Heathkit AJ 1510A Assembly Manual

Page 1

copyrighm 1972
Hum Company
All mum run-mm]

ce $2.00
595-1673-02

Page 2

HEATH COMPANY PHONE DIRECTORY

The following telephone numbers are direct lines to the departments listed:

Kit orders and delivery information .......... . ........ I. , , (616) 982-3411

Credit ...........

Replacement Parts . .

Technical Ass/stance:
Fl/C. Audio, and Electronic Organs .. .
Amateur Radio ......... . ........ ..
Test Equipment, Strobe Lights, Calculators,
Clocks, Weather Instruments .
Television ............. . ........
Automotive. Marine, Appliances,

....... (616) 982-3561
....... (616) 982-3571

..., (616) 982-3310
r . . .. (516) 982-3296

......... ..l,.,t.....(616)982-3315
...... (616) 982-3307

Security. General Products ....... . ............. . . . ,. (616) 982-3496

YOUR HEATHKIT 90-DAY FULL WARRANTY

During your first ninety [90] days of ownership, Heath Company will replace or repair tree of charge - as soon as practical -
any parts which are defective. either in materials or workmanship. You can obtain pans directly from Heath Company by
writing as or telephoning us at (616) 982-3571. And we'll pay shipping charges to get those parts to you - anywhere in the
world,

We warrant that. during' the first ninety [90) days of ownership, our products, when correctly assembled. calibrated. adjusted,
and used in accordance with our printed instructions, will meet published specifications,

2: ii a defective part or error in design has caused your Heathkit product to malfunction during the warranty period, through no
fault of yours. we will service it free upon delivery at your expense to the Heath factory, Benton Harbor. Michigan. or to any
Heathktt Electronic Center (units of Schlumbarger Products Corporation]. or through any of our authorized overseas dis-
tributors.

You will receive free consultation on any problem you might encounter in the assembly or use of your Heathklt product. Just
drop us a line or give us a call Sorry, we cannot accept collect cells.

Our warranty, both express and implied. does not cover damage caused by use of corrosive solder. defective tools, incorrect
assembly, misuse. fire. customer-made modifications, flood or acts of God, nor does it include re-imbursernent (or customer
assembly or set-up time. The warranty covers only Heath products and is not extended to non-Heath allied equipment or
components used in coniunction with our products or uses of our products for purposes other than as advertised.

And if you are dissatisfied with our service - warranty or otherwise - or our products, write directly to our Director of

Customer Services, Heath Company, Benton Harbor, Michigan. 49022. Telephone [616) 982-3524. He'll make certain your
problems receive immediate, personal attention.

HEATH COMPANY
BENTON HARBOR, Ml. 49022

Prices and specifications subject to change without notice.

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Page 16

Page 13
-HEATHKIT

STEP-BY-STEP ASSEMBLY

IDENTIFICATION
DRAWING

( ) Position the power supply circuit board as shown in
the identification drawing. Then complete each step
on the Pictorials.

PART
NUMBER

The steps performed in this Pictorial are in
this area of the circuit board.

START

"'

NOTE: When installing diodes, note the
position of the banded end. See the
"Diode Mounting" Detail (fold-out from
Page 10). '

J/l 1N2071 diode (4457-27) at D101.

CONTINUE

. O

W 1N2071 dlodel#57-27l at D102.

1/] 1N2071 diode (#57-27) at D103.

( {I 39 k9 iorange-whiteorange).

INZO71 diode [#57-27I at 0104

( ) 2000 $21 5% (red-blaek-red-goldl.

(VI M22362 diode (#56-74) at D105.

( l 4700 Q, 5% (yellowwlolet-redgoldl.

1/} M21000~23 diode (#5647) at

ZD10l. ( l 4700 S2, 6% (yellow-violet-redgold).

( I 10009(brcwn-black-red).

l 1500 (I, 5% (brown-green-red-gold).

( l 4700 n, 5% (yellow~violet-red-goldl. ( ) 18kn(brown»9ray~0ranuel.

. l 33 k9, 5%, Illm iorangeorenge-
orange-gold).

( l 2200m,5%(red-red-red-gold).

