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Mercury HOLLY TERROR Assembly Manual

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VERSION 111611

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Summary of Contents for Mercury HOLLY TERROR

  • Page 1 VERSION 111611...
  • Page 2 Copyright © 2006–2010 by Mercury Magnetics. All Rights Reserved. Mercury Magnetics, Mini-Choke, “Holy Terror,” “Holy Terror” Upgrade Kit, and “The Heart & Soul of Your Amp” slogan are trademarks of Mercury Magnetics. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Orange Amps and Tiny Terror are trademarks of Orange Amps. Mercury Magnetics is not affiliated with Orange Amps. This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials. Mercury Magnetics products are UL (Underwriters Laboratories Inc.) recognized components for the USA and Canada. OBJY2 component systems, electrical insulation, E120568. UL Recognition, class 130(b) – Class 200(n). OBJY8 component systems, electrical insulation, certified for Canada, class 130(b) – Class 200(n). Mercury Magnetics transformers and other products are in compliance with the European Union RoHS Directive 2020/95/EC with respect to the following substances: lead (Pb), mercury (Hg), cadmium (Cd, hexavalent chromium (CR (VI)), polybrominated biphenyls (PBB), and polybrominated diphenyl ethers (PBDE). Attention: Modifying your Tiny Terror amp voids the Orange Amp warranty! Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 3: Table Of Contents

    If this happens you’ll have to fabricate a repair, or created a jumper to a trace. See this manual’s appendices for tips. POWERING UP A GUITAR AMP: After making any modifications to an amp’s circuit (e.g. this Upgrade) use a Variac along with an current meter (some have both) to slowly apply power to the amp while checking for warning signs of circuitry errors or shorts. See the section on “Using a Variac” at the end of this manual. LOADING OUTPUT TRANSFORMERS: You must connect a speaker or speaker cab to your amp before powering it up. Without a load the output transformer will blow. MINI-CHOKE FACTOID: A Mercury Mini-Choke replaces a resistor and adds a disernable amount of tonal dimension to the circuit. ™ TRANSFORMER BREAK IN PERIOD: As a general rule, transformers require approximately 30 hours of playing time to be fully broken in. Please refer to Mercury’s website for more information. BE SAFE! ALWAYS USE PROTECTIVE EYEWEAR! Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 4: Holy Terror Upgrade Component Identifier

    (orange/orange/yellow/gold) OTHER COMPONENTS ~12 in. double-poled, coils Shielded RED, BLUE & YELLOW wire double-throw switch ~6 in. ~6 in. Unshielded lament wire insulation “spaghetti” guitar case sticker Mercury Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 5: Recommended Tools For The Project

    Component Identification Your for the Orange “Tiny Terror” includes: Holy Terror Mercury Upgrade Kit Axiom® Holy Terror Upgrade Kit for Versions 2, 3 & 4 of the “Tiny Terror” .......TT-KIT1 • Axiom® Power Transformer (part #: ORP-TT-A) ..................1 • Axiom® Output Transformer (part #: ORO-TT) ..................1 • Magnetics “Equipped with” metal plate (part #: MM-Plate-1) ..........1 Mercury •...

  • Page 6: Assembly Sequence

    8. Mount the transformers in the locations and directions indicated in the illustrations noting which hole each cluster of wires pass through. Use Loctite on the bolts. 9. Following the illustration, unsolder the components from the main PCB as indicated. 10. Following the illustrations, solder on all new components onto the main PCB. If you are installing the optional PTS, tin and solder in the leads and extensions to R1 and R2, but do not connect them to the actual switch, yet. We recommend building the “Voltage Divider” and the optional “RC Network” separately to make installation easier. At this point, triple check your work to make sure that nothing is missing or incorrectly modified. You are about to reassemble the amp. If you later have to debug your work, it’ll take considerable more time later. 11. Bolt back in the main PCB back into the chassis, using Loctite, but follow the hook-up sequence indicated below. a. Trim, tin and solder the OT’s Blue/Red/Blue-White leads onto their indicated locations on the main PCB. Note to cut the wires so that they can be tucked off the top edge of the board. b. Trim, tin and solder the Blue/Red/Black leads to the output PCB, and re-attach it back into the chassis. Note to tuck the wires towards the far wall of the chassis, away from the main PCB. c. Complete the hookup of the PTS and bolt it into place. Depending upon your technique, you may find it easier to bolt it into place first and complete the soldering from there. Do NOT over tighten the PTS’s retaining nut or you will strip the threads. d. Reattach the chassis ground lead (Green-Yellow), trim and tin the PT’s Green-Yellow lead – bolt them both into the chassis in the original location. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 7: Indentifying Your Version Of The "Tiny Terror

