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  1. #11

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    Bob, you may want to see if you can reinforce the pins by damming and flowing epoxy to add a structual element to the connector (the one that was cost engineered out...)

  2. #12
    Nicholas Lindan's Avatar
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    Quote Originally Posted by Bob-D659 View Post
    I'd give the connector pins a very close inspection
    That problem isn't so bad with PTH 2-sided boards, but is a big problem with single sided boards.

    If a single sided board fails then 99% of the time the problem is a cracked trace or solder joint. Often the connector pin or the lead on a heavy component lifts the pad and the foil cracks where the trace meets the pad. The other problem is that there is not enough solder to form a good fillet between the pin and the pad and an annular crack forms where the solder bridges from the pin to the pad.

    Examine the pads around the transformer pins for solder cracks, broken traces and lifted pads. The transformer pins should be clinched (bent over tightly) as there is no hardware securing the transformers to the board.
    Last edited by Nicholas Lindan; 03-10-2009 at 09:36 PM. Click to view previous post history.
    DARKROOM AUTOMATION
    f-Stop Timers - Enlarging Meters
    http://www.darkroomautomation.com/da-main.htm

  3. #13

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    Quote Originally Posted by epatsellis View Post
    Bob, you may want to see if you can reinforce the pins by damming and flowing epoxy to add a structual element to the connector (the one that was cost engineered out...)
    No need, the tranny is 99.99% worn out and the car just had it's 21st birthday.

  4. #14
    ic-racer's Avatar
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    Hey guys thanks for the posts. Realize that in the first post some of the 'problems' with the units are intermittent. For example, the one that blows bulbs is adjusted right to spec at 80.0 v and the few other voltages on the schematic are in spec. Bob-D659, on that board, BTW I did find a cold solder joint on the connector leading to the lamp. I also put in a fresh TRIAC, and saw that the old one was not making good contact with the heat sink. I used that board last night and no blown bulbs so that board may have had its life-span extended.

    The schematic does not give any useful voltages or document appropriate signal behavior. In terms of the service manual, the board is treated as a 'replaceable item.' Another issue is that access to the board is very limited once it is in place in the head. Extended jumpers and 'breakout' boards would need to be constructed to do any major diagnostics to this board. I did look into turning my 'spare parts' head into a test dummy just to test this board as I agree with you all the it is probably some 5 cent part that is amiss, however, constructing a 'test head' would be quite a project in itself.

    As I stand now the 'spare' board is already stripped and IC sockets are in. So once the parts arrive I just need to plug in the ICs and add the few resistors and caps.
    Last edited by ic-racer; 03-11-2009 at 01:58 PM. Click to view previous post history.

  5. #15
    ic-racer's Avatar
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    Just for interest, here is the schematic for the board.


  6. #16
    Mike Wilde's Avatar
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    I second the comment about the electrolytic caps. I have rebuilt three Vivitar timers and process controller power supplies, circa early 80's The caps dry out and go flaky. The other area of concern to look at are zener diodes, and thier pull down/pull up resistor. If the resistor at OEM time is too small, it will burn out and all sorts of wierd voltages then appear. I have replaced them with voltage regulators.
    my real name, imagine that.

  7. #17
    ic-racer's Avatar
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    Another thing that may not be evident (unless you own a D5500) is that this power supply board lives up in the lamphouse. In fact the thermal overload thermistor is on this board.

    That big orange electrolytic capacitor has a date code of 1983 on it and this unit came from a busy lab. So, I suspect every component on the board has had a rough life.

    I was looking over the components I removed and I did find a fried 27 ohm resistor leading to the power pin of the IC U14, which contains a bank of general purpose transistors. It still reads 27 ohms and its not likely the cause of the light not working, but just an example of how every component on the board has likely been stressed.

  8. #18

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    Reconditioning a 5500? Isn't that a little bit like doing a ground up resto on an AMC pacer?

  9. #19

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    Quote Originally Posted by frotog View Post
    Reconditioning a 5500? Isn't that a little bit like doing a ground up resto on an AMC pacer?
    To us D5500 aficionados them' fightin' words

    Bob H
    "Why is there always a better way?"

  10. #20
    ic-racer's Avatar
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    Quote Originally Posted by frotog View Post
    Reconditioning a 5500? Isn't that a little bit like doing a ground up resto on an AMC pacer?
    I do not know (the last car I restored was a 1979 Ferrari) but some one must know the answer

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