Ten-Tec 4229 - Output Balun Coil Assembly; Toroid Core and Wire Preparation; Coil Winding and Termination; Solder Lug Attachment

e
8.
LO.
Ah,
Cap.
This
assembly
is
now
completed.
Inspect
for
adequate
and
any
excessive
sol-
der
that
may
cause
unwanted
shorts
between
adjacent
foil
paths.
OUTPUT
BALUN
COIL
ASSEMBLY
#80960
$$$
ree
ovo
Fasten
the
two
toroid
cores
together
in
a
stack
(face
to
face)
and
secure
with
the
two
nylon
ties
supplied.
Locate
the
two
ties
diametrically
opposite
each
other
with
the
locks
of
each
tie
on
the
outside
edges
of
the
stack.
Draw
snugly
after
positioning.
Leave
excess
length
or
cut
off
as
desired.
To
prepare
the
Teflon-insulated
wire
for
winding,
uncoil
and
straighten
the
wire
supplied
and
cut
one
piece
ten
feet
(10')
in
length.
Now
bend
double
the
wire
at
the
mid
point
of
its
length
-
DO
NOT
CUT.
You
now
have
two
5!
wires,
joined
at
one
end.
We
must
identify
each
end
of
each
wire.
Place
a
piece
of
self
adhesive
tape
around
the
wire
and
back
over
itself
to
provide
a
flag
for
marking
with
a
suitable
pencil
or
pen.
Locate
these
markers
on
each
wire
about
1"
from each
end
and
from
the
center
fold.
How
to
mark:
A.
On
one
wire
mark
the
flag
near
the
bend
as
"1".
Mark
the
flag
on
the
cut
end
of
this
same
wire
as
"2",
B.
On
the
other
wire,
mark
the
flag
at
the
bend
as
"3".
Mark
the
cut
end
Ole Lis. wire as, "4",
Before
starting
to
wind
this
coil,
find
the
large
domed
rubber
(1"
diameter
x
1"
long)
bumper
that
is
included
in
the
kit.
This
will
be
handy
to
use
when
winding
is
finished.
The
objective
is
to
wind
this
coil
around
the
toroid
core
with
both
wires
at
the
same
time
keeping
them
parallel
to
each
other
(not
twisted
or
overlapped).
Form
them
as
tight
to
the
core
as
practical
without
forcing
the
corners
of
the
core
to
cut
into
the
insulation
on
the
wires.
Start
winding
by
passing
the
folded
end
of
the
wires
(1
&
3)
through
the
cen-
ter
hole
and
around
the
stacked
cores
and
leaving
about
six
inches
(6")
of
these
wires
extending
to
the
outside
of
the
core.
Now
continue
winding
in
the
same
direction
around
the
core
by
inserting
the
cut
ends
(2
&
4)
through
the
center
hole
and
around
the
stacked
core.
Continue
this
until
fifteen
turns
of
both
wires
have
been
applied.
Spacing
is
not
critical,
but“be
sure
to
keep
the
wires
parallel
to
each
other
and
not
twistéd
or
crossed.
As
the
winding
comes
to
one
of
the
ties,
skip
over
avoiding
the
square
locks
on
the
tie
strips.
When
the
last
(15th)
full
turn
has
been
applied,
the
winding
will
have
just
about
come
full
circle
around
the
core
and
the
starting
and
ending
leads
should
be
near
together.
Insert
the
rubber
bumper
plug
to
hold
the
winding.
This
plug
remains
in
position
for
mounting
the
balun.
Assuming
that
the
markers
are
still
attached
to
the
ends,
you
are
now
ready
to
terminate
them.
You
can
now
cut
the
wires
at
the
bend
leaving
the
markers
on
each
wire.
Bring
ends
"1"
and
"4"
together
and
twist
a
couple
of
turns
(these
two
leads
comprise
the
center
tap
connection
of
the
balun
coil).
The
remaining
two
free
wires
("2"
&
"3")
are
the
outer
ends
of
the
balun.
If
the
marker
tags
have
become
detached,
a
continuity
meter
will
assist
you
to
determine
which
is
which.
Just
know
that
the
center
tap
connection
is
made
up
of
the
starting
end
of
one
wire
and
the
finish
end
of
the
other
wire.
‘If
the
marker
tags
have
remained
intact,
they
may
now
be
discarded
and
all
leads
can
be
cut
to
approximately
4"
in
length
--
keep
1
and
4
twisted
for
identification
,
:
Attach
solder
lugs
(quantity
3)”to
the
leads
from
the
balun.
Strip
all
ends
approximately
1/2".
Twist
both
bare
wire
ends
of
"1
and
"4
together
and
solder
to
a
barrel
type
solder
lug.
Solder
a
like
lug
to
the
bare
ends
of
wires
"2
and
"3.