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Heathkit W5M rebuilds

There was much discussion here about isolating the RCA input connector from the chassis...DON'T! As a broadcast (FCC 1st Class) engineer, one of the first rules learned is ONE ground point to chassis at the input. With the old tube consoles sometimes literally a few feet from the transmitter, this was the only way to prevent RF and HF oscillations within the audio gear which, by the way, was never grounded to the power line via the "third pin" on the power cord.

One ground is good and more are worse because you create ground loops where current flows due to the minute differences in resistance between ground points. It usually sounds like the 120Hz buzz you referred to.

The best ground point was the one Heathkit chose, but some amps may not still be properly grounded, explaining the perceived improvement when lifted. I would sand all oxidation away from the chassis around the inside where the RCA jack is mounted and insure the jack is pristine, as well, so as to make a solid electrical connection to the chassis. Then install the old jack using star lockwashers under the heads of the mounting screws to penetrate the paint just for good measure. If you don't mind altering the original look a bit, a high quality, stud mount jack with nut would be even better, once the chassis is cleaned. This should be the one and only ground point connection to the chassis for the ground buss wire that extends throughout the amp. If I were doing a total rebuild, I would use 12ga copper from some scrap romex house wire instead of the wimpy stuff Heath supplied, which is small enough to have a minute loss from one end to the other, adding noise.

In radio stations we used 4 inch wide copper sheet with the transmitter bonded to one end and the audio console to the other, and braided copper strap to every turntable and tape machine chassis. No shields were connected at both ends for the same reason, only at the input of the console.

In the W-5M, connect the shield to the RCA jack only or, better yet, to the ground buss at V1, which is the real input to the amp.

And bypass that V1 input capacitor for tighter bass. Auricaps, Sonicaps and Obbligatos can't hold a candle to a straight wire. The best amplifiers are the ones with the fewest coupling caps.
 
I attached a copy of the schematic to help follow along.

The original 100 ohm dropping resistor in each amp were an old 7 watters that looked as though they had been baked in a charcoal grill. They were replaced by two 220 ohm 10 watt resistors in parallel, for 110 ohms. Why didn't I use two 200 ohm resistors? Easy enough: I didn't have any in my junk box! Besides, the original was a 10% tolerance part, so 110 ohms would have still been within tolerance and the additional 10 ohms over 100 won't make much difference. Now we have a dropping node with a dissipation rating of 20 watts vs the original 7 watts. It should run a tad cooler!


Thanks so much for your great write-up! A real treasure trove of info as I look at my 2 old 5WMs on the top shelf.. just waiting for a restore.
However I have a curious question about what you stated above, and you mention it in other threads. Namely that increasing the power rating of resistors will make them run cooler? Why do you say that? It is the voltage/current applied to the resistor and its resistor value that determines how much power it will dissipate. In the above, if it is in a voltage driven circuit, then reducing from 110 ohms to 100 ohms would increase dissipation by roughly 10% due to P=V^2/R. The fact that it is a 20 watt resistor means it will be able to hold up to the power, it will be larger and have more surface area to dissipate the power, and thus not heat up as much itself, (just like the junction temperature of a TO3 will be lower than in a TO220 because the former's junction to case thermal resistance is lower), but the power/heat still has to be dissipated to the outside air and handled by the chassis thermal design and ventilation. If the chassis thermal resistance to ambient air is the same, then you will still get the same temperature increase inside the chassis from that resistor power dissipation.
In other words, whether you put a small 7 watt 100 ohm resistor or a physically larger 20 watt 100 ohm resistor in a closed box, and drive both with 20 volts, resulting in 4 watts dissipated, the box will still go up by the same temperature. Do I make sense?
 
I attached a copy of the schematic to help follow along,....

Reviving this zombie thread,...
Does anyone see the attachment that @ab0ez is referring to? Was wondering if it was just the schematic of a stock W5M or has he added his own mods that are included?
 
Almost done...6CG7 change over...I couldn't stand the power input laying across the output tube sockets..I robbed the ceramic standoffs from some old tube tektronic equipment I got that was used at Woods Hole on cape cod.. An Engineer friend of mine I worked with at the Pilgrim Nuclear plant gave it all to me. I pulled like 8 Telefunken 12AU7's out of them. The component layout in that equipment is amazing. My only issue now with the amplifier is after a few hours of listening the PT gets almost to hot to touch...luckily I have a Chicago PHC-200A transformer that would fit..just have to do some chassis work..bummer.

heathw5.jpg
 
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