Mercury Holly terror User manual

VERSION 111611

2 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.

Ifyoudonotknowhowtoreadaschematic,westronglyrecommend

thatyoutakethisprojecttoaqualiedtechnicianforinstallation.

AllMercury Magneticsproductsare100%handmadebyusinCalifornia,USA.

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afliated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,certied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!

Written & produced by the staff of

Circuitry design by Alan Cyr

(www.Amp-Exchange.com)

9167IndependenceAve.

Chatsworth,CA91311

(818)998-7791•FAX:(818)998-7835

Skype:paul.patroneteorpatrick.selfridge

www.MercuryMagnetics.com

info@MercuryMagnetics.com

Orange “Tiny Terror”•Mercury “Holy Terror” Upgrade Kit 3

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

SOLDERING NOTE:TheOrange“Tiny Terror”isassembledusingRoHScompliant,lead-freesolder.Workingwithlead-freesolderis

differentthanstandardsolder.Generallyahotterironisnecessary.Formoreinformationwerecommenddoingaweb-earchfor“lead-

freesolderingtechniques.”

CAPACITOR DISCHARGE WARNING:Safedischargingofltercapacitorsmatters.Itisessentialforyoursafetyandtoprevent

damagetotheamp’scircuitry,thatlargeorhighvoltagecapacitorsbefullydischargedbeforemeasurementsaremade,solderingis

attempted,orthecircuitryistouchedinanyway.Forinformationonhowtodothis,web-search“capacitordischarging.”Alsoseethe

appendixforadditionalinformation.

CAPACITOR POLARITY:Notethatmanycapacitorshavepositiveandnegativepolarity,andarestampedaccordingly.Besurethat

theirpolarityiscorrectwhensolderingtoaPCB.

BRAIDING, TWISTING AND COILING LEADS:Donotbraid,twistorcoilthepowertransformer’sB+leadwire.Checkourreference

illustrationsandphotostoseewhichleadsaretwistedtogether.Typicallyonlythelamentleadsofthepowertransformer.Otherposi-

tioningofleadsmaybenecessarytominimizeampnoise.Followarediagramsandinstructsforoptimalperformance.

TRIMMING TRANSFORMER LEADS:Tominimizenoise,measureandtrimthesolderableleadlengthsofthetransformersandMini-

Choke™.Routeallwirescleaningaroundthetubes,chassis,etc.

CLIPPING vs. UNSOLDERING PCB COMPONENTS:TomakethisUpgradeitwillbenecessarytoremoveseveralcomponentsfrom

theMainPCBoftheamp.Duetoqualityissueswithmodernoff-shorePCBmanufacturing,itcanbedifculttounsolderanitemwithout

creatingotherproblems,themosttypicalofwhichisaneyeletdetachingfromthePCB.Thereforewe’veindicatedwhichcomponents

shouldbeclippedvs.unsoldered.Tounsolderheatyourironto800ºF,thenveryquicklyheatinguponesideoftheexistingsoldercon-

nectionwhilepullingitthroughontheother.Iftheironisnothotenough,oryoulingertoolong,theeyeletwillgetdamaged(orfalloff).

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modications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!

Table of Contents

Holy Terror Upgradecomponentidentier........................................................................................................4

HowtoIdentifywhichversionofthe“Tiny Terror”youhave...................................................................................... 4

Recommendedtoolsfortheproject.............................................................................................................................. 5

Assemblysequence...................................................................................................................................................... 6

Indentifyingyourversionofthe“Tiny Terror”............................................................................................................. 7

MercuryPowerandOutputTransformersdiagrams................................................................................................ 8

Chassismodicationtemplate.................................................................................................................................... 10

Stock “Tiny Terror” versions 1, 2 & 3 ......................................................................................................................11

 Wiringschematics............................................................................................................................................... 12

 MainPCBdisassemblyandreassemblyillustrations......................................................................................... 14

Holy Terror referencephotos......................................................................................................................... 18

Stock “Tiny Terror” version 4 .................................................................................................................................. 27

 Wiringschematics............................................................................................................................................... 30

 MainPCBdisassemblyandreassemblyillustrations......................................................................................... 34

Holy Terror referencephotos......................................................................................................................... 18

