Warrior Linear Amplifier Model HA-10 HEATH COMPANY - BENTON HARBOR, MICHIGANAssembly land Operation of the ass “WARRIOR” LINEAR AMPLIFIER MODEL HA-10 HEATH COMPANY, ENTON HAREOR, ICHIGAN TABLE OF CONTENTS Circuit Description. . . 3 Bchematic,...¢seseeeeceeeseesee | oF Construction Notes. eee |e Parts List... Sern eS Proper Soldering Technique: ee dat Step-By-Step Procedure............ | 9 Step-By-Step Assembly...........2. | 10 Testing... Repnoone = | ies Cabinet Installation. .............. | 29 Installation, 6.62... 66 80 Operation........44 32 Bibliography......... 2. ae | In Case Of Difficulty. ...... - [4 ‘Troubleshooting Chart; .. . ~ | 38 Service Information, 36 38 37 87 38 ‘*Fold-owt from page, All prices are subject to change without notice. The Heath Conipany reserves the right to discontinue instruments and to change specifications at any time without incurring any obligation to incorporate new features in instruments pre viously sold. eee shonePage 2 eS SPECIFICATIONS Driving Power Required:. , Maximum Power Input. «44+ Output Impedance:, . Input Impedance,........ ‘Panel Controls: . INTRODUCTION With the increasing popularity of single-side- ‘and, suppressed-carrier phone transmission a5 a mode of amateur commmicstion, more amateurs are finding it possible to run higher transmitter power inputs than they could pre- viously afford with conventional AM equipment, Since high-level modulating equipment is not necessary in single-sideband service, the cost of converting to high power is considerably re- duced, Jn keeping with this trend toward higher power in single-sideband service, the HEATHKIT "Warrior," Model HA-10 Linear Amplifier was 50 to 75 watts, depending on frequency. SSB - 1000 watts PEP, CW = 1000 watts. AM 1 "400 watts (600 watts using controlled carrier modulation). RITY- 650 watts, 50 to 75 ohms variable pi network output efreuit, Approximately 70 ohms, Broadband input cir- cuit requires no tuning. 80, 40, 20, 15, 10 meters, 0-200 ma grid current, 0-100 ma plate current, 0-200 volt plate voltage. 0.1000 relative power. ‘Band Switch ‘Tuning Meter Switch Loading Relative Power Sensitivity Power-On-Oit High Voltage-On-of 4 811A 2 - 866A Filament, bias, 1500 V DC plate supply, and blower ~ self-contained, 1250 watts maximum, 117 volts, 50/60 cycles. 19-1/2" wide x 11-5/8" high x 16" deep. 90 Ibe, 100 Ibs, designed to provide high power capability and complete versatility. Nearly any of the popular SSB, CW, and AM exciters available today can be used as e driver for this amplifier. ‘The amplitier RF compartment is completely enclosed by perforated steel shielding. This type of construction increases amplifier sta- bility and greatly decreases radiations that could cause TVL The amplifier is forced-air cooled to promote longer tube life, ‘Unique built-in cirouitry provides a constant RF sampling output to a monitoring scope, re- gardiess of frequency.Page 3 CIRCUIT DESCRIPTION SHIGH-VOLTAGE POWER SUPPLY ‘The high-voltage supply consists of the plate transformer, fall-wave 886A rectifiers, swing- ing choke input filter, oil-filled capacitor, and 8 60 KR bleeder resistor. Frequently, well designed power supplies using conventional values of electrolytic eapacitors in the filter network have been found to make vio- lent voltage excursions as loads are suddenly applied or removed, These voltage excursions are Imown as the dynamic regulationcharacter- Asties of the power supply. In a linear amplifier, poor dynamic regulation results in lower peat power output and increased distortion products, To assure good dynamic regulation, this power supply incorporates an 8 fd oil-filled capacitor and a filter choke that "swings" between 50 and 5 henrys, from no load to full load, This type of ‘choke is used to keep the filter inductance near ‘the critical value for all load conditions, In order to remove the high DC voltage from the swinging choke, the choke is connected between ‘the plate transformer center tap and chassis ground, INPUT CIRCUIT ‘The four 8114 tubes are connected in parallel in a cathode driven, or grounded grid, Class B configuration. Driving power is coupled to the ‘lament circuit of the 811A tubes through two .O1 uid ceramic capacitors, To keep the fila~ ment~transformer capacity from shunting the RF driving voltage to ground, the filament trans former is isolated from the input cireuit by a broadband filament choke. The plate current return for the 811A tubes is provided by the transformer center tap to ground. Ina grounded grid amplifier, positive feedback is ‘rom plate to cathode through the plate-cathode, or plate-filament, capacitance of the tube. A neutralizing coil is wound on the filament choke and is polarized for negative feedback, The Yoltage ied back through the neutralizing coil balances the voltage fed back through the plate- ‘Wament capacitance. OUTPUT CIRCUIT ‘The output circuit uses a conventional pi net= Work for maximum harmonic suppression and ease of tuning. The plates of the 811A tubes are shunt fed, using an appropriate RF choke, Dlocking capacitor, bypass capacitor, and par- asitic chokes. The tuning capacitor on the in- put side of the tapped inductor ie a 850 upt variable, rated at 2 kv, The loading capacitor on the output of the tapped inductor is a 2- variable with a total capacitance af 874 yf, rated at 1 ky, A fixed 500 uf, 2 kv mica capo, itor is switched in parallel with the 2-gang variable on 40 meters. Another 500 uu, 2 kv saica capacitor is switched in parallel on 80 meters, making