Elenco Electronics AM-550K Assembly And Instruction Manual

AM RADIO KIT

MODEL AM-550K

INTEGRAL CIRCUIT, 3 TRANSISTORS, DIODE

Assembly and Instruction Manual

Copyright © 2007, 1999 Elenco®Electronics, Inc. Revised 2007 REV-S 752550

No part of this book shall be reproduced by any means; electronic, photocopying, or otherwise without written permission from the publisher.

Elenco®Electronics, Inc.

-1-

PARTS LIST

If you are a student, and any parts are missing or damaged, please see instructor or bookstore.
If you purchased this kit from a distributor, catalog, etc., please contact Elenco®Electronics (address/phone/e­mail is at the back of this manual) for additional assistance, if needed. DO NOT contact your place of purchase
as they will not be able to help you.

RESISTORS

Qty. Symbol Value Color Code Part #

1 R14 10Ω 5% 1/4W brown-black-black-gold 121000
1 R13 47Ω 5% 1/4W yellow-violet-black-gold 124700
1 R8 100Ω 5% 1/4W brown-black-brown-gold 131000
1 R10 470Ω 5% 1/4W yellow-violet-brown-gold 134700
1R6 1kΩ 5% 1/4W brown-black-red-gold 141000
1 R12 2.2kΩ 5% 1/4W red-red-red-gold 142200
2 R3, R11 3.3kΩ 5% 1/4W orange-orange-red-gold 143300
1 R9 10kΩ 5% 1/4W brown-black-orange-gold 151000
1 R2 12kΩ 5% 1/4W brown-red-orange-gold 151200
1 R5 27kΩ 5% 1/4W red-violet-orange-gold 152700
1 R7 39kΩ 5% 1/4W orange-white-orange-gold 153900
1 R1 56kΩ 5% 1/4W green-blue-orange-gold 155600
1R4 1MΩ 5% 1/4W brown-black-green-gold 171000
1 Pot/SW1 50kΩ (nut & washer) 192522

CAPACITORS

Qty. Symbol Value Description Part #

1 C1 Variable Tuning 211677
1 C15 .001μF Discap (102) 231036
2 C3, C10 .01μF Discap (103) 241031
5 C2, C5, C7, C8, C9 .02μF or .022μF Discap (203) or (223) 242010
1 C16 .047μF Discap (473) 244780
3 C4, C11, C12 10μF Electrolytic Radial (Lytic Capacitor) 271045
1 C6 100μF Electrolytic Radial (Lytic Capacitor) 281044
2 C13, C14 470μF Electrolytic Radial (Lytic Capacitor) 284743

SEMICONDUCTORS

Qty. Symbol Description Part #

1 D1 1N4148 Diode 314148
3 Q1, Q2, Q3 2N3904 Transistor NPN 323904
1 U1 LM-386 Integrated Circuit 330386

COILS

Qty. Symbol Description Part #

1 L2 Oscillator (red dot) 430057
1 T1 IF (yellow dot) 430260
1 T2 IF (white dot) 430262
1 T3 Detector (black dot) 430264
1 L1 Antenna with Holders 484004

MISCELLANEOUS

Qty. Description Part #

1 PC Board 517037
1 Battery Holder 590096
1 Speaker 590102
1 Knob (pot) 622017
1 Knob (dial) 622030
1 Earphone Jack with Nut 622130 or 622131
1 Radio Stand 626100
1 Earphone 629250
3 Screw 2-56 x 1/4” 641230
1 Screw 2-56 x 5/16” 641231

Qty. Description Part #

3 Screw M2.5 x 3.8mm 641310
4 Nut 2-56 644201
1 IC Socket 8-Pin 664008
8 Test Point Pin 665008
1 Label, Dial Knob 720421
1 Manual 752550
1 Speaker Pad 780128
1 Wire 4” 814920
1 Solder Lead-Free 9LF99

Punch out one antenna shim from the front flap of the box.

**** SAVE THE BOX THAT THIS KIT CAME IN. IT WILL BE USED ON PAGES 24 & 29. ****

PARTS IDENTIFICATION

-2-

RESISTORS CAPACITORS SEMICONDUCTORS

Resistor

50kΩ

Potentiometer

with Switch

Discap

Electrolytic

Radial

Tuning

Diode

Transistor

LM-386 IC

Antenna Assembly

Coil

Coil

Plastic Holders

Ferrite Core

Color Dot

Knob (pot)

Earphone Jack with Nut

Knob (dial)

Radio Stand

COILS

MISCELLANEOUS

Label, Dial Knob

Battery

Holder

Earphone

OR

Speaker PadSpeaker

IC Socket

Test

Point Pin

Screw

2-56 x 1/4”

Screw

M2.5 x 3.8mm

Nut

2-56

Screw

2-56 x 5/16”

-3-

IDENTIFYING RESISTOR VALUES

Use the following information as a guide in properly identifying the value of resistors.

BANDS

METRIC UNITS AND CONVERSIONS

Abbreviation Means Multiply Unit By Or

p Pico .000000000001 10

-12

n nano .000000001 10

-9

μ micro .000001 10

-6

m milli .001 10

-3

– unit 1 10

0

k kilo 1,000 10

3

M mega 1,000,000 10

6

1. 1,000 pico units = 1 nano unit

2. 1,000 nano units = 1 micro unit

3. 1,000 micro units = 1 milli unit

4. 1,000 milli units = 1 unit

5. 1,000 units = 1 kilo unit

6. 1,000 kilo units = 1 mega unit

IDENTIFYING CAPACITOR VALUES

Capacitors will be identified by their capacitance value in pF (picofarads), nF (nanofarads), or μF (microfarads).
Most capacitors will have their actual value printed on them. Some capacitors may have their value printed in
the following manner. The maximum operating voltage may also be printed on the capacitor.

Second Digit

First Digit

Multiplier

Tolerance*

Note: The letter “R”
may be used at times
to signify a decimal
point; as in 3R3 = 3.3

103K

100V

The letter M indicates a tolerance of +20%
The letter K indicates a tolerance of +

10%

The letter J indicates a tolerance of +5%

Maximum Working Voltage

The value is 10 x 1,000 =
10,000pF or .01μF 100V

*

Electrolytic capacitors have a positive
and a negative electrode. The
negative lead is indicated on the
packaging by a stripe with minus
signs and possibly arrowheads.

Warning:

If the capacitor is
connected with
incorrect polarity, it
may heat up and
either leak, or cause
the capacitor to
explode.

