Oct 23, 2007 KB3LZP Tube Radio Restoration Paul from Penn Hills KB3LZP.

Oct 23, 2007Oct 23, 2007 KB3LZPKB3LZP

Tube Radio RestorationTube Radio Restoration

Paul from Penn HillsPaul from Penn Hills

KB3LZPKB3LZP


Introduction.Introduction.

This lecture is to cover the basic techniques of This lecture is to cover the basic techniques of Tube Radio chassis electronics restoration. Tube Radio chassis electronics restoration.

Cabinet is not covered.Cabinet is not covered.

ResourcesResources

No knowledge of electronics is required No knowledge of electronics is required but it does but it does help a lothelp a lot..

A properly restored tube radio can give many A properly restored tube radio can give many year of service, pleasure and a sense of year of service, pleasure and a sense of accomplishment. accomplishment.


What is covered.What is covered.

1.1. What level of technology are we dealing What level of technology are we dealing with.with.

2.2. Identify your tube radio candidate.Identify your tube radio candidate.3.3. To plug it in or not.To plug it in or not.4.4. Safety.Safety.5.5. Steps to restoration.Steps to restoration.6.6. Parts identification.Parts identification.7.7. Why replace good looking parts.Why replace good looking parts.


What is covered Cont’d.What is covered Cont’d.

8.8. Tubes go bad often, NOT.Tubes go bad often, NOT.9.9. Replacing CapacitorsReplacing Capacitors10.10. Replacing ResistorsReplacing Resistors11.11. Power Cords and polarized cords.Power Cords and polarized cords.12.12. Cleaning, Dial cords, Miscellaneous.Cleaning, Dial cords, Miscellaneous.13.13. Power up. Power up. 14.14. Initial tests and checksInitial tests and checks15.15. Alignment equipmentAlignment equipment


What is covered Cont’d.What is covered Cont’d.

15.15. AlignmentAlignment

16.16. Burn-in Burn-in

17.17. Alignment again.Alignment again.

18.18. EnjoyEnjoy

1940 MotorolaCatlin US $2,550.00 Sep-05-07

22:39:25 PDT (6 days 1 hour) 280148206978


1. Level of technology1. Level of technologyPre war 1930’s up through 1960s Pre war 1930’s up through 1960s Hollow state.Hollow state.AMAMOld FM 42 - 49 megahertz pre-war band Old FM 42 - 49 megahertz pre-war band – The Zenith Bakelite set pictured had the old 45MHz FM band. The Zenith Bakelite set pictured had the old 45MHz FM band.

Domestic or EuropeanDomestic or EuropeanThese restoration techniques apply to any vintage These restoration techniques apply to any vintage technology, Hollow or solid state. technology, Hollow or solid state.


Radio TubesRadio Tubes

80 12SA7 12SQ7

http://en.wikipedia.org/wiki/Vacuum_tube

http://en.wikipedia.org/wiki/All_American_Five


Tube DataTube DataBeam Power PentodeBeam Power Pentode

High Voltages


2. 2. Identify your tube radio candidate.Identify your tube radio candidate.

Is it a family radio of sentimental value?Is it a family radio of sentimental value?

Do you like the way it looks?Do you like the way it looks?

Will you like tube sound.Will you like tube sound.

Do you just like it?Do you just like it?

Is the price right? Is the price right?

– $101 and 25hrs left$101 and 25hrs left

– 150154946655 150154946655


•Black Dial•Tube Count•Popularity•Exposure


•Wires•Alignment•Availability•Cost•Sockets

37-611


•Hallicrafters. HAM GEAR

Oct 23, 2007Oct 23, 2007 KB3LZPKB3LZPGrundig

Saba 310w 1930

Sonorette France

Volksempfänger (Germany)

•Like Brands•Cost, availability,•Personal choice•Restorable


•Cost High End•Chassis•Case/cabinet


eBay item 320150565279

Zenith Stratosphere console radio 16-A-63 Zenith Stratosphere console radio 16-A-63

Closed at: US $21,000.00Estimate: US $12,000.00 - US $15,000.00History: 23 bids Auction Date:Sep-15-07 07:00:00 PDT High Bid: Internet BidderItem location:Nashville, Tennessee USA

http://offer.liveauctions.ebay.com/ws/eBayISAPI.dll?ViewBids&item=320150565279


3. To plug it in or not.3. To plug it in or not.

Do not plug in your newly acquired Do not plug in your newly acquired UNRESTORED radio.UNRESTORED radio.

