CASSETTE PLAYER KIT

MODEL AK-200

Assembly and Instruction Manual

Elenco Electronics, Inc.

TM

TM
Copyright © 1994 Elenco Electronics, Inc. Revised 2003 REV-L 753260
SECTION 1 - PARTS LIST
If any parts are missing or damaged, see instructor or bookstore. DO NOT contact your place of purchase as
they will not be able to help you. Contact Elenco Electronics (address/phone/e-mail is at the back of this
TM

manual) for additional assistance, if needed.

RESISTORS
Qty. Symbol Value Color Code Part #
2 R1, R2 390W 5% 1/4W orange-white-brown-gold 133900
1 R7 1kW 5% 1/4W brown-black-red-gold 141000
1 R8 8.2kW 5% 1/4W gray-red-red-gold 148200
2 R3, R6 12kW 5% 1/4W brown-red-orange-gold 151200
2 R4, R5 180kW 5% 1/4W brown-gray-yellow-gold 161800
1 VR2 1kW Potentiometer 191411
1 VR1 50kW Potentiometer 191533

CAPACITORS
Qty. Symbol Value Description Part #
3 C5, C6, C16 0.001mF (102) Discap 231035
2 C20, C21 0.005mF (502) Discap 235016
4 C1, C2, C18, C19 0.02mF (203) Discap 242010
1 C17 0.1mF (104) Discap 251010
4 C3, C4, C10, C13 10mF Electrolytic (Lytic) 271045
4 C9, C12, C14, C15 100mF Electrolytic (Lytic) 281024
1 C11 220mF Electrolytic (Lytic) 282223

SEMICONDUCTORS
Qty. Symbol Value Description Part #
1 IC2 AN6650 Integrated Circuit 336650
1 IC1 AN7108 Integrated Circuit 337108

MISCELLANEOUS
Qty. Description Part # Qty. Description Part #
1 PC Board 517020 1 Battery Cover 626011
1 Battery Contact + 610815 1 Stereo Headset 629202
1 Battery Contact – 610816 2 Screw 7/32” 643150
1 DC Jack 2.5mm 621013 1 Screw 3/32” 643155
1 Phone Jack 3.5mm 621015 2 Screw 1” Black 643196
1 Top Plate 623106 1 Socket IC 8-pin 664008
1 Bottom Plate 623204 1 Wire 1.6” Red 825320
1 Thumb Wheel 626006 2 Wire 2.8” Black 834510
1 Tape Deck 626007 4 Wire 2.8” Red 834522
1 Lid 626008 1 Wire 1.2” Bare 845400
1 Clip 626009 1 Solder 9ST4

PARTS IDENTIFICATION
Resistor W Pot
1kW Phone Jack DC Jack Semiconductors Capacitors Thumb Wheel
Integrated Circuits

W Potentiometer
50kW

16-Pin
Battery Contacts
Electrolytic Discap
Positive Negative
(+) (–) 8-Pin

-1-
IDENTIFYING RESISTOR VALUES
Use the following information as a guide in properly identifying the value of resistors.

BAND 1 BAND 2 Multiplier Resistance

1st Digit 2nd Digit Tolerance
Color Digit Color Digit Color Multiplier Color Tolerance
Black 0 Black 0 Black 1 Silver +10%
Brown 1 Brown 1 Brown 10 Gold +5%
Red 2 Red 2 Red 100 Brown +1%
Orange 3 Orange 3 Orange 1,000 Red +2%
Yellow 4 Yellow 4 Yellow 10,000 Orange +3%
Green 5 Green 5 Green 100,000 Green +.5%
Blue 6 Blue 6 Blue 1,000,000 Blue +.25%
Violet 7 Violet 7 Silver 0.01 Violet +.1%
Gray 8 Gray 8 Gold 0.1
White 9 White 9
BANDS
1 2 Multiplier Tolerance

IDENTIFYING CAPACITOR VALUES

Capacitors will be identified by their capacitance value in pF (picofarads), nF (nanofarads), or mF (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.

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

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

First Digit Note: The letter “R” may be used at times

10mF 16V

to signify a decimal point; as in 3R3 = 3.3

Second Digit
Multiplier

103K Tolerance
The letter M indicates a tolerance of +20%
100V 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 .01mF 100V

METRIC UNITS AND CONVERSIONS

Abbreviation Means Multiply Unit By Or 1. 1,000 pico units = 1 nano unit
p Pico .000000000001 10-12 2. 1,000 nano units = 1 micro unit
n nano .000000001 10-9
m micro .000001 10-6 3. 1,000 micro units= 1 milli unit
m milli .001 10-3 4. 1,000 milli units = 1 unit
– unit 1 100 5. 1,000 units = 1 kilo unit
k kilo 1,000 103
M mega 1,000,000 106 6. 1,000 kilo units = 1 mega unit
-2-
SECTION 2 - INTRODUCTION
It is the goal of this project to educate the builder in 3) An explanation for each part (Theory of
the principles of magnetic tape recording and to teach Operation).
the skills necessary to build this kit. The AK-200
Stereo Cassette Player is divided into two parts - In addition, specifications and a schematic diagram
Motion Control and Audio. This manual contains: are given. A Quiz (with answers) is included to
1) Detailed assembly instructions for each part. For demonstrate the overall knowledge gained by
ease of assembly, both parts are built at the building this kit.
same time.
2) Specifications and a test procedure for each part
coupled with a troubleshooting guide for each test.