Polarity
Marking

BAND 1

1st Digit

Color Digit

Black 0
Brown

1

Red 2
Orange 3
Yellow 4
Green 5
Blue 6
Violet 7
Gray 8
White 9

BAND 2

2nd Digit

Color Digit

Black 0
Brown 1
Red 2
Orange 3
Yellow 4
Green 5
Blue 6
Violet 7
Gray 8
White 9

Multiplier

Color Multiplier

Black 1
Brown 10
Red 100
Orange 1,000
Yellow 10,000
Green 100,000
Blue 1,000,000
Silver 0.01
Gold 0.1

Resistance

Tolerance

Color Tolerance

Silver ±10%
Gold ±5%
Brown ±1%
Red ±2%
Orange ±3%
Green ±0.5%
Blue ±0.25%
Violet ±0.1%

1

2 Multiplier Tolerance

Multiplier

For the No. 0 1 2 3 4 5 8 9

Multiply By 1 10 100 1k 10k 100k .01 0.1

-4-

Figure 1

Section 4

Section 3 Section 2 Section 1Section 5

FIRST

IF AMPLIFIER

SECOND

IF AMPLIFIER

DETECTOR

AUDIO

AMPLIFIER

MIXER

LOCAL

OSCILLATOR

AGC

Speaker

INTRODUCTION

The Elenco®Superhet 550 AM Radio Kit is a
“superheterodyne” receiver of the standard AM
(amplitude modulation) broadcast frequencies. The
unique design of the Superhet 550 allows you to
place the parts over their corresponding symbol in
the schematic drawing on the surface of the printed
circuit board during assembly. This technique
maximizes the learning process while keeping the
chances of an assembly error at a minimum. It is
very important, however, that good soldering
practices are used to prevent bad connections. The
Soldering Guide should be reviewed before any
soldering is attempted.

The actual assembly is broken down into five
sections. The theory of operation for each section, or

stage, should be read before the assembly is started.

This will provide the student with an understanding
of what that stage has been designed to accomplish,
and how it actually works. After each assembly, you
will be instructed to make certain tests and
measurements to prove that each section is
functioning properly. If a test fails to produce the
proper results, a troubleshooting guide is provided to
help you correct the problem. If test equipment is
available, further measurements and calculations are
demonstrated to allow each student to verify that
each stage meets the engineering specifications.
After all of the stages have been built and tested, a
final alignment procedure is provided to peak the
performance of the receiver and maximize the
Superhet 550’s reception capabilities.

The Superhet 550 can best be understood by
analysis of the block diagram shown in Figure 1.
The purpose of section 1, the Audio Amplifier Stage,
is to increase the power of the audio signal received
from the detector to a power level capable of driving
the speaker. Section 2 includes the detector circuit
and the AGC (automatic gain control) circuit. The
detector converts the amplitude modulated IF
(intermediate frequency) signal to a low level audio
signal. The AGC stage feeds back a DC voltage to
the first IF amplifier in order to maintain a near
constant level of audio at the detector. Section 3 is
the second IF amplifier. The second IF amplifier is
tuned to 455kHz (Kilohertz) and has a fixed gain at
this frequency of 100. The 3dB bandwidth of this

stage should be approximately 6kHz. Section 4 is
the first IF amplifier which has a variable gain that
depends on the AGC voltage received from the AGC
stage. The first IF amplifier is also tuned to 455kHz
and has a 3dB bandwidth of approximately 6kHz.
Section 5 includes the mixer, oscillator and antenna
stages. When the radio wave passes through the
antenna, it induces a small voltage across the
antenna coil. This voltage is coupled to the mixer, or
converter, stage to be changed to a frequency of
455kHz. This change is accomplished by mixing
(heterodyning) the radio frequency signal with the
oscillator signal. Each of these blocks will be
explained in detail in the Theory of Operation given
before the assembly instructions for that stage.

GENERAL DISCUSSION

-5-

CONSTRUCTION

Introduction

Assembly of your AM-550 AM Radio Kit will prove to be an exciting project and give you much
satisfaction and personal achievement. If you have experience in soldering and wiring
techniques, then you should have no problem with the assembly of this kit. Care must be given
to identifying the proper components and in good soldering habits. Above all, take your time
and follow these easy step-by-step instructions. Remember, “An ounce of prevention is worth
a pound of cure”. Avoid making mistakes and no problems will occur.

Safety Procedures

• Wear eye protection when soldering and during all phases of construction.

• Locate soldering iron in an area where you do not have to go around it or reach over it.

• Do not hold solder in your mouth. Wash your hands thoroughly after handling solder.

• Be sure that there is adequate ventilation present.

Assemble Components

In all of the following assembly steps, the components must be installed on the top side of the
PC board unless otherwise indicated. The top legend shows where each component goes.
The leads pass through the corresponding holes and the board is turned to solder the
component leads on the foil side. Solder immediately unless the pad is adjacent to another
hole which will interfere with the placement of the other component. Cut excessive leads with
a diagonal cutter. Then, place a check mark in the box provided next to each step to indicate
that the step is completed. Be sure to save the extra leads for use as jumper wires if needed.

Soldering

The most important factor in assembling your AM radio kit is good soldering techniques. Using
the proper soldering iron is of prime importance. A small pencil type soldering iron of 25 - 40
watts is recommended. The tip of the iron must be kept clean at all times and well tinned.
Many areas on the PC board are close together and care must be given not to form solder
shorts. Size and care of the tip will eliminate problems.
For a good soldering job, the areas being soldered must be heated sufficiently so that the
solder flows freely. Apply the solder simultaneously to the component lead and the component
pad on the PC board so that good solder flow will occur. Be sure that the lead extends through
the solder smoothly indicating a good solder joint. Use only rosin core solder.
DO NOT USE ACID CORE SOLDER! Do not blob the solder over the lead because this can
result in a cold solder joint.

Heat Sinking

Electronic components such as transistors,
IC’s, and diodes can be damaged by the heat
during soldering. Heat sinking is a way of
reducing the heat on the components while
soldering. Dissipating the heat can be
achieved by using long nose pliers, an alligator
clip, or a special heat dissipating clip. The heat
sink should be held on the component lead
between the part and the solder joint.

Mount Part

Bend Leads to Hold Part Solder and Cut Off Leads

Foil Side

Rx - 100Ω 5% 1/4W Resistor

(brown-black-brown-gold)

Heat Sink

(this can be ordered as part of Elenco’s Solder Ease

Kit Model SE-1).

Soldering Iron

Solder

Heat Sensitive
Component (Diode)

PC Board

-6-

What Good Soldering Looks Like

A good solder connection should be bright, shiny,
smooth, and uniformly flowed over all surfaces.

Soldering a PC board

1. Solder all components from the copper foil side
only. Push the soldering iron tip against both the
lead and the circuit board foil.

2. Apply a small amount of solder to the iron tip.
This allows the heat to leave the iron and onto
the foil. Immediately apply solder to the
opposite side of the connection, away from the
iron. Allow the heated component and the
circuit foil to melt the solder.

3. Allow the solder to flow around the connection.
Then, remove the solder and the iron and let the
connection cool. The solder should have flowed
smoothly and not lump around the wire lead.

4.

Here is what a good solder connection looks like.

Types of Poor Soldering Connections

1. Insufficient heat - the solder will not flow onto
the lead as shown.

2. Insufficient solder - let the solder flow over the
connection until it is covered. Use just enough
solder to cover the connection.

3. Excessive solder - could make connections
that you did not intend to between adjacent foil
areas or terminals.

4. Solder bridges - occur when solder runs
between circuit paths and creates a short circuit.

This is usually caused by using too much solder.

To correct this, simply drag your soldering iron

across the solder bridge as shown.

A poorly soldered joint can greatly affect small current flow in circuits and can cause equipment failure. You can
damage a PC board or a component with too much heat or cause a cold solder joint with insufficient heat.
Sloppy soldering can cause bridges between two adjacent foils preventing the circuit from functioning.