( I 120017.. 5% (brown-red-red-gold).
S FETY WARNING: Avoid eye injury

w en you cllp off excess leads. We suggest
that you wear glasses, or at least clip the

off the excess lead lengths.
Ie ds so the ends will not fly toward your

f l Solder all leads to the foil and cut

9 Est

( l Solder all leads to the fell and cut
off the excess lead lengths.

PICTORIAL 1-1

Page 36

HEATHKIT Page 33

START
.7

- ( l Cut of! eight strips of seven lC
connectors and set them asidel

NOTE: Refer to "IC Preparation and
Installation " Detail (loldvout from Page
10), for information on installing lCs.

/
( ) SN7400N |C(#443-1)atl%0'8. . -

' l l SN7427|C(#443-65)at|0905/,

( ) SN74HlON RI (#44368) at $307;

) SN74OON IC (#4434) at 190?.

,) Cut off eight strips cf eight IC
connectors and set them aside.

( ) SN74192 IC (#443456) at 104133.

'1 ( ) 5N74192lct#443-56)an0494.

.
"l ) SN7476NIC(#443-16)atl0;,02.

( ) SN74192 it (#44366) at 19%,.

1 t

155%.}.-

Fm"

PICTORIAL 4-2

. , wkxanwnww gm»

Page 41

P

age 38

IDENTIFICATION
DRAWING

START
, "

l-{ 1500 S1, 5% Ibrown-green-red-goldl.

PART
NUMBER

The steps performed in this Pictorial are in
this area of the circuit board.

IJ) 27 kn, 5% Ired-violeborange-gold).

NOTE: When you install diodes, note the
position of the banded end. See the
Diode Mounting" Detail (ioldmut from
Page/10),

Ii/I INIQI diode (#56-26, brown-

. white-brownl at D501.

L/

I I 4700 n, 5% Ivellow»viole\-red-goldl.

Solder all leads to the foil and out
off the excess lead lengths.

I I

-EEATI-IKIT5

CONTINUE

I G

Ive/l] 220 SI, 5% lred-red-brown-goldl.

I/I

I,5600 Q, 5% Igreen-blue-red-gold).

I 0 i78" jumper,

IV 470 Q, 5% Iyellow-violet-brown-

/go|d).

I 1N191 diode (#55-26, brown»

white-brownl at D502. I

470 Q, 5%
gold).

Iyel low-violet-brown-

( l/ 2200 n, 5% Ired-red»red-gold).

Solder all leads lo the foil and cut
off the excess lead lengths.

l

PICTORIAL 5-2
1/: 1/2 3/1 l (wcHEs) 2 3 4 5 7
'1 CHE I SIB 7{BI I I A
,ungmu r , I I . , I, I I, I J. I IT fl 1'. I; )I J | I .1 I I I . Ifi l I
1 (CM) 2 3 4 5 s 7 a E 10 11 12 13 14 15 1a 17

O

Page 58

Page 54

START

V

(J LC filter (#52453) at F601. Solder
all pins to the foil,

M LC filter (#52453) at F602.

IJ I-F coil (#52154) at L602. Solder
all four pins to the foil.

PICTORIAL 6-8

-HEAJI-IKIT

CONTINUE

O

( ) Phono socket. Insert the phono
socket into its hole from the foil
side of the circuit board. Position
the lug of the socket on the compo-
nent side of the circuit board as
shown. Then solder the socket to
the foil. On the component side of
the circuit board, solder a 1" bare
wire between the lug of the socket
and hole A. Cut off any excess lead
lengths.

@ FOIL SIDE or
I] CIRCUITBOARD

SOLDER

( ) Check the three resistors near LC
filters F601 and F602, and be sure
they do not touch the filters. (If a
resistor was scratched when a filter
was installed, and the resistor is now
touching the filter, it may produce a
short circuit when the Tuner is
turned on.)

This completes the assembly of the circuit
board. Check all connections to be sure
they are soldered and that no solder
bridges exist between foils, Set the circuit
board aside temporarily.

FINISH

Page 91

_I-IEATI-IKIT@

341
d2

Page 87

IDENTIFICATION
DRAWING

NUMBER

The steps performed in this Pictorial are In
this area of the circuit board.

START

"

( K Position the circuit board compo-
nent side up as shown.

V/Prepare two 16" lengths of smell
shielded cable as shown in Detail

10-14A.

NOTE: Solder the following cables and
WIIIS as they are installed.