SECTION 3 - GENERAL OVERVIEW

The main features of the Model AK-200 Stereo Figure 3-1 shows a block diagram of the cassette
Cassette Player are: player. No mechanical assembly is required on the
a) Plays 4 track 0.15” tape cassettes. Two tracks are tape deck. It comes completely pre-assembled and
played at the same time. When the cassette pre-aligned. You need only to build the PC board,
reaches the end of the tape, it can be turned over wire it to the tape deck, insert the batteries and the
and reinserted to play the remaining two tracks. tape cassette and you are ready for your favorite
kind of music.
b) Drives stereo headphones.
c) Runs on two “AA” size batteries or an external 3
volt power supply via an AC adapter (not
included).

Tape Drive Pushbutton Tape Deck

Heads Assembly
(Motor, Pulleys) Controls

Motion
Audio Earphones
Control

Figure 3-1

-3-
TAPE DECK ASSEMBLY
See Figures 5-3 and 5-5. Stop - Pushing STOP takes the AK-200 out of PLAY
Tape Deck Assembly consists of three main parts: or FAST FORWARD mode and stops the tape. After
opening the lid, STOP may be used again to pop up
1) Tape Drive Train - The Tape Drive Train contains the tape cassette for easy removal.
a motor which turns at a constant speed. The
motor is connected by a drive belt to a large 3) Heads - The purpose of the heads is to convert
pulley which turns the capstan. When the AK-200 the magnetization on the tape into an electrical
is in Play Mode, that is, with the Play button signal. The AK-200 has two playback heads.
pushed, the pinch roller clamps the tape against Each head plays one of the four tape tracks when
the capstan. This causes the tape to be pulled the cassette is inserted one way and another
across the head at a constant speed. track when the tape is turned over.
At the start of tape play, the tape is winding onto
an empty take-up reel. As the tape builds up on MOTION CONTROL
the take-up reel, it takes more tape to go once When the two 1.5V batteries are new, they put out
around the reel. Since the tape is moving at a their full 3V rated voltage. In time, as the batteries
constant speed, the take-up reel must turn faster are used, this voltage drops. If the battery voltage
at the start of tape play than at the end. A belt was applied directly to the motor, the motor would
from the capstan drives a small pulley to turn the slow down as the battery voltage dropped. Tape
take-up reel. This pulley, if it were rigidly speed would then decrease, causing music to be off
connected to the take-up reel, would drive the key and voices to sound too low. The Motion
reel much faster than required even at the start of Control Section is therefore used to keep a constant
tape play. A slip clutch is therefore inserted voltage on the motor and insure uniform tape speed.
between the small pulley and the take-up reel to
allow the reel to turn at the different speeds AUDIO AMPLIFIERS
required to wind up the tape. The audio amplifier section consists of two separate
2) Push-button Controls - Three push-buttons amplifiers, one for each head, each amplifier driving
control tape play. Pushing any button places the one of the stereo headphone speakers. The gain of
AK-200 in that mode until another button is both amplifiers is set by the thumb wheel on the side
pushed. of the tape player. The amplitude on the low
frequencies from the head is lower than that of the
Play - Pushing the PLAY button closes the ON high frequencies. The frequency response of the
switch which supplies power to the motor, motion amplifiers is therefore set to emphasize the lows
control and audio amplifier electronics. In and thus equalize the overall response.
addition, the head and tape guide are moved into
contact with the tape and the pinch roller clamps
the tape against the capstan. You may then listen
to the tape through the stereo headphones.
Fast Forward - Pushing FAST FORWARD closes
the ON switch which, as in PLAY mode, supplies
power to the motor, motion control and audio
amplifier electronics. The head, tape guide and
pinch roller are not moved into contact with the
tape. The tape is therefore driven solely by the
take-up reel. Since there is little drag, there is
little or no slippage in the slip clutch and the tape
moves forward at high speed. FAST FORWARD
is used to space forward to a particular section of
tape or, after using the tape over, for rewinding.

-4-
CONSTRUCTION
Introduction
The most important factor in assembling your AK-200 Stereo Cassette Player 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. 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 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 Types of Poor Soldering Connections

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

1. Solder all components from Soldering Iron 1. Insufficient heat - the

Rosin
the copper foil side only. solder will not flow onto the
Component Lead
Push the soldering iron tip lead as shown.
against both the lead and Foil
the circuit board foil.

Soldering iron positioned

Circuit Board
incorrectly.

