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    Heathkit GC 1000 H Manual

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    Igor

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    MOST ACCURATE CLOCK Model GC-1000-H 595-4016-02 aCe nlate HEATH COMPANY PHONE DIRECTORY The following telephone numbers are iret lines to the de- partments listed Kit orders and delivery information Creat Replacement Pars 6-982-3411 16-982-2561 16-982-9871, ‘Technical Assistance Phone Numbers (6.00 AM. 10430 P.M. Easier Time, Waeksays Only) Education Products ‘Amateur Racio Test Equipment, Weather instruments, Cocks Television Home Products, Stereo, Securty, Telephone, Marine, Automotive ‘Computer — Hardware YOUR HEATHKIT 1 YEAR LIMITED WARRANTY Consumer Protection Plan for Heathkit Consumer Products ‘issu Cone Paton Sak cay" as Cant ES WARMAN ns tae te US Concer ‘roa Worry and Pager ase Caves erramat A Tha mony pes Yu pete a 2 ‘isamay Saas oder apace ee = Heath's Responsibility is Seen ne sera me nae rerio ‘Morocriepronng uso Bf) 080 S71 Arne wlpoy eongchogs ge Pune pty aryenrin anor YY Sens eon ears ny an ga ree en es cere Sore are aes eta Ri Peenmaioress oreasac oe iscvones cone hon 0 SotectecogyEicronesCoreran ear 3! aurotzes oversess GMs suc cnt oN ge eee nero = yo TONGAN, tedster taco fe conan g too memes cee eee on etn ogee grand he Cra erty Ths wares tes nls monet omnes ea Sot Fated Tse a omen congrats Pa sone vs concn SA TetrA Se next rom Any SoetAt WomeeY MCCEIA OX CouBeODENTAT DAMAGES: DOME BUY ‘Briere ro aa Coss or BUSMEGS OA FRORTS. whem OA NOT Sor in ‘en hon oF corer damages, 0 stove tao o exc ‘Owner's Responsibility ‘STprchew when ou quest mnt Sono Bans : ee ees ‘ASSeMoLy — ovary sourg waranty seve, you utd cpt ese cry cnn he marl actos, ite etnce percercanna Compile acon ta aguernents a ar coor eseraly ‘ACCESCORY eQUPUENT ~ Peramance marcos nig Se ene ecm aoonet areees mio COMED ‘scons pero aa Sota owl oes Se ara ar aa BS apr Serr es ol he sceg tres ne asamtyraraos Oanoge Soe nant raking cama ‘Seca an Company Berton Haro’ e022 He a ane car Fou pbs cee ene eT ‘616-982-3980 (616-962-3296 616-962-3915 616-962-3907 616-962-9496 (616-982-3309 MOST ACCURATE CLOCK Model GC-1000-H 595-4016-02 ‘Copyright © 1988 HEATH COMPANY foun Fseie? BENTON HARBOR, MICHIGAN 49022 Printed in Hong Kong Heathkit WARNING Federal Communications Commission requirements prescribe verification of computing devices in Part 15 Subpart J of the rules and regulations. This com- puting device will moet these requirements when constructed in strict accordance with the instruc- tions in this manual, using only components and ‘materials supplied with the kit or the exact equiva- lent thereof. ‘This equipment has been verified to comply with the limits for a Class B computing device, persuant to Subpart J of Part 15 of FCC Rules. This equipment generates and uses radio frequency energy for its operation and if not installed and used properly, that is, in strict accordance with the in- struction manual, may cause interference to radio and television reception. It has been type tested and found to comply with the RF emission limits for a Class B computing device which is intended to pro- vide reasonable protection against such interference in a residential installation. However, there is no guarantee that interference will not occur in a par- ticular installation. If this equipment does cause in- terference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interfer- ence by one or more of the following measures: © Move the equipment away from the re- ceiver being interfered with. © Relocate the equipment with respect to the receiver. © Reorient the receiving antenna. Plug the equipment into a different AC outlet so that the equipment and receiver are on different branch circuits. If you need additional help, consult the dealer or ask for assistance from the manufacturer. Customer service information may be found on the inside back cover of this manual or on an insert sheet supplied with this equipment. You may also find the follow- ing booklet helpful: “How to Identify and Resolve Radio-TV Interference Problems.” This booklet is available from the US Government Printing Office, ‘Washington, D.C. 20402 ~ Stock No. 004-000-00345- 4 WARNING: This instrument is not de- signed for outdoor use. To prevent fire or shock hazard, do not expose this instru- ‘ment to rain or moisture. Pages. Heathkit TABLE OF CONTENTS CC Waring .. Lina Assembly. ‘ 66 Introduction. . seeeeeeeees ‘Theory of Operation .. 68 ‘Unpacking. Peer voll Operation. Operating Characteristics Assembly Notes... 7 Fincio sss eve Display Circuit Board In Case of Difficulty. Parts List... seX0 Generale... Step By Step Assembly - “12, Troubleshooting Chart. Tone Decoder Circuit Board Specifications. Parts List...... a a 2 Step By Step Assembly .--.s.ssscesecssessee 33 ceceseeeee Bl Main and Test Cireuit Board Creat Board X-ray View. ......scseeseesseeseses Parts List. aneantaaes . é Illustration Booklet, Page 18 ‘Step By Step Assembly - 30 Semiconductor Identification Chart . 86 Cabinet Parts List... Receiver Circuit Board cancnosianaee Step By Step Assembly Pars List. % Initial Tests and Calibration Schematic. Fold.in Primary Wing ek. ceeceeeeee Calibration 63 Warranty... «Inside front cover Customer Service «Inside rear cover Pages INTRODUCTION ‘The Most Accurate Clock, Model GC-1000, utilizes circuitry which automatically synchronizes it with the National Bureau of Standards radio broadcast station, WWV. ‘The Clock has a preassembled, prealigned receiver which automatically switches for the best signal be- tween the WWV channels at 5, 10, and 15 MHz. ‘The Clock’s time can be corrected for factors such as propagation delays, daylight-saving time, time zones, and UTC1, NOTE: For a more detailed de- scription of these features, refer to the “Theory Of Operation” section of this Manual. Other Clock features include: © A 7-digit LED display which show hours through tenths of a second, © A 12-hour or 24-hour format with AM and PM indicators for the 12-hour format. © A loca/UTC (Universal Coordinated Time) time switch. © Any of 23 time zones selected via a dip switch, ‘© Corrections for WWV propagation delay in 1.25 ms (milliseconds) increments from 0 through 18.75 ms for up to 3600 miles from Ft. Collins, Colorado. © Automatic switching for daylight-saving time. Heathkit Selection of the UTC1 correction factor for “solar” time. Channel lockout in the event that interfer- ing signals are present near a WWV chan- nel. ‘Automatic audio muting when WWV can- not be received. A volume control for adjusting the audible signal, with an “Off” position for manually muting the audio signal. A built-in telescoping antenna, and an an- tenna connector for an external antenna hookup. Operation from 120 VAG (or 220 VAC when wired accordingly), 50/60 Hz or with 4.12 VDC power source. An on-board, crystal-controlled oscillator, ‘trimmed by the microprocessor whose out- put is connected to a rear panel socket so it may be used as a reference signal. ‘A microprocessor-controlled crystal oscil- lator whose frequency is automatically trimmed to within a few parts per minute (pm). A “capture” LED indicator to indicate when WWV's signal is locked in. ‘A“HiSpec” LED indicator to show that the clock is within the specified accuracy. Pages Heathki © An LED indicator to show which of the The Clock can be used for both accurate time mea- three WWV channels is being received surements and celestial navigation. There is also an optional RS-232C Output Accessory (Model GCA- © A “data” LED indicator to show that the 1000-1) available for output to a computer. 