KAT5 InfraRed Upgrades - Installation Guide


Before you start

The following tools are required for fitting the upgrade boards:

  • Pozidrive No.1 Point Screwdriver
  • Wire Cutters
  • Wire Strippers
  • Fine Pointed Nose pliers
  • Fine Tipped Soldering Iron
  • Drill fitted with 6mm Drill bit suitable for Aluminium
Identifying the Parts of the IR Upgrade Kit


Receiver Upgrade PCB

Transmitter Upgrade PCB

Receiver Connector Harness

Transmitter Connector Harness

Components and screws supplied with kit.

Overview of the upgrade process:

Fitting the Infrared Upgrade boards is a fairly straightforward task that involves the following steps. The procedure for both the Transmitter and Receiver upgrades is similar, the main difference being the connection points for the interface connector.

  1. Removing the existing PCB
  2. Fitting/Replacing 1 or 2 components
  3. Preparing the interface connector
  4. Connecting the interface connector
  5. Fitting the upgrade PCB
  6. Reassembling the unit

1.       Removal of the existing PCB from the case:

  • Remove two screws from the bottom of the case and remove the lid.
  • Remove four screws holding the PCB into the bottom of the case.
  • Remove the two end panels from the PCB.
  • Drill a 6mm hole in the connector end panel to the right of the RJ45 socket to accommodate the 3.5mm jack socket as shown below.

2.       Fitting/Replacing components

Receiver PCB

The existing KAT5 receiver PCB requires two small component changes before the connector harness is connected.

  • Resistor R902 needs to be changed from 1Kohm to a Zero Ohm link

  • The existing Capacitor C603 needs to be removed from the PCB and replaced by an identical 470uF capacitor laid flat against the PCB. Ensure correct polarity.

Transmitter PCB

The existing KAT5 transmitter PCB requires one resistor to be fitted before the connector harness is connected.

  • The vacant location for Resistor R902 needs to be fitted with a Zero Ohm link

  • The video termination resistor mounted on the rear of the SCART socket (highlighted in yellow) may need gently bending over if it stands higher than the top of the SCART socket to avoid fouling on the upgrade PCB.

3.       Preparing the Interface Connectors

You will see that the interface connector contains 4 pairs of identically coloured wires, Orange, Brown, Blue and Green. Thes must be lightly twisted together along their length before being soldered to the main PCB as shown below.

Twisted Harness

When connecting the wires to the PCB, approximately 8-10mm of insulation should stripped from the end of the wire and the strands should be twisted neatly so that there are no strands overlapping otherwise the wire will not fit through the holes in the PCB. Don't strip the wires until you are ready to connect them.

Be VERY careful if you decide to "tin" the wires before inserting into the PCB.
They may not fit through the holes if you apply too much solder!

4. (TX)  Connecting the Transmitter Interface Connector

NOTE: You should already have fitted Resistor R902 shown in blue on the overlay below.

The wires from the interface connector are connected to the points shown above.

  • Orange Wires to the top end of the markings for R602 and R605
  • Brown Wires to the top end of the markings for R608 and R611
  • Blue Wires to the top end of the markings for R502 and R505
  • Green Wires to the top end of the markings for R508 and R511
  • Purple wire to the top of the marking for C502
  • Black wire to the bottom of the marking for C502
  • Red wire to the top of the marking for J902
  • White wire to the middle of the marking for J902
  • Yellow wire to the bottom of the marking for J902
Once the harness is connected the Transmitter board should look like this

4. (RX)  Connecting the Receiver Interface Connector

NOTE: You should already have replaced R902 and C603 shown in blue on the overlay below.

The wires from the interface connector are connected to the points shown above.

  • Orange Wires to the top end of the markings for R303 and R306
  • Brown Wires to the top end of the markings for R403 and R406
  • Blue Wires to the top end of the markings for R103 and R106
  • Green Wires to the top end of the markings for R203 and R206
  • Purple wire to the top of the marking for C203
  • Black wire to the bottom of the marking for C203
  • The Red, White and Yellow wires are connected to a 3 pin socket.
  • Remove the existing jumper link (if fitted) from the header pins
  • Fit the 3 pin socket to the header ensuring that the RED wire is to the top of the board
  • If the header pins are not fitted, cut the 3 pin socket off the harness and solder the Red, White and Yellow directly to the PCB in the same way as for the Transmitter.
Once the harness is connected the Receiver board should look like this

5.       Fitting the Interface board

  • Looking at the lid of case you will see that one end of the case has several moulded ribs around one end. This is the end of the case that the upgrade PCB should be fitted to.
  • The interface board is fitted to the lid of the case with two M3 screws.
  • Make sure you fit the correct upgrade board into the KAT5 unit !!!

6.       Re-assembling the unit

  • Fit the 3.5mm jack socket to the hole in the connector panel ensuring the panel is the correct way round.
  • Refit the KAT5 PCB into the bottom of the case remembering to fit the metal end plates first. The SCART socket should be at the ribbed end of the case. Take care not to overtighten the fixing screws.
  • Attach the interface connector to the upgrade PCB ensuring that the orange wires are adjacent to the jack socket wires
  • Replace the lid ensuring that no wires are trapped when closing the case and refit the two case screws
Your KAT5 units should now work as detailed in the InfraRed Upgrade User Guide


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This page last updated : 1st November 2004