68
._ 1|. £1 5%.: Q .z_ -. . 00603627 Rev.-21430 ASSEMBLY MANUAL 8lO5C

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Page 1: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

._

1|.

£15%.:

a» Q.z_ -.

.

00603627Rev.-21430

ASSEMBLY MANUAL

8lO5C

Dave Spalla
The Workbench Logo
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ISBN 8653? " O3l -‘i

. TM

ASSEMBLY MANUAL

8|O5C

@COP‘|"Fl|GHT 1977DEVHY INC.

ALL RIGHTS RESERVEDxii?-Fm‘; 6AC5}-

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range.

IMPORTANT NGTICEFOR

81050, EL—1010B and TL—101OB

CAPACITOR MARKING

If the capacitor is marked with an E.I.A. code, refer to the following chart to

determine the temperature range and the maximum capacitance change over that

-‘__ ___ ___1_------ __ -_ ---— __ __ _ ---—- ___ — _________ - - __ _ " ' u-In

Low Temp. Letter High Temp. E Numerical Change Over LetterRequirement Symbol Requirement l__ Symbol Temp. Range Symbol

Max. Capac.

+10“ C-30? C-55°C

+45“ C+65“ C+85“ C

+105° C+125°C "'---lU‘1{.7-‘I-P‘-I"-J

+1i1i213i4i7

"$10-‘£15122

+22%,+22%:+22%,

_........._. . .._...... _..._ _ J ..... .- - .- .- ..... .-

0%5%2%3%7%5%0%0%0% i-33%-56%-82%

l. in. _--',,|- -- ____ 7 _____-_',-l _-_-I |_||T-|| _1_ ----- - ---— ___]. " ___-

‘=1’-'.'CI--IU'JSU'CJ"1'lI'T'l@f._JCUj==

| .!E

NOTE: If the capacitor is not marked with an E.I.A. code, refer to the manu-

facturer's catalog

The capacitance value will be marked in either of two formats.- For example,

.012 and 1032 both represent .01 uF capacitors. The "Z" in each format repre-

sents the tolerance (+80%, -20%). The following chart defines each tolerance

letter. I

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1032, it is being expressed in picofarads, where the first two d1g1ts repre

sent the significant figures and the last digit spec1f1es the number of

zeroes to follow. Therefore, 1032 is 10,000 pf, or 01 nF +80% 20%

tolerance.

The Case Breakdown voltage is assumed to be 100V unless otherw1se specified

by a two- or three—digit number followed by the letter V for volts

CAP. MARK./IN

_.__ .._.. ' '-

CapacitanceTolerance

AI"--1\1..f'1'"‘lIIIE7<~‘I'_a£|",)1'l'EJf.'I'ZlI

.I—

‘£0.25 pf10.5 pfi1 pf12%i5%i10%120%+100% -0%

5 1 ‘“

+80%, 20%

when a capacitance value marking uses the three-digit number format, such as1. ___

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Basic Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Completing the Basic Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Regulated i15V Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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INTRODUCTION CONSOLE so

CONSOLE BOTM is a multifunction design console that provides breadboarding facilities for both analogand digital circuits. Features include a dual 0 to 15 volt adjustable and regulated power supply, a +5volt fixed, regulated power supply, a 12.6 VAC power supply and a 2 Hz to 20 kHz function generatorwhich provides sine, square, and triangular waveforms. An area provided with plastic strip fasteners per-mits the rapid mounting of various breadboard units as well as other subassemblies.

CONSOLE SOTM is housed in an attractive and rugged instrument case. A storage area holds the line cordand other accessories such as additional breadboard units. The deep case cover provides clearance to per-mit assembled test circuits to remain on the unit when the cover is closed.

This manual provides complete construction details for the unregulated power supply section ofCONSOLE 80 along with a circuit description and troubleshooting information.

SPECIFICATIONS

9:15 VOLT POWER SUPPLY: 0-—-15V @ 500 mA short-circuit protectedfii‘

+5 VOLT POWER SUPPLY: 5V @ 1A short-circuit protected.

12.6 VAC POWER SUPPLY: 12.6 VAC center-tapped, @ 500 mA.

FUNCTION GENERATOR: Sine, square and triangular output waveshapes.2 Hz to 20 kHz in four ranges, uncalibrated.Buffered, adjustable output 0--20 VP.P.Will operate into a 509 load @ 10 VP-P.

BREADBOARD FACILITY: Plastic strip fasteners on 6” X 7-1/2” area.

POWER CONSUMPTION: 11‘? VAC @ .750A.

SIZE: 13-1/2”W, 5-1/4”H,10”D.

WEIGHT: 8 lbs.

ADDITIONAL FEATURES: High-impact plastic case with a three-wire, grounded line cord. Fuseprotection in AC line. Five-way binding posts.

*i15 volt supply does not go down to 0 volts. Actual low end voltage depends upon regulator charac-teristics, and is typically 1 to 1.5 volts.

1-1

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CONSOLE S0

_ REQUIRED TOOLS .

Use of the following tools is suggested for the assembly of CONSOLE 80

P Soldering Iron, 40 to 60 Watts

Q Screwdriver, Blade Size 1/4”

P Nut Driver, 1/4”

9 Long-Nose Pliers

9 Diagonal Cutting Pliers

A Wire Strippers

@ Adjustable Wrench, 6” or 8” Long

1-2

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MCHANICAL ASSMLY T 8.I.

Parts Needed

The following parts are used for the mechanical assembly of CONSOLE 80. To help you identify thevarious components, reference numbers in the list correspond to the component pictorial drawings inFigure 2-1.

Quantity

-I

.1

-I

1-:

J

-1:

J

-I

3

1

4

5

1

1

1

1

11

2

2

13

2

18

2

1

1

I.

Reference

Fig. 2-1AFig. 2-1BFig. 2-10Fig. 2-1D

Fig. 2-1EFig. 2-1F

Fig. 2-1GFig. 2-1HFig. 2-1HFig. 2-1HFig. 2-1IFig. 2-1JFig. 2-1KFig. 2-1LFig. 2-1MFig. 2-1MFig. 2-1NFig. 2-INFig. 2-1PFig. 2-1PFig. 2-1QFig. 2-1R

Description

Top Panel

Side Panel A (inside view)

Side Panel B (inside view)

Power Transformer

3-Point Terminal Strip

4-Point Terminal Strips

6-Point Terminal Strip

Black Five-Way Binding Posts

Red Five-Way Binding Posts

Yellow Five-Way Binding Post

Bridge Rectifier

Fuse Holder

SPST Toggle Switch

6-32 X 1/2” Flat-Head Screws

6-82 X 5/16” Binder-Head Machine Screws

8-32 X 5/16” Binder-Head Machine Screws

6-32 Hex Nuts

8-32 Hex Nuts

No. 6 Lockwashers

No. 8 Lockwashers

3/8" Rubber Grommet

LED Indicator

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CONSOLE 80

Front Panel Assembly

Orient the top and side panels as shown inFigure 2-2. Then, use a pencil to numberthe various holes in the side panels and onthe back side of the top panel, as shown.Use a sheet of paper on your work surfaceto protect the front surface of the toppanet

Mount the side panels to the rear, un-labeled side of the top panel. U.-is a-s2 ><1/2” flat-head screws, No. 6 lockwashersand 6-32 nuts, as shown in Figure 2-3. Usecare when tightening the screws so thatthe screwdriver does not slip and mar thefront surface of the top panel.

Refer to Figure 2-4 for the orientationand location of the various terminal strips.Each terminal strip is mounted to theback side of the top panel as shown inFigure 2-5, with a 6-32 X 1/2” flat-headscrew, two No. 6 lockwashers, and a 6-32nut. Label each terminal lug as shown inFigure 2-4. With a pencil, label the lugs onthe panel and not on the terminal strip, asgraphite is a conductor.

Following Chart 2-1, mount a 6-point andthree 4-point terminal strips.

Terminal Strip I Location Label L"" -- ' " " " " " -.'.':';'::..1 --------- -- *1

4-POINT , 19 I TSA

4-POINT 20 TSB L

4-POINT A 24 TSD------------- --------I----- ---- --

___. __________ _ __ ______ ....... . _ 1

6-POINT I 23 TSC

CHART 2-1 I

Mount a 3-point terminal strip at hole 35of Side Panel A using a 6-32 X 5[16”binder-head machine screw, two No. 6lockwashers, and a 6-32 hex nut. Noticethat this terminal strip is mounted on theinside of Side Panel A and should beoriented as shown in the detail of Figure2-4. Label this terminal strip TSE.