Solder

Soldering Iron

Foil

Solder

Soldering Iron

Foil

Component Lead

Soldering Iron

Circuit Board

Foil

Rosin

Soldering iron positioned
incorrectly.

Solder

Gap

Component Lead

Solder

Soldering Iron

Drag

Foil

-7-

TEST C

TEST D

High Resistance

Diode

Low Resistance

Diode

Ω

Ω

COM

Ω

Ω

COM

TEST A

TEST B

Low Resistance

NPN

EBC

High Resistance

NPN

EBC

Ω

Ω

COM

Ω

Ω

COM

SEMICONDUCTOR PARTS FAMILIARIZATION

This section will familiarize you with the proper method used to test the transistors and the diode.

TRANSISTOR TEST

Refer to the parts list and find transistors. These are
NPN transistors. Refer to Test A for locating the
Emitter, Base and Collector. Using an Ohmmeter,
connect the transistor as shown in Test A. Your meter
should be reading a low resistance. Switch the lead
from the Emitter to the Collector. Your meter should
again be reading a low resistance.

Using an Ohmmeter, connect the transistor as shown
in Test B. Your meter should be reading a high
resistance. Switch the lead from the Emitter to the
Collector. Your meter should again be reading a high
resistance. Typical results read approximately 1MΩ
to infinity.

DIODE TEST

Refer to the parts list and find a diode. This is a
silicon 1N4148 diode. Refer to Test C for locating the
Cathode and Anode. The end with the band is the
cathode. Using an Ohmmeter, connect the diode as
shown in Test C. Your meter should be reading a low

resistance. Using an Ohmmeter, connect the diode
as shown in Test D. Your meter should be reading a
high resistance. Typical results read approximately
1MΩ to infinity.

-8-

SECTION 1

AUDIO AMPLIFIER

The purpose of the Audio Amplifier is to increase the audio power to a level sufficient to drive an 8 ohm speaker. To do this,
DC (direct current) from the battery is converted by the amplifier to an AC (alternating current) in the speaker. The ratio of
the power delivered to the speaker and the power taken from the battery is the efficiency of the amplifier. For the Audio
Amplifier, we use the integrated circuit (IC) LM-386. In Figure 2, you can see equivalent schematic and connection diagrams.
In a Class A amplifier (transistor on over entire cycle), the maximum theoretical efficiency is .5 or 50%. But, in a Class B

amplifier (transistor on for 1/2 cycle), the maximum theoretical efficiency is .785 or 78.5%. Since transistor characteristics are
not ideal in a pure Class B amplifier, the transistors will introduce crossover distortion. This is due to the non-linear transfer
curve near zero current or cutoff. This type of distortion is shown in Figure 3.

In order to eliminate crossover distortion and maximize efficiency, the transistors of the audio amplifier circuit are biased on
for slightly more than 1/2 of the cycle, Class AB. In other words, the
transistors are working as Class A amplifiers for very small levels of power
to the speaker, but they slide toward Class B operation at larger power
levels.

To make the LM-386 a more versatile amplifier, two pins (1 and 8) are
provided for gain control. With pins 1 and 8 open, the 1.35kΩ resistor sets
the gain at 20 (see Figure 4a). The gain will go up to 200 (see Figure 4b)
if a resistor is placed in series with the capacitor. The gain can be set to
any value from 20 to 200. The amplifier with a gain of 50 is shown in
Figure 4c.

The amplifier in our kit with a gain of 150 is shown in Figure 5. Capacitor C11
couples the audio signal from the volume control to the input of the audio
amplifier. Capacitor C13 blocks the DC to the speaker, while allowing the AC to pass.

Figure 3

Figure 4a

Figure 4b

Figure 4c

Figure 2

Figure 5

from detector

C15

C11

C14

9V

R13

C12

C16

R14

C13

TP7

TP6

U1

6

1

8

5

7

4

2

3

-9-

ASSEMBLY INSTRUCTIONS

We will begin by installing the speaker. Be careful to properly mount and solder all components. Diodes and
electrolytic capacitors are polarized, be sure to follow the instructions carefully so that they are not mounted
backwards. Check the box when you have completed each installation.

Cut two 1 1/2” wires and one 1” wire and strip 1/4” of insulation off
of both ends. Solder the wires in the locations shown.

Figure D

1 ½”

Wires

Figure C

Foil Side

Mount the jack with the nut from the foil side of the PC board (terminal #1 on
the GND pad of the PC board). Be sure to line up the tab with the pad on the
copper side of the PC board. Solder terminal #1 to the pad of the PC board.

1” Wire

1

Part # 622131

Part # 622130

1 - GND
2 - Tip
3 - N.C. Tip

1 ½”

Wires

1” Wire

1

3

2

Jack

1 - GND
2 - Tip
3 - N.C. Tip

Your kit may contain a different type of earphone jack. Before installing
the jack, determine which one you have. Solder the GND terminal to the
PC board pad.

GND Pad

Nut

Jack

2

3

Nut

GND

Pad

From Terminal 3

Figure B

If the speaker pad has center and outside pieces, then
remove them. Peel the backing off of the speaker pad and
stick the pad onto the speaker. Then stick the speaker
onto the solder side of the PC board as shown.

Pad

Speaker

Backing

Remove

Backing

J1 - Earphone Jack
with Nut

(see Figure C)

SP1 - 8Ω Speaker
Speaker Pad
Wire 4”

(see Figures B & D)

Battery Holder
1 Screw 2-56 x 5/16”
2 Screw 2-56 x 1/4”
3 Nuts 2-56
Solder and cut off
excess leads.

Part # 622131

Part # 622130

-10-

ASSEMBLY INSTRUCTIONS

Diode

Be sure that the band is in
the correct direction.

NPN Transistor

Figure G

Mount so E lead is
in the arrow hole
and flat side is in
the same direction
as shown on the
top legend. Leave
1/4” between the
part and PC board.

Figure H

EBC

E

B

C

Flat
Side

Band

CathodeAnode

Integrated Circuit

Insert the IC socket into the
PC board with the notch in
the direction shown on the
top legend. Solder the IC
socket into place. Insert the
IC into the socket with the
notch in the same direction
as the notch on the socket.

C14 - 470μF Lytic Capacitor

(see Figure Fa

C13 - 470μF Lytic Capacitor

(see Figure F)

TP7 - Test Point Pin

(see Figure E)

C16 - .047μF (473) Discap

TP8 - Test Point Pin

(see Figure E)

R14 - 10Ω 5% 1/4W Resistor

(brown-black-black-gold)

Figure I

Notch

TP6 - Test Point Pin

(see Figure E)

C12 - 10μF Lytic Capacitor

(see Figure F)

C11 - 10μF Lytic Capacitor

(see Figure F)

R13 - 47Ω 5% 1/4W Resistor

(yellow-violet-black-gold)

U1 - IC Socket 8-Pin
U1 - Integrated Circuit LM-386

(see Figure I)

Pot with Switch
Nut & Washer
Knob

Solder 5 lugs

to PC board.

Top Side

Test Point Pin

Foil Side
of PC Board

Figure E

Nut

Washer

Electrolytics have a polarity marking indicating the
(–) lead. The PC board is marked to show the lead
position.

