Category Archives: Various

HP 6038A System Power Supply: all fixed!

After some weeks, the spare parts arrived – RIFA X2/Y2 rated capacitors (now made by Kemet), a full set (see earlier post, 6038a repair).

The new X2 capacitor, let’s hope RIFA has improved the resin and durability. Albeit, the old capacitors lasted for a long time…

And a fan, from China. The fan, upon close inspection, it has a broken frame, but fair enough, I will use this one while a replacement is on the way.

A lot of dust removed from the case and boards, all completely disassembled. The X and Y capacitors all replaced – the old capacitors are still working, but cracked and it is good practice to replace them, unless, you want to risk a lot of smoke and stench (usually, at least no fire risk).

Always good to use high quality tools – I only have low quality tools here, and bits that crack!

All cleaned and put together…

…finally, some testing. It is working, the fan is providing a substantial amount of cooling, it is definitely big enough for the unit.

HP 3326 Two-Channel Synthesizer: a bad lot of tantalum capacitors

This HP 3326A was found for a ridiculously low price, non-working, so I decided to pick it up, in case I need some spares for my good 3326A, or as a source for some HP parts. But when it arrived, it was in such good shape that a repair appeared worthwhile.

The symptom, it just doesn’t start up, the +15 Volt and -15 V rails shorted. Brief check showed that the power supply is working. There must be a short somewhere in one of the modules. How to find such short?

The 3326A has a cast aluminum cage construction, which houses all the modules in separate cavities, all heavy cast metal! To find the defective module, we first have to undo 100s of screws… and usually the last module will be the one at fault.

Half an hour later – found that both (!) phase detector boards – these are identical for channel A and B – have shorts.

Some more probing later – the reason a couple of shorted tantalum caps, 15 microfarads.

These are in general high quality capacitors, but it must have been a bad batch. So, let’s desolder all the 15 uF caps, and solder in new ones.

Even with the dead caps cut-out, the 3326A is working again! No issues with any of the self tests, including the service self test (push button self test-%-6 to activate).

Some maintenance is also needed on the power supply. Checked all the transistors which are known to develop issues with the sockets. And added some thermal compound to the 5 Volt rail transistor which was running a bit hot.

Also, the connector to the transformer has the typical bad soldering and cracked solder joints, all now re-soldered with a generous amount of good old lead containing solder.

This unit even has option 001, the precision ovenized reference.

There is no manufacturer datasheet available for this Japanese OCXO, but the HP manual has all the data. It is not an ultra-stable timing standard, but by far good enough for a two tone synthesizer.

HP 8754A 4 MHz to 1300 MHz Network Analyzer: an analog computer, and a few rusted transistors

There is no specific need for a 1.3 GHz Network Analyzer in my workshop, because there are already several more modern instruments, but this HP 8754A is a real marvel, it was original designed as a “moderately priced, compact” type network analyzer, whatever was considered moderate by HP at the time (maybe the value of two or three small cars?). Finding the offer for a rediculouly low price, for a non-working unit, on Yahoo Japan, I could not resist to place a very moderate bid. Turns out, I was to only bidder, in whole Japan. My original thought was to use it for some experiments, and then, use it a as a source of HP spare parts (there are many FETs, Opamps, transitors, etc. in this machine).

Once the unit arrived, I powered it up, only to find out two things – the -10 Volt and +5 Volt power supplies are not working. And the CRT is very good and sharp. Maybe not many hours of use. Also, the unit is generally clean and in original condition – no other repair attemped. Even the HP instrument feet were included.

The -10 Volt, it required some troubleshooting of the low voltage assembly (corroded transistor legs), see below. The +5 supply, the issue could be traced to a defective TO-3 HP 1820-0430 integrated regulator, alias LM309K.

This regulator is mounted on an aluminum plate in the chassis, with some rather thick ceramic insulator, and what appeared to be only traced of thermal grease. Usually, these are protected against short and overheating, maybe, it was just running a bit hot for year, eventually, accelerating aging and finally triggering natural/random failure with no external even. We will never know, we only know, we have to fix it.

The LM309K tends to become rare and expensive, I still have some back at the Ludwigshafen, Germany workshop, but not here in my temporary Japanese workshop. Checking the offers, I found some very inexpensive LM323K.

The LM323K, it is a very similar device – just higher current capability. It is not critical for the 8754A, the 5 V rail is only loaded by about 0.25-0.3 Amp (as checked with a power supply).