CAUTION: In Steps 5 and 6, do not overtightenf_the;.-mounting screws.

Following the mounting arrangementshown in Figure 2-6, mount the bridgerectifier at hole 21 of the top panel.Orient the bridge rectifier as shown inFigure 2-4, with the red dot pointingtoward the lower left-hand corner of thedrawing. Label the bridge rectifier CR1.

Mount the fuse holder at hole 36 on theinside of Side Panel A in the positionshown in the detail drawing of Figure2-4. Use a 6-32 X 5/16” binder-headmachine screw, a No. 6 lockwasher and a6-32 hex nut, as shown in Figure 2-7.Label the fuse holder FH1, as shown inFigure 2-4.

Mount the SPST toggle switch at hole 17of the top panel following the mountingarrangement illustrated in Figure 2-8. Useyour long-nose pliers or a suitable flatwrench to tighten the nut on the backside of the top panel. Do not try to tight-en the switch with the knurled nut, as youmay slip and scratch the front surface ofthe top panel. Label the switch as SW1.

The ten binding posts are mounted to thetop panel as shown in Figure 2-9. Thebinding posts fit into “double D”-shaped

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CONSOLE 80

holes to provide the proper alignment.The hex nut should be tightened with awrench. Do not overtighten or the bind-ing post threads will be stripped.

Mount the red, black, and yellow bindingposts following Chart 2-2. Refer to Figure2-2 for the hole openings and label eachpost as shown in Figure 2-4 and Chart 2-2.

coton. l HOLE LABEL""""" '1' |_ . .L

'"-- ___:.......-1 .. 1

BLACK 7 B11 ..__._.

I

“Thepower transformer is mounted toholes 44 and 45 on the inside of SidePanel A with 8-32 X 5/16” binder-headmachine screws, No. 8 lockwashers and8-32 hex nuts, as shown in Figure 2-12.Be sure to orient the transformer asshown in Figure 2-4 so the side with thered, yellow, and black leads is away fromthe top panel.

This completes the mechanical assembly. Checkyour work to be sure all components aremounted and labeled as indicated in Figure 2-4.

8 B2RED. W """"""""""|—

I

S 9 . asJ RED

BLACK 10 B4

asp i 11 1 B5

1 BLACK 12 so f

T RED 13 B7 -I

YELLOW 1 14 B8

BLACK 15 , as j------------ 1 .

' Btu) i 1a ¥ B10 5

CHART 2-2

Push a 3/8” rubber grommet into hole 38. 1' on Side Panel A. The grommet should fit

as shown in Figure 2-10.

The LED power indicator is pressed into;_.'_.-* hole 18 in the front panel as shown in

J Figure 2-11. Use a 1f4” nut driver asshown to push the indicator into hole 18.Route the wires from the LED indicatorthrough the grommet in hole 38 as shownin Figure 2-4.

2-3

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CONSOLE 80

2-4

aOQ¢i><a<1¢>O O

O‘ o o

IoQ U

I O‘ O O

.00 Q

I i I..... -------------TOP PANEL {sacs snsl

FIGURE 2- IA

, Q ,O ID D

o o0

O

OO

TOP SIDS PANEL A [INSIDE]

FIGURE 2-'IB

_ _— 7=-

O OD D

D

O‘l0 O

TOP SIDE Panel. s rnvsroslFIGURE 2"'IC

. .. LI} 0 K

Y“-.

Page 12: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

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CONSOLE 80

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IE

POWER TRANSFORMER

FIGURE 2"ID

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FIGURE 2 "IK

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FIGURE 2- IG

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FIGURE 2'II

FIGURE 2-IL FIGURE 2-IM

FIGURE 2-IN FIGURE 2-IF

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I

NINMMDOE

Q0‘RN

goUm9MNO_mmNNmo_v__

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SUEPANEL 6-32 HEX NUT\m@/

M1,“fwo s LDCKWASHEH

Rm TOP PANEL

mi ii‘,//£§;§d£ FLAT:-h'EAD SCREW

FIGURE 2-3

CONSOLE 80

sins PA NEL DE TAIL0 I

2 FHI

ill.-'--s 2.

,..-... "h- ~. ......‘k __ _ .-‘ “J:

In _-: .1.--*" .-\\\\\\"" '

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O

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TS A

Q:I

2

3

4

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TSB

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lap.i:I.-w 1,,

.r

3 5

s I4 . .i'I- I.‘ - .i:5

Tso - I

2 ' I3 .......... ..

4 ’<?-‘I

FIGURE 2-4

RED

YELLOW

RED

BLACK

BLACK

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CONSOLE 80

I TERMINAL5 STRIP/ s-as scar-asap

' scasw

I Q no s LOCKWASHERmi”

I TP_ O#r4'44r-:4 %N PANEL

, -anH.-.w.-amramwrama—-I6-32 FLAT-HEADH-'*""‘ scnsw

FIGURE 2- 5

\"\."\“\."\.'\."\.'\

m.\m.\.xx1..\~c

sxsz wax norm’/no.s Lockwaswsaan-4*’;

BRIDGERECTIFIER

'19‘ FAREL

1 eras FLAT-HEADIA,--'""sca.-:w

FIGURE 2 '6

s-aafisxwur so s LOCKIPASIER

-:-:;-;._..' ' :-:-:::-.-.-IZQHEL ..~'“"""'

$".s'.~1$:::::s i

E-w-"I.¢lI§-Rr““§§é2F“

FIGURE 2" 7

ETDP PANEL ‘fi‘§_u:iIT

TOPOFSWITCH

__ _ _ _n_:-::I='i'.'|-I-I|i'i:i:1n|I|u"svI I _ _ _

T. "I\\\

W f-|"|"' '|'|' 'n.'n.'.'.

I-‘inouns 2-e

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2-8

FIVE WAY 5'BIAIDWGPOST

PANEL

lid?\ as FIGURE 2—IO

.5 sIIn-|-1|I--I-I _-I'-"um!

GROHMET5II -':

-jg PANEL A

N

FIGURE 2"9

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I '1I-1.<-

I I/4" norDRIVER

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:5 :_'-1-, '. 5/_' .L roe PANEL;

armstrans

FIGURE 2-II

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FIGURE 2'"I2

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ASICPOW SUPPLY ASSMLY CONSOLE 80

_ Parts Needed

The following parts are used for the assembly of the basic power supply section of CONSOLE 80. Thereference numbers correspond to the component pictorial drawings of Figure 3-1.

Quantity Reference Description

1 3-1A 1.5 kfl , 1/2W, i20% Resistor(Brown-Green-Red)

2 3-1A 10 kfl, 1/2W, i20% Resistors" (Brown-Black-Orange)

2 3-1B 1000 ;.rF, EOWVDC Electrolytic Capacitors

8’ each color No. 22 Solid Red, Yellow and Black Hookup Wire

Solder, 60/40

Power Supply Assembly

During assembly of the power supply, various lengths of hookup wire are called for. Cut each wire to thespecified length and strip 1/4" of insulation from each end, as shown in Figure 3-2, unless otherwisedirected.

To aid in the assembly, component lead lengths are also specified when necessary. Carefully measure andout each lead to the specified length, as shown in Figure 3-3.

When making electrical connections to lugs and terminals, the component leads or hookup wires shouldbe wrapped around the lugs or terminals as shown in Figure 3-4. _ '

Some terminals have more than one connection. Solder only when indicated..,,»All power transformer leads are 12” in length. To neatly wire the supply, various excess lengths

1 of wire must be removed from each lead. Route the leads as shown in the indicated figure andthen remove the excess wire, allowing enough wire at the end to strip 1/4” of insulation. Charts3-1, 3-2, and 3-3 indicate the approximate amount of wire to be removed. Check the lead lengthbefore cutting since some variation in transformer lead length can occur.

Select the brown and two blue transformer leads. ‘These leads will be on the side of the trans-former nearest to the top panel. Trim the leads and connect them to the binding posts specified in

3-1

‘R

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CONSOLE 80

Chmt 3-1. Route the leads as shown inFigure 3-5. Wherever a pair of leads withthe same color is called for, either leadcan be cut to the shorter length.

H ' I: """""

Lead - Length Connect JColor Removed _ To Solder

""""_ ------- --I _ __________ -l _ __ __ 1 " 1I Blue 2-1/4" l as , YESi - ----—-— . ..