2. Insufficient solder - let the

2. Apply a small amount of solder flow over the Solder
Soldering Iron
solder to the iron tip. This connection until it is
allows the heat to leave the Solder
covered. Use just enough
iron and onto the foil. solder to cover the
Immediately apply solder to Foil
connection. Gap
the opposite side of the Component Lead
connection, away from the
iron. Allow the heated 3. Excessive solder - could
component and the circuit make connections that you
foil to melt the solder. Solder
did not intend to between
adjacent foil areas or
3. Allow the solder to flow
Solder Soldering Iron terminals.
around the connection.
Then, remove the solder
and the iron and let the Foil
connection cool. The
solder should have flowed 4. Solder bridges - occur
Soldering Iron
smoothly and not lump when solder runs between
around the wire lead. circuit paths and creates a
short circuit. This is usually
caused by using too much
4. Here is what a good solder solder. To correct this,
connection looks like. simply drag your soldering
iron across the solder Foil Drag
bridge as shown.

-5-
SECTION 5 - ASSEMBLY INSTRUCTIONS
TOOLS NEEDED: Small Blade Screwdriver, Phillips Screwdriver (small point size), Diagonal Cutters, Long
Nose Pliers and a Soldering Iron (25 - 40 watts).
PC BOARD ASSEMBLY - Your kit may contain several extra capacitors and wires. Please disregard these parts.
Identify and install the following parts as shown in Figure 5-1. After soldering each part, place a check in the
box provided.
Figure A Figure B
Use a discarded resistor lead
C6 - .001mF (102) Capacitor for a jumper wire.
(Lay flat on board)
C5 - .001mF (102) Capacitor
(Lay flat on board)
C3 - 10mF Lytic Capacitor
(see Figure C)
R1 - 390W 5% 1/4W Resistor
(orange-white-brown-gold)
C1 - .02mF (203) Capacitor
R3 - 12kW 5% 1/4W Resistor
(brown-red-orange-gold)
R4 - 180kW 5% 1/4W Resistor
(brown-gray-yellow-gold)
C7 - Jumper Wire
(see Figure A)
C20 - .005mF (502) Capacitor
(This location may not be marked
on the PC board. Use the picture.)
C8 - This is not used.
VR2 - 1kW Potentiometer
(see Figure B)
R7 - 1kW 5% 1/4W Resistor
(brown-black-red-gold)
8-pin IC Socket
IC2 - AN6650 Integrated Circuit
(see Figure D)
Figure 5-1
C16 - .001mF (102) Capacitor
C17 - .1mF (104) Capacitor Figure C
These capacitors are polarized.
R8 - 8.2kW 5% 1/4W Resistor
Be sure to mount them with the
(gray-red-red-gold)
“+” lead in the correct hole as
C11 - 220mF Lytic Capacitor marked on the PC board. Mount
(see Figure C) the capacitor lying flat on the PC
board as shown below.
Jumper Wire (see Figure A)
C12 - 100mF Lytic Capacitor
(see Figure C)
(–) (+)

-6-
ASSEMBLY CONTINUED
Identify and install the following parts as shown in Figure 5-2. After soldering each part, place a check in the
box provided.

R2 - 390W 5% 1/4W Resistor

(orange-white-brown-gold)
C4 - 10mF Lytic Capacitor
(see Figure C)
C2 - .02mF (203) Capacitor
R6 - 12kW 5% 1/4W Resistor
(brown-red-orange-gold)
R5 - 180kW 5% 1/4W Resistor
(brown-gray-yellow-gold)
C21 - .005mF (502) Capacitor
C9 - 100mF Lytic Capacitor
(see Figure C)
C18 - .02mF Capacitor
(This location may not be marked
on the PC board. Use the picture.)
Phone Jack (see Figure E)
C19 - .02mF Capacitor
(This location may not be marked
on the PC board. Use the picture.)
DC Jack (see Figure F)
C15 - 100mF Lytic Capacitor
(see Figure C)
IC1 - AN7108 Integrated Circuit
(see Figure Da)
Figure 5-2 C14 - 100mF Lytic Capacitor
(see Figure C)
C13 - 10mF Lytic Capacitor
(see Figure C)
Figure D Figure Da
C10 - 10mF Lytic Capacitor
Insert the IC socket into the PC Insert the IC into the PC board with
board with the notch in the the notch in the same direction as (see Figure C)
direction as the marking on the PC the marking on the PC board.
board. Solder the IC socket into
place. Insert the IC into the socket
with the notch in the same direction AN7108 IC
as the notch on the socket.
AN6650 IC

Figure E Figure F
Socket Notch
Phone Jack DC Jack
Notch

PC Board

PC Board

-7-
TAPE DECK ASSEMBLY
Solder two red 2.8” wires to the ON switch as
Fast
shown in Figure 5-3. Stop Forward Play
Large Pulley
Mount the thumb wheel to pot VR1 as shown in
Figure 5-4.
Drive
See Figure 5-5. PUSH THE POT TO THE RIGHT Belts
AGAINST THE PC BOARD so that the thumb
wheel will not hit the top or bottom plate when
the unit is completely assembled. Then solder
the pot in place as shown in Figure 5-5. It is
helpful to Scotch® Tape VR1 in position leaving
one or two terminals open to solder the Motor
remaining terminals.