I Either shielded cable: Inner lead to
LEFT CHAN, shield lead to GND.
The other end of this cable will be
connected later.

I Other shielded cable: Inner lead to
RIGHT CHAN, shield lead to GND.
The other end of this cable will be
connected later,

OTE: When you prepare hookup wire,
emove 1/4" of insulation from each end
f the wire.

I 18 blue wire at SCOPE VERT, The

*3/4"

-- [1/4
I [3

/ff

CUT THE CABLE ACCORDING TO THE DIMENSIONS
BELOW. PREPARE EACH END AS SHOWN.

HAL-1 ._
i l

Detail 10-14A k

SHIELD
LEAD

other end of this wire will be
connected later.
( 18 violet wire at SCOPE HORIZ.
_ The other end of this wire will be
connected later,

This completes the assembly of the master
circuit board. Check all connections to be
sure they are soldered and that no solder
bridges exist between foils. Set the master
circuit board aside until it is called for.

% o 1"
I

PICTORIAL 10-14

2
I

I

3H 4"
I l i 1 i |

Page 95

Page 91

-HEATI-IKITE
. fi-BZ x3/8"
@ SCREW §FUSEH0LDER
SCREWATYPE ' / § BLEUNcDgLiiS
TERMlNAL STRlP Q 2/ AFTER

INSTALLATlON

RUBBER WASHER

LOCKWASHER
NUT

lssowsn LUG Detail 'l1-1E

@

6-32 NUT (V{ Refer to Detail 'll»lE,and mount the fuseholder at AR

l\
u R .
/ #6 LOCKWASHE with the hardware supplied with the fuseholder. Be
@ sure to position the lugs as shown.
6-32 NUT /
( ) Bend lug 2 of the fuseholder away from the fusehoider
Detail 11-1C body as shown.

( v/ Remove the fuseholder cap by twisting it
counterclockwise. Then install the .SA slow-blow fuse
and replace the cap.)

( 4i Mount the screw-type terminal strip on the outside on
the chassis as shown in Detail ll-lC. Position the lugs
as shown and use a 6'32 x 3/8" screw, a #6 solder lug,
and a 6-32 nut at AL. Be sure to position the solder
lug against the terminal strip lug as indicated in the
Pictorial. Use 6-32 x 3/8 hardware in the remaining
hole.

INSET

(J Refer to Detail 1110 and mount the 2-lug terminal
strip at AN with 6-32 x 3/8" hardware. Position the
lugs as indicated in the Pictorial.

Detail 11-1F

2~LUG -/' . , .
TERMlNAL STRIP NOTE: When you install the ac socket in the followmg
steps, be sure to position the socket with the wide slot as

shown in the inset drawing.

. \ . (i/l install the ac socket into the chassis by pressing it into
Detall -113 6-32 NUT@ position at AP as shown in Detail 11-1F.

#6 LOCKWASHER {7
Ct

Page 109

MASTER CIRCUIT BOARD
PARTS PICTORIAL

Page 113

READOUT
CIRCUIT BOARD

100A 206A E06A

#1813 LAMP #1813 LAMP #1813 LAMP

PICTORIAL 12-1

PICTORIAL 12-2

Page 132

WIRE
HARNESS

PICTORIAL 13-5

Page 155

Page 133

-HEATHKIT
CONNECT BLACK CONNECT RED METER SHOULD
TEST LEAD TO: TEST LEAD TO: READ:
. . l I
GND pin REPROG SQ pm WI) / 5
///ii
. \ 47 /
+15V pm. o g 5
. gi I I
AGC CONT pin. 0 g 5
AGC LEVEL pin. 4&2 i l , 5
+5V pin. 1'
SQ OVRiD pin.
STOP sw pin. 0 5/? I 5
4/
ST ONLY 2 pin.
/ l I
so DEFEAT pin. 0% ' 5
//,l
+ METER pint
| 1
34\ / 5
S MTRLpin 60
_METEm o \ 'gs
\ ._
\
' '/ I 1
ST LT CONT pin. 0 1% I 5
/
R CHAN pin.
/ \ l l /
4/ 5
:9' L CHAN pin. 0,
(/i Remove the circuit board connector that was installed ( L/ Remove the tuner/phaselock-Ioop circuit board that
on the multiplex circuit board. was installed earlier. The tuner/phase-iock-Ioop, H,
and multiplex circuit boards will be installed during
( ) Press the POWER ON button to the off (out) position. the following Adjustments."