Now, to the corroded transistors. This only seems to affect the boards thats are close to the air inlet, maybe some contamination from ambient air (salt?) is accelerating the effect, related to gold plated steel wire leg transistor. Other transistors have copper, or special alloy wire, but especially the “4-404” and 2N2222A transistors used by HP in the late 1970s seems to be affected by this phenomenon. Not so much in dry countries, but in instruments subject to humind and salty (sea?) conditions here in Japan – just a few km from the cost in most cases.

The 4-404 transistor, alias SS9333, 1854-0404 HP part number, it is a kind of mystery, no data available, and I have seen this part in may Hp instruments, always replacing them with some 4-404 scavenged from part units, etc. But for the 8754A, should we really buy some expensive old HP parts or wait for a long time to go back to Germany to the parts storage? Time for some characterization – found one good, only slightly rusted 4-404, and did some gain, DC performance and frequency response tests at typical currents.

Some basic data could be found – nothing special, the voltage rating rather moderate, and power rating, as well.

Some tests and calculations, it is medium to high gain NPN transistor. BC337-25 or BC337-40 can be valid replacments, I used BC337-25, selected for a gain of 250-300.

High frequency performance is nothing special, it can be easily met by a BC337.

Several 2N2222A are a bit easier to replace – just replaced the TO-18 metal can units with some generic TO-92 2N2222A (or whatever silicon fragments the mass producers put into the 2N2222A case nowadays).

After these initial fixes, the power is up, and the transistors all good. Initial assessment –
(1) front panel “analog computer” is working, some contact cleaner will do the trick, there is no mechanical damage
(2) the CRT will need a filter, it is missing.
(3) the RF output seems to work, at least there is power – need to check with a counter and properly align the linearity, etc.
(4) The VCO and PLL of the receivers seems to have some trouble, but the samplers are working! That’s a relieve.

See below this is a 35 MHz input signal, sampled with the VCO at about 33 MHz, giving a 1 MHz frequency.

So, what is wrong with the PLL? The PLL, it’s purpose is to have a line of a comb generator/multiplier (which is generating the sampler pulses by a step recovery diode) always 1 MHz away from the RF, to give a 1 MHz IF for the R, A and B channels.

This is achieved by first pretuning the VCO, by setting a frequency close to the needed multiple of the VCO, then the PLL is activated and phase lock achieved.

The phase detector, first, I thought is not working, because there is no proper output. But once desoldered, all the transistors tested OK.

The pretune, also this seems to be working, but hold – it is working too well! It is overruling the phase detector.

Further study shows that there are FET switched controlled by a logic signal, via a LM339 comparator. And, as it turns out, the LM339 is dead (both switches on)…

Temporarily fixed the issue by disabling the pre-tune, and enabling the PLL – and, it does lock (albeit, not a fast sweeps – which needs the pretune). But it works of you slowly increase the frequency starting from 0 MHz (this way, you can even measure as 1000 MHz, phase locked!).

After the PLL had been fixed, still some more issues – the R channel detector is not giving a proper output (switching the A8 and A11 boards showed, that the A8 board, which is the same board but used for the A-B channel is working!). Also some issues with the IF switching of the A/B channel, let’s fix this first. The IF switch is part of the A6 assembly mentioned before (which has the VCO and comb generator-diode pulser). To check it, without any fancy extender boards, you can just solder a few wires to the board. I generally prefer solid core telephone wire, this has a very strong and thin insulation, and doesn’t cause shorts easily, because of the single, solid core.

Also here, a dead LM339! Hardwired it for now to conduct the A channel IF.Ordered some LM339N, 10 pcs for USD 1.37.

Now, a few general views, top view:

You can see the card cages, power supply, and the RF sections with oscillators, mixers, samplers.

The bottom side, there are several dangerous DC voltages exposed, don’t touch!

The remaining issue, fixing the R detector and log amplifier, assembly A11. After some probing and thanks to having a working assembly (the A8 A/B detector assembly), the fault could be traced to the log amplifier, and furtunately, not to the transistor pair, which would be very difficult to source or replace, but to the reference amplifier, U2. This is a simple LM301, alias HP 1820-0223.

The LM301, a really early Signetics model! Unfortunately, it is dead, the inputs are somehow leaking negative current.

I already have some LM301 on order, but for the time being, used an old LM301, slightly rusted that I had desoldered recently from a 4191A power supply.

After all these fixed, the unit’s basic functions have all been restored. Sure, there will be through alignement and check, but I will do this once the LM339 and LM301 have made it to Japan. Checked for other issues, by running the units for several hours – very stable. To track the frequency stability, I used a 830 MHz bandpass filter.