Appendices

 AddingaMini-Choke:HowtoinstallBobMcGilpin’s“McMod”........................................................................... 41

 UsingaVariac&CurrentMeter........................................................................................................................... 49

 Tips’nTricks:WorkingonPCBs......................................................................................................................... 52

 AboutFilamentSupplyLeads............................................................................................................................. 54

 TheOutputTransformerCircuitby Sergio Hamernik.......................................................................................... 55

 DischargethoseFilterCaps!............................................................................................................................... 56

CAUTION!Thevoltagesinyourampliercanbedangerous.Transformersandchokesarenotuserservicable

parts.Installationofthesecomponentsshouldalwaysbeperformedbyanexperiencedtechnician.Thesimpleability

touseasolderingironisnotenoughtoqualifya“do-it-yourselfperson.”Thosewhoareinexperiencedinworking

withelectroniccircuitsshouldneverattempttoservicetheirampliers.Householdlinecurrentscanbedeadly!!

Transformers,chokesandlargeltercapacitorscanstoredangerouschargesforseveraldays,orlonger,afterthe

amplierhasbeenunplugged.Nevertouchtheterminalsofthesecomponentswithoutbeingcertainoftheircharge

status.Riskofshockanddamagetoequipmentmayresultfrommishandlingand/orimproperuseofthesecompo-

nents.Pleaseusecommonsenseandalwaysthinksafetyrst.Afterall,greattoneismostenjoyedwhenyouare

alivetohearit.

4 Orange “Tiny Terror”•Mercury “Holy Terror” Upgrade Kit

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

Component Identication

Identifying the components included with the Holy Terror Upgrade Kit:

CAPACITORS (electrolytic)

CAPACITORS (silver mica)

10KΩ 1/2W

(brown/black/orange/gold)

470KΩ 1/2W

(yellow/violet/yellow/gold)

~6 in.

insulation “spaghetti”

Shielded RED, BLUE & YELLOW wire

ORP-TT-A

(power transformer)

ORO-TT

(output transformer)

330KΩ 1/2W

(orange/orange/yellow/gold)

~12 in.

coils

2.2KΩ 1/2W

(red/red/red/gold)

RESISTORS (carbon film)

OTHER COMPONENTS

680ρF

.022µF

100KΩ 1/2W

(brown/black/yellow/gold)

1µF

Mercury

“Holy Terror”

sticker

Mercury nameplate

1x 4.7µF

10µF

Note that many capacitors have +/- polarity.

Be sure to study the schematics for the correct

directions when Upgrading your amp.

300KΩ 1/2W

(orange/black/yellow/gold)

1.8KΩ 1/2W

(brown/grey/red/gold)

double-poled,

double-throw

switch

Instructional CD ROM

“.022µF” capacitor

may be marked

as “223K”

8-32 size washers

10µF

Mercury guitar case sticker

Unshielded lament wire

~6 in.

Orange “Tiny Terror”•Mercury “Holy Terror” Upgrade Kit 5

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

Component Identication

Your Holy Terror Mercury Upgrade Kit for the Orange “Tiny Terror” includes:

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

 • Mercury Magnetics“Equippedwith”metalplate(part#:MM-Plate-1)..........................................1

 • Holy TerrorI.D.sticker(goesovertheoriginal“Tiny Terror”onthefrontoftheamp)....................1

 • CD-ROMwithphotographicinstructions(withschematics)....................................................................1

 • Coilofwireinsulation“spaghetti”......................................................................................................... ~6"

 • Coilofunshieldedwire......................................................................................................................... ~6"

 • Coilsofred,blueandyellowinsulatedwire................................................................................. ~12"ea.

 • 8-32washers(formountingtransformerstochassis).............................................................................8

 • 1mF(electrolytic)capacitor.......................................................................................................................1

• 4.7mF(electrolytic)capacitor(VERSION2KOREANPCBONLY).........................................................1

 • 10mF(electrolytic)capacitor(radial)........................................................................................................1

 • 10mF50V(electrolytic)capacitor(axial)(VERSION4CHINESEPCBONLY).......................................1

• 680rF(silvermica)capacitor(VERSION2KOREANPCBONLY)........................................................1

 • .022mF(silvermica)capacitors................................................................................................................2

 • 1.8KW½W(carbonlm)resistor.............................................................................................................1