100 Hz BCD (Binary Coded Decimal) infor- ‘mation is being received. ‘The unit is housed in an attractive case which has built-in speaker. © Easy modification for use with either WWV. (Colorado) or WWVH (Hawai). NOTICE: Since the GC-1000-H| Most Accurate Clock depends on station WWV for its operation and ac- curacy, @ good antenna is a necessity. If the signal conditions in your area are poor, you will find it nec- ‘essary to construct an outdoor antenna before your GC-1000-H can operate properly. If possible, check with a local ham radio operator in your area to see what the signal conditions are, and what type of antenna you will need. You may also check with your local Heath Electronics Center for this information. Pages UNPACKING Your kit is packed in one carton which contains Packs 1 to 3 and a final pack. A number of loose parts, some of which are wrapped, will be consid- ered the “Final Pack” parts. A “Pack Index Sheet” is provided to show you the location of each Pack. ‘You will be instructed to open each pack as it is needed. Do not remove any Packs or individual parts from the carton until they are specifically called for ina Parts List. Heathkit ‘This Manual has a Parts List for each pack, with its own unpacking instructions which you should read carefully. The sections marked 1-3 on the “Pack Index Sheet” contain the parts for the circuit board assemblies. It is very important to refer to the “pack index sheet” when the Manual instructs you to lo- cate a certain pack. Heathkit ASSEMBLY NOTES TOOLS You will need these tools to assemble your kit. CUI apne ne \ PLIERS: i Diaconat curTeRS, DesoLotRinc sues WUE STARTER DES OLOERING ar etastay oRar ASSEMBLY 1. Follow the instructions carefully. Read the en- tire step before you perform each operation. 2, The illustrations in the Manual are called Picto- rials and Details. Pictorials show the overall op- eration for a group of assembly steps; Details generally illustrate a single step. When you are directed to refer to a certain Pictorial “for the following steps,” continue using that Pictorial until you are referred to another Pictorial for another group of steps. PHILLIPS SCREMORIVER ataoe SCREWDRIVERS VE SOLDER FROM CIRCUIT CONNECTIONS Page7 Ron Pencil SOLDERING IRON (22 10 25 WATTS) hee. Most kits use a separate “Illustration Booklet’ that contains illustrations (Pictorials, Details, etc.) that are too large for the Assembly Manual. Keep the “Illustration Booklet” with the As- sembly Manual. The illustrations in it are ar- ranged in Pictorial number sequence. Position all parts as shown in the Pictorials. Solder a part or a group of parts only when you are instructed to do so. Pages: 6. Each circuit part in an electronic kit has its own component number (R2, C4, etc.). Use these numbers when you want to identify the same part in the various sections of the Manual. These numbers, which are especially useful if a part hhas to be replaced, appear: — Inthe Parts List, — Atthe beginning of each step where a com- ponent is installed, — In some illustrations, — Inthe Schematic, — In the section at the rear of the Manual. 7. When you are instructed to cut something to a particular length, uso the scales (rulers) pro- vided at the bottom of the Manual pages. SAFETY WARNING: Avi jury when you cut off excessive lead lengths, Hold the leads 80 they [cannot fly toward your eyes. Heathkit SOLDERING Soldering is one of the most important operations you will perform while assembling your kit. A good sol- der connection will form an electrical connection be- tween two parts, such as a component lead and a circuit board foil. A bad solder connection could pre- vent an otherwise well-assembled kit from operating properly. It is easy to make a good solder connection if you follow a few simple rules: 1. Use the right type of soldering iron. A 22 to 25-watt pencil soldering iron with a 1/8” or 3/16” chisel or pyramid tip works best. Keep the soldering iron tip clean. Wipe it often ‘on a wet sponge or cloth; then apply solder to the tip to give the entire tip a wet look. This process is called tinning, and it will protect the tip and enable you to make good connections. ‘When solder tends to “ball” or does not stick to the tip, the tip needs tobe cleaned and retinned. NOTE: Always use rosin core, radio-type solder (60:40 tin-lead content) for all of the soldering in this kit. This is the type we have supplied with the parts. The Warranty will be void and we will not service any kit in which acid core solder or paste has been used. Pages Heathkit RESISTORS RESISTOR COLOR CODE CHART Band ] Band2 | Benda | mutipter Resistors are identified in Parts Lists and steps by | (tse) their resistance value in 0 (ohms), kA (kilohms), or | MQ (megohms). They are usually identified by a | C0" feDi] ard kt Se color code of four or five color bands, where each [Back ° ° ° 1 color represents a number. See the “Resistor Color | Brown 1 1 1 | 1 Code” chart. These colors are given in the steps in i H 3 4 fo their proper order (except for the last band, which _| Yenow ‘ ‘ ‘ indicates a resistor's “tolerance”; see the “Resistor _| Green 5 5 5 Tolerance Chart”). You do not need to memorize the | Be, ; ‘ . color codes. Gray 8 8 8 write 8 9 8 Sivor —]—-—J— Mastoter BANDS: 12) oes Sas —|— | — OAND RESISTORS 00 RESISTOR TOLERANCE CHART ‘COLOR OR LETTER ‘+BAND RESISTORS =I0% SILVER sie (GOLD z Banos: 2 MANOS: 1 2 eter Tolerance me RED c BROWN F ; “ ae (GREEN o Occasionally, a “precision” or “power” resistor may aaa ors a have the value stamped on it. The letter R, K, or ur mor fs M may also be used at times to signify a decimal - point,asin: 2n2=220 = Sah, 2x2 = 22kf,0r220001 2Ma = 22M0 MULTIPLIER CHART Precision resistors may also be marked as shown in tower on | meer | ave the following examples. The values of the mult 5 + 7 ono pliers are shown in the "Multiplier Chart,” and the 7 Fa 5 aoTOD tolerance values are shown in the “Resistor Toler- * : z 70 @ 00% ance” chart. 3 000 2 oH Resistor —Mutiper ‘awe Tolrance CAPAGITOR TOLERANCE CHART 1 Toor OR ‘OVER EXAMPLES: 70096 1000.1 ~108, METER 109F 10010 = 100% 10= 10000, =0.5% a c CAPACITORS a F ae Capacitors will be called out by their capacitance 6 value in KF (microfarads) or pF (picofarads) and Ht type: ceramic, Mylar®, electrolytic, etc. Some 7 capacitors may have their value printed in the fol- r3 0% lowing manner: a 20% Lemans EXAMPLES: 151K = 151 se aye (530) frat & second digs by a NOTE: The letor“A* may be used at tines to signy @ decimal the proper vale rom he pol, asin: 2R2'= 222 (pF or uF) “Mutipier Chan” ! Totind the tolerance of the capacitor. took up this eter in the capactior Tolerance char. Page 10 Heathkit DISPLAY CIRCUIT BOARD PARTS LIST Refer to the Pack Index Sheet and locate Pack #1. Open the pack and check each part against this Parts List. The key numbers correspond with the numbers on the “Display Circuit Board Parts Pictorial” (Illust- ration Booklet, Page 1). Return any part that is in a small envelope back into the envelope after you have identified it, until that part is called for in a step. Do not throw away any packing material until ‘you account for all the parts. To order a replacement part, use the Parts Order Form furnished with this kit or refer to “Customer, Service” inside the rear cover of this Manual. KEY HEATH QTY. DESCRIPTION circurr KEY HEATH QTY. DESCRIPTION circu No._ PartNo. Comp.No. | No, PartNo. ‘Comp. No. RESISTORS TRANSISTORS — INTEGRATED CIRCUIT (IC) NOTE: All resistors are 1/4-Walt, 5%, unless otherwise indi- cated AL 6-150 7150, 12Watt(om-gen-dk) R101—R107 Rofer directly to “Display Circuit Board! on the enclosed re- sistoridiode sheet and follow the instructions at the top of that sheet to check the folowing resistors. AY 22012 1 22M (redved-bk) R189 AY 622112 5 22011 (red-red-bm) Fiat Anas, Al 610212 7 10000 (om-Dkred) 108, F109, Rint R116: AL 610312 7 10KI2(ben-dKeorg) Rise—R138 AI 63312 4 SBKMN(org-org 019) Ri24—R127 Al 647312 1047 kM (yetvichorg) Rite—Arta, Ri2t—Aiz3, ize, F129, Rist CAPACITORS a 277 14 yF (104) Mylar cro 2 25-405, 1 1000 pF electrolytic 102 NOTE: Transistors and integrated circuits are marked for identification in one of the following four ways: 1. Partnumber. 