a total of 1874 wut, BIAS SUPPLY ‘The bias supply of a class B linear amplifier should be quite "stiff," because any changes in bias voltage, caused’ by the large amounts of grid current drawn by the amplifier, would re- sult in non-linearity. The built-in bias supply consists of the bias winding on the filament transformer, a silicon rectifier, a 5 0 surge resistor, 21000 ufd electrolytic filter capacitor, andthe 119 bleeder resistor. The 4.5 volts de~ veloped result in a bleeder current of slightly over 400 ma. This large amount of bleeder cur~ rent, together with the high-capacity ilter ca- factor, results in a bias supply that is quite sti CONTROL CIRCUIT A notable design feature is the protective switching arrangement for the POWER and HIGH VOLTAGE switches, Since the rectifier tubes require a warmup’ period before high voltage is applied, the POWER ana HIGH VOLT- AGE switches are connected so that both mist be turned ON to apply high voltage, and both awitches must be turned OFF to turn the flament circuits aff, This feature prevents the possfbility of turaing the amplifier aff with the POWER switch alone while leaving the HIGH VOLTAGE switch in the ON position and thus setting up a condition where high voltage AC would be applied to the rectifiers when the POWER switch was again turned ON,#40 351 FILAMENT CHOKE, (= 6 SHEET METAL ‘SCREW x 6-32 x 2°FHMS a-aexd” PHMS 45-52 135 UH PLATE RFC ua e-saxt JSLOT-HEAD SET SCREW 434-42 PHONO SOCKET —2— me 845-53 PARASITIC CHOKE (es eet (he “10 SHEET METAL ‘SCREW - o-32xd BHMs. o-s2x$'BHMs e-a2Kf ALLEN- HEAD SET SCREW © ¥cowrro wor pin ean Tomb 1o+24 NUT — a-32x2 PHMS to-saxd' Tams o-22x 2'RHMS o-24x-ERuws 8-32x2" h FHMS (SLOTTED) | 4 281-1 SPADE ‘BOLT io Fat Ft wagner © WASHER , I 8-32 NUT Cia —38 © 1o-24X7 RESISTOR STUD CONTROL FLAT eeFIBER SHOULDER WASHER y #255-31 PHENOLIC SPACER * 260-23 CERAMIC PLATE CAP io FLAT, C= WASHER 20D #6 SOLDER sea eee CRYSTAL : DIODE 207-3 THICK STEEL WASHER QR CABLE: CLAMP 57-20 #8 SOLDER LUG ‘SILICON RECTIFIER #SLOCKWASHER @ oe a tus #7-2 tle cate eeet la CERAMIC FEED- THROUGH INSULATOR _ o> 466 SMALL SOLDER LUG 2 contRoL LOCKWASHER my op Bir CONTROL SOLDER STANDOFF #260-34 LUG INSULATOR PLATE CLIP ##10 LOCKWASHER ‘#3 LOCKWASHER Se joass-si @ aA Sosa A 205-M275 75-30 NEUTRALIZING LINE CORD #12 LOCKWASHER CAPACITOR PLATE © STRAIN RELIEFCONSTRUCTION NOTES ‘This manual is supplied to assist you in every ‘way to complete-your kit-witt the least possible chance for error, The arrangement shown is fie result of extensive experimentation and trial. 1 followed carefully, the result will be a stable instrument, operating at a high degree of dependability. We suggest that you retain the manual in your files for future reference, both fn the use Of the instrument and for its main- tenanee, UNPACK THE KIT CAREFULLY AND CHECK EACH PART AGAINST THE PARTS LIST, In so doing, you will become aequainted with the parts, eter to the charts and other information onthe inside covers of the manual to help you identify ‘the components. FE some shortage or parts damage is found in checking the Parts List, please read the Replacement section and sup- ply the information called for therein, Include ‘all ingpection slips in your letter to us, Resistors generally have a tolerance rating of 10% unless otherwise stated in the Parts List. Tolerances on capacitors are generally even greater. Limits of +100% and -20% are common for electrolytic capaciters. ‘We suggest that you do the following before work is started: 1. Lay out all parts so that they are renaity available. 2, Provide yourself with good quality tools, Basic tool requirements consist of a screw- river with a 1/4" blade; a small scraw— driver with a 1/8" blade: long-nose pliers; wire cutters, preferably separate diagonal cutters; a pen Inife or a tool for stripping insulation from wires; a soldering iron (oF gun) and rosin core solder. A set of nut drivers and a nut starter, while not necos- sary, willaid extensively in construction of the Jat,‘Most kit builders find it helpful to separate the various parts into convenient ostegories, Muffin tins or molded egg carts make convenient trays for small parts, Resistors and capaci tors may be placed with thetr lead ends in- serted in the edge of a piece af corrugated cardboard until they are needed. Values can be written on the cardboard next to each component, The iIlustration shows one method ‘that may be used. PARTS PART PARTS DESCRIPTION PART PARTS DESCRIPTION No. PerKit Per Kit No. Resistors Chokes-Transformer Tie 1 6,8 KN 1/2 watt YT Filament choke (Biue-gray-red) 1 10-meter coil, 1-200 1 0 20 KR 1/2 watt 1 Mutti-tand eoit (brown-black- orange) 1 Limb RFC 148 1 390.0. 1/2 watt 1138 uh plate RFC (crange-white-brown) 4 Parasitic choke 1s 8 4 OA /2 watt 1 5-50 henry filter choke Gellow-violet-goid) 1 Plate transformer 123° 1 © 22 KQ1 watt 1 Rectifier filament trans~ (Fed-red-red) former 1BS 1 LO RN 2 watt 1 Filament and bias trans- (orowa-biack-orange) former ms 1 2283 (0d-red-gok 1B-21 0 2 =. 202 2 watt ‘Gpphgtt- Terminal Strips Knobe © (red-plack-plac wer 1) faeme gr 8 “vire-wound a1 4s me 2010S watt 431-40 1 4-lug terminal strip BY-7 = 160 Kn 100 watt 481-45 2 Glug terminal strip cea 434-42 1 Phono socket Bes 1 Puot aap socat green capacitors = 1 Pitot lamp socket (red) Spence sat aae tee go eeneeet ce 2-81-4102 ytd dise 480-5. 2 Coaxial jack 2% = 4 L0DS pidge Lay. Beir 2 Pusedpiag = 0 ut 8 kv tubal 86. Small r ee a 462-158 3. Lange imob 21-90. 