Brown} 4” B4 YES

Refer to Figure 3-6 for connections tobridge rectifier CR1. Route the leads asshown in Figure 3-5.

l Color iRemoved To SolderI Lead Length , Connect

1 - -- --———-----r l --------------..r'-'---T-'-"I-"T

Yellow 4-1/2” TSD 1 NO

Red 1 s-1/2“ CR1-3 YESi

Red O 2-1/2" CR1-1 YES ’Blue 5" as YES s 3

l aaaa it cnnur s-sCHART 3-1 .

.-'1r

.-

Connectthe black transformer leads asindicated in Chart 3 2. The black leads areNOT SOLDERED at this time.

Lead E Length Connect7 Color Removed To Solder

Black 2-1/2" TSE 1 NO

Black s" rsss i N0

CHART 3-2

Connect a 2-1/2” length of black hookupwire from lug 2 of SW1 to lug 1 of fuseholder FH1. Solder both connections.Carefully check these connections to besure that there me no bare wire ends closeto or touching the chassis.

Connect a 2" length of black hookup wirefrom lug 2 of FH1 to lug 1 of TSE. Solderonly lug 2 of FH1. Do not solder lug 1 ofTSE.

"Selectthe yellow and two red transformerleads. These leads are on the side of thetransformer away from the top panel.Connect the leads as shown in Chart 3-3.

3-2

--------------------------------------- I

Connect a 2" length of black hookup wirefrom lug 1 of TSD to lug 3 of TSD. Donot solder either connection.

'1

The white and green transformer leads aretemporarily connected at this time. Leavethe leads full length and connect them toTSA as indicated in Chart 3-4. Do notloop the wires around the lugs but justslide them through, as shown in Figure3-7. Solder the connections but use onlyenough solder to hold the leads in place.Route the leads as shown in Figure 3-5.

Lead Color Connect To Solder."". ' ' _ —‘_ _ ' ' _ ' ' ' ' ' ' ' ' ' ' _ ' ' _ — ' ' ' ' _ ___ I '_""

Green TSA 1 YES

White TSA 2 YES

a

Green _ TSA 3 YES 1

Chart 3-4

Remove 1-1/2” of wire from the red andblack leads connected to the LED powerindicator. Connect the red lead to TSClug 1 and connect the black lead to TSClug 2. Route as shown in Figure 3-5. Donot solder either connection.

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CONSOLE 80

./P.’

3;t:;;<i~~ "cehheet a e-1/2" length of black hookupwire from lug 2 of TSC th lug 1 of TSD.Route as shown in Figure 3-5. Do notsolder either lug.

.-"I "'._---

Connect a 2” length of red hookup wirefrom lug 4 (red dot) of bridge rectifierCR1 to lug 3 of TSC. Route as shown inFigure 3-5. Solder lug 4 of CR1 only.

_“Connect a 4” length of yellow hookupwire from lug 2 of CR1 to lug 5 of TSC.Route as shown in Figure 3-5. Solder onlylug 2 of CR1.

.. ‘

Cut the leads ht a 1000 hr, 50v capacitor(C1) to lengths of 1” each. Orient thecapacitor as shown in Figure 3-5. Connectthe NEGATIVE (~) lead to lug 1 of TSDand the POSITIVE (+) lead to lug 3 ofTSC. Solder only lug 1 of TSD.

.. f-'.—’-I-Ir,’-Ill

( the leads of a 1000 ;uF, 50V capacitor(C2) to lengths of 1” each. Orient thecapacitor as shown in Figure 3-5. Connectthe NEGATIVE (-H) lead to lug 5 ofTSCand the POSITIVE (+) lead to lug 3 ofTSD. Solder only lug 3 of TSD.

Cutthe leads of a 10 kn, 1/2w, t20%resistor (brown-black-orange) to lengthsof 3/4” each. Connect this resistor, R1,from lug 3 of TSC to lug 2 of TSC asshown in Figure 3-5. Do not solder eitherconnection.

.;.~"

Cut the leads of the other 10 kc, 1/2w,i20% resistor to lengths of 1” each. Con-nect this resistor, R2, from lug 2 of TSCto lug 5 of TSC. Do not solder either con-nection.

Cut the leads of the 1.5 ho, 1/2w, t20%/‘I resistor (brown-green-red) to lengths of 1”

each. Connect this resistor, R3, from lug 1

|'~_/'

r.

_.?

of TSC to lug 3 of TSC. Solder only lug 1of TSC.

The following connections to binding posts B8,B9, and B10 are temporary. Wrap the leadsloosely and solder sparingly. These leads will beremoved later for connection to the regulatorcircuits.

btihheeta 0-1/2" length of black hehhhp,4 wire from lug 2 of TSC to B9. Route the

wire as shown in Figure 3-5 and solderboth connections. Be sure to solder all theleads connected to lug 2 of TSC.

'COI1I1GCl; a 11-1/2" length of red hookupwire fiom lug 3 of TSC to B10. Route thewire as shown in Figure 3-5 and solderboth connections. Be sure to solder all theleads connected to lug 3 of TSC.__/

Connect a 10” length of yellow hookupwire from lug 5 of TSC to B8. Route thewire as shown in Figure 3-5 and solderboth connections. Be sure to solder allthe leads connected to lug 5 of TSC.

This completesthe assembly of the basic powersupply. The next section of this manual coversthe connection of the line cord and mounting ofthe assembly in the carrying case. -

3-3

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CONSOLE 80

coiofi, NOTE.‘ -{NEGATIVE} END HAYALSO BE IHEICATED BYA BLACK BAND

BA-NBS\_ 1:=====:===-‘1=1==*=‘50l*' moo J~'1Ff-§=::£§1::§;§2§ii5§;§s{ i _ _

FIGURE 3-IA FIGURE 3'-IB

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fi_.1_i__.,h-_\-E- - - - - - --,-; - -, -,-,- -“- all-'}I/t I/=1"

SPECIFIED LEHGTHip- SPECIFIED LENGTH epi |._

FIGURE 3 - 2FIGURE 3 -3

twat: LEAD - ”'f§§”“waaeezcmauve PTERHFHM-L -__-t

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mwt\\\-.-::-‘J’ ‘_

- - -. ..-..- .___. _,.4".;/-:,-.-.r.-,.-___,..- ..-

FIGURE 3-4

RED TRANSFORMER_ LEAD

rrtrow, T 55$“ no ncrrooeWIRE AROUND

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RED Ta-MvsFoeh£a;=:1:--'-'---- 0 "='.1:1:-:- -.are 15”“ . 1.- -" ’:f:"":".-':-"5.ilT*- T“ ‘-' “ - "' -"=57"-T-=_-'1" ‘:'-'-.

rsrtowDOT

FIGURE 3-6 FIGURE 3 - 7

3-4

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REGULATED i"I5V POWER SUPPLY ASSMLY CONSOLE so

Parts Needed

The following parts are used for the regulated il5V power supply section of CONSOLE 80 The reference numbers correspond to the component pictorial drawings of Figure 5-1. ‘

Quantity Reference Description

Fig. 5-1A 1.5 kl} Potentiometers (0023106 5)

Fig. 5-1BFig. 5-10Fig. 5-1nFig. 5-IEFig. 5-1FFig. 5-ro

Knobs

4-40 X 3/8” Spacer

LM317T Positive Voltage Regulator

LM337T Negative Voltage Regulator

Rectangular Insulators

.1 ,uF Disc Capacitors

r15V Regulated Power Supply PC Board

3/8” Lockwashers

3/8” Flat Washers

No. 4 Lockwashers

1109, 1/2W, 15% Resistors

5 ,uF, 50WVDC Electrolytic Capacitors

4-40 X 1/4” Binder—Head Machine Screws

3/8 - 32 X 1/2” Hex Nuts

Hex Nylon Nuts .

Nylon Screws

No. 22 Solid Red, Black, and YellowHookup Wire

Solder, 60f40

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CONSOLE 80

Ir

I-M-t-:-Y..",.,_1._l|_:1_.-v-n-_\-Ck:

* M...---.

lnstall two 110-ohm resistors on the PCboard following the chart in Figure 5-2.

Install two 5 ;rF, 50V capacitors at thelocations shown in the chart of Figure5-2.

Carefully bend the leads of the Llvl317Tand the LM337T regulators as shown inFigure 5-3.