Solder two red 2.8” wires to the two head terminals

and the PC board as shown in Figure 5-5. ON Switch Red Wires Small Pulley
NOTE: The head may have only two terminals. Figure 5-3
If so, solder to those terminals.
3/32”
Connect a 1.2” piece of bare wire to the two/four Screw
head terminals and the head common terminal
as shown in Figure 5-5. Solder the wire to the Thumb
two/four head terminals but not to the head Wheel
common terminal.

Solder one end of a 2.8” black wire, and the bare 50kW Pot
wire from the head, to the head common (VR1)

terminal. Solder the other end of the black wire Figure 5-4
to the PC board as shown in Figure 5-5.

Head Common Capstan

Terminal
Pinch Roller

4 Head

Tape Guide Black Wire

Bare Wire
2 Head Red Wire

Red Wire

VR1
Bare Wire

Figure 5-5

-8-
CONNECTING THE PC BOARD - See Figure 5-6. Solder the other end of one of the wires on the
The wires connected to the PC board should be motor case terminal to the PC board as shown in
positioned so that they do not touch the pulleys or Figure 5-6.
drive belts and do not interfere with the placement
of the batteries. Solder the other end of the remaining 1.4” wire
on the motor case terminal to the (–) battery
Fasten the PC board to the tape deck using two terminal as shown in Figure 5-6.
7/32” screws as shown in Figure 5-6. Be sure the
two wires from the ON switch are accessible at Solder one end of the red 2.8” wires from the ON
the right of the PC board. switch to point A on the PC board as shown in
Figure 5-6.
Insert the (+) and (–) battery terminals into their
slots as shown in Figure 5-6. Solder the other red 2.8” wire from the ON switch
and the red wire from the motor to point B on the
Solder the 1.6” red wire to the (+) battery terminal PC board as shown in Figure 5-6.
and the PC board as shown in Figure 5-6.
Solder the black wire from the motor to point C
If there are any wires already attached to the on the PC board as shown in Figure 5-6.
motor case terminal, remove them.

Cut a black 2.8” piece of wire into two 1.4”

pieces. Strip 1/8” of insulation off the new end of
both wires. Solder one end of both 1.4” wires to
the motor case terminal as shown in Figure 5-6.

7/32” Screw

Point C Black

Point B

Motor Case
Terminal

Point A

Red
(–) Battery
Wire
Terminal

(+) Battery Terminal Red 7/32” Screw

Figure 5-6
-9-
SECTION 6 - TEST PROCEDURE - MOTION CONTROL
MOTOR SPEED TEST 7. Tests 7 and 8 require a voltmeter. If you do not
1. Insert two “AA” size batteries into the battery have a voltmeter, go on to test 9. Connect the
compartment. See Figure 5-6 for polarity. voltmeter between point A (+ lead) and C (– lead)
to measure the reference voltage (see Figure 6-2).
2. Set VR2 to midway between its two extremes.
It should be close to 1.3V. If it is not 1.3 +0.05V:
3. Insert a tape cassette and push the PLAY button. a) Check the values of R7 and R8.
If the tape runs out during testing, turn it over and b) Check the soldering around R7, R8, VR2
play the other side. Do not perform the tests with and IC2.
the tape reels not moving.
8. Connect the voltmeter between points A (+ lead)
4. Observe that the motor turns and that the tape and B (– lead) to measure the motor voltage (see
moves across the head. If it does not: Figure 6-2). It should be approximately 1.8V. If
a) Check that the batteries are good. it is not:
b) Check that both drive belts are seated a) Check the values of R7 and R8.
correctly on their pulleys. b) Check the soldering around R7, R8, VR2 and
c) Check that the wires to the PC board are IC2.
wired as shown in Figures 5-3 and 5-6. c) Check that the motor is wired to the PC
d) Check that the ON switch closes when the board as shown in Figure 5-6.
PLAY button is pushed. See Figure 5-3.
e) Check that IC2 is mounted with the notch as 9. Push the FAST FORWARD button. Observe that
shown in Figure 5-1. the tape moves forward faster than when in
f) Check the soldering at IC2. Be sure that PLAY mode. If it does not:
there are no solder shorts between the pins. a) Check the wiring to the ON switch.
g) Check for a gap between the pulley and b) Check that the PC board does not interfere
motor. If there is no gap, then loosen the with the STOP button.
screws mounting the motor and move it to
the right (see Figure 6-1). IMPORTANT: When using the PLAY, F.FWD, and
STOP controls, be sure to push the button straight
5. Turn VR2 fully counter-clockwise. Observe that down. Pushing the button sideways can cause it to
the motor turns faster. Turn VR2 fully clockwise. jam.
Observe that the motor turns slower. If either of
these tests fail: To repair a loose button on the cassette player,
a) Check the value of R7 and R8 as shown in apply some glue on the sides of the button and slide
Figure 5-1. it back over the control arm.
b) Check the soldering around R7, R8, VR2
and IC2.
6. Reset VR2 to midway between its two extremes.