 • 2.2KW½W(carbonlm)resistor.............................................................................................................1

 • 10KW½W(carbonlm)resistors............................................................................................................2

 • 100KW½W(carbonlm)resistors..........................................................................................................2

• 300KW½W(carbonlm)resistor............................................................................................................1

 • 330KW½W(carbonlm)resistor(VERSION4CHINESEPCBONLY).................................................1

 • 470KW½W(carbonlm)resistor............................................................................................................1

 • Switch—double-poled,double-throw(forPentode/Triodemodes).........................................................1

• Goodquality25–35Wsolderiron

(capableoftempsat~800ºF)

• Electronicsgradesolder(60/40rosencore)

• Soldersuckerand/orwick

• Setofscrewdrivers(Philips)

• Smallneedle-noseplyers

• Wirestripper&cutter

• Needle-nosepliers

• Variousopen-ended&box-headedwrenches

(metric)

• Drill&drillbitsformaking1/4"&7/16"holesin

metalchassis

• Loctite 290(green)

• Pureisopropylalcohol&Q-tipsorelectronic-

gradecontactcleaner

• Variac&currentmeter

• DremelTool–canbeusedfordeburring&

enlargeningsmallholes,etc.

Recommended tools for this project:

6 Orange “Tiny Terror”•Mercury “Holy Terror” Upgrade Kit

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

Holy Terror Assembly Sequence

Please see individual Version sections for specic instructions

0. Therstthingyoumustdoisdeterminewhichversionofthe“Tiny Terror”youhave.Themanual

coversseveralversionssoinordertogettheoptimumtonefromyourUpgradedamp,you’llneedto

followthecorrectinstructions.LookforthemainPCB’s(printedcircuitboard)righthandcornerforthe

“ORO-PC211-X”(where“X”isanumberfrom1to4).Then,usingthecluesinthemanual,determine

whichversionof“Tiny Terror” youown.

1. Removetheamp’stopandbottomcovers.Removethetuberetainersandpullthetubes.

2. Dischargethecaps!Seeappendix.

3. DisconnectclipleadsfromthemainPCBfortheOT(outputtransformer)andPT(powertransformer).

4. RemovetheoutputjackPCBbyunscrewingthe3outputjackretainingnuts.Thendesolderthethree

transformerleads.

5. PulltheknobsandunscrewanyretainingnutsfortheVolume,Tone,GainandGuitarJack.Theknobs

arepressure-t,souseeitheraknob-puller,oralargescrewdrivertocarefullyplythemoff.

Note:Donotremovethelamp,butyou’llneedtouncliptheyellow&blackleadsinordertogetthe

mainPCBoutofthechassis.Alsoremoveanyleadsgoingtoswitches,chassisground,etc.,from

thePT.

6. Removebothtransformersandsavethebolts,you’llreusethemwhenmountingtheMercury

transformers.

7. Onthechassis,markoffanddrillthenewholes(perthespecicationsofthemanual’sillustrated

diagrams)fortheOT,andtheoptionalPentode/TriodeSwitch(PTS)ifyouareplanningtoinstallit(we

recommendthatyoudo).FortheOTonly,swaptherubbergrommetsfromtheoldholestothenew

holes.DoNOTboltthePTSintothechassis,yet.

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modied.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

nditeasiertoboltitintoplacerst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 7

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

e.TightlytwistthetwinYellowleadsfromthePT,trimtinandattachtomainPCBnodesTX4andTX3.

f. Trim,tinandsolderthePT’sGreyandPurpleleadstothe“7/15Watt”switch.

g.Trim,tinandsolderthePT’sBlackleadtotheOn/Offswitch.

h.Trim,tinandsolderthePT’sGreenleadtomainPCBnodeTX2.

i. Trim,tinandsolderthePT’sBrownleadtotheI.E.C.tabasindicatedintheillustrations.

j. ReconnectallYellow&Blackplug-inleadsontothemainPCB,includingthelamp’sconnector.

k. Re-connecttheVolume,Tone,GainandOutputJack’sfasteners–butnottheknobs,yet.

l. Re-attachedthetuberetainersandtubesintotheirsockets.