Working!!

Also, the instrument originally came with a plastic printed Smith chart that can be attached to the CRT. Wanted to print one, or have one made by photo printing on lightsetting film. But this is more for decorative purposes, and can be done later.

HP 6038A System Power Supply: A 150 Watt Option (Option 100)

The 6038A is a very capable switchmode power supply, which features great reliability, 10 Amps of current, up to 60 Volts, and 200 Watts – for the regular unit. The unit discussed here is an Option “100” unit, this means, it can work here in Japan, with 100 Volts AC mains voltage (50 or 60 Hz, depends on where you are in Japan…) – at 75% of the rated power, say 150 Watts max.

Well, 150 Watts is fair enough for my purposes, and I got this unit for next to nothing, “doesn’t power on, blows fuse”.

Indeed, the fuse was blown. An it has low resistance when measuring across the mains. Difficult to find the issue.

Looking at the datasheet, it is definitely worth the repair. New, it was around USD 3000 list price (maybe more like USD 5k in nowadays dollars)!

Somehow, I could not find anything wrong with the power board. Maybe a short on the main board?

That’s the main power board – checked all components, no issues, no specific signs of heat or excessive aging. Anyway, we have to take this thing apart for thorough cleaning.

Finally, after a lot of probing – the short disappeared. How can it be? After even more probing – it turned out that the fan (!!) had a hard short. This fan is a SU2A5 fan, quite common in HP equipment of that time, but pretty rare and expensive nowadays, and I really don’t want to fit an old fan, but rather a new part with new bearings.

After quite some study, I found a good offer for a NMB B30 fan, which is quite similar.

Best to compare not only the numbers, but the full pressure vs. flow curve, because the instruments has many cavities and corners, so the flow resistance can be quite substantial. But as it turns out, the B30 design is a high pressure fan, it will meet or exceed the performance of the original part.

Now, we have to wait for the delivery of the fan – at least, I tested the supply without the fan, and it does work and start up. So it is confirmed, the repair will be worth the effort.

Additionally, all the X and Y rated capacitors are RIFA type, of the cracking epoxy-coated series. They will all need to go, and will be replaced with new RIFA caps – hope they have improved the design – at least, these will last another 20 years.

Micro-Tel SG-811 Signal Generator: a second unit

By luck and coincidence, I found another Micro-tel SG-811 generator on eBay, at a very reasonable price – sold as not working. Even non-working, these units are great because of the many microwave components contained: YIGs, filters, GHz-capable relais, SMA cables… and a lot of old-fashioned analog circuits.

First check – the fuse! Someone recklessly put a 10 Amp fuse in, because the smaller fuses would blow. That’s never a good idea. Most probably we will have to deal with a power supply repair.

After detail assessment – the 24 V tantalum cap is shorted, maybe this triggered a sequence of faults: the main primary transistors (MJ12002), the rectifier, and two thermistors that limit the inrush current.

Micro-tel didnt safe on screws when they designed the power supply!!

These power thermistors are hard to get – I just desoldered two similar ones from old switchmode power supplies.

A dead rectifier – easily fixed.

All the parts labeled – also replaced the 2N2222 driver transistors, and two tantalum caps that were leaking current.

The most precious parts – the RF section.

A most complicated arrangement of oscillators, switches, couplers, and so on

Some of the oscillators originally used in these units required a variable supply voltage to get stable power output, but strangely enough, the YIG oscillators fitted have built-in voltage regulators, and the supply voltage has no effect at all on their output. Still, the power supply board caused issues – end even overheated, because the voltage is set by very sensitive trimmers, and drifted above 18 Volt…

The YTO has a voltage protection diode – it was completely fried when I received the unit. Checked some good Advantek YTOs, these have 18 V 1.3 W Zeners for voltage protection.

With power back on, and the voltage at the YTOs OK, still no good output – how can it be? Some issues with the oscillator driver board that sets the current of the main coil, and without a proper magnetic field, there won’t be any oscillation.

The precision resistors, seems they were hand soldered with some bad solder (traces of corrosion, and high melting point).

First, some trouble to find the dead part – thought it is one of the opamps, LM308, replaced it with a OP02. But no luck.

So I changed it back to the old LM308, just to keep all in original state.

The bad guy… a 4051 multiplexer CMOS, these are notorious!

Another interesting assembly, the reference assy – the 1N 827 reference diodes where still very accurately set, only a few ppm of the 11.000 V, and -11.000 V!