VR2
ADJUST
Gap

A B C

Figure 6-1 Figure 6-2

-10-
SECTION 7 - TEST PROCEDURE - AUDIO
Tests 3 through 7 require a voltmeter. If you do not 6. Connect the voltmeter between point D (+ lead)
have a voltmeter, skip these tests to go on to test 8. and point G (– lead) to measure the driver DC
output voltage (amplifier A, pin 14). It should be
AUDIO TESTS 1/2 the input voltage +0.3V. If it is not:
See Figure 7-1 for test point connections.
a) Check the soldering around IC1 and IC2.
B
7. Connect the voltmeter between point E (+ lead)
and point G (– lead) to measure to volume
control voltage to pin 9. Rotate the thumb wheel
E fully clockwise. The volume control voltage
should be within 0.1V of the reference voltage
measured in Step 4 on the previous page.
C 1 8 Rotate the thumb wheel fully counter-clockwise.
16 9
The volume control voltage should be less than
4 5 0.1V. If either of these tests fail:
1 8 a) Check that the thumb wheel will turn about
G 240 degrees.
b) Check the soldering around IC1, VR1, and
D A C9.

Figure 7-1 c) Check the value and soldering of R1 and R2.

8. Plug the stereo headset into the phone jack and

1. Insert two “AA” size batteries into the battery
listen to your tape. Check that the thumb wheel
compartment. See Figure 5-6 for polarity.
adjusts the playback volume. If it does not:
2. Insert a tape cassette and push the PLAY button. a) Check that the head is wired to the PC board
If the tape runs out during testing, turn it over and as shown in Figure 5-5.
play the other side. Do not perform the tests with
the tape reels not moving. b) Check that all other wires are wired to the PC
board as shown in Figure 5-6.
3. Connect a voltmeter between point A (+ lead)
c) Check that both drive belts are seated
and point G (– lead) to measure the input
correctly on their pulleys.
voltage. It should be around 3 volts. Record the
input voltage: ________V. d) Check that the thumb wheel will turn about
240 degrees.
4. Connect the voltmeter between point B (+ lead)
and point G (– lead) to measure the reference e) Check the soldering around IC1, VR1 and
voltage. It should be 1/2 of the input voltage C9.
+0.2V. If it is not: f) Check the value and soldering of R1 and R2.
a) Check the wiring between the ON switch and
9. Adjust VR2 so that the pitch and tempo of the
the PC board.
music sound right. If it cannot be adjusted
b) Check that IC1 is mounted with the notch as properly:
shown in Figure 5-1. a) Check that both drive belts are seated
c) Check the soldering around IC1, R2, R3, VR1 correctly on their pulleys.
& C9. b) Check the soldering around IC2 and VR2.
5. Connect the voltmeter between point C (+ lead) c) Check the value and soldering around R7
and point G (– lead) to measure the driver DC and R8.
output voltage (amplifier A, pin 14). It should be
1/2 the input voltage +0.3V. If it is not:
a) Check the soldering around IC1 and C15.
-11-
SECTION 8 - FINAL ASSEMBLY
Place the tape deck on the bottom plate. Be sure Place the clip over the three mounting holes in
that the wires to the PC board do not touch the the top plate as shown in Figure 8-2. Press down
pulleys or drive belts and will not interfere with to snap the clip onto the top plate.
the batteries. Snap on the top plate and fasten
Put two “AA” size batteries (alkaline works best)
with two 1” screws as shown in Figure 8-1.
into the AK-200. The polarity is shown on the
If not already in place, snap the lid onto the case. Then, slide the battery cover in place as
bottom plate as shown in Figure 8-1. shown in Figure 8-2.

1” Screws

Bottom Plate

Top Plate

Lid

Tape Deck

Figure 8-1

Top Plate

Clip
“AA” Batteries

Battery Cover

Figure 8-2
-12-
SECTION 9 - SPECIFICATIONS
Tests 3 through 7 require a voltmeter. If you do not have a voltmeter, skip these tests and go on to test 8.
INPUT VOLTAGE RANGE: 2.2V - 3.5V
TAPE SPEED: 1 7/8 IPS
AMPLIFIER IC SPECIFICATIONS: (Ta = 25C, Vcc = 3V, fo = 1kHz, volume = 100% unless noted otherwise.

