all the board connections.  While I’m waiting on caps to begin arriving for the values I don’t have in hand, I’ll be cleaning up the solder joints and testing connections on each board.  During alignment I also noticed that the RIT control isn’t working at all and no signal is present at the test point.  I’ll retest after cleaning it up and soldering.

07/14/2011 Well sourcing caps will take some time unless I can find a ready made list of values and sizing.  If anyone has such a list please let me know.  Otherwise I’ll come up with one as I go and post here to make it easier on others to repair their TS-430S .

08/08/2011 I’ve been continuing work by section in the posts below. I was able to source caps, as needed, from Mouser and Digikey

Below are other articles which continue the work on the 430S

IF Board

Control Board

PLL Board 

Filter Board

 

08/18/2011  The TS-430S is now completely functional and freshly aligned.  I’ve only made a few contacts on 40 meters but reports were good.

SB710Key – TM-D710A Keyboard Adapter

Prototype boards have arrived.  I’ll be working with these for the next few weeks to hopefully finalize a line powered PS2 keyboard adapter for the Kenwood TM-D710A.  Here are some pics of the proto board.07/14/2011 – UPDATE waiting on some missing parts to arrive in mail.

07/20/2011 – All parts arrived except for the osc. It’s on backorder for at least two weeks.

07/29/2011 – Still no osc.  I’m researching alternatives.

08/05/2011 – Finally located something that should work.  2 week leadtime on this part so more waiting.

11/30/2011 – I ‘ve assembled and tested the few boards I had left and due to limited application of this I will be doing some sort of open source release of the project in December for those that want to build one of these and improve the software.

OSW 1.0D Kit TM-D710A keyboard adapter.

05/02/2011  07:12 AM – The order for the 1.0D board has been processed and passed design checks with manufacture.  We all should see boards from the group buy in the next 3-4 weeks hopefully.  Parts have already arrived.  I’ll be posting more information and documentation during those long 3-4 weeks of waiting here.  I recommend to everyone to use an AVR platform for MCU development an interface but you are welcome to use what you want.  The goal is to end up with something that is under the 100ma current of the MIC interface. Read more…

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