F

Install the LM31’7T positive voltage regu-lator rhte the foil or solder side of the rcboard at the location shown in Figure5-4A. Press the regulator into the boarduntil the distance between the board’s sur-face and the regulator is 3/8”, as shown inFigure 5-4B.

F

Install the LM337T negative voltage regu-’ lator using the same procedure described

in Step 4.

Install the wires listed in Chart 5-1. Cuteach wire to the specified length and strip1/4” of insulationfrorn each end. Soldereach wire as it is installed.

Lead Lead _ ConnectionColorre rrrrr is - r rrrrrrrrrrrrrrrrrrr isI Length I Point

E Black __ 9” I' - ------- -- J.

Red 9" 3

- we 1 .... -Black 3” - -

Red 5» 4J.-" “R .

I ' " " """"""H " S. ' --' K

Yellow 4 " 5

CHART 5-1

5-2

_______ ..............................

- Regulated r15V Power Supply Assembly

;jCheckyour work and be sure that theregulator leads are positioned as shown inFigure 5-4A. Set the PC board aside. Itwill be used later.

-/Mountone of the 1.5 kill. potentiorneters(00281065), R5, at hole 1 of the toppanel, using the mounting arrangementillustrated in Figure 5-5. Use long-nosepliers to remove the locating lug from thepotentiometer as shown. Orient potenti-ometer R5 as shown in Figure 5-9.

J.

IZI lvreuht the other 1.5 he potentiometer(00231065), R7, at hole 2 of the toppanel, using the same procedure describedin Step 8.

Turn the potentiometer shafts fully coun-terclockwise and push on each knob withthe pointers oriented as shown in Figure5-6.

. -If

Me-hht the 4-4.0 >< s/s" spacer at hole 52of Side Panel B using one 4-40 X 1/4”binder-head machine screw and one No. 4lockwasher, as shown in Figure 5-7.

The red, yellow and black wires temporarilyconnected to binding posts B8, B9, and B10will next be removed and connected to theregulator circuits in the following steps. Bindingposts B8, B9, and B10 are the output connec-tion points for the 1-15 VDC supply.

/3”Yellow 8”» __ __ 7 Remove the yellow wire from B8 and

connect it to Point 8 of the PC board.yder this connection.

Remove the black wire from B9 and con-nect it to Point 9 of the PC Board. Solderthis connection.

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§

mt _

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:1-~*.=‘-=-:1'-- . -:'-

, .-_;~,;.- - ' . --", -.-" .--* .-_;:‘-.1511-_;t1'; 1:11 1'.\'_‘,.+-:1.-:1.-:1“

1:1‘-_-_:11_;:":--III-'--—-.._____,..-I-I'_

-;~;::'-'2-'--:- ir .

@)\ .1 ThwsaosoKNOB setcsa

CONSOLE 80

POSITIVE VOLTAGEPOTENTIOME TER REGULATOR

FIE‘

A

-|-‘-._--U‘

INSULATORS

NEGATIVE VOLTAGEREGULATORE

I100.fill

rust? ,

FIGURE 5 I

H011LM33T

-h {I

O .. eIl F ( Ii

CAPACWOR

G

‘r

2 B+ F + 5 F

II!Ira.

00042242 H5‘! REG. POWER SUPPLYI

9

D

RESISTORS CAPACITORSStep 1 Step 2

1 110 ohm, 1/2W, 10% A 2 5 HF, 50V ElectrolyticBrown, Brown, Brown Capacitors

LSolder and remove excess Solder and remove excesslead length. lead length.

II

it

IFIGURE 5-*2

5-5

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CONSOLE 80

LM 3171'. &I LM 33??‘

I-'mI I

#'% _b - X8 fi§'¢=$Mn.

-32 x£z2I'HEx~ur

I RSI Frar WASHER

FIGURE 5 - 3 - 5,5’ rocxwasnseasucvsLOCATING H,LQJG

tmsrrr POTENTIOMETER-n-l""

-I- "i""\ ;-'-:~:-.-I-:-.-.“__=.‘.=5: r :-"-+.3:I'-6:1‘-'-3:5-''.;:_;? -‘-‘.';+'-'." -"-"-* "-1'."

.-'(( ‘mm.thew ‘/ugh FIGURE 5-5._ u '1 + |5v POWE H._ _ su PPLY

FOIL or: screen 6- '° 2

Z £6I?

A P05. ADJ.

isl-F .... .. H

‘F8

2 IB

B use. ecu. WFIGURE 5-4 " "

FIGURE 5-6

4-40 xr/4 sansa 4-"40 X 3/B SPFICER

./- ..-- _ _ , __,___.,_C___,I/

r-I .

~04 rocxsnsa ,

Q4

(,4U

FIGURE 5- 75-6

s ‘°|2' ( ,5 t4 I

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Remove the red wire from B10. Shortenthe wire two inches and connect it toPoint 2 of the PC board. Solder this con-

-nection._a

Install the PC board as shown in Figure5-3. .

Make the connections listed in Chart 5-2between the PC board and potentiometersR5 and R’? and binding posts B3, B9, andB10. Route the leads as shown in Figure5-9.

H, .

Cut a 2” length of black wire. Strip 114”of insulation from each end and connectit between R5-3 and R’?-3. Solder bothconnections. '

Refer to Figure 5-10 and prepare twocapacitor assemblies consisting of a 5 ,uF,50V capacitor and a .1 ,uF disc capacitor.

Connect one capacitor assembly’s “—"

CONSOLE 80

(negative) lead to B9 and its “+” (positive)lead to B10. Solder only B10.

Connect the other capacitor assembly’s“-” (negative) lead to B8 and its “+”(positive) lead to B9. Solder both con-nections.

Lead ConnectionLength From To Solder

_' - ------------------------ -- I- -_ --

Rgd _p_(}.3 N0. I\.|-..--" ' I.

. ' _ _....1~ '*""-- ... ...,-|---'-"-

iiiiii iiiiiiiiiiiiiiiiiiii I iiiiiFFYellow B8 “NO .

Red PC-4 R5-2 R5-2.,_\_ Tl

"Yellow, 3 PC-5 R7-2 R7-2

A NOBlack 1 PC-1 as-s

CHART 5-2

115V Regulated Power Supply Test

Turn the Pos. Adj. and Neg. Adj. controlsfully counterclockwise. With the consoleturned on, connect the voltmeter betweenReg. DC binding post “O” and bindingpost “+”. You should measure approxi-mately 1.2 VDC, 1.10%. If you do notmeasure the correct voltage, refer to con-dition 1 in Troubleshooting Chart 5-3.

Turn the Pos. Adj. control clockwise. Thevoltage reading should increase to approx-imately 17 VDC, i~10%. If you do notobtain this voltage, refer to condition 2 inTroubleshooting Chart 5-3.

Connect the voltmeter between bindingpost “O” and “—” of the Reg. DC output.

You should measure approximately -1.2VDC, i10%. If you do not measure thecorrect voltage, refer to condition 3 inTroubleshooting Chart 5-3.

Turn the Neg. Adj. control clockwise.The voltage reading should increase toapproximately ~17 VDC, 110%. If youdo not measure the correct voltage, referto condition 4 in Troubleshooting Chart5-3.

This completes the assembly of the i15V regu-lated power supply of your console. The +5Vregulated power supply and function generatorwill be completed in the next three sections ofthis manual.

5-3

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CONSOLE 80

TROUBLESHOOTING CHART

p counrrrou

1. 1.2 VDC measurement measures zero volts.

1.2 VDC measurement measures high.

2. 17 VDC measurement measures low.

E 4. ~17 VDC measurement measures low

3. —'-1.2 VDC measurement measures zero volts.

-1.2 VDC measurement measures high.

Q CHECK

- Wiring to terminals B9 and B10.

Voltage regulator wiring.

Voltage regulator wiring; R5connection; defective regulator.

Wiring to terminals B8 and B9.

Voltage regulator wiring.

Voltage regulator wiring; R7connection; defective regulator.

1I ii. ._IlIDIl*i

CHART 5-3

Circuit Description

A schematic diagram of the i15V‘ regulatedpower supply is shown in Figure 5-11. Thepower supply consists of two adjustable voltageregulators (IC-5 and IC-6). .

The separate positive and negative outputs fromthe unregulated 40-volt power supply are ap-

5-4

plied to +V1N and —-VIN, respectively. Inputcapacitors C5 and C6 stabilize the regulator cir-cuits. The resistor divider networks, R4 and R5(positive circuit) and R6 and R7 (negative cir-cuit), develop the reference voltages for theirrespective regulators. The output capacitors (C7,C8, C9, and C10) filter the regulator outputs.

