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    of 19
    HRSA. RADIO WAVES, January 2017 Page 21 POWERING BATTERY AND VIBRATOR RECEIVERS | Part The MkIV, MkV and MkVI power supplies by RODNEY CHAMPNESS ‘THE DILEMMA OF SUPPLYING POWER powered receivers in our eollections. It is a different matter and often quite a challenge fo power valve receivers that are not designed for use from the mains, such as battery and vibrator powered receivers. E IS EASY to power 200 to 260 volt AC mains The first receivers dating from the 1920s were battery powered, as suitable valves and power supplies had not been developed to utilise AC mains power. In remote and some not so remote areas, mains power was unavailable. ‘This meant that until the end of the valve era in the 1960s receivers had to be battery powered, either by using separate batteries for the filaments, bias and high tension ‘or by power supplied by vibrator power supplies from lead acid batteries. Also, because they were often in remote locations battery sets had to be quite sensitive, Lf battery and vibrator sets are to show their ‘stuf? today 1 power source that could replicate the original power sources is needed, whether to replace dry batteries or lead acid accumulators. How can we power these various, battery receivers? ‘The requirement is to provide a variety of output voltages of pure DC at appropriate currents to suit different makes and models of receiver and to provide up to half a dozen different voltages all at the onc time, ‘This may seem a daunting task, For example the voltages required may be 2 volts at around 750 milliamps (mA), 133 volts at 15 ‘mA, 67.5 volts at $ mA, and bias voltages at -1.5 volts, -4.5 volts and -9 volts all at virtually zero current. Another set may require 1.4 volts at 300 mA and 90 volts at 13 mA, and a very old TRF set with half'a dozen 201A, valves may require 5 volts at 1.5 amps, and several different HT voltages ranging from 22.5 volts to 135 volts as well as several bias voltages up to -9 volts snd sometimes higher. ‘Vibrator power supplies became common as the cost of recharging a 2, 4 of 6 volt lead-acid battery was much HRSA. RADIO WAVES January 2017 (eee spear sia less than the cost of purchasing 2 batch of dry batteries every few months, These household vibrator sets require currents of 0.7 to 2 amps. Can all the voltages and currents necessary for battery and vibrator sets be provided by one ‘black box"? T have checked through the Australian Offielat Radio Service ‘Manual (AORSMs) and it appears more than 99.9% of battery operated household and portable sets listed, as well as most battery sets prior to 1937, can be powered by the supplies about to be described, Car radios and 32 volt receivers are excluded from this statement, since their dedicated 6 volt, 12 volt and 32 volt DC supplies that ean deliver up to 6 amps at 6 volts, or 3 amps at 12 volts and 2 amps at 32 volts are necessary for this purpose, THE GENESIS OF A BATTERY ELIMINATOR STARTED building battery eliminator power supplies back in the late 1970s when I built supplies to power Ary battery powered portable WWI military transceivers jin my possession, Today batteries are seen mostly 9s exhausted passive display items. Now there are few if, any batteries available for valve battery radios. 1 believe that many eolleetors and restorers have shied away from battery and vibrator receivers as they had no means of powering them, [ built my first supply, the Mk I, for domestic receivers in 1991, and it has given sterling service ever since. Subse- quent versions have enhanced facilities and the Mk IV is 14 most satisfactory unit, However, Ian Johns alerted me to the fact that a number of components depending on supplier had specifications, etc that varied considerably from the original published specifications, which meant they were unsuited for the supply. The key component ~ the 2156 power transformer - used as the main trans- former in the supply was no longer available’ with a 7.5 ‘volt tapping, which was essential to the design. It would appear that only the Diek Smith version had the 7.5 volt tapping. The Mk IV design can be used if people want information on it BATTERY ELIMINATOR SPECIFICATIONS LETTING the supplies to the stage where they ean be replicated with confidence has taken some time. ‘The wise counsel of lan Johns in the earlier design stages ‘where he pointed out that some components from differ- cent suppliers had slightly different specifications to the ones I had, even with the same type numbers proved to be a probiem, These variations had to be taken into consideration and meant a complete redesign of one section of the supply. Ian also spent many hours working with me by remote control on the PCB layout. Without his