2. Type number. (On integrated circuits, use only those numbers and letters in BOLD print. Disro- ‘gard any other numbers or letters.) 3. Partnumber and type number. 4. Part number with a type number other than the one listed. C1 417-974 7 2NaG06 transistor ‘at01-a107 C1 417-801 14 MPSA2O ransietor ‘2108, a109,, ant-ars, a124—a129, rst C1 417-881 7 MPSA1a ransitor ‘an6-ante, 121,022, 123 CAUTION: The following integrated circuit can be easily damaged by static electricity. DO NOT remove this IC from its foam pad until you are instructed to do soin a step. C2 449-981 MO14543 itogratedoreut Ur01 Heathkit Page 11 KEY HEATH QTY. DESCRIPTION cincur | KEY HEATH QTY. DESCRIPTION circurr No. PartNo. Gomp.No. | No. PartNo. Comp. No. LIGHT-EMITTING DIODES (LED) MISCELLANEOUS D1 411-860 4 Large -sogment large) vos -viou 8592201 1 Display ceuitboard 02 411-864 3 Small7-sogmont (smaller) Vi05- Vio7 G1 204-2683 2 Angle bracket Ds 412653 «5 Red Dit, D102, 5661 1, Sleeving Drea biog, | G2 494208 7 tapiniC socket Brea G2 44209 1 T6-pinIC socket Ds 412-641 1 Amber bree G3 432547 125 pinconnector xt01 03 412682 © 2 Grgon Diow,o10s | G4 2308460 «1 Nutstanor : GS 420-111 1 IC puller 8 490-185 1 Dosoldering bras HAI G7 49055 + Poarng pin RDWARE 597-260 1 PartsOrder Form £1 230-8290 (2 M3x6mm screw | Rosiehetiods shest £2 moses 2 Ment 1 Marat oo Page er £2 2008840 2 MSlockwashor Ban LABELS* FY sot 1 Foe Fe 3902459 1 Function Fa 80-5423 1 Model * Located inside tho Manual. Sot thom asise ater you check thom, a 2 “ . ° 7 fier te ph ttt ty Ly betta Page 12 STEP-BY-STEP ASSEMBLY Im the following steps, you will be told how to install and solder the frst prt on the circuit board, Read and perform each step carefully. Then use the same procedure whenever you in stall parts on a eecuit board, (1) Position the circuit board as shown with the printed side up. ‘The side ofthe circuit booed op: posite the printed side will bere ferred tows the foil side, () Locate R137, a 10 Kf (ben-bke ‘rosistor on the “Display Cir cult Board” resistor strip ond clipits loads close to the tap. 0 ) Hold the resistor lead with lon nose pliers close to the body of the resistor. Then bend the leads straight down to fit the hole spacing in the eitcuit board ne PUSH own HERE |) R197: Push the leads through the holes at the indicated location fon the circuit board. The end with color bands may be positioned either way ) Press the resistor against the cir ‘ait board. Then bend the leads ‘outward slightly t0 hold the Fe i PICTORIAL 1-1 Heathkit ees (C) Solder the evsistor leads to the uit board a follows: Push the soldering iron tip ‘gaint oth the lead and the Circuit board fol. Heat both fortwo or thee seconds SOLDERING TRONS, com ponent LEAD Folly. 2. Then apply wider to the ‘other side of the connection IMPORTANT: Lat the heated lead and the circuit board foil melt the sol SOLDERING ‘As the solder begins to melt, fallow it to flow around the onnection. Then remove the solder and the irom and the connection cool SOLDERING NOTE: Do not use too much solder Althe holes on this board are plated hough” holes snd solder will flow ‘onto the other side of the board, Use 2 minimum of solder and be careful not to fill nearby holes with solder. (C1 Cut off the excess lead lengths close to the connection, WARN: ING: Glip the leads so the ends will not fly toward youreyes. (Check the connection, Compare it to the illustrations on Page 13 Aer you have checked the sol der connections, proceed with the assembly on Page 14, Use the same soldering procedure for ‘each connection, Heathkit Page 13 A GOOD SOLDER CONNECTION | aaah ai aaa” [ souver FLows ourwaRo AND GRADUALLY BL WITHTHE FOIL AND THE LERD Le CORR I pe 1 oe ~oositionea | I I 1 When you heat the lead and the circuit board foil atthe same time, the solder will flow evenly onto the lead and the foil. | The solder will make a good electrical connection between | Lithe lead and the foil | POOR SOLDER CONNECTIONS SoLveR Dots NoT Flow ONTO LEAD. h DARK ROSIN [ Bea SuRRoNos ano tn INSULATES THE LERD on [the Connections. I otk ROSIN “5 SorpeRinG J TRON a Pos itonco INCORRECTLY SOLDER APPEARS To FLOW 4°” ” so.neRing INWARD AND SIT ON TOR.“ <° SOUBERI F THE FOIL 07 postiionen INCORRECTLY rou aah | When the lead is not heated sufficiently, the solder will not flow onto the lead as shown above. To cor- I rect, reheat the connection and, if necessary. apply a small amount of additional solder to obtain a good L_connection, When the foil is not heated sufficiently the solder will blob on the circuit board as shown above. To correct, reheat the connection and, if necessary. apply a small amount of additional solder to obtain a good connec- tion, SOLDER BRIDGES A solder bridge between two adjacent foils is shown in photograph A. Photograph B shows how the con- nection should appear. A solder bridge may occur if you accidentally touch an adjacent previously sol: dered connection, if you use too much solder, or if you “drag” the soldering iron across other foils as you remove it from the connection. A good rule to follow is: always take a good look at the foil area around each lead before you solder it. Then, when you solder the connection, make sure the solder remains in this area and does not bridge to another foil. This is especially important when the foils are small and close together. NOTE: It is alright for solder to bridge two connec tions on the same foil. Use only enough solder to make @ good connection and lift the soldering iron straight up from the circuit board. If a solder bridge should develop, turn the circuit board foil-side-down and heat the solder be- tween connections. The excess solder will run onto the tip of the soldering iron, and this will remove the solder bridge. NOTE: The foil side of most circuit boards has @ coating on it called “solder resist.” This is a protective insulation to help prevent solder bridges ——— LS Page 14 Heathkit CONTINUES Install seven 15 0, 1/2.watt (ben-gen- bik resistors as follows: first part on Pago 12 before you pro- ceed, (R138: 10 ko brn blkcorg) [) Rtgs:220.0 [eed-rod-ben) () Rie ) R124:39 KA ong-org-org) () Rios. 5:33 kA (orgongorg )R126:39 KA (org-org-or) ) R127:39 kA (ong-org-org () Rios. ) Solder the leads to the fail and mine, cutoff the excess lead lengths. td [-) Solder the leads to the foil and ) R128: 47 KA (yel-vi cet off the excoss lead lengths # R120: 47 a (yel-viol- or Install seven 1000 9 (brn-blkered) re slstors as follows: ) R131:47 kA (yel-viok-or. () Rio. ) R130: 220 (red-red-bik}. = 2 () Rios. ) R141: 220.0 (red-tod- ben). () Rta2:220.0 (red-t0d-ben). () Ria () Ru. ( ) Solder the loads to the foil and cot ff the excess lead lengths ( ) Solder the leads to the foil and cutoff the excess lead lengths PICTORIAL 1-2 Page 15 Heathkit. NOTE: Before you install an IC sock. st, make sure the pins are straight. If there is any kind of identification mark (notch, dot, arrowhead, etc) at for near one end of the socket, place this marked ond toward the index mark on the circuit board (this index mark should still be visible after you {install the socket), Start the pins into the circut board holes. Then turn the circuit board aver, be sure there pin in each of the holes, and sol ‘two dlagonal comer pins to the fol Check to make sure the IG socket is flat against the circuit board; then sol- der the remaining pins tothe fol STARTS (-) R132: 100 (brn-blk-org (1 