CHARACTERISTIC TEST VALUE

CONDITIONS TYPICAL
Gain Input = -75 dBm 54dB
Volume = 50%
Distortion Input = -70 dBm 0.7%
Distortion Input = -60 dBm 0.5%
Volume = 50%
Maximum Output Load = 32W 30mW
THD = 10%

SECTION 10 - THEORY OF OPERATION - MOTION CONTROL

The tape speed is determined by the voltage across input goes negative, creating a positive
the motor. The purpose of the Motion Control difference at the inputs, the output goes positive.
Section is a) to set the tape speed by adjusting the The transistor then turns on harder and the
motor voltage, and b) to keep the motor voltage collector voltage drops. This voltage drop is fed
constant as the battery voltage drops. To do this, back via RA to the (+) input which tends to
the Motion Control Section contains a voltage remove the original difference between the
divider (R7, R8 and VR2) and a motor control IC inputs. Since the gain of the op-amp is very high,
(AN6650). See the schematic diagram, Section 13. the two inputs are kept at virtually the same
The IC contains the following major parts: voltage.
The motor voltage is adjusted by VR2. Turning
1. Reference Voltage - This circuit together with the
the wiper of VR2 toward R8 lowers the voltage at
current source feeding it maintains a constant
the (–) input of the op-amp. This, as in the
1.3V between pins 2 and 1 (and thus across the
example above, lowers the transistor collector
voltage divider) until the supply voltage to the IC
voltage and increases the voltage on the motor.
drops to approximately 1.6V.
Once the motor voltage is set, the motion control
2. Op-amp - The op-amp amplifies the voltage section keeps the voltage constant as the battery
difference between the (+) and (–) inputs. If the voltage drops. If, for example, the battery voltage
difference is positive (+ input more positive than drops by 0.5V, point A will drop by 0.5V. Due to
– input) the output goes positive. If the difference the constant 1.3V across the voltage divider,
is negative (+ input more negative than – input) point C, and the (–) op-amp input also drop by
the output goes negative. The gain of the op- 0.5V. As explained above, this drops the
amp is high. A small difference at the inputs transistor collector voltage (point B). In our
produces a large change in the output. example, the collector voltage must drop 0.5V to
make the (+) op-amp input equal to the (–) input.
The op-amp circuit consisting of the op-amp, the
Since points A and B both drop 0.5V, the motor
transistor and resistors RA and RB (see
voltage remains constant.
schematic diagram, Section 13) employs
negative feedback. This means that the op-amp
output changes so as to reduce any voltage
difference at the inputs. For example, if the (–)
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SECTION 11 - THEORY OF OPERATION - AUDIO
MAGNETISM there is no induced voltage. When the magnet is
BAR MAGNETS - Figure 11-1a shows a bar withdrawn, a voltage of opposite polarity is induced.
magnet. The magnet is similar to a compass
needle. It has a North seeking end and a South FERROMAGNETISM - An electron spinning around
seeking end and thus its ends are labeled N and S. the nucleus of its atom is an electric current just like
The magnetic field consists of lines of force the current in the coil mentioned above. It therefore
(magnetic flux) which form closed paths through the generates a small magnetic field. The electron
magnet. By convention, the lines are thought of as spinning on its own axis also contributes to the field.
flowing out of the North end (pole) back around to In a piece of ordinary matter, the small magnetic
the South end and then through the magnet back to fields generated by the individual electrons are
the North end. The lines shown indicate the randomly oriented. They therefore cancel each
direction of the magnetic field, that is, at every point other out, leaving the material as a whole
they are tangent to the direction, a compass needle unmagnetized. When certain materials known as
would point if placed at that point. The strength of ferromagnetic materials are subjected to an external
the magnetic field is indicated by the density of the magnetic field, some of the small magnetic fields
lines, that is, the number of lines per unit area. For align themselves with the external field and the
example, a field strength of 1 gauss has 1 line material field itself becomes magnetized. Thus, if a
square centimeter. cylinder of ferromagnetic material were inserted into
the coil of Figure 11-1b, the cylinder would become
If we apply a voltage to a coil of wire, shown in magnetized and the field around the coil would
Figure 11-1b, a current will flow in the wire and a greatly increase. A cylinder of a non-ferromagnetic
magnetic field will be produced. The magnetic field material would have no effect on the field. The main
produced by the current is the same as that of the ferromagnetic materials are iron, cobalt, nickel, and
bar magnet. It can, however, be easily varied by some of the oxides and alloys of these metals.
changing the current in the coil. If the current in the Some compounds of manganese and chromium
coil is reversed, the field is proportional to the dioxide are also ferromagnetic.
current. Doubling the current will double the A hard ferromagnetic material is one that retains a
strength of the field. large portion of its magnetization after the external
field is removed. Hard magnetic materials are used
in permanent magnets and in the coating of
magnetic recording tape. Soft ferromagnetic
materials retain very little of their magnetization
N S N S after the external field is removed. Soft magnetic
materials are used in relays, transformers and
magnetic recording heads.
Current