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CONSOLE 80

l

SIDE FANEL DETAIL:-_:_-j-';'.-'_I :':-I 5 E :-I-I-I-I-I ‘I. ‘.1.-I-_| E ;.j-_|_:_.j-_:_.j-_:_-j.-:.j-_:_.j-_:_:_.j-_:_:_: ; .-.-j.j.j.-j.j-_: :': | : | | : : 5 I-.'.1.-I-I‘.-I-.=.'I-‘I-‘I-I :-‘I-I'.=.':: :'L=_:':': :" I 1 1 I I'-':'-'1".'-':'-'I".' I';'-:_:'_I-:-I-:_'-I-I I i |'I'-:-I-I-.1.1.1.1.1.-I-I-I-'I-I-I-I-I'.1.1.'-I-I-'I'.=:'|':-I-I-L: I i 'I17:'.1.=L=.='l-.I.=_I'.='I-I'.= i :-‘I-"_"; :': i :1 i :-I-I'I:I-1:1

‘I.

-_ ____ O

........ ‘*1-—'l_ /i J’; 2 FH’

.......... BI 52 B3 @ B4 @ @ B5

' O ® iiii ~

inns?

0|, WHITE

_-‘I 2 ‘ 2 ,_....-all I0 , E .4-.......|||||

I allRE;II\ V I I ....... -

O \\ \\'\

/

‘J29\

CAUTION: Be sure to connect the positiveand negative leads of C1 and Cg as shown.

///4 ._ 32' .......... - \\\\\““~“£aih‘“*i‘_// / " “ hie

Tsa GREEN Tss' I | I I

ll

6=\“\\\-Q

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R3L5 R-Q I O 0 It

5/ ......... .... I BLACK

R2 gM~4| qp ummwunnmmuuummuuut U , ,0k |I000 /JF 0L_,_ ... - ...

3-5

I FIGURE 3“-5

'_=;.;;;.,;,,-,;.;.5=,-.;::=;:.;,- . .. VW

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COMPLTING TH ASICCONSOL CONSOLE 80

Parts Needed

The following parts are required for final assembly of the basic console. To help you identify the variouscornponents, reference numbers in the list correspond to the component pictorial drawings of Figure 4-1.

Quantity Reference Description

1 4-1A Case1 4-1B Line Cord (three wire)1 4-LC Line Cord Bushing1 4-1D 1A Slow Blow Fuse2 4-1E .01 ,uF Disc Capacitors (AC 1400)1 4-IF AC Insulator Shield1 ‘ 4-1 G Breadboard2 4-1H Plastic Fasteners (Hook)2 4-11 Plastic Fasteners (Loop)4 4-1J Rubber Feet4 4-1K No. 4 X 1/2” Sheet-Metal Screws3 6-32 X 1,i'4” Binder-Head Machine Screws

3 6-32 Hex Nuts3 No. 6 Lockwashers1 Foil Label

Completing the Console Wiring--*

Select the line cord and line cord bushing. The three-wire line cord leads are prestripped. Twist theindividual strands on each wire together and tin the stranded wires before assembly.

Position the bushing on the line cord at the location shown in Figure 4-2. The line cord is held inthe bushing by pressing the bushing’s cap into the bushing with your long-nose pliers.

Insert the line cord and bushing into hole 51 (from the outside) of side panel B. Position the linecord bushing so that the line cord is directed towards the top panel. You may have to use yourlong-nose pliers to press on the bushing cap while pushing the assembly into the hole.

As shown in Figure 4-3, route the line cord directly towards side panel A. Connect the white wire

-\-?~_..,,._.,.,_,

I to lug 3 of TSE. Do not solder this connection. -

4-1

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CONSOLE 80

Connect the black line-cord wire to lug 1of SW1 and solder the connection.

Connect the green line-cord wire to lug 2of TSE. Do not solder this connection.

Cut both leads of a .01 ,uF disc capacitorto lengths of 1/2” each. Position thecapacitor, C3, as shown in Figure 4-3 andthen connect one lead to TSE lug 1 andthe other lead to TSE lug 2. Solder onlylug 1 of TSE.

Cut both leads of the other .01 ,uF disccapacitor to lengths of 1/2 each. Posi-tion the capacitor, C4, as shown in Figure4-3 and then connect one lead to TSElug 2 and the other lead to TSE lug 3.Solder both connections.

Double-check your wiring in this area asline voltage (AC line) is present when theunit is operating. Be sure that no wires areshorted. The .01 ,uF capacitors, C3 andC4, should be lying down near, but nottouching, the switch.

Snap the one-amp fuse into the fuseholder.

Select the cardboard shield. The materialhas a self-adhesive backing. Before remov-ing the backing, refer to Figures 4-4A and4-4B, and go through the following stepsonce to see how the shield fits. When youare satisfied with the assembly procedure,remove the backing and assemble theshield.

Referring to Figure 4-4A, fold downflap A and flap B. The edge of flap B isfolded up as shown.

Flap C is folded inward next, as shown inFigure 4-4A.

E

CReferring to Figure 4-4B,, fold down flapD as shown. Line up the hole in flap Dwith the hole in flap C and press together.

Fold flap E around and press to flap A.

Position the shield as shown in Figure 4-5.Line up the mounting holes in the shieldwith holes.34, 37, and 42 of side panel A.Secure the shield with three 6-32 >< 1/4”binder-head machine screws, three No. 6lockwashers, and three 6-32 hex nuts.

The line cord should pass through the slotin the shield.

“Selectthe two 6” lengths of plasticHOOK fastener material. Referring toFigure 4-6, position the console with thefront side of the top panel facing you.The plastic hook fasteners are to bemounted on the top panel in the areasindicated by the rectangular boxes.Remove the backing from one length ofthe hook fastener material and press itinto position as shown in Figure 4-6.Remove the backing from the otherlength of hook fastener material and pressit into position.

Take the breadboard and lay it on yourwork surface face down. Take one lengthof LOOP pattern plastic fastener materialand cut off two 2” lengths. You can cutthe material with diagonal cutters. Leavethe backing in place while cutting theloop fastener material. Then remove theloop fastener backing.

Using the dimensions and orientationindicated in Figure 4-7, place the loopfastener material on the back of thebreadboard unit. The breadboard can nowbe placed on the Console top panel andremoved as desired.

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CONSOLE 80

Retain the remaining loop fastener mater-ial for additional breadboards.

Mount the console into the case as shownin Figure 4-8. Use No. 4 sheet-metalscrews passed through the recessed hole inthe rubber feet to secure the consoleassembly to the case. You can use apointed tool or small screwdriver to lineup the holes in the side panels with theholes in the bottom of the case. Do notovertighten the mounting screws. Thesheet-metal screws will “start hard,” asthey are cutting threads into the sidepanels.

Peel the backing from the foil label andcarefully place it in the depression in thetop cover of the case as shown in Figure4-9.

Console Tests

With the power switch on, measure theH H resistance between the ground blade and

both of the other two blades of the ACline cord plug. You should measureinfinity. If you do not obtain this read-ing, check the AC line cord wiring.

Connect the console line cord to an ACoutlet and turn on the unit. The LEDpower indicator should glow. If it doesnot, turn off the unit and disconnect theline cord. Remove the console from thecase and recheck your wiring. Refer toTroubleshooting Chmt 4-1, condition 1and check the indicated items.

With the console turned on, measure theAC power supply voltages. You shouldmeasure approximately 13.6 VAC acrossthe 12.6 VAC terminals and 6.8 VACfrom the common (center) terminal to

- either of the 6.3V terminals, as shown inFigure 4-10. A 10% voltage variation iswithin specifications. If you do not meas-ure the correct voltages, refer to condition2 in Troubleshooting Chart 4-1. When aproper load is connected to this voltagesource, the voltage will decrease to approx-imately 12.6 and 6.3 VAC, respectively.

With the console turned on, measure theI I I DC power supply voltages indicated in

Figure 4-10. You should measure about42 volts across the entire supply and +21and ~21 volts with respect to the com-mon terminal. A 10% variation is withinspecifications. lf you do not obtain thecorrect voltages, refer to conditions 3 and4 in Troubleshooting Chart 4-1.

This completes the assembly of the basic powersupply for your console. The +5V regulator andfunction generator will be completed nextterm. You will be able to use the console forexperimental work now. Its features will allowyou to conduct tests away from the schoollaboratory, at your convenience. When com-pleted, the console will enable you to work witha wide range of analog and digital circuits.