R135: 100 (brn-bik-org (R143: 220 0 (red-red-bem} (R133: 10 kM (brn-blk-ong () R145:220.0 (red-red-brn) Tastall seven 14-pin IC sockets as fl lows: () Solder the leads to the foil and 1 ¥103. cet off the excess lead lengths. [ier (Cy Ris: JC) Check the foils for solder bridges. Ifa solder bridge has oc curred, hold the circuit board foilside-down as shown, and hold the soldering iron tip be: tween the two points that are bridged. The solder will flow down the soldering iron tip, crecuir SOGKET PICTORIAL 1-3 (7 Solder the leads to the fol and cutoff the exeass load lengths souraine fl nine [NS S036 Page 16 Heathkit NOTH: Hefore you inslall an electro Inti capacitor. took ati the feuds, Only ome ke citer a megative () mack uF post tise (1) muirk nee it on the sie of the capacitor (The marking fo Coss Install seven 2N006 (#417-874) Uwansistors as follows: gative feud may look like wn ublong bur sometimes with a circle around it inside an arrow) «He Sure install the yative head he tiveemarked hole, gad the positive lead in the positivesmurked ale NEGATIVE (-) MARK (1 Qioa S| POSITIVE «+1 MARK. (( ) G102:1000 uF electrolytic. NOTE: When you Install each of the flowing transistors, position the flat Jon the transistor over the outline of the flat on the circuit board. Then in- ert the leads into the circuit board holes and space the transistor 316" from the ericult board. Solder the leads tothe foil and cut off any excess lead lengths. Far, 1 Qi06, Install twelve MPSA20_(#417-801) transistors as follows aes oe See gs S aS. + I [) Q1at: MPSA20 transistor (#417. dain ) Qt0s, (anes, () Qu2a PICTORIAL 1-4 Heathkit’ Page 17 J C101: 1nF (104) Mylar. Solder the loads to the foil and eut off the excass load length. U) Gut sixteen 2/8” pieces of sloey- ing. Save tho remaining slooving for later. (C) Slide 3/8" pieces of sleeving over the leads of eight LEDs NOTE: When you install each of the position the short the flat outlined on the cireuit board, Insert the leads into the cireut board holes until the black slooving is against the circuit board. Solder the leads to the foil and cut off the excess led lengths. NOTE: ‘Make eure each LED is perpendicular to the circult board and is not tipped before you solder it. Also, make sure all of the LEDs are the same height. ‘Reheat the leads to straighten tipped LEDs. ten Shor LEAD alee . SUEEVING: Fat (4 D107: Red LED. ) Dior: Red LED, () D108: Amber LED. ( ) D103:Red LED. PICTORIAL 1-5 a ae a 4 5 Lyetan't seta] f i na Heathkit eT CAUTION: When you install the fol: lowing protected IC (mounted on a foam pad), be sure it dows not get damaged by static electricity. Once you remove the foam pad. DO NOT let go ofthe IC. Install it as follows. Read the entire step before you pick up the. 1. Pick up the IC and touch the foam pad with both hands. 2. Hold the IC with one hand and remove the foam pad with the other hand, NOTE: When you install the large and small 7-segment LEDs in their sock ts, check very carefully to make sure that all of the pins are straight and in Tine with each other. If you bend 4 pin over accidentally. you may break itaff when you try to straighten it again. Postion each LED with the decimals as shown with the pins Storted into their holes. Check to make sure they are going into the holes properly. Then push the LED the rest of the say ita the socket Detail 1-6 Gs WS end 4 DECIMAL PoinT 3. Refer to Detail 1-64. and continue to hold the IC with fone hand and roll the IC pins onto a flat surface to ‘make sore they ae parallel 4. Pick up the cituit board sn your other hand. le 5. See Detail 1-68 and align the pin 1 end of the IC with the index mark on the cir. cat board —---42------- OQ Install four large 7-segment LEDS (4411-860) into the IC sockets asf: lows 6. Then push the IC pins into the IC socket. Once in the socket, the ICs protect, ee” \ 1 vi0s SP C) vio ©) vine. Install three small 7-seyment LEDS (7411-864) into the IC sockets as fo: Jows. Do not use the two holes a th ‘erdgof the socket NOTE: The pin 1 end of ialine inte pecimat trated circuit may be marked in a sau te robe cf wai wi mae —______ ort eS Ee eS Savalas rar bas aoc ‘<> remove an IC, uso the IC puller. (set bo nor ust the IC puller beneath the ICs then bo not usd ENO HOLES be Agr as : peuy sock it Bak and fr to it () tot: Mcx4543 integrated cir cult (#489931), Se Sp ma "1 Detail 1-68 05 N 4 fe. ) v107 PICTORIAL 1-6 Heathkit Page19 25-PIN CONNECTOR Povaai Zin: PIW PICTORIAL 1-7 Page 20 iSPLAY can Ma NUT Ma LOCK WASHER: Heathkit ‘SHORTER ‘SIDE Maxam ‘SCREW PICTORIAL 1-4 Refer to Pictorial 1-8 for the following steps. (.) Position the display circuit board as shown, NOTE: Use the plastic nut starter to hold and start M3 and 1MB.S nuts on screws. () Mount angle brackets at C and D with M3 x 6 mm screws, M3 lockwashers, and M3 nuts. Mount the shorter side of each bracket to the circuit board and position the brackets as shown. CIRCUIT BOARD CHECKOUT Carefully inspect the circuit board for the following conditions. (). Unsoldered connections (_ ). Poor solder connections. (_} Solder bridges between foil patterns. (_) Protruding leads which could touch together. (_.) Transistors for the proper type and installa- tion, (). Electrolytic capacitor for the correct position of the positive (+) and negative (—) lead. (}. Integrated circuit and LEDs for the proper in- stallation, This completes the “Display Circuit Board Assem- bly.” Set it aside until itis called for later. Heathkit Page2t TONE DECODER CIRCUIT BOARD PARTS LIST Remove the parts from Pack 2. and check each part against the following list. The key numbers corres- pond to the numbers on the “Tone Decoder Parts Pictorial” (Illustration Booklet, Page 2). Return any part that is in an individual envelope back into the envelope after you have identified it until that part is called for in a step. Do not throw away any pack- ing material until you account for all the parts. KEY HEATH QTY, DESCRIPTION circutt To order a replacement part, always include the PART NUMBER. Use the Parts Order Form fur- nished with this kit. If a Parts Order Form is not available, refer to “Replacement Parts” inside the rear cover of this Manual. KEY HEATH QTY. DESCRIPTION circum No PartNo. |” Comp.No. | No. PartNo. Gomp. No. RESISTORS 2 622012 1 220010 (red 00-08) reas NOTE: Allresistors are 1/4-watt 42 GATZI2 44700 yolwolred) azo, nase, ago, ae? Reter directly to “Tone Decoder Circuit Board" on the en- | AZ 622312 1 -22kMA(edred-org) Rais osed resistordiode sheet to check your resistors and | A? 6273-12 27 k0(rod-viokorg) Rat, meas, oe 2 610812 3 100KM (bebo Raid, R422, Reza 1% Resistors 2 GA26I2 1 12OKID(Omrod-ye) Rar? 22 622412 2 22OKM(osredy—) Rana, RB AY 6-1691-12 21690 (brblewht-brn) RAB, RABS | AZ 1 ee ae Al 6792112 17320 Wokorgved-bm) AAS 22 63912 2 380KN(orgorg yo) R98 A) Saat . 2 Gmontceeaes pes 22 G47412 2 A7OKNIyetwvotye) ats, Raa7 AY 6190242 1 13kN (bm-org-bk-red) Raga a2 6084-12 1 OROkN Rae gey-yed rae AY 6-4002-12 2 40K (yehbik-bik-red) azs,paas | AZ 6105-12 1 Seo bd AY 6158312 2 18BKIL(Omgm-gry-org) AZT, RABI 5% Resistors CONTROLS Bs cee) «7 ANG si 10311 2 5000 (5K) Rasa, Ras A 6:10212 2 1000!(bmrdkcrd) aad, Rest "Part used for WWVH reception ony Page 22 Heathkit KEY HEATH IY. DESCRIPTION -—cincUT.