Page 162

O

Page 140

-HEATHKIT®

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a

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ej///%\\\\\\

Detail 152D

1/ell3ElE/E7/Bi,l ll)
I

1/.

1/2/4

lm'ululml v

7

.s

1 (CM) 2

Detail 15-2E

I (INCHES) 2

a a 5

l.l.l.i
| l1

a

l

Refer to Pictorial 15.2 for the following steps.
( ) Cut two 14»l/2" lengths of the foam gasket material.

( l Refer to Detail 15-2D and remove the paper backing
from the foam gasket material. lnstall this foam gasket
as shown on the underside of the top rail. Be sure you
install it on the correct side. NOTE: Be very careful
you do not remove the adhesive along with the paper
backing.

( ) Position the top rail on the chassis as shown in Detail
15-2E. Then mount the free end of the braid coming
from FD on the tuner to the top rail at FE with a 6»32
x 1/ " screw and a 6-32 nut.

( ) Carefully press the top rail into position on the chassis
as shown in Detail 15-2F. Then mount the top rail to
the chassis with four #6 x 1/4 sheet metal screws.

( ) Connect the antenna push-on connectors from the

tuner-PLL circuit board to the screw-type terminal
strip as shown in the Pictorial.

Refer to Pictorial 16-1 for the following step.

( ) Pasition the top shield on the tuner as shown, being
careful not to pinch any wires.

( l Mount the top shield to the tuner with six 6-32 x 3/8"
black flat head screws.

This completes the Final Assembly." Proceed to the
lnstaliation" section that follows.

Page 169

OPERATION

The following paragraphs and Figures will help you become
familiar with the operation of your new Digital FM Stereo
Tuner. Note that there is no volume control on the Tuner, as
the audio output is held to a fixed audio level.

The sound output of your entire Tuner-Amplifier system
will be determined by the level control settings of your
Amplifier.

TUNING MODES

Three separate tuning modes are available on your Digital
Tuner: the Keyboard Mode, the Auto-Sweep Mode, and the
Preprogrammed Mode. Each one will be described separately
in the following pages. And since some of the pushbuttons
and controls are used in all tuning modes, their operation
will only be described once.

Set the controls and switches as follows. Do not change any
of their settings unless directed to do so in a step.

53.: T_0

Out (released) position.
Fully counterclockwise.
Fully counterclockwise.
Fully counterclockwise.
SIGNAL.
STEREO.

All pushbuttons

AUTO-SWEEP SPEED control
NOlSE SOUELCH control

AGC SQUELCH control
SlGNAL-MULTIPATH switch
STEREO-BLEND-MONO switch

KEYBOARD MODE

Refer to Figure 3-1 for the following paragraphs. The
pushbuttons and controls that are shaded are used in the

IaIE.9_'TLI-IIEI'I®

Keyboard Mode of operation.

( ) Press the POWER ON button to the ON (in) position.
Then turn on your amplifier system and set the
amplifier for a low-level sound output.

( ) Select a local fm station, preferably one that
broadcasts in stereo, and note its frequency (106.9
MHz for example).

( ) Press the KEYBOARD button to the ON (in) position.
The front panel RE-PROG RAM lamp should light and
the readout should display 001 MHZ.

NOTE: Press the RESET button to clear any undesired
frequency that has been programmed into the Tuner. If in
the following step you press a wrong keyboard button,
simply press the RESET button and start over again. Note
also, that only a single digit gig number can appear to the
right of the readout decimal point. A two or three digit odd
or even number can appear to the left of the readout
decimal.

147

Page 199

Page 172

INDICATION

Meter reads greater than 2.5.

-HEATI-IKITG

POSSIBLE CAUSE

0108 or its associated foil
is shorted.

0109 or its associated toll
is shorted.

0111 or its associated foil
is shorted.

C1112 is defective.

Meter reads less than 1.8.

0108 is defective.
0109 is defective.
0111 is defective.
C113 is defective.

Meter reads less than 3.5,

051 and/or D52 defective.

Meter reads greater than 4.5.

TEST CHARTZ

PROGRAMMER AND DATA MU LTIPLEX
CIRCUITS
NOTE: It is necessary that the keyboard circuits are working

properly before you perform the following steps. (Refer to
chart 11 on Page 183.)