1.001 pd $ kv disc 462-120 2 Small skirted knob 21-128 2-500 yf 2000 V ativer mica 24-5 1B uf 2 kv oil filled. 25-78. 11000 fd 15 V electrolytic Hardware 26-25 1380 uyf variadl 250-8 18 #5 sheet metal screw 26-78 1487 wut per section, 250-28 1 «6-93. x 1/4" slot-head set- 2egang variable screw 31-35 1180 wut compression mica 250-47 «1-6 -82.x 2" FHMS (flat head with shatt machine screw)Page 6 I PART PARTS DESCRIPTION PART PARTS DESCRIPTION No, Perkit No. Barkit Eandware (Cont'd) Controls-Switehos (250-49 8 3-48 x 1/4” PHMS (pan head 10-118 1 2 KO control machine screw) 61-3 2 DPST toggle switch 250-50 10 10-32 x 3/8" PEMS (Philips 63-253 - Meter switch head machine screw) 63-254. 1 ‘Bend switch 250-51 8 oy ir screw 7 250-56 37 6-32 x 1/4" BHMS (binder leter-Tubes: head machine screw) WT T 1 ma, 50.9 meter 280-89 44 6-32 x 3/8" BEMS (binder 411-130 2 ‘866A tube head machine screw) 411-151, 4 811A tube 250-93 8 8-32 x'1/4" Allen head set- 412-2 2 3 watt, 120 V lamp screw 421-21 2 15 ampere fuse, 3AB 250-126 2 10-82 x 1/2" coe (truss ‘head machine screw) Metal Parts 250-134 12 6-32 x3/4"REMS(roundhead 100-M304F492 machine screw) a. Chassis base 250-137 10 8-82 x 3/8" PHMS (pan head —-203-Mz28F494 machine screw) 1 Front panel 250-152 4 10-24 x 3/4" REMS (round 204-M249 1 Coil mounting bracket head machine screw) 204-M371_ 1 Amplifier tube mounting 250-189 1 10-24 x 7-1/2" resistor stud bracket 250-199 1 8-32 x 2" FEMSneutr: (204-M373 1 ‘Neutralizing capacitor capacitor adjust screw mounting bracket 251-1 16 Bpade bolt 204-M375 2 Filter eapacitor mounting (252-1 8 3-48 nut bracket 252-3 oJ 6-32 nut 205-M271_ 1 Chassis top plate 252-4 15 | 882 nut 205-M272 1 Reciifier tube mountingplate 262-7 6 3/8" control nut 208-M273 1 RF shield top plate (252-28 1 8-32 thambout 205-M274F433, 252-80 10 10-24 nut 1 Eseuteheon plate 252-31. 4 10-24 wing nut 205-M275 2 Neutralizing capacitor plate 252-39 1 1/4 - 32 nut 206-M148 1 RF shield, front section 253-1 24 #8 flat fiber washer 206-M149 1 RF shield, rear section 253-8 8 #10 Mlattiber washer, 1/2"OD 212-M3.— 1 Silver plated strap (253-6 2 ‘¥10 flat fiber washer, 11/16" oD Miscellaneous 253-10 3 3/8" control fist washer 56-4 T Crystal diode 258-16 1 Fiber shoulder washer 31-29 1 Silicon vectifer tee #10 Hat stot wauber, 9/4" 712 1 Cormate feat through oD : insulator 259-27 1 Thtek stool washer M4 1 Ceramle.standott insulator 284-1 118 #6 lockwasher 7-1 45/6" rubber grommet 254-2, 14 ¥8 lockwasher 13-4 2 5/16" rubber grommet. 254-3 9 #10 lockwasher Thed ee ‘Roll of tape 254.4 5 3/8" control lockwasher 78-30 1 Line cord strain relief 254-7 8 #8 lockewasher 1 Line cord 24-14 e #12 lockwasher 1 Cabinet 255-31 4 Phenolic spacer 2 Cable clamp ea ny i. solder lug 2 Ceramic plate cap 256. solder log 4° Spring type plate o 259-5 1 #10 solder Ing 4 Rubber fect - 259-6 2 #6 email solder Jug 266-21 91 Fan blade 259-101 3/8" contro! solder Ing 340-1 1 Length #14 bare wireeS Page 7 PART PARTS DESCRIPTION PART PARTS No Ber Kit Miscellaneous (Cont'a,) DESCRIPTION 348. 1" Length RG-8/Ucoaxiateable 420-8) 1 Motor 453-106 1 Extension ahatt 58-10 38/8" bushing 455-31 21/4" bushing 56-7 1 Shaft coupling 490-6 15/64" Allen wrench 331-8 Solder 595-402 1 = Manual No, Per Kit ‘Miscellaneous (Cont'd. set pe oor) mngth RG-8/U coaxial cable 420-8 1 Motor 453-106 1 Extension shaft 455-10 38/6" bushing 455-31 2 1/4" bushing 456-7 1 Bhatt 490-6 15/64" Allen wrench 381-6 Solder 595-402 1 Manual PROPER SOLDERING TECHNIQUES Only a small percentage of HEATHKIT equip- ment purchasers find it necessary to return an instrument for factory service, Of theseinstru- ments, by far the largest portion of malfinctions are due to poor or improper soldering. i terminals are brightand clean andfree of wax, frayed insulation and other foreign substances, (po difficulty will be experienced in soldering. \.Correetly soldered connections are essential if ‘the performance engineered into a kit is to be fully realized, E you are a boginner with no experience in soldering, a half hour's practice with some odd lengths ct wire may be a worth- ‘while Investment, For most wiring, a 25 to 100 watt iron or its equivalent ina soldering gunis very satistactory. -A lower wattage iron than this may not heat the ‘connection enough to flow the solder smoothly over the joint, Keep the iron tip clean and bright ‘by wiping ‘it from time to time with a cloth, CHASSIS WIRING AND SOLDERING 1. There are several types of wire furninhed with this Kit, Use the type of wire called for in each wiring step, In preparing a Jength of hookup wire, 1/4" of insulation Should be removed from each end wiless directed otherwise in the step, 2, To avoid breaking internal connections when ‘stripping insulation from the leads of trans- formers or similar components, care should ‘taken not to pull directly on the lead, In stead, hold the lead with pliers while tt t= being stripped, a 1 ‘Leads on resistors, capacitors and similar ‘components are generally much longer than ‘they need to be to make the required con- nections. In these cases, the leads shouldbe cut to proper length betore the partis added to the chassis, In general, the leads should tbe just long enough to reach their termin- ating points, ‘Wherever there is aposstbility of baze leads shorting to other parts or tothe chassis, the Jeads. should be covered with insulating Sleeving, Where the use of sleeving is spe- cifically intended, the phrase "use sleeving”” 4g included in the associated construction step, In any case where there is the pos- sibility of an