help and that of Alen Runsley and David Waring the supplies may not have seen the light of day except as a ‘one off for my own use, Tthank all three for their valued help. ‘There are four semi-independent power supplies built into them, It is necessary to supply filament power (A battery LT) with one supply providing 1.4 © 6 volts, ‘whilst another supplies 7.5 and 9 volts. These two have a common negative bus. The high tension (B battery HT) supply provides up to 135 volts, and bias (C battery) voltages up to -22 volis are supplied, The filament supplies are quite separate from the bias and HT supplies so that cither the positive or negative terminal of the filament supply can be connected to earth of lef floating. {All sections of the supply are floating and are not earthed to mains earth, although they can be. There is a 0.01 wF capacitor from the ‘earthy’ point in the filament supply ‘and another from the bias/ht ‘earthy point to mains earth. ‘The power transformers have their frames earthed to the ‘mains earth ‘The voltages at the output terminals of each supply section will be within +5% of the specified value. Some selection of zener diodes may be necessary to maintain voltages between these limits, Lower than nominated voltages can be applied to sets to see just how they work with reduced voliages, as occurs when the battery supplies are nearly flat. This is a handy test tool The key high tension supply voltages are nominally regulated at 22.5, 45, 67.5, 90, 135 volts and because itis available 112.5 volts and all of these can be used at the fone time provided the total current drain does not exceed around 20 mA, although this can be increased to 25 mA if required. Voltages such as 60, 120 and 150 volts have been used in some sets and with little modification the unit could supply these, to. HRSA. RADIO WAVES, January 2017 The bias supply voltages are nominally regulated at «1.5, 9) volts and can supply a variable bias from -9't -22 volts, and all of these can be used at the one time, The bias supply can provide around 4.5 mA which suits most class B stages using valves, such as the 19 or 1166. The main filament supply can supply 1.4, 2,3, 4,5, and 6 volts regulated at up to 3 amps continuously from the Mk YV and 1.5 amps from the Mk VI if no other parts of the | supply are drawing current and the HT is switched off. Another independent lament supply line can provide ‘or 9 volts for receivers that have series connected S0 ‘mA filaments such as the 14, 3V4 series valves, as are used in battery’mains powered valve portables of the 1950s as well as many transistor sets. It can provide up to (0: mA with a suitable heat-sink attached to the LM317 regulator, The lower filament supply voltages can only be provided one at a time from the supply, for example 2 Volts or 5 volts but not both atthe same time. ‘The supplies have been designed to operate on mains voltages between 200 volts and 260 volts and to do so ‘without overheating on hot days. However, the actual power that a supply uses climbs with inereased mains voltage hence the LT output currents have to be reduced {to compensate for this so that not more than 60VA is drawn from the mains by the larger transformer in the MK V. The Mk VI which uses an old power transformer from a $ valve mantel or radiogram receiver is likely to have a rating between 40 and 60 VA. Check what the claimed power drain was for the receiver, then measure it vsith one of the plug-in watt meters s0 that you can be sure the transformer ratings are not being exceeded. The current drain on the HT’ and bias lines remains constant ‘no matter what is applied to those lines, GENERAL CONSTRUCTIONAL INFORMATION FORMATION on the design of the supplies and construction ideas follows in Part IL of the article. A printed circuit board is available for constructors and it accommodates most of the components, This makes construction easier. Using the PCB will ensure fewer wiring errors are likely to occur. In addition a kit of components for the board and a few small items off the card are also available, The boards and kits will be supplied with the required information as printed in this nid the following article. See my advertisement on age 24 The PCB is designed with mounting holes that suit the Alronies HO482 and Jaycar HB-5910 plastic boxes or with a squeeze into the next smaller box. The complete jpply will fit easily into the larger boxes but the MkVI cay not fit into the smaller boxes. The PCB mounting oles for all four boxes are accommodated. It is neces- sexy to trim several of the mounting pillars underneath where the printed circuit board is mounted, as some pillars ate immediately below soldered joints and the >oard cannot sit evenly on the pillars used t© attach the PCB to