Parts can be made of “Unobtainium”.Parts can be made of “Unobtainium”.

Shorted rectifier tubes can let the magic Shorted rectifier tubes can let the magic smoke out of the power transformer.smoke out of the power transformer.

Varriac Dim Bulb testerVarriac Dim Bulb tester

Emerson Catlin$610 4days left.Hairline crack.


1929 Radiola 60 after power up1929 Radiola 60 after power up

The Unobtainium leaked out.


4. Safety 4. Safety

Power CordPower Cord

AA5’s are Transformer lessAA5’s are Transformer less

Isolation TransformersIsolation Transformers– Store boughtStore bought– Home made Home made – VA verses WattsVA verses Watts

Transformer internal shorts use a meter.Transformer internal shorts use a meter.– Dim bulbDim bulb

Work Surface, Shoes, humidity.Work Surface, Shoes, humidity.


Isolation TransformerIsolation TransformerKey Features:Key Features: Primary 115VAC, 50/60 Hz., Secondary Primary 115VAC, 50/60 Hz., Secondary 115VAC 115VAC Provides circuit isolation. Provides circuit isolation. Electrostatic shield between primary & Electrostatic shield between primary & secondary. secondary. Hi-pot tested to 2 KV RMS. Hi-pot tested to 2 KV RMS. Circuit breaker in primary. Circuit breaker in primary. Standard 3-wire, grounded plug & Standard 3-wire, grounded plug & receptacle. receptacle. Input (primary) connected to 5 foot long Input (primary) connected to 5 foot long cord & standard North American plug cord & standard North American plug (NEMA 5-15P). (NEMA 5-15P). Output (secondary) connected to 1 foot long Output (secondary) connected to 1 foot long 3-wire, standard North American grounded 3-wire, standard North American grounded receptacle (NEMA 5-15R). receptacle (NEMA 5-15R). North American Mark of Safety - C UL & UL North American Mark of Safety - C UL & UL listed (File #E211544) listed (File #E211544) RememberRemember - These units do NOT convert - These units do NOT convert line frequency line frequency

http://www.hammondmfg.com/171.htm


5. Steps5. Steps

DocumentationDocumentation

Pull Schematic and Alignment procedurePull Schematic and Alignment procedure

BAMA

www.nostalgiaair.org/Resources/

www.radiomuseum.org

http://bama.edebris.com/manuals/

http://tdsl.duncanamps.com/


More ResourcesMore Resources

http://www.ppinyot.com/ Click on “Links”http://www.ppinyot.com/ Click on “Links”

PHILCO REPAIR BENCH •

http://www.radiomuseum.org

http://antiqueradios.com

http://www.philcorepairbench.com/

USENET GROUP - News:rec.antique.radio+phono alt.binaries.pictures.radio


5. Steps to restoration - Gear5. Steps to restoration - Gear

ISOLATION TRANSFORMERISOLATION TRANSFORMER100w gun, Flux, Solder, sponge100w gun, Flux, Solder, spongeSolder suckerSolder suckerPliers, screw drivers, socketsPliers, screw drivers, socketsVOM DVM impedanceVOM DVM impedanceAlignment toolsAlignment toolsRF Oscillator with modulation toneRF Oscillator with modulation toneFreq meter or Digital SW receiver.Freq meter or Digital SW receiver.Screw drivers, nut drivers etc.Screw drivers, nut drivers etc.Work surfacesWork surfaces



5. Steps to restoration – Chassis prep5. Steps to restoration – Chassis prep

Separate chassis and cabinetSeparate chassis and cabinet

Protect dial glass!Protect dial glass!

Cover speakerCover speaker

Close tuning gangClose tuning gang

Blow off dust outside.Blow off dust outside.

Clean chassis Clean chassis

Fabricate chassis stand.Fabricate chassis stand.