Circuit Description

A schematic diagram of the partially constructedconsole is shown in Figure 4-11. The basic 40-volt power supply is a full-wave bridge rectifierwith separate positive and negative outputs.

The primary of power transformer T1 connectsto the 120 VAC line through fuse F1 and powerswitch SW1. Line filter capacitors C3 and C4keep line voltage noise and transient signals outof the power supply.

Power transformer T1 has three center-tappedsecondary windings. The top winding shown in

4-3

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CONSOLE 80

Figure 4-11 supplies the 12.6 VAC CT supplyvoltage. The center winding is not connected atthis time. Later, it will be connected to a bridgerectifier circuit used for the +5 volt regulatedDC supply and function generator.

The bottom secondary winding is connectedto bridge rectifier CR1 which, together withfilter capacitors C1 and C2, form a dual-polarity,

full-wave rectifier circuit. R1 and R2 are bleederresistors that discharge C1 and C2 when thepower supply is turned off.

An LED power indicator is connected to thepositive section of the power supply throughR3, which limits LED current to its requiredvalue of approximately 15-20 mA.

TROUBLESHOOTING CHART

CONDITION CHECKT I " 'i"'"""'l';T_.:_" " "' ' T.::_'_I_f.|'__|_‘ ---------- -——- ———— --_-_—-—1-_--——_-_---- ----—-1 ll"'."'II|lH(..._ _.

1. LED INDICATOR DOESNOT GLOW WHEN UNITIS TURNED ON

FUSE; SWITCH WIRING; TRANSFORMER IWIRING (RED & YELLOW LEADS); LED AWIRING; BRIDGE RECTIFIER WIRING;C1 CONNECTIONS; R3 CONNECTIONS

2. 12.6 VAC MEASURES 0 VOLTS,LED INDICATOR GLOWS

____ __ _ _ ' ' '_ _ _ _ _ "_ _ _________________ _______ ___ ______________ _ __.__. .'__ _. _._.'_.._..'.. ._._.I__.'__. _.__ _'..'.'_..".'_ 'I'..'.."_.' '.'.'._'l'|a

TRANSFORMER WIRING (BLUE & BROWNLEADS) TO TERMINALS B3, B4, & B5 i

3. +15V SUPPLY MEASURES0 VOLTS LED INDICATORGLOWS

WIRING TO TERMINALS B9 & B10

4. —15V SUPPLY MEASURES0 VOLTS, LED INDICATORGLOWS

BRIDGE RECTIFIER WIRING; C2CONNECTIONS; WIRING TOTERMINALS B8 8: B9

CHART 4-1

4-4

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CONSOLE 80

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CONSOLE 80

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“"555” ‘I’ ' --'é_"—-i-i-_' -"""'_'_—-___. 2Z3:5:I='i'§‘:'E'i3:1I3:5.i ‘;'5.. . '."" * ii-'FEE’ I =_-. .- =.---£"'—”“‘~o 4 ssssr METAL scssw/""1 - -.: " -.-

_.-I - -'_.? -_- :_ L; - -..' 1-_ ._- -' ~ --"'1 -Z :- ._-_~_ *_- .7’ ‘ |._ _._- _'.-L-__ ..-_ \-. - _ ‘ _'- _ _ '_ _ -_ -"__1. ._ ._ -.__- :': ._ I‘ -__- * .;' . ._' _:::;§.;_:_=:'_=_;____;:E;-:; __ _f ' __ - _ - _ - _ __ _ __ _ r-. " ‘ - _ . , ---_ - '. - .- -' -- - ':.. - _-~._._"_ -- _-.-: ..-,--'- .--_.- ' -' : _-- '3.-'-." -. _- ""-;-'_-::;:-_.. _- __' . . _- '_ _-. - - -' - _ - ,=-' _-_-: --I- .-1 _- ‘___;-__ ._,,_ .- 1,-_._-_ ‘:1; _ _1- -1‘ _ I: _- :‘_:__‘-‘.'_____.| __.__.“-;_ ,\‘_ ‘__l__,_ :3;-__ .'.‘,__ _ I. . ._ _ _- _‘ ._ I , ‘ I P ___. ‘P I __ L II

.-_._ 1 ..-_._- ‘-.‘-ll |-.- -_._+_ _._-_-_,_'. __1;-I.__. : _-3:‘ __.. ‘-3- _, .- '..'|--,,,_!-_'_ -. __ -_-‘ _ ._1-.--1; -_,‘-_* .-_"T._ ' 1- -I. -|;\.I"_-f .- ‘_ .__ 1_,._: . ,,' - ' -I ‘ ._ .-:

_i-‘-!“ ‘.- _ :- -'_-,- -_. ;__. 5-_ .- -'-._- .: _-_' : -_-. f;-_~-__' :.- _._' _-'._- 1-_;_ - ._-; _. _- _ - ‘.1-9'. -_| ., ' ;_- __ "3' = .- .1 .- ;-;‘,.:..-__§_> I , 1-j '- " --_ - _' .-' - *' .1‘ -:2‘ _-!.- r _ t '

' ' ' ' #"'- ' "-' - - . ‘I -". _.::i' .1"-ti" '% ._=

at ‘ “I-1-

_ . . . . . . __ . ‘,u,___._..1-FIGURE 4-8 1-I.4

FIGURE 4-" 9

4-7

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CONSOLE80

4»E3

E.B'v'AC I-ii —h| EBVAC + ET13.6 VOLTS AC

BELLaH].LI—LLEEl..If.flfl‘!]'l[iQEl.l5 £25 VULTS AC. FUHCTFON G-ENERATDR

EELLEHDLUELLE3 D E3 DUTP‘U"|'

ON tl5 "u"DLTS DC +5 VULT3 DC

@PCWEH '5-i—-—-HEGQDC-i---—I t-HEG.D{.'I—?

BLACKiii?’ “E-

2|vnc--]-EHJ izrvuc

BLACK

Hy-~*42vuc--{J

FIGURE 4' I0

Bws B3

BROWN

? BLUE

.0!

__, wHrrE

raovnc GREENeon; __L

_-

unu-Q

- GREEN ___

ii RED

B4 I1 or l2.6VACas I

ém. I __

T“ _

iiiiiiii b -ww-15-3'H"D

WHITE Tm? 1 "LED mmA ’cormEcrEu TmE GREEN l

RCR] 3

“E+ T

:o00,uE§-1*sov -#63 an' rm::~»

B9OCOM

20V DC

20'?‘ DC

11FIGURE 4-H

| BB-- I I 0

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CONSOLE 80

COMPONENT suns or BOARD) NO. 4 LOCKWASHER

4 — 40 x I/4 BHMSNYLONscams "...... @_____ _ G_ ___ _ ___ _%

$m._._. .4 3m— ¢_.. _,.._ _ _ . NYLON nurs

RECTANGULAR rusumrons

FIGURE 5 — 8

3|

$3P

9 '5 in

B ' YE, " _ . B7 _ BL as

\ ~ _ \\ \ Ac . RED Em\m\ V, 1@£$3?‘Q2)"ii 55%

FIGURE 5-9

5-7

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CONSOLE 80

I\I;I [C OR C I I

sowen\ our:-ERCONNECTION -" CONNECTION_._.__ _._._.

__;_: _+;.;.:.:,:,;_-;.;.::_._._._. _ , _ ,-_-_-_ ._..'+,_ I---1.-...*.+

. . . _- -_ -_~_ -__++- I I ._,.‘,‘_,_, -‘+- wER Clo,

FIGURE 5%‘ IO

I_.PE E°@£‘_| ._I.._lr2:.4vJ "5 VOLT tr? ‘W‘H/INQ I2 I REGULATOR -- 3-

1 VIN Ic-5 I/ourADJ (15.5%/JM N ;;0_{1 ;

I + I 4 P08. no.1. I..--.. C5 CYL °s5 pf-' I __ R5 5 ,uE'T‘ I ‘Ir ,uFI I

..IE.2O

—“ |i I I1-

I

—|—\-1—u- 5'41L...

I ‘I L5 Iifl;_ I

F9I-|Q_____|_COM I I I I

I Fl’?1.5 an 4.5+

fi5,uF I I II_ I NEG. ADJ. 5,uF I .1 ,uFI-1?"/J ADJ. II II II II I Hon.

