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****** Page 1 ****** RESISTANCE SUBSTITUTION BOX MODEL RS-400 / K-37 RESISTANCE SUBSTITUTION BOX 0 EL MOOEI es-aoo Assembly and Instruction Manual Electronics, Inc. Copyright 0 1990 ElencoTM Electronics, Inc. Revised 2003 REV-G 753RS400

****** Page 2 ****** The Resistance Substitution Box is a convenient instrument in determining the desired resistance values in circuits under design or test. The values selected for your resistance substitution box were determined to be the most commonly used in modern solid-state circuits. The values are from 100 to 1,000kQ (1 meg) in 24 steps. All resistors are 5% tolerance 1/2 watt. PARTS LIST If you are a student, and any parts are missing or damaged, please see instructor or bookstore. If you purchased this resistance substitution box kit from a distributor, catalog, etc., please contact ElencoTM Electronics (address/phone/e-mail is at the back of this manual) for additional assistance, if needed. Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 01 01 01 01 Qty. 1 1 02 04 02 1 1 Symbol RI RIO RII R 12 RI 3 RI 4 RI 5 RI 6 R 17 R19 R20 R21 R22 R23 R24 Description IOQ 5% 1/2W 220 5% 1/2W 470 5% 1/2W 1000 5% 1/2W 2200 5% 1/2W 3300 5% 1/2W 4700 50/0 1/2W 6800 5% 1/2W 1kQ 50/0 1/2W 2.2kQ 5% 1/2W 3.3kQ 50/0 1/2W 4.7kQ 5% 1/2W 6.8kQ 50/0 1/2W 10kQ 5% 1/2W 22kQ 5% 1/2W 33kQ 5% 1/2W 47kQ 5% 1/2W 68kQ 5% 1/2W 100kQ 5% 1/2W 220kQ 5% 1/2W 3301<0 5% 1/2W 470kQ 5% 1/2W 6801<0 5% 1/2W IMC) 50/0 1/2W RESISTORS Color Code brown-black-black-gold red-red-black-gold yellow-violet-black-gold brown-black-brown-gold red-red-brown-gold orange-orange-brown-gold yellow-violet-brown-gold blue-gray-brown-gold brown-black-red-gold red-red-red-gold orange-orange-red-gold yellow-violet-red-gold blue-gray-red-gold brown-black-orange-gold red-red-orange-gold orange-orange-orange-gold yellow-violet-orange-gold blue-gray-orange-gold brown-black-yellow-gold red-red-yellow-gold orange-orange-yellow-gold yellow-violet-yellow-gold blue-gray-yellow-gold brown-black-green-gold MISCELLANEOUS Description PC Board Switch SPDT PC Mount . Switch 12 Position Knob Part # 121001 122201 124701 131001 132201 133301 134701 136801 141001 142201 143301 144701 146801 151001 152201 153301 154701 156801 161001 162201 163301 164701 166801 171001 Part # 517007 541103 542013 622009 Case with Cover 62RS400 Screw 4 x 1/2" Phil A Nut 9mm Washer 9mm x 15mm Alligator Clip Black Alligator Clip Red Wire Black Stranded 12" Wire Red Stranded 12". Solder .. 642465 644102 645103 680001 680002 814210 814215 9ST4 ****** Page 3 ****** PARTS IDENTIFICATION Switch PC Mount Switch 12 Position —CÜJ— 9mm Nut Washer Alligator Clip Resistor PC Board sw3 RED HÄO– BLK o R22 —Cüj:::}- R19 —ajYJ- R23 R24 SW2 R14 6 IDENTIFYING RESISTOR VALUES ELENCO ELECTRONICS RS 400 Use the following information as a guide in properly identifying the value of resistors. BAND 1 1st Digit BAND 2 2nd Digit Multiplier Color Multiplier Resistance Tolerance Color Black Brown Red Orange Yellow Green Blue Violet Gray White Digit o 1 2 3 4 5 6 7 8 9 Color Black Brown Red Orange Yellow Green Blue Violet Gray White 1 Digit o 2 3 4 5 6 7 8 9 2 Black Brown Red Orange Yellow Green Blue Silver Gold BANDS Multiplier 1 10 100 1 ,ooo 10,ooo 100,000 0.01 0.1 Tolerance Color Silver Gold Brown Red Orange Green Blue Violet Tolerance +10% +5% +20/0 +30/0 +.5% +.25% 01100 -2- ****** Page 4 ****** CONSTRUCTION Introduction The most important factor in assembling your RS-400 Resistance Substitution Box 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. Safety Procedures • Wear eye protection when soldering. • 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. Solder contains lead and is a toxic substance. thoroughly after handling solder. • Be sure that there is adequate ventilation present. Assemble Components Wash your hands 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 in the board and are soldered on the foil side. Use only rosin core solder of 63/37 alloy. DO NOT USE ACID CORE SOLDER! What Good Soldering Looks Like A good solder connection should be bright, shiny, smooth, and uniformly flowed over all surfaces. Types of Poor Soldering Connections 1. 2. 3. 4. Solder all components from the copper foil side only. Push the soldering iron tip against both the lead and the circuit board foil. 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. 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. Here is what a good solder connection looks like. Soldering Iron Component Lead Foil wmzm;zmz Circuit Board Soldering Iron Solder Foil 747/7/////Æ4//vmI Solder Foil Soldering Iron 1. 2. 3. 4. Insufficient heat the solder will not flow onto the lead as shown. Insufficient solder – let the solder flow over the connection until it is covered. Use just enough solder the to cover connection. Excessive solder – could make connections that you did not intend to between adjacent foil areas or terminals. 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. Rosin W'////"/////Ä Z'///"Z'WW//J Soldering iron positioned incorrectly. Solder Gap Component Lead Solder 7//M////M////zzvz Soldering Iron 0 Foil Drag -3- ****** Page 5 ****** ASSEMBLY INSTRUCTIONS Begin the PC board assembly with resistor R12. Be sure to identify the correct value by reading the color code. Place the resistor into the PC board with the leads coming out on the copper foil side. Solder in place and clip off the excess leads, close to the connection. RED -C&I- R12 – 4.7k') 5% 1/2W Resistor (yellow-violet-red-gold) Ril 3.30 50/0 1/2W Resistor (orange-orange-red-gold) RIO – 2.2kQ 5% 1/2W Resistor (red-red-red-gold) R8 – 6800 5% 1/2W Resistor (blue-gray-brown-gold) R7 – 4700 5% 1/2W Resistor (yellow-violet-brown-gold) R9 – 1kQ 5% 1/2W Resistor (brown-black-red-gold) RI – IOC) 50/0 1/2W Resistor (brown-black-black-gold) R2 220 5% 1/2W Resistor (red-red-black-gold) R3 – 470 5% 1/2W Resistor (yellow-violet-black-gold) R5 – 2200 50/0 1/2W Resistor (red-red-brown-gold) R6 – 3300 5% 1/2W Resistor (orange-orange-brown-gold) R4 – 1000 5% 1/2W Resistor (brown-black-brown-gold) SWI SWI R20 R19 R17 O RIS ELENCO ELECTRONICS RS 400 sw3 SW2 -cgjn- O BLK o ELENCO ELECTRONICS RS 400 -4- R19 – 100k') 5% 1/2W Resistor (brown-black-yellow-gold) R20 – 220kQ 50/0 1/2W Resistor (red-red-yellow-gold) R21 – 330kQ 50/0 1/2W Resistor (orange-orange-yellow-gold) R23 – 680k') 5% 1/2W Resistor (blue-gray-yellow-gold) R24 – IMQ 50/0 1/2W Resistor (brown-black-green-gold) R22 – 470kQ 50/0 1/2W Resistor (yellow-violet-yellow-gold) RIB – 68kQ 5% 1/2W Resistor (blue-gray-orange-gold) R17 47kQ 5% 1/2W Resistor (yellow-violet-orange-gold) R16 – 33k') 5% 1/2W Resistor (orange-orange-orange-gold) R14 IOkQ 5% 1/2W Resistor (brown-black-orange-gold) R13 – 6.8kQ 5% 1/2W Resistor (blue-gray-red-gold) R15 22kQ 5% 1/2W Resistor (red-red-orange-gold) R23 SW2 RI 3 R14 ****** Page 6 ****** swg PC Mount Switch Mount SW3 in the place shown on the PC board. Solder into place. Red Test Lead Black Test Lead Cut off 1 1/2" of wire off of both the red and black wires (SAVE them for later use). Strip 1/4" of insulation off both ends of the 10 1/2" red and black wires and insert them into the holes as marked on the PC board. Solder into place. Tie a knot with both wires 1 1/2" from the surface of the PC board as shown in Figure 1. Pull the wires through the hole in the cover. Slide the alligator boots onto the wires. Solder the wires to the alligator clips. Then, slide the boots onto the clips. SW3 RED swi BLK SWI SW2 Bend the tab on the switches down (see Figure 2). Attach the two switches loosely to the front panel with the 9mm nuts and washers. Line up the holes of the PC board with the switch lugs, as shown in Figure 3. Be sure that the board lays flat, then solder the lugs into place. Tighten down the 9mm nuts. Washer 9mm Nut Figure 3 Jumper wire from SWI Jumper wire from SW2 Bend Tab Over Figure 2 PC Board Cover SW2 RESISTANCE SUBSTITUTION 3m 470 68 47 BOX 100 470 47 10 4700 ELENCO 33 10 L RS-aoo Bend Tabs Over Wire Figure 1 Wiper Pin SW2 Strip 1/4" of insulation off of both ends of the 1 1/2" red and black wires. Solder one end of the wire to the wiper pin on the 12 position switches and the other to the pad without a hole, as shown in Figure 4. Installation of Knobs if an Ohm Meter is Available Place the knobs loosely on the switch posts. Push the slide switch to the "Q" position. Connect an ohm meter to the output. Line up the pointer of the knob with the value shown on your meter, then push the knob onto the shaft. Push the slide switch to the "KQ" position and repeat the same procedure. Jumper Wires Wiper Pin SWI 51 7007 Figure 4 -5- ****** Page 7 ****** Installation of Knobs without an Ohm Meter If an ohm meter is not available, turn both switches so that the wiper contact is in the position shown in Figure 5. Start with switch SW 1, follow the copper run on the PC board from the lug in contact with the wiper to the 4700 (R7) resistor, to be sure that the switch is set in the proper position. Align the knob on the SWI (Q) switch to the 470 position, push the knob onto the shaft. Follow the same procedure for switch SW2 (KQ), except follow the copper run to the 6.8KQ (R13) resistor. Align the knob on the SW2 (KQ) switch to the 6.8 position. TESTING THE CIRCUIT PC Board Lug Wiper Contact Figure 5 The following test is to be made with your meter to determine that the resistors are in their correct circuit positions. The resistors used in your circuit are gold banded with a tolerance of ±5%. That means that a 10k') resistor could measure between 9,500Q and 10,500Q and be correct. Each of the 24 resistance value positions will be tested and recorded in the chart below. SWI Q POSITION Value Position 220 47Q 2200 3300 4700 6800 1 OOOQ 22000 33000 4700Q SCHEMATIC DIAGRAM Meter Readin n 470 1k RIO 2.2k RII 3.3k SW2 KQ POSITION Value Position Meter Readin 6.8KC) 1 OKQ 22 KQ 33KQ 47KQ 68KQ 1 OOKC) 220KQ 330KQ 470KC) 680KQ 100 47 RI 10 330 R12 4.7k kn 22k -6- RI 7 47k RI 4 10k R13 6.8k R18 68k R24 1M RED R19 R20 220k R21 330k R22 470k 680k ****** Page 8 ****** ElencoTM Electronics, Inc. 150 W. Carpenter Avenue Wheeling, IL 60090 (847) 541-3800 e-mail:








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