5. Steps to restoration cont’.5. Steps to restoration cont’. Initial checksInitial checks

Check for bad parts made of UnobtainiumCheck for bad parts made of UnobtainiumVarmintsVarmintsBand switch!Band switch!Power transformer Power transformer (Pwr Xfmr) (Pwr Xfmr)

Audio Output transformer (OPT)Audio Output transformer (OPT)IF transformersIF transformersOscillator coilsOscillator coilsPots.Pots.Bias resistors CANDOHMsBias resistors CANDOHMsVariable air capVariable air capAntenna coilsAntenna coilsLow volts Power Transformer checkLow volts Power Transformer checkFull voltage no Pwr Xfmr load check. Full voltage no Pwr Xfmr load check. Tube TestingTube TestingUse the Red and Green pencil on the schematic.Use the Red and Green pencil on the schematic.


Nice Radio?Nice Radio?


Mr. Jingles slept hereMr. Jingles slept here


5. Steps to restoration cont’5. Steps to restoration cont’Selecting and acquiring partsSelecting and acquiring parts

CapacitorsCapacitors– ElectrolyticElectrolytic– Silver MicaSilver Mica– Poly……Poly……

ResistorsResistors– Inductive resistorsInductive resistors– PowerPower

Tubes, Tubes, – Test with Emissions or mutual conductance tester. Test with Emissions or mutual conductance tester. – See See http://www.tpub.com:80/content/neets/14178/index.htmhttp://www.tpub.com:80/content/neets/14178/index.htm

for some tube theory.for some tube theory.– Metal Tubes Pin 1. Tube base size in Philco shields. Metal Tubes Pin 1. Tube base size in Philco shields.


Using GT tubes as substitutes Using GT tubes as substitutes for non-GT tubesfor non-GT tubes

From "Radio News"From "Radio News"Warrn J. Dougherty11/44 Warren J. Dougherty, a serviceman of Kinkaid, Warrn J. Dougherty11/44 Warren J. Dougherty, a serviceman of Kinkaid, Kansas, has called to our attention one of the factors most overlooked when Kansas, has called to our attention one of the factors most overlooked when replacing G-type tubes with the more newly-designed GT tubes. replacing G-type tubes with the more newly-designed GT tubes. Invariably these GT tubes, with metal base, have their No. 1 pin grounded. Invariably these GT tubes, with metal base, have their No. 1 pin grounded. Inasmuch as many manufacturers use all available socket pins for common Inasmuch as many manufacturers use all available socket pins for common tie-points, considerable damage may be caused when grounding the No. 1 tie-points, considerable damage may be caused when grounding the No. 1 pin. pin. A particular case is the RCA Model BT-42 which was originally equipped A particular case is the RCA Model BT-42 which was originally equipped with G-type tubes. When changing to GT tubes with metal base, the with G-type tubes. When changing to GT tubes with metal base, the condenser, C16, 400-µfd. condenser and 1-megohm resister, R7, in the condenser, C16, 400-µfd. condenser and 1-megohm resister, R7, in the plate circuit of the 1H5 should be disconnected from the No. 1 pin of the plate circuit of the 1H5 should be disconnected from the No. 1 pin of the 1N5 tube socket, as in this particular case, it was used as a common 1N5 tube socket, as in this particular case, it was used as a common terminal connector. The metal base occasionally will short out the plate terminal connector. The metal base occasionally will short out the plate voltage from the 1H5 tube, resulting in a nonoperating receiver.voltage from the 1H5 tube, resulting in a nonoperating receiver.

© 1996-2004, Nostalgia Air© 1996-2004, Nostalgia Air


GasGas

Bad Tube


5. Steps to restoration cont’5. Steps to restoration cont’

Wire, hookup, power cord.Wire, hookup, power cord.

Dial glass/plastic, Dial scales.Dial glass/plastic, Dial scales.

HardwareHardware

Cabinet parts for another day.Cabinet parts for another day.


Tubular Axial Capacitors

Metalized Polypropylene FilmGood replacement for Wax/paper caps. Metalized Polyester FilmSelf-healing property

Orange Dips

Metal-Foil Polypropylene Film

•Orange epoxy coated for superior heat, solvent and moisture resistance. •Excellent stability for High Current / High Frequency / Temp. Compensation Applications.