Warning: If the capacitor is connected with
incorrect polarity, or if it is subjected to voltage
exceeding its working voltage, it may heat up and
either leak or cause the capacitor to explode.

Polarity Mark

Polarity Mark

Capacitor C14

For safety, solder capacitor C14
on the copper side as shown.
Bend the leads 90Oand insert
into holes. Check that the
polarity is correct, then solder in
place. Trim the excess leads on
legend side.

Figure F Figure Fa

(–) (+)

+

–

-11-

STATIC MEASUREMENTS

RESISTANCE TEST

You have completed wiring the Audio Amplifier. We shall proceed in testing this circuit. You will need for static
measurements, a Volt-Ohm-Milliammeter, preferably a digital type.

Adjust the Volt-Ohm-Milliammeter (VOM) to the highest
resistance scale available. Connect the VOM to pin 6 of
the IC as shown in Figure 6. Do not connect the battery.
The VOM should indicate a low resistance first and then
as C14 charges, resistance should rise to
approximately 4MΩ. If you get a lower reading, reverse

multimeter leads. If you get a reading lower than
100kΩ, check the circuit for shorts or parts inserted
incorrectly. Check C14 to see if it’s leaky or inserted
backwards. If you get a reading higher than 10MΩ,
check for open copper or bad solder connections on all
components.

Figure 6

Figure 7

Set your VOM to read the highest possible current.
Connect the meter to the circuit as shown in Figure 7.
Make sure that the On/Off switch (SW1) is in the OFF
position.
While watching your VOM, flip switch SW1 to the ON
position. The VOM should indicate a very low current.

Adjust your meter for a more accurate reading if necessary.
If the current is greater than 25 milliamps, immediately turn
the power off. The current should be between 3 and 15
milliamps. If you circuit fails this test, check that all parts
have been installed correctly and check for shorts or poor
solder connections. Turn OFF SW1.

POWER UP TEST

DC Amps

Amps COM V/Ω

+

Ω

Amps COM V/Ω

TP8

-12-

Adjust your VOM to read 9 volts and connect it to test point 7
(TP7) as shown in Figure 8.
Make sure that the battery, or a 9 volt power supply (if available),
is properly connected and turn the power ON. The voltage at
TP7 should be between 4 to 6 volts. If you get this reading, go
on to the next test. If your circuit fails this test, turn the power
OFF and check that the integrated circuit is correctly inserted in
the correct locations.

Move the positive lead of the VOM to test point 6 (TP6). Make
sure that the power is ON. The voltage at TP6 should be close
to 0V. If your circuit passes this test, leave the VOM connected
and go to test 1 in the Dynamic Measurements Section. If your
circuit fails this test, turn the power OFF and check the IC. All
static tests must pass before proceeding to the Dynamic Tests or
the next section.

OUTPUT BIAS TEST

Figure 8

INPUT BIAS

V

Amps COM V/Ω

TP8

Battery

If you do not have an audio generator, skip the following test and go directly to Section 2.

DYNAMIC MEASUREMENTS

Connect the VOM and audio generator to TP6 as shown in Figure 9.
Turn the power ON. Normally the AC gain is measured at a
frequency of 1 kilohertz (kHz). Your VOM, however, may not be
able to accurately read AC voltages at this frequency. It is
recommended, therefore, that this test be performed at 400Hz.
Set the audio generator at 400Hz and minimum voltage output.
Set your VOM to read an AC voltage of 1 volt at the output of your
Audio Amplifier (TP7). Slowly increase the output of the audio

generator until the VOM reads 1 volt AC. Leave the audio at this
setting and move the positive lead of your VOM to TP6. Record
the AC voltage input to the amplifier here: Vin=___________
volts. You may have to change scales on your VOM for the most
accurate reading. Turn the power OFF. The AC voltage gain of
your Audio Amplifier is equal to the AC output voltage divided by
the AC input voltage, or 1/Vin. Your calculated AC Gain should
be approximately 100/180.

If an oscilloscope is not available, skip the following test and go directly to Section 2.

Figure 9

V

Amps COM V/Ω

Output Adjust

TP8

TP8

Battery

10μF

Generator

AC GAIN

-13-

DYNAMIC MEASUREMENTS

Figure 10

Connect the oscilloscope and audio generator to your
circuit as shown in Figure 10.
Set the audio generator for a frequency of 1kHz and
minimum voltage output. Set the oscilloscope to read
.5 volts per division. Turn the power ON and slowly
increase the generator output until the oscilloscope
displays 2 volts peak to peak (Vpp) at TP7. Move the
oscilloscope probe to TP6 and record the input voltage
here: Vin=___________ Vpp, (at this point you may
want to verify the AC Gain). Move the oscilloscope
probe back to TP7 and slowly increase the frequency
from the audio generator until the waveform on the
oscilloscope drops to .7 of its original reading, 1.4 Vpp

or 2.8 divisions. Use the oscilloscope probe to check
TP6 to make sure the input voltage did not change. The
frequency of the generator when the output drops to .7
of its original value is called the high frequency 3
decibel (dB) corner.
Repeat this procedure by lowering the frequency from
the generator to obtain the low frequency 3dB corner.
Leave the oscilloscope connected to TP7 and turn the
power OFF. By subtracting the frequency of the low
corner from the frequency of the high corner, you
calculate the bandwidth of the Audio Amplifier. Your
bandwidth should be greater than 100kHz.

AC BANDWIDTH

10μF

Oscilloscope

Generator

Output Adjust

TP8

TP8

Probe

-14-

Measure the maximum voltage peak to peak when
clipping first occurs and record that value here:

Vclp = _______ Vpp.

The maximum power output before distortion due to
“clipping” can be calculated using the voltage Vclp
obtained in step 3 as follows:

Vpeak (Vp) = Vclp/2
Vroot mean squared (Vrms) = Vp x .7
Max power out = (Vrms)

2

/8 ohms = (Vclp x .35)2/8

Maximum power output should be greater than 200
milliwatts.

MAXIMUM POWER OUTPUT

Connect the generator and oscilloscope as shown in
Figure 10. Set the generator at a frequency of 1kHz,
turn the power ON and adjust the generator output

until the peaks of the sinewave at TP7 are clipped as
shown in Figure 11.

DISTORTION

Clipped

Crossover
Distortion

Figure 11 Figure 12

By measuring the DC power taken from the battery
at the maximum power output level, the efficiency to
the Audio Amplifier can be calculated. Power from
the battery is equal to the current taken from the
battery times the voltage of the battery during
maximum power output. It is best to use a power

supply to prevent battery voltage from changing
during this measurement. Efficiency can then be
calculated as follows:

Eff =

EFFICIENCY

Max power output

Battery power

/

-15-

The purpose of the detector is to change the
amplitude modulated IF signal back to an audio
signal. This is accomplished by a process called
detection or demodulation. First, the amplitude
modulated IF signal is applied to a diode in such a
way as to leave only the negative portion of that
signal (see Figure 13). The diode acts like an
electronic check valve that only lets current pass in
the same direction as the arrow (in the diode symbol)
points. When the diode is in conduction (On
Condition), it will force capacitors C9 and C10 to
charge to approximately the same voltage as the
negative peak of the IF signal. After conduction
stops in the diode (Off Condition), the capacitors will
discharge through resistors R11, R12 and the
volume control. The discharge time constant for this
circuit must be small enough to follow the audio
signal or high frequency audio distortion will occur.
The discharge time constant must be large enough,
however, to remove the intermediate frequency
(455kHz) and leave only the audio at the volume
control as shown in Figure 13.