—| KEY HEATH QTY. DESCRIPTION ——_cRGUIT No" Parho Gonp.No, | Nov Pate Comp No CAPACITORS NOTE: Tenis and iegaed casts may bo mated Mylar fr derfton any nesting ur aye . Partcunber cr ara 2 c0e2 yr (922) canst, cater 4 + r Ch amie 4 or re cws.cass, |? ie numbers ng lots BOLD pin Dio- 2aeapes |any other numbers or | cr an) 8 ano at, ce, jan oacremioecs crite) a. RaRnSS ype ruven Suaters, 4. Part number with a type number other than the ewe cus ole ce sant angen ous be rer} wretcormnsser un Electrolytic 344271 1. LM3900 integrated circuit Uso4 8s Mouse 2 esermapaescee ate, Uae a crea C3 25-900 11 pF cara MISCELLANEOUS Ca 25201 2 22ur (202 or 2u2 or 205) 6421, C425 ‘ntl eezoert 1 Tredeercetboes co ase 1 Toa cane m1 moar 2 Comecorpm C3 (25-887 1 220pF came Fe 432.947 1 25-pin connector mia 2 osnicemen SEMICONDUCTORS FS 434-208 1 1-pin IC socket ra fees okiagpe bi ese Nato dede oe-bate "Parts used for WWVH reception oniy Page23 Heathkit STEP-BY-STEP ASSEMBLY ) Position the tone decoder crcart board with the printed num bored and letered side up NOTE: Remove the resistors from the “Tone Decoder Circuit Hoard” resi tor strip for this section CONTINUE < Q ) R418: 220 kA (r0d-r0d-yel), (C ) R488: 27 0 (red-viol-org) NOTE: When you install « diode, sk: ways match the band on the diode with the band mark on the cirevit board. THE CIRCUIT WILL NOT WORK CORRECTLY IF A DIODE IS INSTALLED BACKWARDS. See De- tail 2-14, BAND. Soup Boov | gato. BANDED END dggee A ) Solder the leads to the foi) and ‘cutoff the excuss lead lengths. ia GLASS cOLoRe Bano Body COLORED I your diode has » solid body, the band is clearly defined. f your diode has 2 glass body, do not mistake the colored end inside the diode for the banded end. Look for @ band painted ‘on the outside ofthe glass. your diode has color bands (yellow: black-yellow-white), the end that has 2 wide yellow band is the banded nd. rd), () R495: 40 KO, 1% (yel-blk bik re), () R413: 22 kA (red-red-org PICTORIAL 2-1 Install four 1N&149 (#56-56) diodes as follows NOTE: DIODES MAY BE SUPPLIED C) pa. IW ANY OF THE FOLLOWING SHAPES. at = ALWAYS POSITION THE BANDED END () Das, AS SHOWN ON THE CIRCUIT BOARD. | Ti) Solder the leads to the foil and Cutoff the excess lead lengths, — W774 () Solder the loads to tho foil and cat off the excess lead lengths 7 ry Detail 2-14 Page 24 f ) RAD7: 158 KA, 1% (bem-g-gry ore () Ra26: 1690 0, 19% (brn-blu-wht om) () R436: 1600 0, 19% (ben-blu-wht ben) ( ) R439:4700 (yel-viol-ted), (Raat: 2200 0 (red-red-ed). (( ) Solder the leads to the foil and cutoff the excess lead lengths. (>) Ras2: 47000 (yel-viol-ted) (.) R432: 4700.0 (yel-viol-zed) () D405: 184149 diode (456-56), NOTE: You will assemble your Most Accurate Clack to receive either st tion WWV (Colorado) or WWVE (Hawaii). Determine which of these {wo stations you can receive; then in stall the appropriate resistor as fol- Tows For WWW: (1 R443; 9080 0,196 (wht blk-wht brn) For WWVH () R443: 7320 0, 1% (viol-orgred- bem} (( ) Solder the leads to the foil and cutoff the excess lead lengths. eas PICTORIAL 2-2 i Heathkit Oo ) R428: 330 kA (org-org ye. ) R438; 330 kA (org org vel ) Ra27: 158 KO, 1% (ben-grmgey- on). ) R431: 1000 0 (ben-bik-red). ) Rast 68 (blu-gry-bk) ) R429: 4700 0 (yel-viol-red. 1 R433: 13 KO, 19% (ben-orgblk red), ) Solder the leads to the foil and cut ff the excess lead lengths Heathkit Page 25 () X401: Position the 25-pin con- bector over the edge of the clr cuit board on the component side and insert the pins into the holes. Solder the pins t the fo Disregard any numbers stamped on the connector. 25-P1N ee connectog 4 COMPONENT SIDE NOTE: Before you install an IC sock ft, make sure the pins are straight. thore is any kind of identification mark (notch, dot, arrowhead, ete) at or near one end of the socket, place this marked end toward the index ‘mark on the circuit board (this index mark should still be visible after you Insal the socket). Then start the pins into the circuit board holes and sol: der them othe foi Dor NoTcH Ss NOTE: It very easy to form a solder bridge between folls on the circuit board. After each solder step, care fully inspect the foil for solder bridges and remove any that have formed 1 solder bridge has occured, hold the circuit board follside-down as shown, and hold the soldering ison tip between the points that are bridged. The solder will flow down tho soldering ion tp ie circurt Z sock soar foi sovoce ne) [MN ovoee RoW NI (/ ) U404: 14-pin IC socket, aRipGce (C ) 40a: &-pin IC socket (C) 0902: 8 pin IG Install each of the integrated circuit (OCs) a8 follows. 1. Be sure the ICs pins are straight. Then lay it down ‘on one of its rows of pins, a shown at A, and roll it ‘over until the pins are at Fight angles or bent in slightly as shown at B. Re peat this. process for the other row of pins, A B rm 2. Pick up the clreuit board in your other hand. Detail 2-34, 3. See Detail 2-34 and align the pin 1 end ofthe IC with the index matk on the ci 4. Then push the C pins into the IC socket () Uaoa: LMa900N (#442-71) IC fio et ua socker tnpex () Ua0s: NES67 (4442-608) I. ( ) 402: NES67 (9542-688) I. Should st ever hecome necessary remove an IC use the IC puller. Insert, the IC puller beneath the IC: then gently rock it back and forth to lift the IC ~~ PICTORIAL 2-3 SOeKeT sense Page26 Heathkit NOTE: When you install a connector pin, push as far as possible into the circult board hole from the compo- rent side, Then solder the pin to the foil. Use solder sparingly to avoid fi: ling the connector. CONNECTOR comPoNENT gem SIDE = oss NOTE: Before you install » polarized locrulytic capacitor, look at it and Identity the leads, One lead will have a postive (+) mark or @ negative) mark nour il, He sure to install the positive lead in the positive-marked hole and the negative lead in the regtive-marked “hole, Be careful tony the negative lead mayb ‘marked, Soo Detail 2-44, incur BoRRD SOLDER () TPi:Connector pin NOTE: When you install the follow: ing transistor, line up the flat of the ‘transistor with the outline of the flat fon the circuit board. Insert the tan- sistor leads into their correct holes Solder the leeds to the foil and cut off any excess load lengths. OL Us: ze Sipe ) €422:.88 uP electrolytic capacitor, always match the positive (+)or colar dot on the eapacitor with the postive (+) mark on the eirewit board Positive (+) coLor Dor i) Qa03: MPSA20 transistor (#417- on) Positive (+) ARK () CA06:.01 pF (203) Mylar () ©428: 22 pF @C2 oF 242 oF 225) tantalum. fl ) Ca24:220 pF electrolytic. NOTE: If you are assembling you Clock to receive WWV, perform the stops under that sector. f you intend to receive WWVH, perform those stops (©) OAR: 22 pF (C2 or 2u2 oF 225) tantalum. () C121 pF electrolytic For wwy: [-) Ca15:.0t w (103) Mytar. () G06: 01 pF (203) Mylar ) CA14: 10 pF electrolytic. (( ) Solder the leads to the foil and cut off the excess lead lengths For WV: (7) C415: 0082 (922) Myla (416: 0082 uF (822) Myla. (( ) Solder the leads to the foil and cutoff the excess lead lengths, Heathkit. ‘pags?’ Fe) C09:.1 wr (108) Mylar, I) C08: 1 we (108) Mylar. J) Catt: a we (108) Mylar. I) C413:.68 uF (604) Mylar. NOTE: ‘You may have to form the leads of this capacitor to fit the eiruit board holes (-) ca17:.01 wr (103) Mylar (€) C419: 2 uF (108) Mylar. () Cat8:.1 wF (108) Mylar. (( ) Solder the leads to the fol and cutoff the excess lead lengths. (Rasa: 5000 (5K) A control (#20- ( BOARD EDGE (_) 8434: 5000 (5k) 0 control (#10. 