the cabinet. Note the Q2 (the output series loser transistor) does not mount on the PCB but is connected by short wires leading to the heat sink. Constructors can build a supply into a convenient cabinet that they have on hand. The supplies are adaptable, using, readily available components and not end of run parts, ‘They can be constructed to suit a particular set, but for a little more cost they can power virtually all domestic battery valve receivers without having to ‘program’ them to do so, As there are several semi-independent supplies fon the one beard and iff you only require one section that will save on cost and you have the convenience of a printed circuit board. tis not intended to supersede Tony Maher's battery radio power supplies as each fills a particular niche. It is very important if New Old Stock components are used that their leads are thoroughly cleaned of tarnish to censure that solder will take to the leads. Baddry soldered joints will either cause the supplies not to work or to be intermittent, As most of us are getting older our eyesight may not be like it was, so the use of a strong light and a ‘magnifying headset are almost essential to check the legrty of any soldered joint particularly on the printed citcuit board. I strongly recommend that you read Rod Humphris's article on soldering on page 19 of the October 2016 issue of Radio Waves. As there is a spread in component sizes and pin spacing ‘the board mounting holes may not always quite match up. Make sure that the components you mount are the correct ‘ones for the position selected and if they are polarized like diodes and electrolytic capacitors ensure that the polarity is correct. If you are unsure of the resistor code used, measure the resistor with a digital multimeter Page 24 HRSA. RADIO WAVES January 2017 FOR SALE: The printed circuit board and parts kit for the MKV and MkVI power supply are availaole and suit both Marks. The supply provides all voltages required for most if not all battery powered radios from the 1920s (including sets using up to 10 201 valves) to the last of the battery valve radios Produced. Vibrator sets requiring 4 or 6 volts at up to @ maximum of 3 amps are also catered for. It does Not cater for car radios or 32 valt receivers. My research indicates that 99.9% of battery powered radios in the AORSM manuals can be powered by this supply. 20 voltages are available at various Current ratings to suit low tension (A), high tension (8) and bias (C), of which 14 are available at any one time. The Mk V provides 3 amps LT current and the MKVI 1.25 amps, the HT and bias supplies are ident- cal. The MV! is considerably cheaper to build. See my article in this issue January 2017 or if not Printed In this issue, following issues for full details on this supply. Gircuit Board is $20 plus postage, The circuit board and all the components that mount an the board, plus a few small components not mounted on the board, $70 posted in Australia. Most components are now with @ few New Old Stock items. You will need to clean the leads of these so that solder will take. The board and kit will be supplied with cirout end informa tion. Large items such as the cabinet, transformers and easily obtainable items, some available from your junk box are not included in the kit. Available from Rodney Champness (Member 0512), 6 Mundoona Court, Mooroopna, Victoria, 3629, E-mail rodlynn6@bigpond.com ‘Phone 03 5825 1354, The circuits of the two supplies have all the components and eireuitry on the printed circuit board drawn in black, ‘The components and cireuitry in red are all external to | the board as are the power transformers. The red | numbered circles are the termination points on the printed circuit board and the numbers shown identify which part of the circuit each point is connected to. The ‘numbers on the citcuit at these points are replicated on the board but are prefixed by’, ‘The next instalment of the article shows the schematics, | describes how the various cirewits work and how adjust them for voltages to be within the 5% specified, as well as questions and answers on the supplies Letter to the Editor DEMOCRAT PORTABLE {rom John Wagener {recently acquired this little Democrat farm radio’ at one of our radio meets. It is a battery portable and I cannot find any information on it Thave seen a few ae versions, but this looks almost like a one off, It is basically complete although missing the loop aerial which would connect to the two brass terminals. The litle handle on top sets it apart trom the few AC versions [ have seen in photos. Its certainly tiny and I can only guess where the batteries would be located. I wonder if another one is in existence. I would like to see a few pics if they exist, Ithas an all-states