The purpose of the automatic gain control (AGC)
circuit is to maintain a constant audio level at the
detector, regardless of the strength of the incoming
signal. Without AGC, the volume control would have
to be adjusted for each station and even moderately
strong stations would clip in the final IF amplifier
causing audio distortion. AGC is accomplished by
adjusting the DC bias of the first IF amplifier to lower
its gain as the signal strength increases. Figure 13
shows that the audio at the top of the volume control
is actually “riding” on a negative DC voltage when
strong signals are encountered. This negative DC
component corresponds to the strength of the
incoming signal. The larger the signal, the more
negative the component. At test point three (TP3),
the audio is removed by a low pass filter, R11 and
C4, leaving only the DC component. Resistor R5 is
used to shift the voltage at TP3 high enough to bias
the base of transistor Q2 to the full gain position
when no signal is present. Resistors R5 and R11
also forward bias diode D1 just enough to minimize
“On Condition” threshold voltage.

SECTION 2

Figure 13

AM DETECTOR AND AGC STAGES

THEORY OF OPERATION

-16-

ASSEMBLY INSTRUCTIONS - AM DETECTOR AND AGC STAGES

R8 - 100Ω 5% 1/4W Resistor
(brown-black-brown-gold)

T3 - Detector Coil

(Black Dot)

TP5 - Test Point Pin

(see Figure E)

D1 - 1N4148 Diode

(see Figure H)

C15 - .001μF Discap (102)

C10 - .01μF Discap (103)

C6 - 100μF Lytic Capacitor

(see Figure F)

R5 -

27kΩ 5% 1/4W Resistor

(red-violet-orange-gold)

T1 - IF Coil (Yellow Dot)

TP3 - Test Point Pin

(see Figure E)

R11 - 3.3kΩ Resistor
(orange-orange-red-gold)

C4 - 10μF Lytic Capacitor

(see Figure F)

C9 - .02μF Discap (203)

or .022μF Discap (223)

R12 - 2.2kΩ Resistor

(red-red-red-gold)

STATIC MEASUREMENTS

Figure 14

With the power turned OFF, connect the VOM to test
point three (TP3) as shown in Figure 14.
Check that the VOM is adjusted to read 9 volts DC
and turn the power ON. The voltmeter should read
approximately 1.5 volts DC. If your reading varies

more than .5 volts from this value, turn the power
OFF and check the polarity of D1, and resistors R11
and R5. Also check that transformer T1 is properly
installed.

AGC ZERO SIGNAL BIAS

With the power turned OFF, connect the positive lead
of the VOM to TP5 and the negative lead to any
ground. Make sure that the VOM is set to read 9
volts DC and turn the power ON. The voltage on the

VOM should be the same as your battery voltage or
power supply voltage. If not, turn OFF the power and
check that T3 is properly installed.

T3 TEST

If you do not have an RF generator, go to Section 3.

V

Amps COM V/Ω

TP8

-17-

Figure 15

DYNAMIC MEASUREMENTS

Turn the power OFF and connect the VOM and RF
generator as shown in Figure 15.

Set the VOM to accurately read 2 volts DC and set
the output of the RF generator for 455kHz, no
modulation, and minimum amplitude. Turn the power

ON and slowly increase the amplitude of the 455kHz
signal from the RF generator until the voltage at TP3
just starts to drop. This point is called the AGC
threshold with no IF gain. Make a note of the
amplitude setting on the RF generator here:
____________. Turn the power OFF.

DETECTOR AND ACG TEST

If your RF generator does not have amplitude modulation or you do not have an oscilloscope, go to Section 3.

Connect equipment as shown in Figure 16.
Set the RF generator at 455kHz, 1kHz at 80%
modulation and minimum output. Turn the power ON
and put the volume control at full clockwise position.

Slowly adjust the amplitude of the RF generator
output until you hear the 1kHz on the speaker. If this
test fails, turn the power OFF and check C11, R12,
volume control, D1 and TP3.

SYSTEM CHECK

Figure 16

Connect equipment as shown in Figure 16. Set the
RF generator at 455kHz with 80% modulation at a
modulation frequency of 1kHz. Set the oscilloscope
to read .1 volts per division. Turn the power ON and
put the volume control at minimum. Increase the
amplitude of the RF generator until the signal on the
oscilloscope is 4 divisions peak to peak. Check the
signal to make sure it is free of all distortion. Leave

the frequency of the RF output at 455kHz, but
increase the modulation frequency until the output
drops to 0.28 Vpp. Record the modulation frequency
on the RF generator here:

____________

This frequency should be greater than 5kHz. Turn
the power OFF.

DETECTOR BANDWIDTH TEST

V

Amps COM V

TP8

Generator

TP8

Output

Adjust

.02μF

Oscilloscope

Generator

Probe

.02μF

TP8

TP8

Output

Adjust

-18-

TP4 - Test Point Pin

(see Figure E)

T2 - IF Coil

(White Dot)

Q3 - 2N3904 Transistor NPN

(see Figure G)

R10 - 470Ω Resistor

(yellow-violet-brown-gold)

R7 - 39kΩ Resistor
(orange-white-orange-gold)

R9 - 10kΩ Resistor

(brown-black-orange-gold)

C7 - .02μF Discap (203)

or .022μF Discap (223)

C8 - .02μF Discap (203)

or .022μF Discap (223)

SECTION 3

Figure 17

.707

452kHz 458kHz

455kHz

The purpose of the SECOND IF AMPLIFIER is to
increase the amplitude of the intermediate frequency
(IF) and at the same time provide SELECTIVITY.
Selectivity is the ability to “pick out” one radio station
while rejecting all others. The second IF transformer
(T3) acts as a bandpass filter with a 3dB bandwidth
of approximately 6kHz. The amplitude versus
frequency response of the second IF amplifier is
shown in Figure 17.
Both IF amplifiers are tuned to a frequency of
455kHz and only need to be aligned once when the
radio is assembled. These amplifiers provide the
majority of the gain and selectivity needed to
separate the radio stations.

The gain at 455kHz in the second IF amplifier is fixed
by the AC impedance of the primary side of
transformer T3, and the DC current in Q3. The
current in Q3 is set by resistors R7, R9 and R10.
Both C7 and C8 bypass the 455kHz signal to ground,
making Q3 a common emitter amplifier. The signal is
coupled from the first IF amplifier to the second IF
amplifier through transformer T2. The IF
transformers not only supply coupling and selectivity,
they also provide an impedance match between the
collector of one stage and the base of the next stage.

This match allows maximum power to transfer from

one stage to the next.

SECOND IF AMPLIFIER

THEORY OF OPERATION

ASSEMBLY INSTRUCTIONS - SECOND IF AMPLIFIER

-19-

Figure 18

STATIC MEASUREMENTS

With the power OFF, connect the negative lead of your
VOM to any ground and the positive lead to the emitter
of Q3 as shown in Figure 18. Set the VOM to read 9
volts DC and turn ON the power. The voltage at the

emitter of Q3 should be approximately 1 volt. If your
reading is different by more than 0.5 volts, turn off the
power and check your battery of power supply voltage.
Also check components R7, R9, R10 and Q3.