E8 I5 VULT VOL;-I-|

-5"Q

"""""! _l 170U)

"'4.5Zwe-EEEEEEE

5-8

FI EM W REGULATQR I..........L. = 53¢)j I“ 2I.6"'/I - I" VIIJ IC 5 L I

FIGURE 5--H

i 5:00 WGUT

ov

‘%mT

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DE\fRYII"!E.

ELLE-HULUELL

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I

00603636Hev.216?c

T

‘ L""ASSEMBLY MANUAL

8IO5D

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- TM

ASSEMBLY MANUAL

8lO5D

©COPYRlGHT 1931DEVRY INC.

ALL RIGHTS RESERVED-Fxfl J-‘E

EH

ISBN 8653'?" O32 -' X Q"BHJED

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TABLE OF CONTENTS

Regulated +5V Power Supply Assembly . . . . . . . . . . . .

Function Generator PC Board Assembly . . . . . . . . . . . .

Completing the Function Generator . . . . . . . . . . . . . . .

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GULATD+V POWR SUPPLY ASSMLY CONSOLE 80

The following parts are used for the regulated +5V power supply section of CONSOLE 80. The reference

Parts Needed

numbers correspond to the component pictorial drawings of Figure 6-1.

Quantity Reference Description

1 Fig. 6-1A +5V Regulator

2 No. 6 Lockwashers

1 Fig. 6-1B No. 6 Solder Lug

1 .1 pl F Disc Capacitor

1 3800 ,uF 50 VDC Electrolytic Capacitor

2 6-32 X 5/16” Binder-Head Machine Screws

3 6-32 X 1/4” Nuts

1 5 ;.zF, 50WVDC Electrolytic Capacitor

1 Bridge Rectifier

1 6-32 X 1/2” Flat-Head Machine Screw

No. 22 Solid Red and Black Hookup Wire

Regulated +5V Power Supply Assembly

Mount the -I-5V regulator, IC-7, as shownin Figure 6-2. Orient the regulator andsolder lug as shown.

Following the mounting arrangementshown in Figure 6-3, mount bridge recti-fier CR2 at hole 22 of the top panel.Orient the bridge rectifier as shown inFigure 6-4, with the red dot as indicated.DO NOT overtighten the mounting screw.Label the bridge rectifier CR2.

The white and green -transformer leads areremoved from their temporary connec-tions at TSA 1, TSA 2, and TSA 3 and arereconnected as indicated in Chart 6-1.Route the leads as shown in Figure 6-4.

___________II _ If --Lead Length Connect IColor Removed To Solder

."::-I-.l;.I-I-I:-":'.'.-I-I:I';'L1IQL;Q_l;'_'l:':__;___iffi'_i:;]i:_::__ '1"-i"I'I'I-‘-3-____Q;_§im"':I:;l:_'_'_ “P

Green 5-1/2” CR2-2 i YES__ ___ _ _ _ _________ __ =___ I __________ __ -....

White 3” TSA 4 NO

I‘ I ¢Green 6’ CR2-4 YES'1 --------------------------- --

/4E""w;'. \,..

CHART 6-1

TSB. Do not solder either lug.

_...__T:_T....___* _..___________ _ __ _ - - AWL ————————— 1:-qr

Cut the leads of a 8300 n F, 50V capac1to1(C11) to lengths of 1” each. Orient thecapacitor as shown in Figure 6-4. Connectthe NEGATIVE (——) lead to lug 1 of TSAand the POSITIVE (+) lead to lug 1 of

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CONSOLE 80

F .

: 1' ,

___II_Thepoint-to-point wiring for the +5Vregulated power supply is specified in

I.‘

r"’Chart 6-2. Route the leads as shown inFigure 6-4.

Cut the leads of a .1 ,uF disc capacitor(C12) to lengths of 1/2” each. Connectthe capacitor to binding posts B6 and B7as shown in Figure 6-4. Solder both con-nections but use only enough solder onB6 to hold the lead in place. Anotherlead will be added later.

Cut the leads of a 5 all‘, 50V capacitor(C13) to lengths of 1/2” each. Connectthe “—” (negative) lead to IC7-3 (solderlug) and the “+” (positive) lead to IO’?-1.Solder both connections.

LeadColor

Lead ConnectionsLength To From Solder

Red1i

I 7 _J_‘ _ ' F"""

rise 1 caz-1 . cnz-1Black

iiiIyI2”3 3 I TisniiliIIIIIII I

5- .|_ _ _ .

TSB 4l**I Black I 81'! I07-3* TSA1-lg

Black 5. 2;!

ikBlack__ ....... ' """' TSA1 es TSA1 lI

!-I

F 4 rsa. 1 TSA are

ilted 24-12" “reel 107-1 'I‘S_B1**2"I

late s-1/2 107-2 s7 :07-2

’i=Solder Lug**Solder the connection but use only enough

solder to hold the leads in place. Anotherlead will be added later.

CHART 6-2

Power Supply Test

With the console turned on, measure thevoltage between TSA 1 and TSB 1 (nega-tive meter lead to TSA 1 and positivemeter lead to TSB 1). You should meas-ure approximately 18 volts. If you do notmeasure the correct voltage, refer to con-dition 1 in Troubleshooting Chart 6-3.

Measure the voltage between bindingposts B6 and B7 (negative meter lead to

B6 and positive meter lead to B7). You' should obtain a voltage reading of +5 volts.If the voltage reading is incorrect, refer tocondition 2 in Troubleshooting Chart 6-3.

This completes the assembly of the +5V regula-tor power supply of your console. The functiongenerator will be completed in the next twosections of this manual.

Circuit Description

A schematic diagram of the +5V power supply isshown in Figure 6-5.

The center winding of transformer T1 is con-nected to bridge rectifier CR2 which, togetherwith filter capacitors C11 and one to be addedlater, form a dual-polarity, full-wave rectifiercircuit. At this time, only the positive full-wavecircuit is used.

6-2

The regulator includes short circuit protectionand thermal shutdown. If the output is shortedor the internal heat dissipation exceeds specifi-cations, the regulator will shut down to preventdamage. I

The regulator input capacitor, C13, and the out-put capacitor, C12, provide additional filteringto prevent oscillation and suppress transients.

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TROUBLESHOOTING CHART

CONSOLE S0

I CONDITION CHECK

1. 0 volts instead of 18 volts. Wiring of CR2 and TSB

2 0 volts mstead of 5 volts Wmng of B7, IC7, defective regulator.

CHART 6-3

6-3

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CONSOLE 80

6-4

0O\0 %+5 VOLT REGULATOR SOLUER LUG

A e IFIGURE 6-I

scrosa:.ue\

\@ 6 43/ +sirt=smEh‘ s H ~ I ' J

39 .., ..___~ X Ii

--. ___‘ H I -0

ii’ RoawLARGERSPACE

FIGURE 6 -2

s/32 HEX norac. e LOCKwasasa

Wkcaress__ ]_ RECTIFIER

yaausr

FIGURE 6—3

s-s2 x 5/};B.H.M.S.

e/32 FLAT-HEAD Iif/scaaw

I:I J

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CONSOLE 80

0 0

0

O I

min-butO 0

rscI"

CAUTION: Connect the positive and negativeleads of C11 and C13 as shown.

er e2 as s4 as

Clg -_:— _;- —'— ——#-—-_|-_

i —-=____--1-L--._ --l_ ,,__ II use

C“ Q! \

ii

56 ‘I3 33U0}JF + ll I A of11, - . O ants _ I

ll WHITE --—; ill, {Ti -i---—

I I

FIGURE 6-4

3 II

4 O

6:2‘!

51 ma “D " ‘O 1 II II 2 i

O I

Q.F“caone

6-5

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CONSOLESO

BLUE B3

aaowu B4 l

B5 2Qqi9'-‘ll F Isracs 3 /‘F I saggy

032.0:

RED

YELLOW

REDT)

6-6

"K

I E15 vou"I sussuriI

H

FIGURE 6-5

O CT I2.6t/AC

-1

CR2

+5 VOLT-@6955“ is is _L WW5 . ass.

I_ II C?_ C4:_Q; + C _'_ C Iwarts sassrv “ '3

| - ).JFaaoo 5 pr

TO BE -CONNECTEO "'LATER

B?+

C12I _,uF

.-

B6

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FUNCTION GNATO PC OAD SMLY c0Ns0LEs0

The following parts are required for assembly of the Function Generator PC Board. To help you identifythe various components, reference numbers in the list correspond to the component pictorial drawingsof Figure 7-1.