dial layout but SA seems to be the dominant one. tis a cute little radio, John Wagener Page 24 HRSA.RADIO WAVES, April 2017 POWERING BATTERY AND VIBRATOR RECEIVERS by RODNEY CHAMPNESS Part Il The Mk IV, Mk V and Mk VI power supplies Component numbers and specifications have S INCE PART Tf his se wos publi ey |The Mk changed as modification have shown tobe benef HE LOW TENSION (1) supplies are conventional cial for constructional ease and generally improv- | 4 The rectifying system uses a bridge reetitier with « ing the specifieations of the supplies, Once again I wish | centre tapped transformer arrangement 90 ~ 9 volts to (o acknowledge the valuable assistance T had from lan | obiain up to 13 volts atthe junction of C2, with CS and 6 Johns in Canberra for PCB design, suitable components | and a voltage of up to 27 volts is obtained on the positive and circuit ideas. Valuable assistance on a local basis | terminal of C2 when the mains voltage is around 260 was provided by Alan Ransley and David Waring. | volts and down as low as 20 volts with 200 volt mains Without the assistance of these people, the power ‘SPECIFICATIONS ripple S my standard wiring, 1 mv with negative track modification, Auxiliary LT 7.5, 9 volts @ 250 ma (higher with bigger heat sinks) Bias $1.5, -3,-4.5.+6,-9 and -9 to -22 volts @4.5 ma continuous HT - 90, 112.5, 135 volts @ 25 mA continuous MKVILT 1.4,2,3,4,5,6,7.5,9 volts @ I to 1.25 amps continuous depending on transformer used., ripple 5 my standard wiring, — Imv with negative track modification, Bias 215, 3,-4.5, -6,-9 and -9 to-22 volts @ 4.5 ma continuous HT 22.5, 45, 67.5, 90, 112.5, 135 volts @ 2Sma continuous Ripple on HT and bias circuits negligible in both versions Voltage regulation is within +5%, usually nearer + 2% regulates the voltage down to 7.5 or 9 volts at up to 250ma, more with a larger heatsink. Note LINK on the oard is permanently wired in place and link 2 is wired in place and link 1 is Teft open cireuit, THE DESIGN - Low Tension The Mk IV HE MK TV will not be described in detail. Its 1.4 10 6 volt LT circuit uses an AZI084-ADJ three terminal With the 13 vole maximum there is quite abit of head room forthe operation ofthe main LT egustor ie S amp low voltage atop out regulator. Iis nt posite wo | but this reduces conerably ten he rai ae 200 haw high cuenta 6 volts the supply voltage drops | volts and the vatage nrots C3 and 6 auld be 10 che too low to the regulator for proper regulation, The | before the ctu i fedlng any nds Whore any nd AZIO84-ADI hs only a 13 vot tating between input |i applied thre wil be considerable pple onthe crgly and output so as only ste to ise when #.75--073 | and'e crops ts sn setae DE ech raha ese volt wansformer wat available, the Diek Smith 2156. | The peak wil sll be peaking a 10 volts othe aun The second LT supply giving 7. and 9 volts isthe same | the voltage on CS and 6 will case to dep vole as used inthe Mk V. it HT circuit is also the same | tore te rectifier san condecting agama ene onto "hat wed in the Mk Vand MVE Should anyone rei | maximom of 1 elt between the all oles 8 copy ofthe icity ofthe MKIV Lean supply it The | smoothed 6 volt oupi, which is safeent or ts Ine Printed ciruit board fr the Mk and Vi wl ls work | drop oot iveuit wed to work effecinety, No ead inthe Mie1V with some madieaton, | avalable and suitable 3 leg low drop-out regultos were : Able tobe obisind | ME CIRCUIT is one which 1 have se in varios omar ever yes and as rove aie Us | HRSA. RADIO WAVES, April 2017 Page25 ‘SPECIFICATIONS OF THE MAIN LOW TENSION SECTION. Specifications:- 245 to 250 volts mains with LT output at 6 volts. Drawn from mains, Maximum 30 watts (limitations on current drawn 60 watts NoHT on, With HT on. MKIV 2.2 amps 17 amps from the LT section on the 5 and 6 volt ranges as ripple becomes pronounced) MK V 3.5 amps 3.0 amps Mk VI 1.25 amps (Gee notes) 1.0 amp (sce notes) 40 watts (AWA 19505 mantel) isa 7SLOS 5 vole regulator. Its output is applied through a switched voltage divider network to give & proportion of | this voltage to pin 3 of U1A a LM3S8 operational ampli jer. In this circuit it is used as a comparator and a sample of the output voltage is taken fiom the moving arm of RVI which is applied to pin 2, If the voltage on pin 3 is higher than that applied to pin 2 the output at pin 20¢8 hhigh and caused Q3 to conduet which then also causes QI to conduct, and the output voltage will rise. Once pin 2 rises to approximately the same as pin 3 of UIA the voltage at pin 1 will stabilize at a value that maintains the output voltage selected even if the current awn alters. If the output voltage is too high UIA will switch off until the output voltage decreases to the prede-

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