Metalized Polyester Film

•Highly reliable with "self-healing" performance

500 Volt Dipped Silver Mica Capacitors

1 pF to 5000 pF,

Electrolytic Capacitors

Y2 Safety and Interference Suppression

Capacitors


Max capacitor voltageMax capacitor voltageReplacing Wet Electrolytics and High Surge Dry EelectrolyticsReplacing Wet Electrolytics and High Surge Dry EelectrolyticsFrom "radio service dealer"From "radio service dealer"Solar Capacitor Sales Corp.9/44 Properly installed miniature size capacitors can Solar Capacitor Sales Corp.9/44 Properly installed miniature size capacitors can replace wet and high surge voltage dry electrolytics in practically all receivers. To replace wet and high surge voltage dry electrolytics in practically all receivers. To insure satisfactory operation, the circuit surge voltage must not exceed the surge insure satisfactory operation, the circuit surge voltage must not exceed the surge peak voltage of the replacement capacitor (525 volts for 450 volts working). In many peak voltage of the replacement capacitor (525 volts for 450 volts working). In many cases this means series connection of replacement capacitors.cases this means series connection of replacement capacitors.

To determine the circuit surge voltage, temporarily replace the faulty unit by a 1 or To determine the circuit surge voltage, temporarily replace the faulty unit by a 1 or 2 mfd., 600 or 1000-volt paper capacitor. Then connect a 1000 ohms/volt or higher 2 mfd., 600 or 1000-volt paper capacitor. Then connect a 1000 ohms/volt or higher reistance voltmenter across the capacitor. Watch the meter pointer as you snap the reistance voltmenter across the capacitor. Watch the meter pointer as you snap the set switch. The surge voltage is the voltage at which the pointer hesitates after its first set switch. The surge voltage is the voltage at which the pointer hesitates after its first swing before begining a relatively slow decrease to operating voltage as the set swing before begining a relatively slow decrease to operating voltage as the set warms up. This test should be made with the highest line voltage which may occur in warms up. This test should be made with the highest line voltage which may occur in the location where the set will be used.the location where the set will be used.

If the surge voltage is too high for a single miniature unit, connect units of the If the surge voltage is too high for a single miniature unit, connect units of the proper capacitance and voltage rating in series to serve as the replacement.proper capacitance and voltage rating in series to serve as the replacement.

Dry electrolytics with a capacitance as low as two-thirds of the original capacitance Dry electrolytics with a capacitance as low as two-thirds of the original capacitance will usually be found satisfactory when replacing wet electrolytics.will usually be found satisfactory when replacing wet electrolytics.

© 1996-2004, Nostalgia Air© 1996-2004, Nostalgia Air


Carbon Film 1/2 w 5% about $0.07

•Watch for inductance.•High quality performance at economical prices •1/2 & 1 Watt •General shotgun replacement.

Carbon composition ½ w about $0.20

•Use above 18 MHz•5 % tolerance •Low inductance •Low capacitance

Metal Film ½ w about 11 cents

1 % tolerance •Epoxy coated precision resistors

• 5 % tolerance

•Power Supply section.•Cathode Bypass•Candohm replacements

Metal Oxide 1 and 2 watt 12/17 cents

POWER Resistors Wire Wound very inductive.

5 watt $0.37Power SuppliesCandohm replacements

10 watt $0.50AKA Sand, cement, Ceramic, wire wounds


HardwareHardware


Ben Dijkman & [email protected]

http://www.oldradioparts.net/dials_intro.html

www.Radiodaze.com

eBay My World: jmpalm ( 190 )

Dial Scales and CoversDial Scales and Covers

mailto:[email protected]

http://feedback.ebay.com/ws/eBayISAPI.dll?ViewFeedback&myWorld=true&userid=jmpalm



DecalsDecals


6. Parts Identification6. Parts Identification

Waxed paper capacitorsWaxed paper capacitorsElectrolyticElectrolyticMica capacitorMica capacitorCeramic CapsCeramic CapsPolystyrene capacitorsPolystyrene capacitorsMicaMold capacitorMicaMold capacitorCarbon Comp resistors, American, EuropeanCarbon Comp resistors, American, EuropeanPower ResistorsPower ResistorsCandohmCandohmSelenium DiodeSelenium Diode


