Tuesday, September 18, 2012

Powering up the Hallicrafters SX-96


The last parts to be soldered...


Six caps on the selectivity switch


S2 with old, and new bees...
Click for larger view

The wires leading to the switch were in good condition, allowing replacement without completely removing it. Sometimes old insulation cracks, or wires break. Once the switch was back in place, I started to check the entire area under the chassis. There were a few times when a cut component lead would disappear into the mysterious fray of wire... I was able to find them all with a little help from a bright light and small amounts of compressed air. There were a few solder splashes, mostly from the solder removal process. Other components were inspected for signs of heat stress - color changes, slight bulges, tiny cracks. I randomly measured some resistor values, and they were within tolerance. I had replaced one resistor earlier in the project, as it appeared to have been stressed with heat. Even though it measured within tolerance, such parts should always be replaced.

Almost there...


 The Buzz...

There is a mysterious 8-pin socket on the back that will allow power via DC operation. If you have a DC supply with 208 volts at 105 ma, and 6.3 volts at 4.1 amps, you're in business - add your batteries or supply for the perfect 40 pound bundle for your trip to the park. Don't forget to throw in your speaker - the one in the metal enclosure. Enjoy the broadcast of the game with this great portable set...

I replaced the power cord. The original wasn't too bad; however, this is always a good idea considering the age of the components. I should have installed a fuse as well... there is a hole in the chassis, originally intended for an rf connector. I will install one before releasing it from the quarantine of my work area.


Initial power up configuration...

The audio output has a terminal strip for a 3.2 Ω or 600 Ω speaker. I have an impedance matching transformer that was hooked to the 600 Ω terminals, then connected the 8 Ω speaker. A random length of wire was strung across the floor in the basement, much to the delight of the cat.

The Powerstat was plugged in, and I looked at the point where the AC output would be near the minimum operating voltage of 105 vac. While the label says acceptable voltages range to 125, I figured that something idle for a few decades would be happier with a lower voltage. The radio was then plugged in to the variable AC supply, and the Fluke meter was attached as well to monitor line voltage as I rolled up the AC.

The manual describes two methods for tuning - also noting that it was calibrated with the bandspread dial fully CCW. I set the main dial near an expected local AM broadcast station. The bandspread was not fully CCW, as I wanted some 'room' to rock the adjustment. Volume and sensitivity controls were set near the low end, and other switches selected the AM broadcast band, and the selectivity at 5kc.




Power up




Leakage current?

Old electronics can be dangerous - I used this Simpson leakage current tester to evaluate the radio's safety. I am going to operate the radio with an isolation transformer, and at a reduced AC line voltage.

It's a keeper. All controls and bands work well. The calibration is off a little - it is close enough for now. I don't have the signal generators to go through the alignment procedure.

Next: I'll post the tiny isolation transformer, voltage step-down project.

Also, a separate blog about past restorations, including an Atwater Kent (a 20 Big Box and a 40), a Crosley Trirdyn, and the Grunow will launch at some point.





Monday, September 3, 2012

Hallicrafters SX-96 Component Replacement

Most of the parts to be replaced are easy to get to. I've replaced most of the caps - saving a potentially annoying section for last.




Part of S2 - Selectivity Switch
Click to enlarge

This section seemed like the most annoying, so I saved it for last. There are six bees hiding in and around this multilayered switch. The good news is that it isn't quite as annoying as I'd initially thought it would be. Note the circled area - three bees and a wire are attached to a single point. The primary concern for something like this is the relatively fragile attachment point - these switches may be difficult to find, and repair is not something I care to think about.


S2 Schematic
Click to enlarge 

Since the connection is delicate, a minimum amount of heat is applied to melt the solder. First, I drew a diagram of the mess, in addition to the photo. Next, I cut the wire lead of the bee close to the body of the part - leaving sufficient wire so that it could be grabbed with needle-nose pliers. Carefully heating the joint with the 25 watt soldering iron, I used a spring powered vacuum device to remove a blob of molten solder. I had to heat it twice, since woven component leads make it hard to get enough solder out of the joint to remove the leads. Once the joint was partially clear, it was heated a second time. Wires are bent like hooks in these joints. I used the needle-nose pliers to grasp one of the wires, and moved it around within the connection when the solder was molten. I removed the heat, and continued to move the wire quickly so that the small amount of remaining solder would not tack it to the point again.


Partially cleared tie point...
Click to enlarge

Note the appearance of the remaining solder - it appears dull and rough. This is the result of moving the wires as the solder cooled, the desired effect so that the part wouldn't re-tack itself, allowing easy removal.


Cleared pad
Click to enlarge

The connection is now clear for the new parts.
Next - The switch with new parts.