    Be sure to read and follow these helpful hints and tips! Tech hint: The main PCB is double-density board – with separate circuits etched on the top and the bottom layer. It is sometimes easier to solder to the top of the board than the bottom, especially if the eyelets have been damaged in the de-soldering of the components you’ve removed. Tip: Use parts trays to hold the parts as you are disassembling the amp. Tip: When removing components from the PCB, remove all of the old solder from the holes. Also, use an electronics-approved contact cleaner to clean the board after the initial parts removal and then again after you’ve made all of the upgrades (but before the PCB is bolted back into the chassis). Note: On some “Tiny Terrors” that the retaining clips of the leads (primarily from the transformers) are “spring loaded.” The clips won’t just pull off – you have to pull back the clear plastic sheathing, and using a tiny screw driver (or something similar) push the retaining metal “lip” in while pulling off the clip. Versions of the “Tiny Terror”: There are currently four versions of the “Tiny Terror.” The original (Version 1) was a relatively limited run and rare. Version 2 can be identified by the “Made in Korea” marking on the back of the amp. Version 3 can be identified by the “Made in PRC” (Republic of China) marking on the back and the marking “ORA-PC211-X” (where “X” is “1,” “2” or “3”) on the main PCB. Version 4 is also “Made in PRC” and has the marking “ORA-PC211-4” on the main PCB. Note: The this manual is divided into two sections, one for Versions 1, 2 & 3 and another for Version 4. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 8: Mercury Power And Output Transformers Diagrams

    NO: “Tiny Terror Output” DATE: 06-22-11 Copyright © 2008–11 by Mercury Magnetics. All Rights Reserved. Mercury Magnetics, FatStack, Mini-Choke & Mercury Vintage are trademarks of Mercury Magnetics. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics is not affiliated with Orange.
  • Page 9 NO: “Tiny Terror Main” Copyright © 2008–9 by Mercury Magnetics. All Rights Reserved. Mercury Magnetics, FatStack, Mini-Choke & Mercury Vintage are trademarks of Mercury Magnetics. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics is not affiliated with Orange.

  • Page 10: Chassis Modification Template

    This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials. Copyright © 2008–9 by Mercury Magnetics. All Rights Reserved. Mercury Magnetics, “Holy Terror” and the slogan “The Heart & Soul of Your Amp” are trademarks of Mercury Magnetics. Axiom and ToneClone are registered trademarks of Mercury Magnetics.

  • Page 11: Stock "Tiny Terror" Versions 1, 2 & 3

    Versions 1, 2 & 3 PCB SECTION The following pages pertain ONLY to Version 1, 2 and 3 “Tiny Terror” amplifiers. You can easily identify which version you have by the main PCB (printed circuit board); look for the following text, printed in white ink, on the lower right-hand quadrant: ORO-PC211-X (where “X” is either “1,” “2” or “3”) Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 12: Wiring Schematics

    Copyright © 2008–9 by Mercury Magnetics. All Rights Reserved. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics, “Holy Terror,” the slogan “The Heart & Soul of Your Amp,” FatStack & Mercury Vintage are trademarks of Mercury Magnetics.
  • Page 13 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials. Copyright © 2008–9 by Mercury Magnetics. All Rights Reserved. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics, “Holy Terror” and the slogan “The Heart & Soul of Your Amp” are trademarks of Mercury Magnetics.

  • Page 14: Main Pcb Disassembly And Reassembly Illustrations

    Schematic drawn by — for the The Pentode/Triode Switch OPTION www.MercuryMagnetics.com If you will be making the www.Amp-Exchange.com Pentode/Triode switch option, VERSIONS 1, 2 (KOREAN) & 3 (CHINESE) disconnect the north terminals VERSION: 08-17-08 (original) REVISION: 10-01-09 of R1 & R2 Remove these components from from the main PCB the top side of the main PCB...
  • Page 15 Revised: 05-26-11 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials.
  • Page 16 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials. Copyright © 2008–2011 by Mercury Magnetics. All Rights Reserved. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics, “Holy Terror” and the slogan “The Heart & Soul of Your Amp” are trademarks of Mercury Magnetics.
  • Page 17 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an...