Current

HYSTERESIS LOOPS - Figure 11-2a shows a

hysteresis loop for a hard magnetic material. If we
Figure 11-1a Figure 11-1b start with an unmagnetized sample with no
magnetizing force, the sample is at the origin (O).
INDUCING VOLTAGE - Above we used a voltage to As we increase the magnetizing force, the field
produce a magnetic field. We may also use a strength increases to point A. At this point, most of
magnetic field to produce a voltage. This can be the small magnetic fields due to the orbiting
done by inserting the magnet of Figure 11-1a into electrons are in line and further increases in the
the coil of Figure 11-1b. The magnetic lines of force magnetizing force produce very little increase in the
of the bar magnet cutting the wires of the coil induce field of strength. The material is then said to be
a voltage in the coil. The voltage is proportional to saturated. When the magnetizing force is removed,
the rate of change of magnetic lines (magnetic flux) the field strength falls back to the remnant
linking the coil. Thus, the faster the magnet is magnetization B. If the magnetizing force is
inserted, the higher the voltage. Once inside the coil reversed, the field strength falls to zero at C. The
and stationary, the number of lines linking the coil is magnetizing force required to do this is called the
high, but the rate of change of the lines is zero and coercive force. As the magnetizing goes

-14-
further negative, the sample again saturates at D. of soft magnetic material. The record and playback
When the magnetizing force is brought positive heads are so much alike that in some inexpensive
again, the field strength follows the path D-E-F back tape recorders the same head is used for both
to A. Figure 11-1b shows the hysteresis loop for a record and playback.
soft magnetic material. Note that the remnant
magnetization and the coercive force are much less Figure 11-3 shows the playback head positioned
than for hard magnetic materials. over a bar magnet with an N pole on the left and an
S pole on the right. The flux from the magnet goes
MAGNETIC RECORDING - The four main parts of clockwise around the head. As the tape moves to
a magnetic recording system are the tape, the the next magnet, the position of the poles and the
record head, the playback head and the erase head. direction of flux reverses. The changing flux induces
a voltage in the head. As each magnet passes
TAPE - The tape consists of a plastic backing, under the head, a voltage of alternating polarity is
usually mylar, about 1 mil thick. On the backing is a induced. If as in the example above there are 2000
thin coating of hard magnetic material, usually iron magnets passing the head each second, a 1kHz
oxide, typically .2 mil thick. signal is induced in the head. This duplicates the
1kHz record head signal that recorded the tape.
RECORD HEAD - The recording head is made up
of thin laminations of soft magnetic material such as ERASE HEAD - The erase head is similar to the
mu metal formed into a ring with a small gap. A wire record and playback heads except that it is wider,
is wrapped around a ring, see Figure 11-3. When a extending across the entire width of the tape, and
current is passed through this winding, the head has a wider gap. A high frequency current of 50 to
becomes a magnet with an N and S pole at the gap. 100kHz is passed through the head. The amplitude
Magnetic flux passing from the N to the S pole is enough to saturate the tape under the gap. Thus,
magnetizes the iron oxide under the gap. The iron as an area of tape passes the gap, its direction of
oxide is a hard magnetic material and retains this magnetization is reversed many times. As the tape
magnetization as the tape leaves the gap area. leaves the gap area, the reversals slowly decrease
Reversing the direction of the head current reverses in amplitude, leaving the tape unmagnetized. This
the direction of magnetization of the tape. In Figure gets rid of anything previously recorded on the tape
11-3, the head current was periodically reversed. and improves the signal to noise ratio of the
The tape is thus a series of small bar magnets recording.
facing in opposite directions.
AC BIAS - Ideally the remnant magnetization in the
If, for example, an audio signal of 1kHz is fed to the tape should correspond to the record head current.
record head, there will be 2000 bar magnets If the current should double or triple, the remnant
recorded each second. At a tape speed of 1 7/8 magnetization should double or triple. That is, there
inches per second, each bar magnet will be should be a linear relationship between the
1.875”/2000 = .9375 mils or approximately one magnetizing force and the remnant magnetization.
thousandth of an inch. As can be seen from the shape of the hysteresis
loop for a hard magnetic material (Figure 11-2), this
PLAYBACK HEAD - The playback head, like the relationship is very non-linear.
record head, consists of a wire wound around a ring

A A Erase Head Record Head Playback Head

B
Field Field
Current
Current

Strength Strength
B
C 0 C F
F 0 E

D E D
N N SS N N SS
Magnetizing Magnetizing
Force Force Tape Coating Tape Backing
Hysteresis Loop Hysteresis Loop Tape Motion
Hard Magnetic Material Soft Magnetic Material