unintentional short cirouit, Sleeving should be used, Extra sleeving 13 provided for this purpose, ‘Crimp or bend the lead (or leads) around the terminal to form 2 good joint without re- Tying on solder for physical strength, If the wire is too large to allow bending or if ‘the step states that the wire is not to be crimped, position the wire so that a good solder connection can still be made, Position the work, if possible, so that gravity ‘will help to keep the solder where you want tt, Place a flat side of the soldering iron tip against the joint to be soldered until it is heated sutficiently to melt the solder. ‘Then place the solder against the hested terminal and tt will immediately flow overPage & ST ‘the joint; use only enough solder to thor- ougily wet the junction, It is usually not necessary to fill the entire hole in the terminal with solder, ‘Remove the solder and then the iron from the completed junction. Use care not to move the ‘leads until the solder is solidified. A poor or cold solder joint will usually look crystalline and have a grainy texture, or the solder will stand up in a blob and will not have adhered to the joint. Such joints should be re- heated until the solder flows smoothly over the entire junction. In some cases, it maybeneces- sary to add a little more solder to achieve a smooth bright appearance, COLD SOLDER JOINT PROPER SOLDER COLD SOLDER JOINT CONNECTION INSUFFICIENTLY CONNECTION CONNECTION MOVED HEATED WHILE COOLING ROSIN CORE SOLDER HAS BEEN SUPPLIED WITH THIS KIT. THIS TYPE OF SOLDER MUST BE USED FOR ALL SOLDERING IN THIS KIT. ALL GUARANTEES ARE VOIDED AND WE WILL NOT REPAIR OR SERVICE EQUIPMENT IN WHICH ACID CORE SOLDER 16 Pesan TuUXES HAVE BEEN USED. TF ADDITIONAL SOLDER IS NEEDED, BE SURE TO PURCHASE ROSIN CORE (60:40 or 50:50 TIN-LEADCONTENT) RADIO TYPE SOLDERaes Page 9 r STEP-BY-STEP PROCEDURE ‘The following instructions are presented in a logical step-by-step sequence to enable you to complete your kit with the least possible con- fusion. Bé sure to read each step all the way through before beginning the specified operation, Also read several steps ahead af the actual step being performed, This will familiarize you with ‘the relationship of the subsequent operations, When the step is completed, check it off in the space provided, This is particularly important as it may prevent errors or omissions, espe- cially if your work is interrupted, Some kit ‘builders have also found it helpful to mark each: lead in colored pencil on the Pictorial as it is added, ‘The fold-out diagrams in this manual may be removed and attached to the wall above your working area; but, because they are an integral part of the instructions, they should be returned to the manual after ‘the kit is completed, In general, the illustrations in this manual correspond to the actual configuration of the (Cyt; however, in some instances the illustra- tions may be slightly distorted to facilitate clearly showing all of the parts. ‘The abbreviation "NS" indicates that a con- nection should not be soldered yet as otner wires will be added. When the last wire is installed, the terminsl should be soldered and the abbreviation "'S" isusedto indicate this, Note that’ a number will appear after each solder instruction, This number indicates the number af Jeads that ‘are supposed to be connected to the terminal in point ‘before it is soldered. For example, if the instruction reads, "Connect a lead to lug 1 (8-2), it will be understood that ‘there will be two leads counectedto the terminal, at the time it is soldered, (Incases whore a lead passes through a terminal or Iug and then con- nects to another point, it will countas two leads, one entering and one leaving the terminal.) ‘The steps directing the installation of resistors include color codes to help identify the parts, Also, if a part is identified by a letter-number designation on the Schematic, its designation wilt appear in the construction step which directs its Installation,Page 10 STEP-BY-STEP ASSEMBLY PINS TAND 4 [ARE LARGE HOLES (Ao AEN Pictorial 1 Refer to Pictorial 1 for the following steps, (_) Referring to Detail 14, mount a tube socket at Vion the amplitier tube mounting bracket, Use 6-32 x 3/4" RHMS, Place a #8 fiber washer on each side of the tube socket and use a #8 aclder lug, instead of 2 lockwasher, on the sorew between lugs 2 and 3, us shown in Pictorial 1, Secure with 8-32 nuts, Take care to properly orient ‘the socket with the large holes at lugs 1 and 4, Center It in its mounting hole before tightening the screws, (/) tn the game manner, mount tube sockets at V2, V3, and V4, wae i Sez= Page 11 6-32 NUT 8 #6 LOCKWASHER 6-32x 3" BHMS Detail 1B . ) Mount 4-lug terminal strip A. Use a 6-32 1/4" BHMS, #6 lockwashers, and 2 6-32 nut as shown’ in Detail 15, Place a lock- washer on each side of the terminal strip mounting foot, and orient the terminal strib as shown in ‘Pictorial 1, Note that lug 2 of this termina) strip is grounded through the mounting foot. | ) Inthe same manner, mount a S-lug terminal strip at location. Orient as shown in Pictorial 1. 