  • Page 18: Reference Photos

    Chassis reference photo: A fully modified main PCB (version 1, 2 & 3). Note that lead colors and standoff to PTS are different than description in manual.
  • Page 19 Chassis reference photo: A fully modified main PCB (version 1, 2 & 3). Note that lead colors and standoff to PTS are different than description in manual.
  • Page 20 Chassis reference photo: A fully reassembled chassis (version 1, 2 & 3). Note that lead colors and standoff to PTS are different than description in manual.
  • Page 21 Chassis reference photo: A fully reassembled chassis (version 1, 2 & 3).
  • Page 22 PTS (Pentode/Triode Switch: Here’s where the switch mounts. Note that the down position is the Triode mode, the up is Pentode mode. Reference photo showing the connections to the PTS. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 23 Reference photo showing how a correctly built and connected Voltage Divider should look. This photo and those on the next 2 pages are intended for reference purposes. Note that the filament leads (the twin yellow leads coming from the PT) are the only leads that must be “braided” – which lessens RF. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 24 Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 25 Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 26 These photos show the “RC Network.” Generally it’s easier to build it first, and install it into the main PCB after it is assembled. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 27: Version 4

    Version 4 PCB SECTION The following pages pertain ONLY to Version 4 “Tiny Terror” amplifiers. You can easily identify which version you have by the main printed circuit board (PCB); look for the following text, printed in white ink, on the lower right-hand quadrant: ORO-PC211-4 Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 28 Copyright © 2008–9 by Mercury Magnetics. All Rights Reserved. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics, “Holy Terror,” the slogan “The Heart & Soul of Your Amp,” FatStack & Mercury Vintage are trademarks of Mercury Magnetics.
  • Page 29 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials. Copyright © 2008–9 by Mercury Magnetics. All Rights Reserved. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics, “Holy Terror” and the slogan “The Heart & Soul of Your Amp” are trademarks of Mercury Magnetics.
  • Page 30 Schematic drawn by — for the www.MercuryMagnetics.com www.Amp-Exchange.com VERSION 4 (CHINESE) VERSION: 12-30-08 (original) Revision: 12-30-08 Make these modifications to the top side of the main PCB ORANGE ‘Tiny Terror’ Black HTR3 HTR4 Remove C18 T250mA 6.3vac Green Brown Note: The Black and Yellow filament supply leads are !!! WARNING –...
  • Page 31 COMPONENT SIDE VIEW OF PCB Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Magnetics. The disclosure of the information herein may pertain to proprietary rights and Mercury the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 32 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials. Copyright © 2008–11 by Mercury Magnetics. All Rights Reserved. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics, “Holy Terror” and the slogan “The Heart & Soul of Your Amp” are trademarks of Mercury Magnetics.
  • Page 33 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an...

  • Page 34: Main Pcb Disassembly And Reassembly Illustrations

    Reference photo: A fully Upgraded and reassembled “Holy Terror” from a Version 4 “Tiny Terror.”...
  • Page 35 Reference photo: A fully Upgraded and reassembled “Holy Terror” from a Version 4 “Tiny Terror.”...
  • Page 36 PTS (Pentode/Triode Switch: Here’s where the switch mounts. Note that the down position is the Triode mode, the up is Pentode mode. Reference photo showing the connections to the PTS. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 37 Note that the “Voltage Divider” in these photographic examples uses a 330KW resistor instead of a 330KW. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 38 Reference photo shows the “Voltage Divider” on an Upgraded Version 4. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 40 Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 41: Holy Terror