7. Why Replace good looking parts 7. Why Replace good looking parts

CapacitorsCapacitorsResistorsResistorsPilot lampsPilot lampsWireWireLine CordLine CordFuseFuseDial StringDial StringKnown problem parts (i.e. Philco 370pf, 6X5 Known problem parts (i.e. Philco 370pf, 6X5 rectifier tube shorts)rectifier tube shorts)



CandohmCandohm

Grounded tab



8. Tubes go bad often, NOT.8. Tubes go bad often, NOT.

Tubes last a long time unless abusedTubes last a long time unless abused

Test all tubes - Does it work in the radio?Test all tubes - Does it work in the radio?

Mutual ConductanceMutual Conductance

EmissionsEmissions

Eye TubesEye Tubes

EM34, 6E5, 6E5C, 1629EM34, 6E5, 6E5C, 1629

Sources of tubes, NOS or UsedSources of tubes, NOS or Used


http://www.akh.se/tubes/eyes.htm


Filament voltage boosterFilament voltage booster

Add a B+ switch to extend tube life


9. Replacing Capacitors9. Replacing Capacitors

Test all new capsTest all new capsLeave tubes in sockets!Leave tubes in sockets!Waxed paper caps clip and solderWaxed paper caps clip and solderElectrolyticElectrolyticRestuffRestuffAdd a terminal stripAdd a terminal stripSolder onto convenient pointsSolder onto convenient pointsRF Bypass/UL rated safety caps. RF Bypass/UL rated safety caps. Transoceanic comments Transoceanic comments Silver Mica DiseaseSilver Mica Disease


C46

Transoceanic B600


C40C45

Silver Mica Disease

~90v~90v


C2


10. Resistors10. Resistors

Test all new resistorsTest all new resistors

Clip and solderClip and solder

Combinations parallel and series.Combinations parallel and series.

Add a terminal strip.Add a terminal strip.

Heat dissipation power resistorsHeat dissipation power resistors

Inductance above 18MHZInductance above 18MHZ

Pilot lamps on a rectifier tube filament.Pilot lamps on a rectifier tube filament.


Volume ControlsVolume Controls

High ResistanceHigh Resistance

TappedTapped

SwitchedSwitched

Cleaning/replacement.Cleaning/replacement.

Linear, logarithmic, audio Linear, logarithmic, audio taper.taper.


11. Power Cord11. Power CordReplace it with Zip Cord and a new plug.Replace it with Zip Cord and a new plug.AA5 Hot chassisAA5 Hot chassisAudio Output tube is to be near neutral Audio Output tube is to be near neutral potential.potential.HUMHUMRef. Ref. Radiotron Designer's Handbook, Radiotron Designer's Handbook, Fourth EditionFourth Edition,, P. Langford Smith, 1952? P. Langford Smith, 1952?– http://geek.scorpiorising.ca/RDH4.htmlhttp://geek.scorpiorising.ca/RDH4.html

GFI on an AA5GFI on an AA5Adding a fuse.Adding a fuse.Power Transformer chassis leakage.Power Transformer chassis leakage.


12. Cleaning, Dial cords, 12. Cleaning, Dial cords, Miscellaneous.Miscellaneous.

CRC Contact CleanerCRC Contact Cleaner

Chassis cleaning (Tape tube sockets)Chassis cleaning (Tape tube sockets)

Replace Dial cord.Replace Dial cord.

Grommets for tuning cap and line cordGrommets for tuning cap and line cord

Dial scale replacement.Dial scale replacement.

Speaker cone repairsSpeaker cone repairs


13. Power up13. Power up

Clean the bench first.Clean the bench first.Look at each tube pin, terminal lug and trace Look at each tube pin, terminal lug and trace parts for cold solder joints.parts for cold solder joints.Use an Isolation Transformer even on Use an Isolation Transformer even on transformered units!transformered units!Use a Variac with Use a Variac with – voltvolt– amp metersamp meters

Amp Clamp Multiplier trickAmp Clamp Multiplier trick

Dim Bulb Tester.Dim Bulb Tester.