Quantity

1 Fig. 7-1A1 Fig. 7-1B4 Fig. 7-1B1 Fig. 7-1B2 Fig. 7-‘LB1 Fig. 7-TLB1 Fig. 7-1C1 Fig. 7-LC4 Fig. 7-1D6221223 Fig. 7-1E1 Fig. 7-1F11 Fig. 7-1G3 Fig. 7-1G61 Fig. 7-CIH1 Fig. ’7I-1H1 Fig. 7-III1 Fig. 7-I'l.J

2

Parts Needed

Reference Description

PC Board

50 kt"). PC Trim Potentiometer (00232733 or R503), Blue

10 kt] PC Trim Potentiometers (00281912 or R103), Red

5009. PC Trim Potentio1neter(00280717 or R501), Green

100 k9. PC Trim Potentiometers (00233803 or R104), Yellow

1 kt} PC Trim Potentiometer (00231029 or R102), White

+12V Regulator (7812CP or LM340T-12)

~—12V Regulator (7912CP or LM320T-12)

6-32 X 1/4" X 3/8" Spacers

No. 6 Lockwashers P

1052 , 1/2W, i10% Resistors

1009 , 1/2W, i10% Resistors

4.7 kit, 1/2W, i1U% Resistor

22 kt). , 1/2W, i10% Resistors

47 kit , 1f2W, i10% Resistors

.1 ,u F Mylar Capacitor

.01 {.1 F Mylar Capacitor

10 pF Disc Capacitor

10 11F, 35V Capacitor

1 uF, 35V Capacitors

6-32 X 1/4” Binder-Head Machine Screws

ZN5223 NPN Transistor

ZN5227 PNP Transistor

8038 Function Generator

NE531 Op. Amp.

1N914 Diodes

71

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CONSOLE 80

Quantity Reference Description

1 Fig. 7-1K 14-Pin IC Socket

1 Fig. 7 -1L 8-Pin IC Socket

2 6-32 X 1/4” Nuts

No. 22 Solid Red, Black, Blue, Yellow, Green,

Brown, and Gray Hookup Wire

Solder, 60/40

PC Board Assembly

The diodes and resistors mentioned in the firsttwo steps are installed tightly against the PCboard. The excess lead lengths are clipped offat the soldered connection. When installing thediodes, be sure that the polarity is correct.Match the band on the diode to the line in thediode symbol on the PC board, as shown inFigure 7-2B.

Install nine resistors on the PC board1“ following the chart in Figure 7-2A.

Install two 1N914 diodes at positions D1ii‘ and D2 on the PC board. Be sure to orient

the diodes as shown in Figure 7-2B.Solder the connections and trim theexcess lead lengths.

Strip the insulation from a 4-1/4” length" of red hookup wire and cut and install

three bare wire jumpers as shown inFigure 7-3.

Install two 1 HF, 35V capacitors near thetop of the PC board, at the locationsshown in Figure 7-3. Orient the capacitorsas shown in Figure 7-4. Solder the capac-itors and trim the excess lead length. Theextra hole under the capacitors is notused.

7-2

.-"_I.'-P’.--"

lnstall seven capacitors on the PC board asI iydicatedin the chart of Figure 7-3.

/’Install a 14-pin IC socket at location IC-1

1'“. and an 8-pin socket at IC-2. Orient the ICsocket as shown in Figure 7-5. Carefullysolder the connections.

3Install the nine trim potentioineters on' the PC board following the chart shown in

Figure 7-6. The trim potentiometers arecolor-coded for easy identification.-E1

'i€Bendthe leads of 10-s and 10-4 (r12VF7“-“F ' ' regulators) as shown in Figure 7-7.

I-.-1

Following the mounting arrangementshown in Figure 7-8, mount the +12Vregulator (7312) at IC-4 and —12V regu-lator (7912) at 1C-3. Solder the leads ofthe regulators and remove the excesslengths.

."HP1'eparethe leads of the 2N5223 (Q1) and“F 2N5227 (Q2) transistors as shown in Fig-

ure 7-9.

I 'Install Q1 and Q2 following the orienta-

r__.-'

tion shown in Figure 7-10. Solder thetransistor leads.

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I' _.'l I __ .. ... . . . F . .

LeadLength

' “F F "1PC BoardHole NoColor

B ueYellowGreeBrowllBlueYellowBrown-RedGray -BlackBlackYellowBrownRgd II I

GreenGray

Lead I

n

_ ""1 *7— --_ ._. _ X“ _-. .'

s-1/2"s-1/2" I I

6 H‘!

64-X211. -1. ..I 6:: -

6::

-power}-F>31.oo:r~a1-f

5.-]__l2_:__1| II ---------- ....

_7_1I;2:I>

6 I!‘

. -1.1

II _ _ 1.3

.1-"

1516

--I3

.' -"

CHART 7-1

CONSOLE 80

_.-

I XInstall 10-1 (seas) and IC-2 (NE531) fol-lowing the orientation shown in Figure7-11.

z_.-

" board are indicated in Chart 7-1. Cut tothe specified wire lengths and strip 1/4”of insulation from each end of each wire.Insert one end of each wire into the PCboard hole indicated, and solder. Theother end will be connected later.

_,{=*-The interconnecting wires for the PC

ii-‘Mountthe four 6-32 >< 1/4" >< s/8"“ii spacers to the PC board using four 6-32 X

1/4” binder-head machine screws andNo. 6 lockwashers, as shown in Figure7-12.

This completes the assembly of the functiongenerator PC board. Check your work to besure that all components and wires are installedproperly.

7-3

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CONSOLE 80

_:TTTiT ' 1 ' ""

77777777777777? 4 ‘F H“ I‘ Pi ___. E‘ H | “:57 f 1* \\ ___.-I_-|-"'-""1 " " -H5<I m '\ (\.~ " \. -|-—*""-}'¢. "F ‘~ -—:*'-=--. - 2"--I \\ "'---.5 ' """ K“ R - 1.-1-—"""'. ‘ \|. ""--,

E F X -—">“ ‘H " I-1-—' " H» *"X 2.--—""" ‘" *“ * -.., __|_____..---"' -R 1- 1.

.//4/3,/'

-I

®//v/V ff

ix/'//-.1%~/IxX

‘\_ \'_'"Y .5‘ ' Km‘ "‘~.\_N‘ - ~__,_...- '\ \._ "-\‘ K” __ "“\..__ -' K. ____;$|-A

.\‘ -.,_ Y‘ ___ fig, N __ __* ="\-Q + .:=-=~""'\'. \ A ‘I -

/1’...---

_____.,--

/’

PC BOARD

A

I I‘I. "4 ,

TRIM APOTENTIOMETERVOLTAGE REGULATOR

B C

...... - -.-.'-.'.'-'1 .*."'." ' - 1: :9.___, _ --.-._._. H, ._ . ._‘_* ‘ '-7-'- 1' _'_ -'-, ' ‘.52, “'_

OR1. .. . l H

.'":1-"5EE'.=I5.'.=.'=I.=.'.5.‘=.'-==' ' '- '1. -.-L.-_.-_-._.;;;.;..;,-._" .. _g

H .\CAPACITOR CAPACITOR CAPACITOR

E F G

@171 'FUNCTION GENERATOR OP AMP 1'4-PIN IC SOCKET

‘E

---"‘ _..- " ‘“-. ' '*"“"‘T'¢:

SPACER

D

TRANSISTOR

H

__=.-;.;=-=2:;;=_I:=_=;_= '

8-PIN IC SO

I -J K L

FIGURE 7-"I

'7-4

I

_ _ _ ._ 19 (i: .I7I777 - |- ‘H’ M-___‘ H‘-.

'\- ' -H. ‘~_.“..“-

CKET

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QNINMEDOEIMF___m__Fm%0%pflMpFIA

_N

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5|MWR

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1_____v§_|W_‘___mF

ltiliiijxmim __m_ ‘ammo;wagH;2HW'5'1Li;wmmuww$050“HugHmgowl_H_HWMM

_H_ M__fimfl£

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Page 57: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

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Page 58: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

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Page 59: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

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Page 61: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

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Page 62: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

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Page 63: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo

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Page 68: The Workbench - Console 80 Assembly Manual 8105Cdave.spalla.com/wp-content/uploads/2014/01/Console80.pdf · 2014. 1. 14. · 1032, itis being expressed in picofarads, where the firsttwo
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