311) (C ) Solder the loads to the oi. PICTORIAL 2-5 () Press « polarizing pin Tao 75- pin camnector hole 5 as shown fon the circuit board. Disregard ‘any numbers stamped on the connector. Fou. Povoriz ine 25-PIN PIN CONNECTOR NOTE: This completes the tone de- coder circuit board assembly. If you {intend to install the optional RS-232C Output Accessory, proceed to thet ‘manual at this time. Otherwise, pro- 0ed to “Circuit Board Checkout, CIRCUIT BOARD CHECKOUT Carefully inspect the circuit board for the following conditions. (_) Unsoldered connections, ( ) Poor solder connections (1) Solder bridges between foil pet- () Protruding leads which could touch together. (_ ) Transistor and ICs for the proper installation. (_ ) Biodes for the proper position {ng ofthe banded end. (_ ) Blectolytic capacitors for the correct position of the positive (+)or negative (—) mark. Set the circuit board aside until itis called fr later. NOTE: You may wish to save the loft ‘over WWV or WWVH components. If not, discard them. MAIN AND TEST CIRCUIT BOARD PARTS LIST Remove the parts from Pack 3 and check each part against the following list, The key numbers correspond 0 the numbers on the "Main and Test Circuit Board Parts Pic- torial" (llustration Booklet, Page 3). Return any part that is in an individual envelope back into the envelope after ‘you have identified it until that partis called for in a step. Do not throw away any packing material until you account forall the parts. ‘To order a replacement part, always include the PART NUMBER. Use the Parts Order Form furnished with this kit. If a Parts Order Form is not available, refer 10 “Replacement Parts” inside the rear cover of this Manual. NOTE: If you find any extra parts in this pack, save them, for use during the assembly of the cabinet. KEY HEATH —GTY. DESCRIPTION CIRCUIT | KEY HEATH —GTY. DESCRIPTION circum No. PartNo. ‘Gomp.No. |} No. PartNo. ‘Comp. No. RESISTORS, 1/4-WATT, 5% a2 137 1 22M0, i2wat,10% R202 1s (eeded-gm) 3405 1 399, 5-watt 5% F201 Reter directly to “Main and Test Circuit Board’ on the en- | aa gsr 1 Resistor pack 223 ‘ldsed resistoréiode sheet to check your resistors and comes, CAPACITORS AY 622012 1 22M (rad-red- DH) rev0 mica Al 627-12 1 270M fedwolom) Reza AY 6471922 470.,yebvio-bm) R212, R16 AL 610212 2 100081(om-berec) raiiraz | 81 20-108 1 130pF (30) cars AY 668212 3 6800 (bleed) zoe. R207, | 81 20-164 1180p (181) cas Rave AL 610912 210k Ommbiorg) r209.F218 | Ceramic AL 620512 3 22kM (red-redorg) 203, R208, R215 At 695312 1 Sak emopor) rat3 2 2t-710 1 ator c205 AL 647312 1 «A7kALYetvioworg) et7 ee a7 270pF @71) ~ cot, ca1s, 104-12 100 KA een : cat a erie 05,208 To teat 1 4700 9F (472) cat 82 2116 01 WF (¥03) ‘C201, c204, OTHER RESISTORS cooricame 822199 AGAMA G202, 6222, NOTE: The following resistors are not located on the resistor! zz diode strip. They are inside the pars bag. esa 2 47071) pF ~ 216, C203 Heathkit KEY HEATH QTY. DESCRIPTION circurr KEY HEATH QTY. DESCRIPTION incur No. PartNo. Comp.No. | No. PartNo. ‘Comp. No. CHOKE - TRANSFORMER Electrolytic D1 2008492 1 26H choko zor i Tasco) cars 02 54-1018 1 Power vansformer Tet tantalum 8s 1 Zur cai CONNECTOR - SOCKETS 85 1 220uF 208 85 2 100 nF 0208, E1 432-915 3. 25pinconnector 208 E2 434-298 1 16;pinIG socket BS 25.005, 1 2200 uF cava £2 434-307 1 24pinIC socket £2 434-253 1 d0-pin IC socket DIODES HARDWARE C1 5656 16 1Nat49 1206-0209, pait-ozie, | FI 2908280 © 1 M3x6mm-scrow e2i,0222, | F2 2308383 4 M3x mm -selltapping screw zee FS 23084381 MSaut cr 5765 5 1Nsoo2 20-0205 | F4 2308440 1 M3 lochwasher C2 5860 1 vaio" 224 MISCELLANEOUS ‘TRANSISTORS - INTEGRATED CIRCUITS a atten Sikes i eex 8528672 1 Mainciruitboard NOTE: Transistors and integrated circuits may be marked G2 2i565 1 Heat sink {or identiication in any one ofthe following tour ways: G3 660 1-1/2" Cleartbing 343-12 650 Mcoaxialcable 1. Part number. (located in the Final Pack) Sra LOT vig ind ca, isso 247-55 12" Bewirorbbon cabio™ 2 Tipe nuter1On Waaoraied hai: v G4 35231 + Thermal compound those numbers and letters in BOLD print. Disro- owe | ones veo {gard any other numbers or letters.) Ge os 1 ae 3. Part number and type number G7 ait 1 916-ampere slow blow usa F201 4. Part number with a type number other than the G7 42137 1 Tampere fuse F202 ‘one shown, CAUTION: The ICs are protected against damage caused by static electricity. Do NOT remove the ICs from their foam ‘pads until you are instructed to do so in a step. C3 417874 123006 tansistor 207 3 417293 © 1 2N577OWansistor ‘Gao C3 417801 5 MPSA2O ansistor 2201, 2202, (G203, 2205, 208 ca aanse 1 UATeOS 202 C4 442-691 1 78MOB or 7808 201 C5 443-1202 © 1 Mc14028 uz04 C5 443-735 = MC14508 205 C5 444-208-1 1 Programmed microprocessor U203, * Part not on resistriiode si. TEST CIRCUIT BOARD PARTS (located In envelope #173-1833)* Hi 610242 1 1000.0, 1¢. wat, 5% (on SOY biked resistor 85.29122 1 Testreutboard He 60-685 1 Slide switch ssn HS 64-967 1. Pushbutton switch 502 * These parts may be locate inthe final pack oy yt ements) 2 2 ‘ 5 * 7 Lomayeten ce Dept Le pla eda pale cast Lettie) Page3o Heathkit STEP-BY-STEP ASSEMBLY MAIN CIRCUIT BOARD PART NUMBER ‘The steps performed in this Pictorial are In this area ofthe eltcuit bord, (ote hd NOTE: When you install a diode in’ the following steps, be sure to posi- I) Position the main circuit board with the white printed side (not the foil side) facing up. NOTE: Only a portion of the circuit board is shown in some Picto- als. The small “Identification Drawing” et the top of a Pictorial shows the area of the circuit board to be assembled IDENTIFICATION DRAWING BAND: sobiD sony — BANDED END R202: 2.2 MM, 1/2-watt, 10% (c0d-red-gra) pano 800% GLASS COL oreo END INS TOE CAUTION: ALWAYS POSITION THE BANDED END OF A DIODE AS SHOWN ON THE CIRCUIT BOARD. If your diode has a solid body, the [band is clearly defined. If your diode has a glass body, do not mistake the colored end inside the diode for the [banded end. Look for a band peinted Jon the outside ofthe glas. Soe Detail SHA. NOTE: DIODES MAY Be SUPPLIED IWANY OF THE FOLLOWING SHAPES ALWAYS POSITION THE BANDED END AS SHOWN ON THE CIRCUIT BOARD. Detail 3-14 Heathkit) Pages The steps performed in this Pictorial fn this area ofthe circuit board (_) Rev4:6800.0 (blugry zed), IDENTIFICATION DRAWING, PART NUMBER Cres Install sixteen 1N4149_ (456-56) diodes as follows. NOTE: If your diodes have color bands (yellow: black yellow-white), the end that has wide yellow band is tho banded ond. () Ra1s:22 kA (red-red-org i ) R208: 100 kA (bmn-blk-yl), (( ) R204: 22 kA red-red-org). J) peas, () Daze (1 pais, (( ) Solder the leads to the foil and cutoff the excess lead lengths. () Data, () paw () Date, PICTORIAL 3-2 (( ) Solder the leads to the fol and cutoff the excess lead lengths. Pages2 Heathkit IDENTIFICATION PART MY NUMBER The stops porformod in this Pictorial are In this area ofthe eirclt board (C-) R208: 100.0 (ben-bik-ye) | ) R206: 6800 0 (blu-gry-ed |) R207: 6800 9 (blu-gry-red), (C ) Solder the leads to the foil and cutoff the exces lead lengths, PICTORIAL 3-3 Heathkit fotowing steps. Make sue all pint are ged. The solder will flow down in soldering roa tip circuit BOARD \ SOLDERING iow \ | J) 1201: 26 yt choke (230-8492) a 1201, Poston the choke body st ‘shown and bend the leads as shown Insert te leads into the crit boar holes and solder them 10 the fi Cat off the exces lead lengths, 2 SoLoer BRIDGE Page33 IDENTIFICATION DRAWING PART NUMBER The steps performed in this Pictorial are fn this area ofthe elrcult board (Ones (C4) R228: Resistor pack. Position dt or bar next to the "2" on the circuit board, Solder the pins to the foil and cut off the excess pin lent E> —> C! Cc ry 1 |, (0 © => PICTORIAL 3-4 Pages4 Heathkit IDENTIFICATION DRAWING parr NUMBER The stops performed in this Pictorial are. In this area ofthe circuit board (F201: Fuse clips. Position the fuse clips shoulders as shown and solder the tabs to the foi Dass you install rach of the ators, position the flat of the transistor over the outline of the flat on the circuit bonrd. Then in sert the leads into the circuit board holes and solder them tothe foil. Cut off any excess lead lengths SHOULOER runt () Prepare the 1-172" piece of clear plastic sleeving as shown, ue ay 2. cur oven 10% eno 1. CUP HALE WAY THROUGH ) Q207: 23906 874), (-) F201: Insert the a/16-ampere slow-blow fuse into 1-12" of leer plastic tubing and install ‘the fuse into the fuse clips. Lo an’ wer | i Page3s Heathkit IDENTIFICATION DRAWING PART NUMBER (So Ra ees 0 ) Remove pin 2 from either