After these repairs, and some adjustment, all is back to working condition!

Checking out the signal on a 8566B analyzer. All good!

The pulse generator, also a great feature of this unit… 1 ms pulse.

down to 1 microsecond, no problem.

… 10 microsecond pulse…

The attenuator, a really high quality HP device.

The manual has some remarkable comments – use a 2 kbyte memory, just in case a “really big program” would be needed in the future.

Still, I will do some alignment of the oscillators and filters… but that’s no big deal.

HP 3580A Spectrum Analyzer: Digital display fix, and ancient CMOS circuits

With most of the 3580A functions working again, we still need to fix the digital display. Essentially, the 3580A uses a digital scope circuit, similar to those use in digital oscilloscopes of the 70s.

First, some study of the ADC. The 1973 HP Journal has all the details, it is successive approximation, peak detecting ADC.

Checking the input to the digital display board, blue trace, and the comparator/approximator input to the ADC, yellow. Seems something is wrong with the ADC ciruit, or it’s timing-counter control systems.

After considerable checking and probing, I found the issue, a dead 4019 CMOS, 4×2 multiplexer. Replaced it with a “new” part, taking great care to avoid any static discharge to the board.

The dead part, it is almost a historic piece! 1974, only a few year after the introduction of CMOS circuits by RCA!

That’s the full board. Multiplayer construction. Plenty of precision resistors that are needed for the ADC circuit.

Another working antique part – the 2102 S-RAM, Intel, 1 kbit per circuit. 8 pieces – a total of 1 kbyte of SRAM!

Working display…

10 kHz reference display… Great!

Even the log scale scan is working.

One tip – put all the screws and parts in a box, and check that it is empty afterwards. So many instrumented I receive here in the workshop are missing some screws or other parts.

HP 3580A Spectrum Analyzer: a few mechanical repairs, and sweep test

With the basic functions of the 3580A restored (at least, it is sweeping again), some attention needs to be paid to the mechanics. Fortunately, all is good with the intricate tuning assembly and digital display, but the knobs have some cracks, probably, a combination of age and stress.

Everything taped up, and the cracks filled with rapid-set epoxy resin.

To apply the resin to the small cracks, you can use a piece of stiff plastic foil, cut to a tool of appropriate size –

Here, a few close-ups of the tuning mechanism. It has fast tuning, and fine tuning, a clutch, several gears – all good old analog technology.

Finally, some test of the sweep circuit – but how to test a 200 second per division (i.e. 2000 second per screen) deflection for accuracy and linearity? Well, I connected it to a 34401a multimeter, and recorded the values for several hours by GPIB interface.

As you can see, the sweep is very linear, only some minor deviation at low voltages (maybe connected to some offset voltages or similar effects of the operational amplifier), at least, we can’t see any leakage current of the capacitor, which would show up as increasing sweep time with higher voltage/later divisions.

Also interesting, see the accuracy of the sweep speed, with warm-up of the instrument (each measurement is 2000 second). Still, after all these years, well within the 5% specification of the sweep time! Amazing!

HP 3580A Spectrum Analyzer: a non-working marvel of engineering

The 3580A is a audio spectrum analyzer of the 1970s, and not only useful for audio, but anything that can be converted to audio frequencies (e.g., noise analysis of GHz sources, provided, you use the appropriate mixers). This marvel is not a FFT machine, but a discrete audio “received”, using a low-noise local oscillator, and covering a frequency range from 5 Hz to 50 kHz. The resolution filters are quarz filters, with bandwidth down to 1 Hz! Dynamic range is over 80 dB.

The device, it comes from my old university, and has been sitting there on the shelf for a while, not working. And in fact, it shows not many signs of life, it is not sweeping properly, and even in manual mode, it is not working reliably (not showing any reasonable signal, but there is some activity on the tracking output which suggests that the instrument is not all dead, also the “overrange” LED is working).

After some study and test it became clear the the issue is with the ramp generator. Unfortunately, it is not a simple ramp generator, as you can see below.

The main circuit is a capacitor being charged by a current source (mechanical switch with resistors).

The voltage at the main capacitor, a 10 µF polyester hermetic cap (really high end with glass seal and metal case), is charged and its voltage amplified by a FET-opamp (the FET input constructed from a discrete FET pair, and a PTFE stand-off to keep this all really high impedance).

All the sweeting action is controlled by a state controller, more or less, a hardwired program with several TTL chips. It took me quite some study to understand how it is supposed to work. But fact is, it doesn’t. Clearly, the issue is with the A3 assembly. This must have been quit an expensive assembly at the time, with all the FET pairs and opamps. Still today, not an easy thing to fix.