1) Cl, Connect a .01 pid dise capacitor be- tween the bottom hole in lug 1 (8-1) and the bottom hole iniug (NS) of terminal strip A. ) C2, Connect another .01 fd dise capacitor between the bottom hole in lug 3 (S-2) and the bottom hole in lug 4 (S-1) af terminal strip A, { ) Comect one end of a length of #14 bare wire through lug 1 of terminal strip A (NS) to lug 1of tube socket V1 ($-1). Use sleeving, Connect the other end af this wire to lug 4 af tube socket V8 (NS), Use sleeving. () Comect one end af 2 length of #i4bare wire through Iug 1 of terminal etrip A (N8)to lug 1 of tube socket V2 (8-1), Use sleeving, Connect the other end of this wire to lug 4 of tube socket V4 (8-1), Use sleeving. Now solder lug 1 (8-4). (/) Connect one end of a length of #14 bare wie through lug 3 of terminal strip A (NS) to lug 4 of tube socket V2 (8-1), Use Sleeving. Connect the other end of this wire to lug 1 of tube socket V4 (NS), Use sleev- ing. () Comect one end of a length of #14 bare wire through lug $ of terminal strip A (NS) to lug 4 of tube socket V1 (8-1). Use sleev- ing, Connect the other end of this wire to lug 1 af tube socket V3 (S-1), Use sleeving, Now solder lug 3 (8-4). ( ) Connect a length of yellowhookup wirefrom tug 8 of tube socket V1 (NS) to lug 3 of tube socket V2 (NS), ( ) Connect a length of yellowhookup wirefrom lug 3 af tube socket V2 (NS) to lug 3 of tube ‘socket V3 (NS). () Connect a length of yellowhookup wirefrom lug 3 of tube socket V3 (NS) to lug 3 of tube socket V4 (NS). {) ©3, Comect a .02 fd dise capacitor from lug 3 of tube socket Vi (S-2) tothe adjacent solder lug (8-1). (+) C4, Connect @ 02 dd disc capacitor from lug 3 of tube socket V2 (NS) to the adjacent solder lug (8-1). () CB. Coect a .02 utd disc capacitor trom lug 3 of tube socket V3 (8-3) tothe adjacent solder lug (8-1). () C6, Connect 2 .02 dise expacitor from lug 3 of tube socket V4 (5-2) to the adjacent solder Jug (NS), () Connect a length of #14 bare wire from lug 2 of tube socket V4 (NS) tothe adjacent solder lug (S-2), ( ) 028, Connect a .01 td dise eapacttor be- tween the bottom hole in lug 1 (S-1) and the bottom hole in lug? (NS) of terminal strip B. ( ) C24, Connect a .01 td dise capacitor be~ ‘tween the bottom hole in lug 3 (S-1) and the ottom holein lug 2 (8-2) af terminal strip B. () L2. Orient the filament choke as shown in Pictorial 1, with the long netralizing lead nearest terminal strip B, Connect one of the lament leads, at thenear endof the choke, to lug! of tube socket V4 (S-2) andthe other filament lead, at the same end of the choke, to lug 4 of tube socket V3 (8-2). { ) Connect one of the filament leads, at the other end of the choke, to lug 1 of terminal strip B (NB) and connect the other filament ead to lug 8 of terminal strip B (NS), () Connect the shorter neutralizing lead tolug 2 of tube socket V4 (S-2). Leave the longer neutralizing lead free at this time, Set this subassembly aside until it is called for later in the instructions,Page 12 NOTE ORIENT sockETS 80. THAT THE LARGE HOLES fl Refer to Pictorial 2 for the following steps, () Locate the rectifier tube mounting plate, Referring back to Detail 14, mount tube sockets V5 and V6, Position the sockets as shown, with the large holes of each socket for lugs 1 and 4, Use small fiber washers on each side of the socket as shown in Detell 1A, tut do not use #6-solder lugs, { } Mount four phenolic spacers, using 6-22 x 3/8" BEMS as shown, IePHENoUc Set this subassembly aside until it is called for SPACER. Tater. a ‘8° eroiet SP Pictorial 3Refer to Pictorial 8 for the following steps, () Mount the chassis top plate to the chassis base as shown in Pictorial 2, Use 6-32 x 3/8" BHMS, lockwashers and nuts, Do not place screws in the mounting holes that ‘will be used for the front and rear RF shield spade bolts, (_) Mount'#6 spade bolts to the front RP shield, Use 8-32 x 1/4" BEMS, #6 lockwashers and 6-82 muts as shown in Pictorial 3. (} Mount the front RF shield to the chassis top plate, using #6 lockwashers and 6-32 nuts, { ) Install 5/16" grommets in holes 1. and HH. ( ) Install 8/8” grommets in holes N and 22, Refer to Pictorial 4 (fold-out from Page 17) for the following steps, () C10, Mount the TUNING capacitor at C, as shown in Detail 44. Use 6-32 x 3/8" BHMS, Place a #10 lat washer between each mounting foot and the chassis top plate, a) 32 we" FMS [COUNTERSUNK FLAT WASHER, "AND NUTS SUPPLIED CORK WasHERS ‘Sores cHasiis 6 SOLDER LUG Detail 4B C9, Assemble and mount the neutralizing capacitor stator plate to the chassis top plate at D, See Detail 4B. The stud supplied ‘with the feed-through insulator is not used, Replace it with a 6-32 x 2" FEMS,Detail 4c () Now assemble the neutralizing capacitor rotor and bracket as shown in Detail 4C. Mount this bracket on the two studs of TUNING capacitor C, Secure only the right side, using a #8 lockwasher and 6-32 nut. «The 10-meter coil will be mounted on the Jeft side Inter.) Notice that the hole in the neutralizing bracket is slightly oversized for the 1/4" bushing, Before securing the 1/4" mut, position the bushing eo thet the rotor plate is aligned directly over the stator. ( ) See Detait.4c inset for proper measurement. After insuring that the capacitor plates are Properly aligned, set the plates sothat they are 9/32" apart and tighten the thambnut, ‘This preset distance gives proper neutra- izing and will not need further adjustments, (Because of the unconventional circuitry involved, the more standard methods of ‘neutralizing will prove ineffective, ) Grom a EB sit Locvasien QD eowro wor 8 LOCKWASHER 2-922" PMs () Use an soepick or similar instrument to enlarge the holes in lugs 8, 4, and § of the ceramic BAND switch (63-254). The holes should be made large enough to accept #12 bare wire. Refer to Figure 4¥ for numbering. () Referring to Detail 4D, temporarity mount ‘the ceramic BAND switch at F. Place acon- ‘trol lockwasher between the switeh and