Q3 BIAS

If you do not have an RF generator or oscilloscope, skip the following test and go to Section 4.

DYNAMIC MEASUREMENTS

With the power turned OFF, connect the oscilloscope
and the RF generator to the circuit as shown in Figure

19. Set the RF generator at a frequency of 455kHz, no
modulation and minimum amplitude output. Set the
oscilloscope vertical sensitivity at 1 volt/division. The
scope probe must have an input capacitance of less
than 50pF or it will detune transformer T3. Turn the
power ON and slowly increase the amplitude of the RF
signal until you have 4 volts peak to peak on the
oscilloscope. Tune transformer T3 for a maximum

output while readjusting the RF generator amplitude to
keep 4Vpp at the oscilloscope. After T3 is aligned,
move the scope probe tip to the base of Q3 and record
the peak to peak amplitude of the signal here:
Vb=__________Vpp. Turn the power OFF. The AC
gain of the second IF amplifier at 455kHz is equal to
4/Vb, and should be greater than 100. If your gain is
less than 100, check components C7, C8, R7, R9 and
R10. Also, make sure that transistor Q3 is properly
installed.

AC GAIN

Figure 19

Oscilloscope

Generator

Probe

.02μF

Output

Adjust

V

COM V

TP8

TP8

TP8

-20-

R4 - 1MΩ Resistor

(brown-black-green-gold)

TP2 - Test Point Pin

(see Figure E)

Q2 - 2N3904 Transistor NPN

(see Figure G)

R6 - 1kΩ Resistor

(brown-black-red-gold)

C5 - .02μF Discap (203)

or .022μF Discap (223)

SECTION 4

Figure 20

With the power OFF, connect your equipment as shown in
Figure 20. Turn the power ON and adjust the RF
generator for .4Vpp at the cathode of D1. If necessary,
realign transformer T3 for maximum output while adjusting
the output of the RF generator to maintain .4Vpp. Slowly
decrease the frequency of the RF generator until the
signal drops to .707 of its peaked value or .28Vpp. Record
the frequency of the RF generator here:
FL=___________kHz.

Now increase the frequency of the RF generator past the
peak to a point where the signal drops to .707 of its peak
value. Record that frequency point here:
FH=___________kHz. By subtracting the frequency of
the lower 3dB corner from the frequency of the higher 3dB
corner you get the BANDWIDTH of the second IF
amplifier. Your results should be similar to the values
shown in Figure 17.

BANDWIDTH TEST

FIRST IF AMPLIFIER

The operation of the first IF amplifier is the same as for the
second IF amplifier with one important difference. The
gain of the first IF amplifier decreases after the AGC
threshold is passed to keep the audio output constant at
the detector and prevent overload of the second IF
amplifier. This is accomplished by making the voltage on
the base of transistor Q2, lower as the signal strength
increases. Since the voltage from base to emitter is fairly
constant, the drop in voltage at the base produces a
similar drop in voltage at the emitter of Q2. This drop

lowers the voltage across R6 and thus reduces the DC
current through R6. Since all of the DC current from the
emitter of Q2 must go through R6, the DC current in Q2 is
therefore lowered. When the DC current in a transistor is
lowered, its effective emitter resistance increases. The AC
gain of transistor Q2 is equal to the AC collector load of Q2
divided by its effective emitter resistance. Raising the
value of the effective emitter resistance thus lowers the AC
gain of Q2.

THEORY OF OPERATION

Oscilloscope

Generator

.02μF

Output

Adjust

TP8

TP8

Probe

ASSEMBLY INSTRUCTIONS - FIRST IF AMPLIFIER

-21-

Figure 21

STATIC MEASUREMENTS

With the power turned OFF, reconnect your VOM to test
point 3 (TP3) as shown in Figure 14. Set the VOM to
read 2 volts DC accurately and turn the power ON. The

voltage should be approximately 1.5 volts. If your
circuit fails this test, turn the power OFF and check Q2
and R6.

Q2 BASE BIAS

With the power turned OFF, connect the positive lead
of the VOM to the emitter of Q2. Connect the
negative lead of the VOM to any DC ground and turn
the power ON. The voltage should be approximately

0.8 volts. Since the current in Q2 is equal to the
current in R6, I(Q2)=0.8/R6 or approximately 0.8
milliamps.

Q2 CURRENT

If you do not have an RF generator or oscilloscope, skip the following test and go to Section 5.

DYNAMIC MEASUREMENTS

With the power turned OFF, connect the RF
generator and the oscilloscope to your circuit as
shown in Figure 21. Using a clip lead, short TP5 to
R8 as shown in Figure 21. This short prevents the
AGC from lowering the gain of the first IF amplifier.
Set the RF generator to 455kHz, no modulation, and
minimum amplitude output. Set the oscilloscope for
a vertical sensitivity of 1 volt/division and turn the
power ON. Increase the amplitude output from the
RF generator until approximately 4Vpp registers on
the oscilloscope. Tune the IF transformer (T2) to
maximize the 455kHz at TP4. After tuning T2, adjust

the RF generator amplitude in order to keep 4Vpp at
TP4. Now move the oscilloscope probe to the base
of Q2 and record the peak to peak level of the
455kHz signal here:

Vb=____________Vpp.

The AC gain of the first IF amplifier is equal to 4/Vb.
The AC gain of this amplifier should be greater than

100. DO NOT TURN THE POWER OFF. GO TO
THE NEXT TEST.

AC GAIN

Move the oscilloscope probe back to TP4 and adjust
the RF generator for 4Vpp if necessary. Remove the

clip lead shorting TP5 to R8. The AGC should reduce
the signal level at TP4 to approximately 0.8 volts

.

AGC ACTION

.02μF

Probe

Output
Adjust

Oscilloscope

Generator

TP8

TP8

Clip Lead

-22-

SECTION 5

In a superheterodyne type receiver the radio wave at
the antenna is amplified and then mixed with the local
oscillator to produce the intermediate frequency (IF).
Transistor Q1 not only amplifies the RF signal but
also simultaneously oscillates at a frequency 455kHz
above the desired radio station frequency. Positive
feedback from the collector to the emitter of Q1 is
provided by coil L2 and capacitor C3. During the
heterodyne process, the following four frequencies
are present at the collector of Q1.

1. The local oscillator frequency, LO.

2. The RF carrier or radio station frequency.

3. The sum of these two frequencies, LO + RF.

4. The difference of these two frequencies, LO - RF.

The “difference frequency” is used as the
intermediate frequency in AM radios. The collector of
Q1 also contains an IF transformer (T1) tuned only to
the difference frequency. This transformer rejects all
frequencies except those near 455kHz. T1 also
couples the 455kHz signal to the base of Q2 to be
processed by the IF amplifiers.

The antenna and the oscillator coils are the only two
resonant circuits that change when the radio is tuned
for different stations. Since a radio station may exist
455kHz above the oscillator frequency, it is important
that the antenna rejects this station and selects only
the station 455kHz below the oscillator frequency.
The frequency of the undesired station 455kHz
above the oscillator is called the image frequency. If
the selectivity of the antenna (Q factor) is high, the
image will be reduced sufficiently.