    Because I now Click on the above photo to see a movie produced by Bob McGilpin to know that adding “I believe when demonstrate his “McMod.” a choke makes you listen to my an amp sound better. It makes for a smoother and sound samples that you will you decide to take your Holy Terror Upgrade Kit all the way by adding the warmer sounding amp with a touch of vintage to the 9 Henry Mini-Choke as well. It’ll give you an even amp’s tone. Continued on page 44 Æ NOTE: If you are adding Mercury’s Mini-Choke after you’ve already made the “Holy Terror” Upgrade you will probably not be able to easily remove the circuit board. So, instead of removing the PCB, you may very, very carefully drill small holes for self-tapping metal screws for the Mini-Choke. Mount and secure your Mini-Choke, pull the leads through the hole, and then follow the instructions for removing the 5 watt 150W resistor and soldering your new Mini- Choke into place. See the chassis diagram on the next page for the hole locations and sizes. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 42 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials. Copyright © 2008–10 by Mercury Magnetics. All Rights Reserved. Mercury Magnetics, “Holy Terror” and the slogan “The Heart & Soul of Your Amp” are trademarks of Mercury Magnetics. Axiom and ToneClone are registered trademarks of Mercury Magnetics.
  • Page 43 This project and its documentation are the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights, and the furnishing of these documents does not constitute an expressed or implied license to use such materials. Copyright © 2008–10 by Mercury Magnetics. All Rights Reserved. Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics, “Holy Terror” and the slogan “The Heart & Soul of Your Amp” are trademarks of Mercury Magnetics.
  • Page 44 Terror Mini-Choke can be done with the PCB in place and transform it into the Holy Terror I completely BUT it require a very steady hand and drilling holes remove the main PCB (printed circuit board) from just large enough for self tapping metals screws.” the entire amp. It makes it much easier to do and allows you to use a de-solder wick or a de-solder “If you are not an experienced tech, you should probably pump and cleanly place the new parts in position find one do the job for you (like me for example!).” before soldering them into place. By doing it this way the component changes will be better anchored and be more reliable over the long term. The Mini-Choke replaces this resistor (R3) Pictures 1 & 2: These show the removal of the circuit board. Disconnect the filaments to the pilot light. Also, clip and remove resistor R3. Leave yourself plenty of the resistor’s lead wire so that you can easily bend a hook to solder the Mini-Choke leads into place. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 45 Picture 3: Once you have an empty chassis mount your new Axiom Power and Output Transformers into place. You now prepare the chassis for the Mini-Choke. Picture 4: This shows where the new 9 Henry Mini-Choke will be placed near the Power Transformer (see the chassis diagram at the first of this section for the exact placement). Mark the holes and carefully drill the 2 holes for Mercury’s Mini-Choke. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 46 Picture 5: The Mini-Choke leads will fit through the existing hole used for the Power Transformer’s leads. Mount your Mini-Choke and carefully pull the leads through that hole. Picture 6: The chassis with the new Transformers and the Mini-Choke in place looks great! Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 47 Picture 7: Prepare to solder the Mini- Choke leads to the clipped resistor leads in location R3. Picture 8: Solder the Mini- Choke leads onto the old resistor wires of R3. REMEMBER to add a little shrink tubing to the ends of the Mini-Choke leads. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 48 Picture 9: Slide the shrink tubing in place and secure. To Make the “McMOD” Give Mercury a call. You’ll need Mercury Magnetics’ Mini-Choke (Part No. MM-9H-CH). Also considering experimenting with other choke values. Mercury makes a Multi-Choke compatible with this amp size (Part No. MM-MULTI-9C). This version of the Multi-Choke can be set from 1 Henry to 9 Henry in single Henry increments. Enjoy! Mini-Choke Multi-Choke Mercury Mercury Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 49: Using A Variac & Current Meter