panel, and use a control flet washer and Control nut outside of the panel, Do not tighten securely yet,() Referring to Detail 48, mount ceramic standoff insulator E, Use a ¥6 lockwasher instead of the flat washer supplied with the insulator, The cork washer goes between ‘the insulator body and the RF shield panel. Remove the hardware from the top of the insulator as it will not be used. #28 SCREW SUPPLIED WITH INSULATOR 8 LOCKWASHER RONT RF SHIELD CORK WASHER SUPPLIED WITH" INSULATOR INSULATOR BODY FEAT wasnen Bee Fo x THicK SS to-veTER con. 36 LockwAsheR fe nsdine Detail 4& () 18, Mount the 10-meter tank coll as shown in Detail 47. Use a 6-92 x 3/8" BEMS through the lower hole in the tank coil, torough a 1/16” thick small flat washer, and into standolf insulator E, Secure the other Detail 4F end of this coll to TUNING capacitor C. Use a #6 lockwasher and 6-22 nut as shown in Detail 4c. () Position ceramic BAND switeh F so the extended end of the 10-meter coll falls be- tween the two number 6 lugs, Now secure the BAND switch by tightoning its control aut, See Detail-4F, () Using long-nose pliers, form each number 6 Ing of the BAND switch so they are against the extension of the 10-meter coil. Securely solder each cumber 6 lug to the coll, (.) Mount a #6 solder Ing at G, Use a 6-82 x 41/4" BHMS, #6 lockwasher "and 8-32 nut, () C12. Referring to Detail 4F, connect a 500 but mica capacitor from hig 11 of BAND switch F (8-1) to ground lug G (NS). Do not allow the lead between the ca: pacitor and Tug 11 to touch the chassis, QNote that the leads are not spaced evenly Between edges of the capacitors, Allow maximum spacing between the chassis and the points where the leads exit from the eapacitors,) () C11. Connect another 500 wut mica ca pacltor from lug 10 of BAND switch F (S-1) to groma lug G (6-2),Page 16 () L&. Referring to Detail 4G, install the moiti-band col on its mounting bracket. Note that one flange of this bracket is 1/18" ‘wider than the other flange. ‘The long flange shoald be placed against the plastic coil mounting stripon the side of the coil opposite its taps, Use 6-32 x 3/8" BHMS, #6 lock- washers, and 6-82 nuts, (} Referring to Pictorial 4 place the cofl on the top ‘two mounting holes behindies " (.) Form the coll leads to fit nto the 10-mete coil and Snto BAND evwitch ings a8 follows Top lead — through the hole in the 10- meter coil, ‘Upper tap through lug 6 of the BAND switch, ‘Middle tap through Ing 4 of the BAND switch, Lower tap through lug 3 of the BAND witch, Bottom lead Form a right-angle bend in this lead so it will fit be- tween the aumber 2 lugs of the BAND switch, () After forming the coil leads as directed in the previous step, secure the coil to the top plate, Use 6-32'x 3/8" BEMS, #8 lock- washers, and 6-82 mts, (.) Double check to be sure that no excess pressure is being applied to the BAND Switch by the coil leads, Then, solder lug 2 (8-1), lug 8 (S-1), tug 4 (S-1), and lug § (S-1) of the BAND ‘switch, Solder the top Coil lead in the hole of the 10-meter call (S-1). () C18, Mount LOADING capacitor H, Use #8 lockwashers and 8-32 nuts on the mounting studs, () Form a hook at one end of a length of #12 bare wire. Secure this book aver the #10 wire going to lug 2 of BAND switch F. Pass the other end of this #12 bare wire through lug 10.of LOADING capacitor # (NS) and connect it to the solder lug under screw 4 of B (G-1). Position the wire as shown in Pictorial 4and Detafl 4H to clear the LOAD- JING capacttor frame, Now solder lug 10 of capacitor H (8-2) and the eyelet at lug 2 of the BAND switch (8-1). (} Mount a #8 solder lug at J, Use a 6-92 x 1/4" BEMS, #6 lockwasher, and 6-32 nut. ( ) Referring to Detail 4J, mount the ceramic form RF choke at K. Place a large flat ‘Siber washer between the ceramic cof form and the chassis. Secure with a 6-32 x 3/8" BEMS, using a #6 lockwasher under the screw head, Detail 47 ) C8, Locate the 1000 nut, 5 kv ceramic tubular capacitor, Mount this capacitor to one end of the silver plated copper strap. ‘Use a 6-82 x 1/4" BHMS, with a #6 lock- washer under the screw head, } Mount the other énd of the copper strap to the top of the RF choke as shown in Pic- torial 4, First remove the screw that is in the choke form. Then, place the same side of the strap that the tubular capacitor is mounted on, over the end of the choke form, Secure with the screw that was removed from the choke. ) Orient and form the copper strap a shown in Pictorial 4, Nowsecure the tubular capacitor to the neutralizing bracket, Use 2 6-32 x 1/4" BHMS, with a #6 lockwasher under the screw head. } CT, Connect the .001 ytd $ kv aise ca pacitor from lug 1 of RF choke strap K (NS) to solder Jug J (8-1), (} Pass one end of the blue high-voltage wire through grommet L and connectitto lug] of strap K (6-2),Page 18 ean, section Refer to Pictorial 5 for the following steps, Solder one wire to each solder terminal of the fan motor, Leave other end of the ‘twisted pair free iemporarity, ia ‘Mount the amplifier tube socket subassembly 36 etna ere, with 6-32 x 9/8" BRMS, ( ) Referring to Detall 5B, mount coax con- Mi ioctnashers,wed-s2nute, Placeaplan’ —‘ ) pact © Dell SB, met coax con clam ser the mowing matt location Pay ane eka a rl ler M, Place the BueatVwiretntougnineclany ‘ME ™e™ the na chow () Momt the aning sexe tormna strip at 7 () Referring to Detafl 5A, mount spade bolts ‘Use 6-32 x 3/8" BHMS with 3-lug terminal fo Se rear RE slald‘Now, mom wefan petnG 2229/8" EMS wih 3-105 motor and blade as atom eran fen gcs0xf en (\) Momt the rear RF shield to the chassis Baier seme top plate, Secure the ends of the BF shields together with 6-32 x 1/é” BEMS, #6 lock- Washers, and 6-32 nuts, Secure the shield to chessis with #0 lockwashere and 8-32 nuts, excepton the second spade bolt from the Se edge, place 4-lug terminal strip JJunder the sm Oront as shoe” ] ( } Cut two 12” tengths of black hookup wire, bccmsatbel Twist those wires together and run the ~68 twisted pair through grommet N, Strip the Detail 5B #3 Lockwasner’ ends of the wires above the chassis and S248 NutPage 19 ee a () Mount a 6-1ug terminal strip at U. Use 6-32 101/40 BHMS and orient 28 shown. {} Mount the phono socket at V. Orient as shown, Use 6-32 x 1/4" BHMS, ( ) C14. Mount the variable mica capacitor at W, Use 6-32 x 1/4" BEMS. { ) C19, Mount the high-voltagefilter capacitor ‘on top of the chassis at NN, Use the two mounting brackets and 10-24 2 8/4" RHMS, Place a #10 solder lug under the nut at location AE, Refer to Detail 5C, ({/) Mount the rectifier tube bracket, Use 6-22 x 3/8" BEMS, Orient with the large sockot pin holes toward the filter capacitor. () Mount the high-voltage plate transformer at ¥, Use four #10 nuts with lockwashers, Orient as shown with the two red-leads toward the rectifier tube sockets, ( ) L5, Mount the high-voltage swinging choke at Z. Use four 8-82 nuts with lockwashers Ortent as shown with the choke leads to- ward the filter capacitor, () Mount the rectifier filament transformer at AB, Use two 8-32 x 3/8" BEMS, Orient with the large greon leads toward the recti- fier tube sockets, Place a #8 solder lug under the nut closest to the rectifier tube assembly, Use 2 lockwasher under the other nut, ( ) Cut the Jeads of the filament and bias transformer as follows: Yellow-green lead 9", green lead closest to mousting foot 3-1/2", green lead farthest from mounting foot 2-1/2", Strip 1/4" of insulation from the ends of these leads and tin, () Mount the filament transformer at AC, Use four 8-32 x 9/8" BHMS, #8 lockwash~ ers, and 8-82 nuts, Orient with the large green leads toward the amplifier tube assembly, { ) Mount a 6-tug termine] strip at KK. Orient 28 shown and seoure with a 6-32 x 1/4" BHMS, #8 lockwashers, and 2 8-32 nut, () Mount a #6 solder lug at AA. Orient as shown in Pictorial § and secure with 2. 6-32 x 1/4!" BHMS and 6-32 nat. { ) Mount the shaft coupling on the end of the shaft of tuning capacitor C, Secure with a 8-32 21/4" BMS, (.,) Mount brass bushings in the front panel at TUNING, BAND and LOADING. Secare with 3/8" control lockwashers and nuts on the ‘back side of the panel,Refer to Pictorial 6 tor the fcllowing steps, () Mount the meter to the front panel as shown! Use the hardware eupplied with the meter, Do not overtighten, () €28, Comect 2 .01 disc capacitor between, the two meter terminals (N3). () Connect a 9" length of red hola wire to the positive (+) meter terminal (§-2) and connect 9" length of black hookup wire to ‘the other meter terminal (6-2). Twist these ‘wires together for a distance of about 8", NOTE: The following step will be easier it the amplifier chassis is placed on the edge of your tabis or workbench, as shown in Plo- torial 6, { } Mount the front panel to the chassis bese, Placing the LOADING capacitor and BAND ‘switch shafts through the properholes, Feed this twisted pair of wires coming from the meter down through grommet HH, () Riz, Place the escutcheon on the tront of the panel and mount both the escutchean and front panel to the chassis by securing SENSITIVITY eantrol CC, as shown in Pic~ torial 6. Orient the control solder Ing ss shown, Do not tighten the control mat yet, Reter to Pictorial 7 (fold-out irom Page 26 ) for ihe following steps. () Mout FUNCTION switch EB, Orient the Switch as shown, with alockwasher between, Switch and chassis apron, Secure withaflat _ ‘Washer and a control mut, Donot tighten yet,Sm, Page 21 () Referring to Detatl 7A, mount the green pilot lamp st DD. First, diseasemble the Socket and secure it with the fiber washer and nut supplied, Screwa bulb intothe socket ‘base and reassemble as shown, ()m a eimitar manner, mount the red pilot lamp at EE, () Mount a DPST switch at FF, as shown in Pictorials 6 and 7, Orient the switch with {ts ON posttion up, as shown in Pictorial 6, () th a similar manner, mount a DPST. switch at GG, Tighten all control and switch nuts to hold the panel and eseutcheon securely, ( ) Cathe red-yellow lead of plate transform- er ¥ to 7-1/2" and strip 1/2" of insulation from the end, () Cut the black lead of swinging choke Z to 7-1/2" and strip 3/8" af insulation from the end, () Slip the 4” length of 1/4""1D plastic sleeving over the red-yellow lead, Twist the ends of the red-yellow and the black lead to- gether and solder the connection, Slide the Plastic sleeving over the conection and tape it in place, () Place a plastic cable clamp under the Jockwasher and nut at location MM, Orient a8 shown and secure after placing the blue ‘high voltage wire through the clamp, “() Cat the blue nigh vottage wire to length and connect it tn log 4 of tube socket V6 (NS), () Connect one of the green leads from recti- fier filament transformer ABto lug 1of tube Socket VB (NB). Save the excess lead wire for use later. () Connect the other green lead coming from filament transformer AB to lug 4 of tube socket V5 (NS), Save the excess lead, () Connect @ length of blue high-voltage wire from lug 2 of high-volinge filter capacitor NN (8-1) to Ing 4 of tube socket V5 (NS). () Using the excess