Inrush Current limitersInrush Current limiters


Initial tests and checksInitial tests and checksTube filament glowTube filament glowSnapping soundSnapping soundMagic smoke.Magic smoke.StaticStatic– Thunder Storm static crashing silenced with volume control.Thunder Storm static crashing silenced with volume control.

HumHum– Tuned to a station swap plug.Tuned to a station swap plug.– No stationNo station– Not affected by volume control.Not affected by volume control.

Check transformer phasing for minimal leakage.Check transformer phasing for minimal leakage.Check all B+ and bias voltages.Check all B+ and bias voltages.


Alignment - Gear RF Generator Alignment - Gear RF Generator

Isolation Transformer time!Isolation Transformer time!Coverage of radios capabilitiesCoverage of radios capabilities– 400khz to 20 MHz 400khz to 20 MHz – HarmonicsHarmonics– 110 MHZ for FM radios110 MHZ for FM radios

IF frequencyIF frequency– 450-470 khz450-470 khz– 225 khz autos225 khz autos– 12.7 mhz FM radios12.7 mhz FM radios

AF modulated toneAF modulated tone


Alignment - GearAlignment - Gear

VTVM or High Impedance DVMVTVM or High Impedance DVM– B+, Line voltage, AGC and Audio OutputB+, Line voltage, AGC and Audio Output

Frequency CounterFrequency CounterDigital SW receiverDigital SW receiverAlignment toolsAlignment tools– IF core IF core

When to use - Wood, plastic, fiberglass, metal, Allen wrench.When to use - Wood, plastic, fiberglass, metal, Allen wrench.– Trimmer capsTrimmer caps

Seal from slipping.Seal from slipping.– Birthday candleBirthday candle– Fingernail PolishFingernail Polish


Alignment - ProcedureAlignment - Procedure

Burn in 30 minutes Burn in 30 minutes No fast moving breezesNo fast moving breezesFollow InstructionsFollow Instructions– IF affects dial linearityIF affects dial linearity– Clean and bake band switchClean and bake band switch– Denatured AlcoholDenatured Alcohol– Bake oscillator and IF coil(s)Bake oscillator and IF coil(s)

Don’t forget to Align dial indicatorDon’t forget to Align dial indicatorUse generator lead draped over chassis, loop or Use generator lead draped over chassis, loop or internal antennainternal antennaWatch max output on HP-606 signal generator.Watch max output on HP-606 signal generator.

Oct 23, 2007 KB3LZP

http://www.nostalgiaair.org/Resources/811/M0014811.htm

AA5Hot Chassis AC-DC Radio.

Oct 23, 2007 KB3LZP

Oct 23, 2007 KB3LZP

Oct 23, 2007 KB3LZP

Oct 23, 2007 KB3LZP

Oct 23, 2007 KB3LZP


Grundig 88U 3 tube 5 sectionsGrundig 88U 3 tube 5 sections

Transformered AC radio


Oct 23, 2007 KB3LZP


Parts SourcesParts Sources

"King Of Controls!""King Of Controls!"

www.dialcover.comwww.dialcover.com

Mark Oppat's Rubber, knobs, buttons

tubesandmore.com

For more vendors see: www.ppinyot.com and follow the “Links” button


ResourcesResources

USENET NewsgroupUSENET Newsgroup

rec.antiques.rec.antiques.

radio+phonoradio+phono

Parallel Resistor Parallel Resistor calculatorcalculator

Converting to a Converting to a 6E5C Octal tube6E5C Octal tube

philcorepairbench.com

DjVu Solo 3.1 Use for BAMA files.

www.Tuberadio.it

www.radiomuseum.org

www.hippy.freeserve.co.uk/e12calc.htm


Philco 38-9Philco 38-9














Thank YouThank You

You can find this presentation on:You can find this presentation on:

www.ppinyot.comwww.ppinyot.com

Links Page.Links Page.

Oct 23, 2007 KB3LZP Tube Radio Restoration Paul from Penn Hills KB3LZP.

Documents

radio slide

kb3lzp introduction

kb3lzp hallicrafters

kb3lzp radio tubes

penn hills kb3lzp slide

surfaces slide

kb3lzp ebay item

tube http