At least, it is a beautifully arranged board, all gold plated and really smells like quality. So it is worth some time and effort to fix it.

Key for such repair, at least in any reasonable time, are a set of good schematics. Fortunately, I have a set around and printed out really large copies – it is worth the effort, because without making some notes, you will struggle to keep all in your brain and still work on the circuit.

With no extender board available, just soldered some wires to the board to monitor the state of the main state counter, and some of its inputs.

Hmmm, after a lot of probing, I was almost tempted to replace a good part of the TTL chips, because it is really hard to find the defect in such a complicated and loop-wired logic circuit, including its analog parts.

But after a bit more consideration and test, I decided to try a step-wise approach, starting from the most likely parts causing issues. One of the 7473 dead, no problem, there are spares around. But the next one – a 7472! This is an AND gated J-K flip flop, with three inputs to each AND gate… in simple words, something old, exotic, and rarely used. Went through all my piles of old boards and ICs, but no 7472 to be found! Quickly arranged a temporary 7472 – from a 7411 3-input AND gate and a 7473 flip-flop.

To be sure, I tested to old 7472 – indeed, it is not working.

With the A3 board temporary fix, a quick test of the unit.

Unfortunately, still some issues, but is is sweeping:

Display issue:

Check with a X-Y scope (on the rear outputs of the 3580A) – all seems good from the analyzer section, maybe some issue with the storage display?

Finally, on xbay, found a set of 5 pcs 7472 at a reasonable price, from Spain! NOS (=new old stock), about the same age as the 3580a!

Some fluxing issue with the soldering of the old ICs (clearly seen at the 7473), beware! Use some good flux, or solder from both sides.

Meridian 506 CD Player: a hot driver

This report is about a really high-end (made in UK) compact disc player – a Meridian 506.
It had some issues with the drive circuit, with the TDA2030 running hot, and sometimes not reacting to the front panel control.

The drive mechanics, it is a quite simple setup – a DC motor with pulley arrangement, and rubber ring.

The cooling plate – just a small piece of metal. Running all good when when the CD compartment is opened and closed quickly, but there will be issues if for some reason the CD deck is not closing quickly – motor switch-off is controlled by the end switches.

The main driver is TDA2030, and an additional issue is the closeness of the heatsink to the metal case. Just some Kapton tape, which had some damage already. Maybe making contact at times (tab is connected to Pin 3, VS-).

Added a big heatsink the TDA2030, which is now also well-insulated from the case.

All working fine again!

The TDA2030 – it’s not a motor driver, but an audio amplifier by design. But essentially, it is a high power opamp, so it can be handy to control motors, coils, etc.

I also made use of the opportunity, please see the zip file.

meridian cd player 506 firmware

You can also find a collection of Meridian schematics in the manuals’ archive: Meridian Schematics, please request the password by email if you need access.

Auna AV2-CD508 HiFi Amplifier: start-up power supply repair

The Auna AV2-CD508 is a quite nice and affordable amplifier, the case is pretty solid, aluminum front, steel case, and the controls are all easy to operate.

It’s a “600 W” peak amplifier, but won’t take more than 80 Watts, so it is more likely a 2x 40 W amplifier – still, 40 Watts are a lot of sound power.

Unfortunately, this set reached my workshop for repair, symptom: it doesn’t switch on, no signs of any activity. After some measurements, the fault is found it the auxiliary 5 V power supply, this is always on, to power-up the main power supply and the rest of the circuit. The auxiliary supply is controlled by a SF5922S switchmode controller, SO-8. Unfortunately, this part is only available in China, and doesn’t seem to last anyway, so I removed the power supply control, and added some wires to an external supply.

… the external supply, a 5 V power supply. Also used it to measure the current. Turns out, the auxiliary supply only needs to provide some 100 mA of current, not a lot.

With the lab supply connected, and the Auna plugged in, it powers up OK and all working!!

That’s the amplifier board, solder side. The auxiliary pwr supply controller marked in red.

With such a device, better not lose too much time, and I decided to add a completely new 5 V supply, from a leftover 5 V power adaptor.

These are the main amplifiers – CD1875 aka LM1875. These are not bad, and can reach -60 to -70 dB distortion, and are generally known as reliable parts.

Some distortions measurement, at two power levels…

… not too bad!

Gain, it’s not quite flat, but OK for the purpose.

Finally, with the new power supply, the Auna has a second life, most likely, even longer than its first.