green lend that was cut from rectifier filament transformer AB, ‘connect a lead trom lug 4 of tube socket V3 (8-3) to lug 4 af tube socket VE (NS). Con- necta lead trom lug 1 of tube socket V5 (8-2) to lug 1 of tube socket V6 (S-1). (() Connect a length of #14 bare wire from lug 1 of filter capacitor NN (8-1) to solder 1 AE (8-1). Be sure the nuts on terminals 4 and 2 of filter capacitor NN are tight, () Connect one of the black leads coming from filament transformer AB to lug 3 of ‘terminal strip AF (NS), ( ) Connect the other black lead coming from filament transtormer ABto lug 1 of terminal strip AF (NS),SS rrr Teer () Comect 2 length of black hookup wire from, lug 1 of terminal strip AF (NS) to lug 6 of terminal strip KK (NS), () Connect a length of black hookup wire from ug 3 of terminal strip AF (NS) to lug 5 of terminal strip KK (NS), () Comect = tength of #14 baxe wire from lug 2 of terminal strip AF (6-1) to tug 2 of screw terminal stzip T (3-1). () Comect one lead af the twisted pair coming ‘through grommet N to lug 3 of terminal strip AF (NS). {) Connect the other lead of this twisted pair to log 1 of terminal strip AF (NS). () Connect a length of black hookup wire from. lug 3 of terminal strip AF (8-4) to lug 4 of terminal strip U (NS). ( ) Comect a length of black hookup wire from Jug 1 of terminal strip AF (S-4) to lug 4 ot ‘switch GG (NS). () Connect the nearest black lead comingfrom Plate: transformer ¥ 49 lug 4 of terminal strip U (NS), () Connect a length of black hookup wire from. tug i of switch FF (NS) to lug 1 of pilot light DD (8-1). ( ) Connect @ length of #14 bare wire from lug 1,of awatch FF (8-2) to ug 4 ot sw GG () Run a length of #14 bare wire through tug 8 (NB) and through lug 2 (N5) af switch FF, Connect the end of this wire tolug 3 of switch GG (8-1). Now solder hugs 2 (8-1) and 3 (8-1) of switch FF, (-) Using #14 bare wire, comect the bottom holes of lugs 1 (8-1) and 2 (8-1) of terminal. strip U. Solder ouly the bottom holes, making sure the solder does notshortto the ais, ( ) Using the large #14 insulated wire, con- noct a length from lug 1 of terminalsteip (8-1) to the bare wire that is connected be- tween lug 2 of switch FF andiug3 of switch Gc @-1). () Connect 2 length of black hookup wire from. lug 1 of pilot ight EE (8-1) to lug 2 of switch GG (NS). () Connect the remaining black lead coming from the plate transformer Y¥ to lug 2 of switch GG (8-2), () Connect alength of #14 insulated hookup wire from lug 4 of switch FF (8-1) to lug 1 ot switch GG (8-1), () Connect a length of black hookup wire from Jug 2 of pilot Ught DD (6-1) to tug 2 ot pilot Might EE (NS). () Connect a length of black hookup wire from lug 2 of pilot ight EE (8-2) to lug 4 of ‘termina! strip U (5). () Connect a length of blue hookup wire from lug 6 of terminal strip U (NS) to lug $ of control CC (NS). Route the wire as shown, (() Connect the crystal diode between lug 6 (6-2) and lug § (NS) of terminal strip U. Orient as shown with the band end of diode to lug 8, When soldering the diode lead, protect the diode body from heat by clamp- ing a pair af long-nose pliers over the lead between the diode body and the solder joint, Refer to Detail 7F. ( ) RS, Comect the2,21K0 (red-red-red) 1 watt resistor betwaon lugs 5 (NS) and (NS) of terminal strip U. () Bid, Connect the 10 KQ (hrown-black-or- ange) 2 watt resistor between lug 5 of ter- Binal strip U (6-8) and Ing 1 of capactor (/) 022, Comect a .005 utd disc capacitor (1400 V) between “lugs 4 (NS) and 3 (NS) af terminal atrip U, ( Nae ie a iad ror capacitor Between Inge 9 O09) ae OS) terminal strip U, () Comect a length of #14 bare wire between lug 2 of capacitor W (NS) andlugi of socket ven.Ce COAXIAL CABLE RG8/U Detail 7B iF — zl COAXIAL CABLE RG-58A/U Dataal TC () Prepare a length of RG-8/U as shown in Detail 7B () Solder the center conductor at one end of this cable in the center pin of coax con- pector R (8-1). ( ) Connect and solder the shield lead to the solder lug adjacent to connector R (S-1). (() Run the other ond of the RG-8/U coax eabie up through hole AG and leave the end free temporarily, (.) Form a hook at the end of a length of #14 bare wire. Solder this hook around ‘the center pin of coax connector R (S-1). Connect te other end to lug 1 of capacitor we-2), { ) Prepare a length of RG-S8A/U as shown in Detail 10, ( ) Solder the center conductor at one end of this coax cable in the center pin of coax connector P (6-1). () Wrap and solder the shield lead to the folder lug adjacent to coax comector P 6-1). (/) Roste the coax under transformer AC as shown and connect the center conductor at he other end to lag 4 of terminal strip A 1). () Solder the shield lead to lug 2 of terminal atrip A (S-1), (/) Connect the shortest green lead of the filament transformer to lug 1-of terminal strip B (6-2), (/) Comiect the other green lead to lug 3 af terminal strip B (6-2), { ) Connect the green-yellow leaf to solder Ing AA (6-1), () Solder the long neutralizing lead coming from the filament choke, nearest terminal strip B, to the solder lug on ceramic standotf D (6-1). Use sleeving, () Connect a tength of white wire from lug 1 of tormizal strip JI (NS) to lug 11 of switch BB 6-1). () Connect @ length of #14 bare wire from tag 9 (8-1) to 4 (NS) of terminal strip Jd. () RIL. Comect a 10K (orown-black-orange) 1/2 watt resistor between lugs 1 (S-2) and 2 (NS) of terminal strip JJ. ( ) R4, Connect 2 20 0 (red-black-black) 2 watt resistor between lugs 2 (NS) and 4 (NS) af terminal strip Jd.