The oscillator circuit must also change when the
radio is tuned in order to remain 455kHz above the
tuning of the desired radio station. The degree of
accuracy in keeping the oscillator frequency exactly
455kHz above the tuning of the antenna is called
tracking accuracy.

MIXER AND OSCILLATOR

THEORY OF OPERATION

-23-

ASSEMBLY INSTRUCTIONS - ANTENNA, MIXER AND OSCILLATOR

L1 - Antenna (see Figure K)

C2 - .02μF Discap (203)

or .022μF Discap (223)

TP1 - Test Point Pin

(see Figure E)

R2 - 12kΩ Resistor

(brown-red-orange-gold)

R3 - 3.3kΩ Resistor

(orange-orange-red-gold)

Figure J2

Fasten the knob (dial) into place
with a M2.5 x 3.8mm screw to
the C1 post.
Turn the dial fully clockwise.
Remove the protective backing
from the label and align the
1600 with the arrow on the PC
board.

Tuning Capacitor

Figure J1

Your kit may contain a 3 lead or a 4 lead
capacitor. Bend the leads as shown. Fasten C1
into place on the top side of the PC board with
two M2.5 x 3.8mm” screws.

C1

Screw Holes

Knob Post

Solder leads

to pads

3 Leads

4 Leads

R1 - 56kΩ Resistor

(green-blue-orange-gold)

L2 - Oscillator Coil (red dot)

Q1 - 2N3904 Transistor NPN

(see Figure G)

C3 - .01μF Discap (103)

C1 - Tuning Capacitor
3 Screws M2.5 x 3.8mm

(see Figure J1)
Knob (dial)
Label, Dial Knob

(see Figure J2)

Foil Side

Solder the tuning capacitor. Be very careful,
excessive heat can damage the capacitor’s
dielectric insulation.

-24-

PC Board Stand

Insert the PC board into the stand as shown.

IMPORTANT: Before installing the antenna coil, determine if you have a 3 wire coil or a 4 wire coil. Assemble
it to the PC board as shown below. Mount the antenna assembly to the PC board.

Put the tab of the first holder into the right hole and twist the tab 90

O

.
Put the tab of the second holder into the left hole and twist the tab 90O.
Slide the ferrite core through the holders.
Slide the antenna coil through the ferrite core.

Note: If the end of a wire from the antenna should break off, strip the insulation off the end with a hot
soldering iron. Lay the wire down on a hard surface and stroke the wire with your iron. The insulation should
come off very easily. CAUTION: The soldering iron will burn the hard surface that you are working on.

3 Wire Type Antenna

Solder the 3 colored wires to the PC
board.

Wire A (red) to the hole marked “RED”.

Wire B (black) to the hole marked
“BLK”.

Wire C (white) to the hole marked
“WHT”.

4 Wire Type Antenna

Solder the 4 colored wires to the PC board.

Wire A (green) to the hole marked “RED”.

Wire B (red and black twisted together) to the hole marked
“BLK”.

Wire C (white) to the hole marked “WHT”.

Figure K

Tabs

Tabs

C (white)

B (black)

A (red)

C (white)

B

A (green)

Twisted Together

Red

Black

A (green)

Red

Black

B Twisted Together

C (white)

OR

Punch out one antenna shim from the front flap of the box.

Insert the cardboard antenna shim between the ferrite core and the
antenna coil. This will temporarily hold the coil in place.

-25-

Figure 23

Figure 22

STATIC MEASUREMENTS

With the power turned OFF, connect the VOM to your
circuit as shown in Figure 22. Connect a clip lead from
test point two (TP2) to the collector of Q1. This short
prevents Q1 from oscillating. Set the VOM to read 2
volts DC accurately and turn the power ON. The DC

voltage at TP1 should be 1.6 volts. If the voltage in
your circuit differs by more than 0.5 volts, leave the
power ON and check the battery voltage. If the battery
voltage is greater than 8.5 volts, turn the power OFF
and check components R1, R2, R3 and Q1.

Q1 BIAS

If you do not have an oscilloscope, go to the Final Alignments With No Test Equipment Section.

DYNAMIC MEASUREMENTS

With the power turned OFF, connect the oscilloscope
to the circuit as shown in Figure 23.
Set the oscilloscope for a vertical sensitivity of 1
volt/division and turn the power ON. The oscilloscope
should display a low voltage sine wave. The

frequency of the sine wave should change when
capacitor C1 is turned. If your circuit fails this test,
turn the power OFF and check components Q1, C1,
C2, C3, L1 and L2.

OSCILLATOR CIRCUIT

If you do not have an RF generator, go to the Final Alignments with No Test Equipment Section.

V

Ohms

COM V

Oscilloscope

TP8

TP8

Clip Lead

-26-

Figure 24

Antenna Trimmer

Oscillator Trimmer

Antenna Trimmer

3 Leads 4 Leads

Figure 25

FINAL ALIGNMENTS

With the power turned OFF, connect the RF generator
and the oscilloscope to your circuit as shown in Figure 24.
Short TP2 to the collector of Q1 with a clip lead to “kill”
the local oscillator. Set the RF generator at a
frequency of 455kHz, modulation of 400Hz 80%,
minimum amplitude output. Set the oscilloscope to
read 0.1Vpp and turn the power ON. Increase the
amplitude of the RF signal until the oscilloscope
registers 0.5Vpp. Align transformers T3, T2 and T1 for
the maximum AC reading on the oscilloscope.
Decrease the amplitude of the signal from the RF
generator to restore 0.5Vpp on the oscilloscope.
Repeat the last two steps until no change in the peak
at the oscilloscope is noticed.

After IF alignment, lower the frequency from the RF
generator until the reading on the VOM drops to 0.707
of its peaked value. Record the frequency of this
lower 3dB corner here:

Fl=____________kHz.

Increase the RF generator frequency past the peak to
the upper 3dB corner and record that frequency here:

Fh=____________kHz.

The bandwidth of the IF amplifiers is BW=Fh - Fl. IF
bandwidth should be between 1 to 2kHz. This
bandwidth will widen as the AGC is approached.

IF BANDWIDTH

With the power turned OFF, connect the equipment to
the circuit as shown in Figure 24. DO NOT connect
the clip lead from TP2 to Q1. Set the RF generator at
540kHz, 400Hz 80% modulation, and a low level of
output. Turn the tuning capacitor fully counter­clockwise. Turn the power ON and a 400Hz tone
should be heard coming from the speaker. Tune the
oscillator coil (L2) for a peak on the oscilloscope.

Adjust the RF generator output during this process to
maintain a peak at 0.5Vpp or less. After peaking L2,
set the RF generator frequency to 1600kHz and turn
the tuning capacitor (C1) fully clockwise. A 400Hz
tone should be heard coming from the speaker. Tune
the oscillator trimmer capacitor on the back of C1 for
a peak on the oscilloscope (see Figure 25).