( ) Press the POWER ON button to the off (out) position.

( ) Remove the programmer circuit board from the
chassis.

( ) Connect the extender circuit board to the programmer
circuit board.

Transformer improperly connected.

install the board combination.

Set the METER switch to the TEST position.

Set the RANGE switch to the 15 Vdc position.

Press the KEYBOARD button to the ON (in) position.
Press the POWER ON button to the ON (in) position.

Press the RESET key and perform the measurement in
the following chart.

CONNECT BLACK CONNECT RED
TEST LEAD TO: TEST LEAD TO: METER SHOULD READ: POSSIBLE CAUSE OF
TROUBLE:

GND pin. Collector (C) D201; 0202; D203;
of0201or 0 \5/2' / 5 D204; |C201, 0201.
collector side ///
of R211 (1000 Q).

Note the meter reading. Then press any of the numbered keys four times. The meter indication should go to
0 as the first number is depressed and remain there as the other three numbers are depressed. Then press the
RESET key. This should cause the meter to return to its original position.

Page 205

Page 1 78

TEST CHART5
MULTIPLEX (MPX-DEMOD) CIRCUIT

( ) Press the POWER ON button to the off (out) position.

( ) Remove the ILL-multiplex demodulator circuit board
from the chassis.

( ) Connect the extender circuit board to the
PLL-multiplex demodulator circuit board.

( ) Install the board combination.

( ) Set the METER switch in the TEST position.

( ) Set the RANGE switch in the 15 Vdc position.

( ) Press the KEYBOARD button.

( ) Press the POWER ON button to .the ON (in) position.
( ) Use the keyboard to select a strong local station.

( ) Perform the measurements in the following chart.

NOTE: Be sure that the SOUELCH DEFEAT and STEREO
ONLY buttons are in the off (out) position for the following

measurements.
CONNECT BLACK CONNECT RED
TEST LEAD TO: TEST LEAD TO: METER SHOULD READ: POSSIBLE CAUSE OF
TROUBLE:
GND pin. Pin 1 of STEREO ONLY switch
ic702. wiring; ic7o2.
Pin 2 of KEYBOARD switch
|C702. wiring.
Pin-40f a, 0716;0717; [0606; 0601;
lC702. o g 5 D611 and/or D609; L602
; not adjusted.
PinSOf ,/ . I O714;D712;D711;
iC702. 0% s O713;O712;NOISE
4/ SQUELCH control wiring.

fiHEATI-IKITB

Page 212

Page 185

-HEAII-IKITB

CONNECT BLACK
TEST LEAD TO:

CONNECT RED

TEST LEAD TO:

METER SHOULD READ:

POSSIBLE CAUSE OF

TROUBLE:
@\ ' /
/ 5
L8. With Key 9 pressed 8809; 0811.
V/ I
\ / /
o -/ 5
é
Any GND pin, SHT. With Key 1 pressed. D813; 0801.
or chassis.
Z/w
\ / /
o 5
SHT. With Key 2 pressed. D814.
/
o \%I 5
6
SHT. With Key 4 pressed. D815.
// I
\ / /
o / 5
SHT. With Key 8 pressed. D816.
'/
0 \4%' / 5
g
SHT. With Key 0 pressed 8811; R805.
// 1
Positive (+) o % / 5
side of 0802. 4
With RESET pressed $812; R811;C802.
W:
o\ g 5 5813; R808;
K R809.
BPS. With no Keys pressed
,@ l i I 5
4/, 5813; R808;
BPS. With BYPASS pressed. R809; C801.

Page 248

-I-IEMHKITB

The right and left channel amplifiers (0701, 0703 and
0702. 0704) are direct coupled and apply the detected
audio signals through R721 and R722 to LC filters L704
and L705. These filters remove all unwanted signals above
15 kHz that may still be present on the audio signals. The
outputs of filters L704 and L705 are coupled through diode
switches D701 and D702 and capacitors C712 and C711 to
emitter followers 0708 and 0707.

Diodes D701 and D702 are part of the audio squelch circuit
and are either saturated or cut off, depending on the state of
the squelch driver 0711. Diode D703 is also part of the
squelch matrix, but is always at a state opposite that of
diodes D701 and D702. The emitter follower output
provides a low impedance output to an external amplifier.