Triple-checkyourwork.Gooveritwitha“ne-toothcomb”comparingitwiththemanual’sdiagrams.Once

youareabsolutelysurethateverythingiscorrect.ItistimetoplugtheampintoaVariac(seeappendix)and

testyourhandiwork.

AfteryouhavesuccessfullypoweredtheampupusingaVariacandverieditisworking,Loctitethe

transformersandthemainPCB’sretainingscrews,re-attachthetopandbottomcovers,andpress-tthe

knobsbackontothefrontpanel.

Congratulations! You’re done!

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

identiedbythe“MadeinKorea”markingontheback

oftheamp.Version3canbeidentied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.

8 Orange “Tiny Terror”•Mercury “Holy Terror” Upgrade Kit

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

BLK

BLU

RED

BLUE

RED

BLUE/WHITE

BLACK

RED (8Ω)

BLUE (16Ω)

SECONDARY

(OUTPUT)

PRIMARY

(INPUT)

2”

2-1/2”

3-1/8”

CLASS: Axiom®

TYPE: Output Transformer

PART NO.: ORO-TT

ORIGINAL ORANGE

PART NO: “Tiny Terror Output”

MOUNTING: Vertical

POWER RANGE: Our OTs are rated

to handle up to 50% more power than

the original manufacturer spec.

DATE: 06-22-11

Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics is not affiliated with Orange.

BLK

BLU

RED

BLU/WHT

RED

BLU

BLU/WHT

RED

BLU

RED

BLU/WHT

BLK

BLU

RED

1-1/8”

2-1/2”

~1-3/4”

2-3/8”

NOTE: Footprint has been

slightly modified to fit the

existing chassis holes.

Mercury Magnetics

9167 Independence Ave. • Chatsworth, CA 91311

(818) 998-7791 • FAX (818) 998-7835

www.MercuryMagnetics.com

100% of our products are designed & handmade in So. California, USA. • Established in 1954

(All dimensions are nominal)

ORO-TT

Origin: Billy Yates of the Venice Amp Company

for the

Orange “Tiny Terror”•Mercury “Holy Terror” Upgrade Kit 9

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

2”

2-1/2”

3-1/8”

PURPLE

B+

BROWN

BLACK

GREEN/YELLOW (SHIELD)

GREEN

GREY C/T

SECONDARY

(OUTPUT)

YELLOW

FILAMENT

PRIMARY

(INPUT)

120V

Low flux/high inductance design with

primary to secondary humbucking

winding configuration.

Mercury Magnetics

9167 Independence Ave. • Chatsworth, CA 91311

(818) 998-7791 • FAX (818) 998-7835

www.MercuryMagnetics.com

100% of our products are designed & handmade in So. California, USA. • Established in 1954

(All dimensions are nominal)

ORP-TT-A

CLASS: Axiom®

TYPE: Power Transformer

PART NO.: ORP-TT-A

ORIGINAL ORANGE

PART NO: “Tiny Terror Main”

MOUNTING: Vertical

VA RATING: 30VA

DATE: 04-14-08

REVISED: 10-01-09

Axiom and ToneClone are registered trademarks of Mercury Magnetics. Mercury Magnetics is not affiliated with Orange.

YEL

PUR

GRY

GRN

YEL

PUR

GRN

GRN/YEL

BLK

BRN

GRN/YEL

BLK

BR N

GRN/YEL

BLK

BRN

YEL

PUR

GRN

1-5/8”

3”

1-7/8”

2-5/16”

2-7/8”

290V

6.3V

Origin: Billy Yates of the Venice Amp Company

for the

10 Orange “Tiny Terror”•Mercury “Holy Terror” Upgrade Kit

thefurnishingofthesedocumentsdoesnotconstituteanexpresedorimpliedlicensetousesuchmaterials.

VERSION: 10-02-09

www.MercuryMagnetics.com

[email protected]

(818) 998-7791

~11-3/4” x 5-1/9” x 2” CHASSIS TOP and BACK PANEL VIEW (all specifications shown are nominal)

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.

Orange Amps and Tiny Terror are trademarks of Orange Amps. Mercury Magnetics is not affiliated with Orange Amps.

12AX7

(v2)

12AX7

(V1)

MERCURY’S POWER

TRANSFORMER

MERCURY’S OUTPUT

TRANSFORMER

GROUND

ORANGE indicates new hole locations

Lead pass thru