Figure 11-2a Figure 11-2b Figure 11-3

-15-
This means that if the record head current It is not practical to fully boost the low frequencies
corresponds to an audio signal, the remnant flux on during the recording process. It is therefore done by
the tape and hence the playback signal will be very boosting the low frequency response of the
distorted. To avoid this distortion, the head is driven playback amplifier. This called post-equalization.
by a composite signal made up of an audio signal The National Association of Broadcasters (NAB)
and an AC bias (see Figure 11-4). The AC bias is a has set a standard response curve for playback
high frequency current well above the audible amplifiers. In general, pre-recorded tapes are
range, usually the same frequency as the erase recorded so that the response is flat over the
head current. The amplitude is several times that of audible range when played back through an
the audio current. When the amplitude of the AC amplifier having this response.
bias current is set to the correct value, the remnant
flux and the playback signal become linear. This CIRCUIT DESCRIPTION - The Audio Section of the
greatly improves the quality of the recording. AK-200 Cassette Player consists of the AN7108
integrated circuit, its associated resistors and
EQUALIZATION - If we use a constant amplitude capacitors, and the phone jack. The AN7108 is a
record head signal and record different frequencies dual channel audio amplifier with a common volume
on tape, we find that the amplitude of the playback control. Since the two amplifiers are identical, it is
signal depends on the frequency of the input signal. only necessary to describe one.
At the low frequency end, about 100 or 200Hz, the
playback amplitude increases at 6dB per octave. As shown on the schematic diagram (Section 13),
This means that if we double the frequency, the each amplifier consists of a pre-amplifier and driver
output amplitude will double. This is because the with a volume control circuit between them. The
induced voltage depends on the rate of change of playback signal from head A is input to the pre-amp
magnetic flux. At a constant amplitude, a 200Hz on pin 3. The pre-amp has a gain of 30dB (about 32
signal is changing twice as fast as a 100Hz signal. times) at 1kHz. Resistors R2, R5 and R6 and
As we continue to increase the frequency, the capacitors C2 and C4 are placed in the feedback
output will continue to increase until about 2 or circuit of the pre-amp to provide the NAB standard
3kHz. The output will then roll off due to head frequency response. The driver provides 30dB of
losses. gain and sufficient driving power to drive the
headphones. Potentiometer VR1 provides a means
To maintain a flat frequency response over the full of varying the volume control voltage to pin 9. This
audible range, both the high and low frequencies voltage is converted to a current and fed to the
must be given a boost. Music and the human voice volume control circuit to control the gain of the
have less power at high frequencies than at lower amplifiers. Figure 11-5 shows the approximate
frequencies. It is therefore possible to boost the frequency response of the amplifier. The voltage
high frequencies during the recording process reference circuit generates a voltage of
without saturating the tape. This is called pre- approximately 1/2 the input voltage (pin 12). This is
equalization. used to provide the IC with a wide operating range
(1.8 to 6.5V).

75

70
Gain (dB)

65

60

.02 .05 .1 .2 .5 1 2 5 10
Audio Signal AC Bias Signal Composite Signal Frequency (in kilohertz)
Figure 11-4 Figure 11-5

-16-
SECTION 12 - QUIZ
INSTRUCTIONS: Complete the following examination, check your answers carefully.

1. The AK-200 motor . . .

A) turns at a constant speed.
B) runs on 120VAC, 60Hz only.
C) changes speed with battery voltage.
D) is directly coupled to the supply reel.
2. The slip clutch . . .
A) causes the tape to slip past the head.
B) allows the drive belts to slip on their pulleys.
C) allows the supply reel to turn at different speeds.
D) allows the take-up reel to turn at different speeds.
3. The Motion Control Section of the AK-200 . . .
A) causes the tape to move forward and reverse.
B) keeps a constant voltage on the motor.
C) reverses the tape motion.
D) powers the audio amplifier only when the tape is in motion.
4. The op-amp in the Motion Control Section . . .
A) amplifies the voltage difference between its (+) and (–) inputs.
B) has a very high gain.
C) goes positive when its (+) input is more positive than its (–) input.
D) all of the above.
5. The magnetic lines of force in a bar magnet . . .
A) form closed paths.
B) flow from the S to the N pole.
C) indicate the voltage between the N and S pole.
D) all of the above.
6. If a bar magnet is inserted into a coil of wire . . .
A) nothing happens.
B) the bar magnet loses its magnesium.
C) a voltage is induced in the coil of wire.
D) the N and S poles are reversed.
7. A ferromagnetic material . . .
A) is always made of iron.
B) may be magnetized by an external magnetic field.
C) never retains it magnetization when an external field is removed.
D) none of the above.
8. The magnetizing force required to reduce the field strength or a magnetic material to zero is called . . .
A) remnant magnetization.
B) coercive force.
C) hyteresis force.
D) soft force.
9. The AC bias frequency is . . .
A) 60Hz.
B) well below the audible range.
C) well above the audible range.
D) 100 to 200Hz.
10. The Audio Section of the AK-200 Stereo Cassette Player consists of . . .
A) a dual channel audio amplifier IC with a common volume control.
B) a dual channel audio amplifier IC with individual controls.
C) a transistor amplifier with an AGC circuit.
D) a single channel audio amplifier with an AGC circuit.

Answers: 1. A, 2. D, 3. B, 4. D, 5. A, 6. C, 7. B, 8. B, 9. C, 10. A

-17-
SECTION 13 - SCHEMATIC DIAGRAM

IC1
AN7108

IC2
AN6650

-18-
 TM
Elenco Electronics, Inc.
150 W. Carpenter Avenue
Wheeling, IL 60090
(847) 541-3800
http://www.elenco.com
e-mail: [email protected]