SETTING OSCILLATOR RANGE

.02μF

Output
Adjust

Oscilloscope

Generator

TP8

TP8

Clip Lead

Probe

-27-

Figure 26

With the power turned OFF, connect test equipment
to your circuit as shown in Figure 26. Set the RF
generator at 600kHz, 400Hz 80% modulation,
moderate signal strength. Set the oscilloscope to
read .5Vpp and turn the power ON. Turn C1 fully
counter-clockwise, then slowly turn C1 clockwise
until a 400Hz tone can be heard coming from the
speaker. Slowly slide the antenna coil back and forth
on the ferrite rod to obtain a peak on the
oscilloscope. For maximum signal, your location of
the antenna coil may have to be on the end of the
ferrite rod (as shown in Figure 27). Change the

frequency of the RF generator to 1400kHz and adjust
C1 until a 400Hz tone can be heard coming from the
speaker. Carefully peak the reading on the
oscilloscope by adjusting the frequency of the RF
generator. Now tune the antenna coil to this
frequency by adjusting the antenna trimmer on the
back of C1 (see Figure 25). This process should be
repeated until both settings of the antenna track the
oscillator tuning. Once the antenna is properly
aligned, carefully apply candle wax or glue to the
antenna coil and ferrite rod (as shown in Figure 27).

ANTENNA ALIGNMENT

After peaking the oscillator trimmer capacitor, return
the RF generator to 540kHz, and capacitor C1 to the
fully counter-clockwise position and readjust L2.
Repeat the last few steps until both settings of the
oscillator are correct. This process sets the oscillator
range at 995kHz to 2055kHz. If a frequency counter

is available, you may verify this alignment by
measuring the frequency at the emitter of Q1 for both
ends of the tuning capacitor (C1). Be careful not to
mistune the oscillator during this measurement. A
coupling capacitor of 82 picofarads or less to the
frequency counter is recommended.

Wire Loop

Close to
Antenna

Probe

Output
Adjust

Oscilloscope

TP8

TP8

Generator

Figure 27

Wax

Wax

Coil

Holders

-28-

DC Voltages

The voltage readings below should be used in troubleshooting the AM radio.

Q1 B 1.5V U1 1 - 1.3V

E 1.0V 2 - 0
C 8.9V 3 - 0

4 - 0

Q2 B 1.4V 5 - 4.5V

E 0.7V 6 - 9V
C 8.9V 7 - 4.6V

8 - 1.3V

Q3 B 1.7V

E 1.0V
C 9.0V

Test Conditions

1. Volume control set to minimum.

2. Connect a jumper wire between capacitor C2 (side
that goes to the lead of the antenna coil L1) to
negative battery.

3. Battery voltage - 9.0V

4. All voltages are referenced to circuit common.

5. Voltage reading can vary +

10%.

FINAL ALIGNMENT WITH NO TEST EQUIPMENT

It is best to use an earphone for this alignment
procedure.

With an alignment tool or screwdriver, turn coils L2,
T1, T2 and T3 fully counter-clockwise until they stop.
DO NOT FORCE THE COILS ANY FURTHER. Turn
each coil in about 1 1/4 to 1 1/2 turns. Set the
antenna coil about 1/8” from the end of its ferrite rod.
Refer to Figure K on page 24.

Turn the power ON and adjust the volume to a
comfortable level. Tune the dial until a weak station
is heard. If no stations are present, carefully slide the
antenna back and forth on its ferrite rod and retune
the dial if necessary. With an alignment tool or
screwdriver, adjust T1 until the station is at its
loudest. Reduce the volume control if necessary.
Adjust T2 until the station is at its loudest and reduce
the volume control if necessary. Adjust T3 until the
station is at its loudest and reduce the volume if
necessary. Retune the radio for another weak station
and repeat this procedure until there is no more
improvement noticed on the weakest possible
station. This procedure peaked the IF amplifiers to
their maximum gain.

Tune the radio until a known station around 600kHz
is found. It may be necessary to listen to the station
until their broadcast frequency is announced. If no
stations are present at the low side of the AM band,

adjust L2 until a station is heard. Once a station is
found and its broadcast frequency is known, rotate
the dial until the white pointer is aligned with that
station’s frequency marking on the dial. Adjust L2
until the station is heard. Tune the radio until a
station around 1400kHz is heard. It may be
necessary to listen to the station until their broadcast
frequency is announced. If no stations are present at
the high end of the AM band, adjust the oscillator
trimmer on the back of the gang. Once a station is
found and its broadcast frequency is known, rotate
the dial until the white pointer is aligned with that
station’s frequency marking on the dial. Adjust the
oscillator trimmer located on the back of the gang
until a station is heard. Repeat these steps until the
oscillator alignment is optimized. This procedure set
the oscillator range at 995kHz to 2055kHz.

Tune the radio for a station around 600kHz. Carefully
slide the antenna coil back and forth until the station
is at its loudest. Tune the radio for a station around
1400kHz. Adjust the antenna trimmer located on the
back of the gang (as shown in Figure 25) until the
station is at its loudest. Repeat these steps until the
antenna alignment is optimized. This procedure set
the antenna to “track” the oscillator. Once the
antenna is properly aligned, carefully apply candle
wax or glue the antenna coil to the ferrite rod to
prevent it from moving (as shown in Figure 27).

-29-

2. Bend the four flaps upward as shown.

1. Start at one edge and carefully remove the baffle from
the bottom of the kit box.

AM-550 Kit Carton

AM-550 RADIO BAFFLE

NOTICE:

Keep the box the kit came in. After you have completed the radio and it operates satisfactorily, you may want to install a baffle

to improve the sound.

The final step in the radio kit will be to assemble and attach a baffle to the speaker. You will need to remove the baffle located in the
bottom of the box. If it does not want to come out easily, use a knife to cut the holding tabs.

When a speaker is not enclosed, sound waves can travel in all directions. As a speaker moves outward, it creates positive pressure on
the air in front of it and negative pressure on the rear. At low frequencies, out of phase front and rear waves mix causing partial or total
cancellation of the sound wave. The end result is a speaker less efficient and distorted.

To eliminate the low frequency cancellation, a speaker is placed inside an enclosure. Now the front sound waves are prevented from
traveling to the back. The speaker will now compress and decompress air inside, increasing its resonant frequency and Q relative to the
free air values. This type of effectively air-tight box is called an Acoustic

Suspension.

3. Bend the top side upward as shown. 4. Bend the two sides upward. Attach the
three sides using scotch tape or glue
(Elmer’s, Duco Cement, or other).

5. Bend the bottom side upward and
attach it to the other sides using scotch
tape or glue. Bend the two mounting
flaps as shown.

Back View

Remove the nut from the top 2-56 x 5/16” screw. Insert the baffle as shown in Step 6. Insert a 2-56 x 5/16” screw and fasten down
the baffle with two 2-56 nuts as shown in Step 6.

Optional: To make an air tight seal, place a bead of seal between the PC board and the baffle.

Seal

2-56 Nut

6.

brown

side

2-56 x 5/16” Screw

(from battery holder)

2-56 x 5/16”

Screw

Screw 2-56 x 5/16”

Nut 2-56

Baffle

-30-

SCHEMATIC DIAGRAM

L1

REV-A

Elenco®Electronics, Inc.

150 Carpenter Avenue

Wheeling, IL 60090

[phone]

Web site: www.elenco.com

e-mail: [e-mail]