NOISE CIRCUIT

Transistors 0712, 0713, and 0714 form a noise amplifier
circuit. This circuit applies a signal to the squelch circuits
that causes the audio to squelch (tu rn off) whenever noise is
present. Resistor R704 and the Noise Squelch control, R54,
provide a variable divider input to the amplifier. Coil L706
and capacitor C721 form a circuit that is tuned to
approximately 100 kHz. When noise is present, it will have a
100 kHz component that can be used as an indication of
signal quality.

Transistors 0712 and 0713 amplify the 100 kHz noise
signal before it is rectified by diodes D711 and D712.
Resistor R746 and capacitor C726 form a delay circuit that
simply prevents random noise pulses from triggeringthe
squelch circuits. 0714 further amplifies the dc signal and
applies it through D713 and D714 to NAND gate lC702A.

SQUELCH CIRCUIT

The function of the squelch control circuit is to accept
inputs from various sources within the Tuner and determine
from these inputs the state of the audio squelch control
voltage (audio on or audio off). These various inputs are
themselves determined by the operational state of the entire
Tuner. In the automatic sweep mode, the squelch control
:ircuit also delivers a stop signal to the auto-sweep circuit.
Figure 6-7 shows the overall squelch circuit.

The main logic element of the squelch circuit is the 4-input
\lAND gate, |C702A. The output (pin 6) of this gate will
'emain high until all the inputs are simultaneously high.
Nhen this occurs, the output switches to a low. Should any
>r all of the inputs become low, the output will immediately
Jecome high. The output of |C702A is coupled through
lelay network D715, R756, and C723 to emitter follower
tansistor 0715.

Page 211

Transistor 0715 drives three circuits; the sweep-stop circuit,
the stereo light control circuit, and the audio squelch circuit,

In the auto-sweep mode, the signal at the emitter of 0715 is
coupled to the sweep-stop flip-flop (|C210C and IC21OD)
on the programmer circuit board. When all of the inputs to
NAND gate |C702A are high, the output is low. This turns
off transistor 0715 and couples a low to the sweep-stop
circuit causing the sweep to stop.

Figure 6-8 shows that transistor 05, which is normally
biased to conduct, places one side of the Stereo lamp at +15
volts. Whenever a stereo signal is present, pin 6 of the
multiplex decoder lC701 goes low. A low turns on 0718
and the Stereo lamp.

When 0715 is turned on by a positive squelch signal from
NAND gate |C702A, a positive signal is also coupled through
R758 to transistor 04. As 04 conducts, 05 is turned off
removing the +15 volts from the Stereo lamp. This holds the
Stereo lamp off whenever a squelch signal is present.

Transistors 0709 and 0711 drive the squelch diode matrix
diodes D701, D702, and D703. Besides the squelch inputs
from 0715, an input from the unlock determining circuitry
on the tuner-PLL circuit board and an input from the
reprograrn circuitry, are also present. Transistor 0709 is
turned on when a positive squelch signal is applied to the
base. When 0709 conducts, the cathodes of diode D703 are
placed at ground and transistor 0711 is turned off.
Transistor 0711, which is normally biased to conduct,
removes the ground from the cathodes of diodes D701 and
D702. This causes the audio signals to squelch.

The SQUELCH DEFEAT switch 358 places the base of
0709 to ground through resistors R759 and R761. This
prevents any of the squelch inputs, with the exception of
the reprogram squelch input, from turning off the audio
signals. Anytime an incorrect frequency is selected, the
reprogram squelch input will override the squelch defeat
switch and cause the audio to squelch.

The stereo only switch, 359, normally places the input to
NAND gate lC7OZB at ground. When the stereo only mode
is selected, this input is connected through diode D717 to
pin 6 of the multiplex decoder, lC701. Resistor R748 new
places +5 volts at the input of NAND gate lC7OZB and
produces a low at the output. If a stereo signal is received,
pin 6 of lC701 goes low and places a low at the input of
|C7028 and a high at the output. As explained previously, a

.high at the output of NAND gate lC702A produces an

unsquelch and sweep-stop signal. Thus, the stereo switch
allows only stereo signals to be heard and causes the
auto-sweep to stop only when a stereo signal is received.

Page 259

l-F CIRCUIT BOARD
(Viewed from foil side)