Relay problem solved. I learned a few things about AC powered relays. You can't bring them up on a variac slowly or they will chatter between 50 and 100 volts. They need to be operated at their full voltage, over 110 volts. It turns out that when using the dim bulb in line with the variac, the voltage drop was too much, and the relay dropped below its cutoff voltage and started to chatter. With 115 volts AC across the contacts, you get to see some sparks (not good). I turned off the dim bulb, set the variac at 120 volts and flipped the switch! The transmitter powered up and started drawing about 1.2 amps. No smoke or explosions :)
The TCS set is finally working. It turned out to be something stupid. Nowhere in the net or in the manual does it sat that the transmitter has to be plugged into the power supply in order to operate the receiver. Apparently there are jumpers and a relay that enable the receiver when the transmitter is plugged in. Finally! I've been banging my head on the wall for a week on this issue. The clue was when I turned on the parts receiver with all good tubes and I got the exact same symptoms. That told me it was most likely something to do with the power supply...
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