    Using a Variac & Current Meter Don’t power-up your amp without ’em! NOTE: IF YOU ARE NOT A QUALIFIED AMP TECH, DO NOT ATTEMPT TO POWER UP YOUR MODIFIED AMPLIFER, YET. INSTEAD, Mercury RECOMMENDS THAT IT BE INSPECTED BY A QUALIFIED TECHNICIAN. AN AMP TECH WILL GO OVER YOUR WORK AND VERIFY THAT IT IS SAFE TO POWER IT UP. After modifying your amp, the next step is to power it up using a variac and current meter. The Variac and current meter allows you to slowly add voltage while checking the indicators to make sure that your handiwork is correct. Without a variac you run the extreme risk of frying your amp or some of its components, getting hurt, electrocuted, etc. A Variac is a standard amp tech tool. No amp tech should be without one. They are available from many electronic stores or online, eBay, etc. Prices start at about $50 and go up from there. The better units (such as the Tenma isolated variable AC power supply shown in these photos) include output current metering. Consider that the cost of a Variac is free, because a single error without one can easily cost more than the Variac itself! As the following instructions show, you’ll need to monitor the output current while increasing power to the amp with the Variac. If your Variac doesn’t have a self-contained current meter this can also be done with a separate amperes meter connected to the fuse-holder of the amp (with the fuse removed). Specific instructions for how to use Variacs and current meters are beyond the scope of this manual. Check the web or owner manuals of the devices for specific methods. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 50 STEP A: Make sure that your amp is OFF. Plug it into the Variac. The Variac is OFF with the output voltage knob set to zero (0). Turn on the Variac’s power. Then, turn on the amp’s power. Variac: A variable transformer used to vary AC voltages. Also the tradename for a brand of variable AC transformer. There are other brands, but the term is generically used to describe all of them. A variac allows adjustment of the incoming AC mains voltage. The better quality units have meters for voltage and current, or both, and fuses for protection. Variacs come in many shapes and sizes. But their function is basically the same. If your variac does not have an amperes (current) meter, you’ll need to use a separate meter. NOTE: The Variac in the photo to the left does not have an amperes meter whereas the Tenma model does. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 51 STEP B: Turn on the amp’s power. STEP C: While watching the current (amp) meter, slowly roll on the Variac’s output voltage knob. The amp should turn on at about 45 volts. When you get to about 60 volts you don’t want to see more than a few hundred milliamps. If the current meter reaches anywhere above half an amp, roll the Variac back to zero, shut everything down, discharge the caps, and look for the error, short or bad component. Correct the problem and repeat until this test passes. STEP D: Once you can reach 120 volts drawing less than half an amp, you are in good shape. NOTE: If you don’t have a current meter on your Variac, remove the fuse from the amp, and with an amp meter across the empty fuse holder socket, turn on the amp and perform the test above. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 52: Tips 'N Tricks: Working On Pcbs

    Repair to a damaged eyelet: The lead from component bypass- es the damaged eyelet and is soldered to either a revealed trace or another terminal on the same trace (as in this example). those made in the west. Therefore they’re likely to require patching and repair work as you make the Upgrade. This is normal, and easy to do – as long as you know a few tricks. Revealing a Trace: Sometimes we need to “reveal” traces so that the PCB can be modified or repaired. An easy way to do this is to take a sharp knife or Exacto and carefully scrape away the lamination to “reveal” the copper foil under it. Use high-grade (99%) Isopropyl alcohol and a Q-tip to clean these new contacts before soldering to them. Various examples: 1. Jumper. 2. Jumper. 3. Trace repair (jumper soldered from terminal to terminal on same trace). 4. Trace repair (ditto). 5. Damaged eyelet repair (lead is soldered to a revealed trace). Continued on next page è Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 53 If an eyelet is damaged or missing or the trace material around it is very thin, then you may consider soldering a reinforcement jumper across it. or a Dremel Tool with a cutting or grinding edge attachment to make the cuts. How to Cut a Trace: A “trace” is the conductive strip (foil) on a printed circuit board. It has a very A trace cut severes the embedded metal laminent thin laminate or lacquer layer over it. Cutting a trace on a PCB. The purpose of a trace cut is to modify or is like clipping a wire. Use a box knife, Exacto knife re-route the electrical flow of the circuit. Here’s two different ways to cut a trace: Dremel Tool Trace Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 54: About Filament Supply Leads

    About the Filament Supply Leads The PT with the Holy Terror Mercury Upgrade Kit has two yellow leads (wires) coming from the secondary side of the transformer’s casing. See the power transformer’s diagram at the front of this manual for clarification. The two yellow secondary leads are the “filament supply leads.” The filament supply leads are the only wires that must be twisted together – a technique that helps to cut down RF. This photograph shows a twisting pattern that you should aim for. Consistent, even twisting is important. Ideally about 10 twists per inch. Cable tie these leads as high off the Main PCB as possible, and as close as possible to both the power transformer. This will minimize amp noise and hum. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

  • Page 55: The Output Transformer Circuit By Sergio Hamernik

    The Output Transformer Circuit Mercury’s circuit equivalent of an Output Transformer Primary Self Capacitance Primary Inductance Secondary Self Capacitance Primary Resistance Interwinding Capacitance Secondary Resistance Primary Leakage Inductance Core Eddy Current Losses Secondary Leakage Inductance Core Hysteresis Losses “Blessed are the Tone Makers”...