end of 25-pin connector to make a 24 pin connector. Remove ‘The stops performed in this Pletoral are in this ares of the circuit board } F202: Fuse clips. Position the fuse clips shoulders as shown and solder the tabs to the fll SHOULDER () P201; Install the 24-pin connec: tor at P201. Insert the short pin fond into the circuit board holes tnd press the connector body against the circuit board. Solder the pins to the fll (- } Remove pin 5 from either end of ‘another 25-pin connector to make a24-pin connector. [() F202: Insert the t-ampere fuse into the Fuse clips, ) 203: MPSA20 transistor (#417 REMOVE 202) () 202; MPSA20 transistor (#417- 01) ( ) Q208: 25770 transistor (#417- 293), ( ) Q201: MPSA20 transistor (#417 801), () 0224: Position the case flat of (Remove pin 3 from either end of te MOVELID feeeou) alone the remaining 25-pin connector. over the outlined flat on the ci. ult board. Insert the leads into the circuit board holes and pos tion the case bottom 1/4” sbove Need tthe fuel onesie Je cuccan Boer tas: OT eae Thrar [() Pa02: Install the 24-pin connec: tor at P202, Solder the pins to the fil REMOVE PICTORIAL 3-6 [() P202: Install the 24-pin connec: tor at P203, Solder the pins to thefoll Heathkit WWENTIFICATION DRAWING PART NUMBER The stops performed in this Pitoral are li this area ofthe cieuit board NOTE: When you install ceramic eapacitors, do not push the insulated portion of the leads into the circ board holes, This could make it dif ult to solder the leads to the foi NOTE: Before you install a polarized electrolytic capacitor, look at it and identify the leads. One lead will have a positive (+) mark or a negative (—) mark near it. Be sure to install the postive lead in the positive:marked hole or the negative lead in the nega ive-marked hoe. ISULATION on ghyecarive E] i MARK POSITIVE(+) MARK () Y201:3.6Mitz crystal, (_ ) C208:.01 wr (103) ceramic () 2232470 1471) pF ceramic, () C2001 103) pF ceramic (( ) Solder the leads to the foil and cutoff the excess lead lengths {_ ] Solder the leads to the foil and o— Cot off the exces lad lengths. — PICTORIAL 3-7 Pages7 Heathkit. The steps performed in this Pictorial are in this area ofthe circuit board PART NUMBER IDENTIFICATION DRAWING NOTE: When you install tantalum electrolytic capacitors, be sure to po- sition the plus (-+) marked or dot () marked lead in the plus (+) marked hole Positive (+) POsiTive (+) MARK PICTORIAL 3-8 Page 38 ‘The steps performed inthis Pictorial are In this area ofthe circuit board, ) Uzor: 78Mos (442-601) inte i cieult. Insert the leads as far as possible into the circuit board holes. Keep the IC perpen: dicular to the circuit board and sclder the leads to the foil and cutoff excess load lengths. METAL SIDE PART NUMBER IDENTIFICATION DRAWING Douste LINE Sue ) Solder the leads to the foil and ‘cut off the excess lead lengths. () Turn the cirevit board over so that the foil side is Facing up, Refer to Detail 3-9A for the following spe () Cut the leads of 47 pF coremic eapacitor to 1 ) 225: Locate the foil pads on the foil side of the circuit bourd for the indicated leads of capacitor C222 and transistor Q205. Placo VY —_ the prepared 47 pF ceramic capacitor so the lead ends are —— ‘over the foil pads and solder the loads to the foils. Keep the capacitor fat ogainst the cireuit board. Cut off any excess lead lengths so you do not bridge the Detail 3-94 Heathkit Pages Heathkit performed in this Pictorial are ofthe eicust board PART NUMBER IDENTIFICATION DRAWING (_ ) €205: 1000 pF electrolytic. ( ) Cuttwo 37 pieces of sleeving. ) Slide the 3/4" sleeving over the 3.9 1, S-watt resistor leads and () R201: 3.90, $-watt, 10% rosstor with sleeving PICTORIAL 3-10 OK % mt cmenem 2 a ‘ . ° 7 jeoerecal f tit Lat ovat stb by SO y Page 40 Heathkit The stops performed inthis Pie In this area ofthe ciruit board WARNING: You will use Dow Corn- ng 340 thermal compound in the nex step. The compound is not caus- tic, but it may cause discomfort if it fgets in your eyes. If this happens, rinse your eyes with warm water Your clothes may require profes sional cleaning if the compound gots PART NUMBER, fon them. The compound contains IDENTIFICATION ine oxide and silicone grease. Al: DRAWING ways wash your hands after using the compound. Keep this and all chemi- cals out ofthe reach of children. } Oper. the thermal compound container () Apply small amount of thermal ‘compound to the bare meta side of the UA78OS integrated circult (4442-54), Discard the remain- ingcompound. WeAT sink vaveos () U202: Assemble and mount 3 transistor heat sink assembly as follows: 1, Moun the prepared IC on the heatsink with a M3 x 6 mam serew, an MB lockwather, and a MS nut as shown, PICTORIAL 3-11 2 Mount the tansisior heat snk assembly ono the eieut board 1 U202 with two M3 mm self-apping screws 3. Solder he unsistr leds tothe fail an eat off the excess lead Jeng. Page 41 Heathkit The ‘eps performed in this Picton inthis area ofthe eitcuit board Te IDENTIFICATION DRAWING CONTINUE () Turn the circuit board over so (CAUTION: When you install the fo: lowing protected IC (mounted on a foam pad), be sure it does not get damaged by static electricity. Once you remove the foam pad. DO NOT let go ofthe IC. Install it as follows. Road the entire step before you pick PART NUMBER ) Cut the loads of 1 uF (1M) eo ramic eopeciter to. 1/8" and Pick up the 1C and touch the foam pad with both hands. 2. Hold the IC with one hand and remove the foam pad With the other hand 3. Continue to hold the 1C with fone hand and roll the IC pins onto a flat surface to ‘make sure they are parallel Cut a 3/8" piece of sleeving and slide t over the 12° capacitor lead. ( } ©8224: Locate the fil pads on the foil side of the circuit board below the indicated leads of ro- sletors R217 and R213. Place the prepared 1 uF esramic capacitor Pick up the circutt board in your other hand. pads and sol foils. Keep the capacitor against the circuit board. C any excess lead lengths £0 you donot bridge the fils. Align the pin 1. end of the IC with the index mark on the circuit board 6. Then push the IC pins into the IC socket. Once in the socket, the ICs protected () Note the foil pattern at $201, Then insert one of the DIP switches into the circuit board foil side holes at $201 with the (0° or "ON" side as shown. Dis regard ony numbers on the switch, Turn the circuit boord back over and solder the pins to the component side foils at ‘8201, Keep the switch body flat against the cirevit board mane on PICTORIAL 3-12 remove an IC, use the IC puller. Insert the IC puller beneath the IC; then gently rock it back and forth to lift the () Similarly, mount the remaining DIP switeh at 5202. Position the switeh sith the O" oF “ON side the same as S201 Set the main circuit board aside tem- porary Page 42 Heathkit COND ea (C ) Cato the for comer pis rom the Slide switch ax shown, this hs not trey been done. TEST CIRCUIT BOARD () Position the test circuit board with the printed side up, (©) Mount the pushbutton swith at ‘S502. Staighten the pine and press ‘hem into the crit board holes a far as possible. Then solder the pins totbefoi, PUSHBUTTON (©) Mount the lide switeh at S501 ress the pins into the cieut board holes as fara posible. Then solder the pins othe ol (©) Moon the test eivcit board assem: bly to the main eireuit board heat sink with two MB x € mm sel tapping screws Msxémm SELF-TAPPING (R01: 1000 0 (brn-bik-red), Sol der the leads to the fol and cut of the excess lead lengths, PICTORIAL 3-13 Heathkit Refer to Pictorial 3-14 (Illustration Booklet, Page 4) for the following steps. NOTE: In the following steps, you will prepare stranded wires from the 8-wire ribbon cable groups. To prepare a stranded wire, cut the wire, or group of wires, to the indicated