  • Page 56: Discharge Those Filter Caps

    “Filter” caps can store fatal amounts of electrical current. The caps are connected near the rectifier Start by unplugging the amp from the wall, the and are part of the power supply, and aid in speakers from the amp, and removing the amp converting AC to DC. In fact, they are a standard chassis from the case. For Fender amps, removing component in any power supply. the chassis involves unscrewing the upper back case panel, then unscrewing the chassis from the If you’re completely lost, and don’t understand this, top of the case. Put the screws, nuts, and lock DON’T MODIFY YOUR AMP. You haven’t enough washers where they won’t get lost. knowledge to work on high voltage/current circuits With the chassis out of the case, you can locate safely. the filter capacitors you’ll want to avoid touching as you perform the tune-up. These will be cardboard Several ways to discharge caps: cylinders (usually orange or tan or vintage Fenders) FIRST, UNPLUG THE AMP! (But that doesn’t with “+” printed near one terminal. It’s also a good make it safe!) idea to steer clear of wiring connected to the power transformer because it’s a discharge path for the THEN, take a screwdriver or a jumper and short filter capacitors. the capacitors leads. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 57 Level of difficulty: Moderate Step 1: Strip about 1/4 inch of insulation off each end of a 2-foot length of insulated copper wire, and solder one end of the wire to one of the leads of a high wattage resistor. The resistance required can be determined by adding 5 to 50 ohms per volt of the capacitor’s rating. For instance, a 100V capacitor would require a resistor rated anywhere from 500 to 5k ohms. Step 2: Attach the other end of the wire to an alligator clip. Filter Capacitor Discharge Tool Step 3: Solder the free lead of the resistor to a short piece of bare copper wire. 1. Safety glasses. Always use safety glasses. If you wire a capacitor in backwards there is a very Step 4: Tape the resistor and bare copper wire to good chance that it will explode in your face. one end of a length of non-conductive material, Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 58 3. From the chassis to a tube pin. This can be (about 5 minutes, if the amp has bleeder resistors this time will be shorter) then, while the discharge done at pin 3 of any power tube, or pins 1 or 6 of any preamp tube. By shorting the chassis tool is still in place recheck all the capacitors with your multi-meter and keep that other hand behind to the correct pin the caps will be forced to drain through the plate load of that tube. This you. Keep checking until the voltage has reached prevents sparking from high current. a safe level. Note: This procedure must be done every time you turn the amp on then off. IMPORTANT NOTE, HOW NOT TO DO IT: In old Remember to remove the discharge tool before electronics books they tell you to use a screw driver with an insulated handle to short out the caps. powering on the amp. Make it a bright color like Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 59 2. Never work while distracted. Filter capacitors are wired in parallel, so draining one should drain them all, but never assume. 3. Never work on an amp around small children. Always recheck for residual voltage in every filter There are just too many dangers involved to capacitor until there’s absolutely no doubt in your take that chance. mind that all are drained. 4. Try to have a plan in case something does go Less than 5 volts is safe, but I prefer to drain mine wrong. You might consider asking someone in to 1 volt for peace of mind. Don’t be surprised if you your household to take a CPR class. find the capacitors slowly recharging themselves. 5. Take your time and don’t rush. This phenomenon is known as dielectric absorption and is quite normal in electrolytic capacitors. The 6. Use common sense. filter caps shouldn’t recharge to a lethal level, but http://tubenewbie.com/discharge_capacitors.html leave the discharge tool in place while working on the amp. Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.
  • Page 60 Orange “Tiny Terror” • Mercury “Holy Terror” Upgrade Kit This project and its documentation is the result of technical investigations made by the engineering staff of Mercury Magnetics. The disclosure of the information herein may pertain to proprietary rights and the furnishing of these documents does not constitute an expresed or implied license to use such materials.

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