length, separate the wires (if in a group) as specified in the Detail, and remove V4" of insulation from the wire ends. Twist the wire strands tightly together at each wire end and apply @ small amount of solder to hold the strands to- gether. (} Locate the 12° 8-wire ribbon cable and sepa- rate the following wires, as a group, from the cable. Use a pair of cutters or a knife to start to separate the wires: One brown and red. One orange, yellow, and green. One blue, violet, and gray. () Guta 2" brown and red wire pair. Page 43 (Refer to Detail 3-14A and separate each end of the 2" red and brown wires for 3/4" and pre- pare the ends. Remove an additional 1/4” of insulation from one end of the brown wire. NOTE: Whenever you are instructed to connect @ wire to the circuit board, solder each wire after you connect it and cut off the excess wire length from the foil side. Connect the 1/4” prepared ends of the red and brown wire pair to the main circuit board as follows. () Red wire at hole K. (} Brown wire at hole J. ‘You will connect the other end of these wires later. () Cuta2" piece of 50.0 coaxial cable and prepare the tends as shown in Detail 3-14B. () Connect the inner lead at end A of the 2" coaxial cable to circuit board hole P and the shield lead 10 hole Q. Solder the leads after you connect them and ccut off any excess lead lengths. You will connect the other end of the cable later. ‘You will connect the other end of these wires later. () Cutas" orange, yellow, and green wire group. (.) Refer to Detail 3-144 and separate the wires at each end of the group for 3/4” and prepare the ends. Detail 3-14 a 2 4 . . fects ises | ri L L n Jeeps teal Daf Page 44 Connect one end of the orange, yellow, and green wire group to the main circuit board as follows: () Orange wire at hole N. (.). Yellow wire at hole L. (.). Green wire at holeM Connect the other end of the orange, yellow, and green wire group to the test circuit board as follows: () Yellow wire tohole L. ( } Orange wire to hole N. () Green wire to hole M. Set the remaining wire aside. Refer to Pictorial 3-15 (Ilustration Booklet, Page 4) Part A for the following steps. () Refer to Detail 3-15A and cut the power trans- former leads to the indicated lengths. Measure the leads from where they leave the transformer body. 1-3/4" BLK-6RN| Li aLK-veL Detail 3-15, 120 VAC Wiring. Heathkit ALTERNATE LINE VOLTAGE WIRING ‘Two sets of line voltage wiring instructions are given below, one for 120 VAG line voltage and the other for 240 VAC line voltage. In the U.S.A., 120 VAC is most often used, while in other countries, 240 VAC is more common. USE ONLY THE INSTRUC- TIONS THAT AGREE WITH THE LINE VOLTAGE IN YOUR AREA. NOTE: The plug on the power cord for this kit is for standard 120 VAC outlets in most of North Amer- ica. For 240 VAC operation in other countries, cut off and replace this plug with a permanent plug that ‘matches your 240 VAC receptacle, (Remove 1/4" of insulation from the end of each power transformer lead Insert the power transformer leads into the circuit board holes as follows. Solder each lead to the foil after you ‘connect it and cut off the excess lead lengths. () Bither red lead at hole G. () Remaining red lead at hole H. () Black-ted lead at hoe F. () Black-yellow lead at hole D. (.) Black lead at hole E. ()Black-green lead at hole C. ‘You will secure the power wansformer later. Leave it loose for now. This completes the "120 VAC Wiring." Proceed to "Circuit Board Checkout.” Heathkit Page 45 Refer to Pictorial 3-15 (Illustration Booklet, Page 4) Part B for the following steps. () Refer to Detail 3-15B and cut the power trans- former Icads to the indicated lengths. Measure the leads from where they leave the transformer body. Detail 3-15B OM mH m1 men 2 2 Lys eae ta te | fi i n 1 240 VAC Wi 8. (Remove 1/4" of insulation from the end of each power transformer lead Insert the power transformer leads into the circuit board holes as follows. Solder each lead to the foil after you ‘connect it and cut off the excess lead length, () Either red lead w hole G. () Remaining red lead to hole H. () Black-red lead to hole F. ( ) Black-yellow lead to hole Y. (_) Black-green lead to hole Z. (Black lead to hole C. You will secure the power transformer later. Leave it loose for now. ‘This completes the "240 VAC Wiring." Proceed 10 "Circuit Board Checkout." Page46 CIRCUIT BOARD CHECKOUT Carefully inspect the main and test circuit boards for the following most commonly made errors: (_) Unsoldered connections. () Poor solder connections. () Protruding leads which could touch together. (_) Diodes installed backwards or at the wrong lo- cation. Heathki (_ ) Transistors and integrated circuits improperly installed. (} Polarized electrolytic capacitors installed backwards. This completes the “Main Circuit Board” and “Test Circuit Board Assembly.” Set the assembly aside and proceed to “Cabinet.” Heathkit CABINET Page 47 PARTS LIST Remove the remaining parts from the carton and check each part against the following list. The key ‘numbers correspond to the numbers on the “Cabinet, Parts Pictorial” (Illustration Booklet, Page 5). Return any part that is in an individual envelope back into the envelope after you have identified it until that part is called for in a step. Do not throw away any packing material until you account for all the parts. To order a replacement part, always include the PART NUMBER. Use the Parts Order Form fur- nished with this kit. If a Parts Order Form is not available, refer to “Replacement Parts” inside the rear cover of this Manual. KEY HEATH QTY. DESCRIPTION CIRCUIT. | KEY HEATH QTY. DESCRIPTION cicur No. PartNo. Comp.No, | No. PartNo. Comp. No. HARDWARE M3 Hardware M3.5 Hardware AL 29004704 Max6 mm sltapring screw 81 220832 © 2 MaSx14mmscow 2 2308200 2 MB 6mm cow 52 moss — 2 MBS mut Aa 208368 MB 8 mm seltapring screw 83 2200446 © 4 MAS T2mmsoltinppng srew Ad 0868 2 Mout Be 2508472 2 MBS round paste spacor AS 2908440 4 MSlockwashor As 2308479 1M stacow (ay bo intalodin kn) AT 230-8483 1 M3 solder lug OTHER HARDWARE. AB 230.8469 2 M3 poss-in nut (May already ct 200848 2 Mosxemmscew i beintaod in cabinet) C2 20730 4 Clam 9 20-8402 Ma Rat washor 63 259.27 2 Large solder lug Ro 7208478 8-MBx 10mm sow AN 22086912 M3x8 mm fathoad sow Page 48, Heathkit KEY HEATH —GTY. DESCRIPTION CIRCUIT KEY HEATH = GTY. DESCRIPTION = CIRCUTT No._ Part No. Comp. No. No._ PartNo. _ Comp. No._ ‘ABLE PLASTIC AND NYLON PARTS o 34312 7 RG-17400axlal Di 75182 1 Stain rate sae aautoonl ws 02 92.828 1 Cabinetiop 34750 20° Dive 03 92.753, 1 Cabinet btm Ds 251-49 4 Foot Ds. deceit Geko MISCELLANEOUS 08 z0eK71 + Knob 07 485-18, 1 Round pg FL 63312 1 33Kft, (org-0rg-16) 08 B54 1 Rectangular pug 1is-wat 5% sister Test F2 230-8473 1 20kftcontol Rt BRACKETS - CONNECTORS. Fa 60-604 } mae S101 Fa e919 1 Line cors F5 7308460 1 Antenna u Et 2308487 1 Backpanel 181-4332 1-_—Assembledreceiver 2 206-2663 © 1_Angle bracket Gennes 3 230-8468 1 Antenna bracket Fo 401178 1 Speaker spr 4 4528855 4 Shole connector te dear 1 Sassi E5 432-856 9 Springconnector Fe Deere Wrseorann £8 432802 2 Female aNCoomector £7 230-8674 1 Male BNC connector £8 230-8484 = 1-Powerjack a £9 2308485 1 Power plug st wm 1 oneness 2 ‘ 5 ° alton sy l Page49 STEP-BY-STEP ASSEMBLY BACK PANEL COMPONENTS () The MB press-in nuts may already be installed. If not, refer to Detail 4-1A and install M3 brass Refer to Pictorial 4-1 (Illustration Booklet, Page 6) for the press-in nuts in cabinet bottom holes AA and AB. following steps. Use your soldering iron to install the press-in nuts as shown. (.) Refer to Detail 4-14 and position the cabinet bot- tom with the bottom side up as shown, so.oeana @ hg enass TRON PRESS.IN

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