Hallicrafters SR-150 Operation And Maintenance Manual
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Hallicrafters SR-150 Operation And Maintenance Manual

Hallicrafters SR-150 Operation And Maintenance Manual

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See also: Operating/service Instructions
SUPPLEMENT
TO
OPERATION AND MAINTENANCE
MANUAL
Please help me. I
HALLICRAFTERS
can still be a great
performer!!
SR-150
Photo courtesy of W4AWM
By Walter Cates WD0GOF (UPDATE 10/30/2013)
1

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  • Page 1 SUPPLEMENT OPERATION AND MAINTENANCE MANUAL Please help me. I HALLICRAFTERS can still be a great performer!! SR-150 Photo courtesy of W4AWM By Walter Cates WD0GOF (UPDATE 10/30/2013)

  • Page 2: Operation And Maintenance Manual

    But with a little tender loving care it can be brought back to life. For those with little or no experience with the SR-150, where to start, and how to proceed can be a daunting task. One section in this document deals with this resurrection process.

  • Page 3: Table Of Contents

    3-5-5 K3 WIRING AND PIN OUT ..............................30 3-6. PA LOADING COIL L32 ................................31 3-7. RECEIVER GAIN IMPROVEMENT............................32 3-8. RX GAIN ANOMALY ................................32 3-9. MIC GAIN AND AUDIO OSCILLATIONS IN THE SR-150 ....................34 By Walter Cates WD0GOF (UPDATE 10/30/2013)
  • Page 4 3-10. PA NEUTRALIZATION ................................35 3-11. SR-150 FILTER PASS BAND EMAIL DISCUSSION ......................36 4. DATA SHEETS ....................................38 4-1. VFO FREQUENCY CORRECTION ............................39 4-2. RECEIVER PERFORMANCE: ..............................40 4-3. TRANSMITTER PERFORMANCE: ............................41 5. PERFORMANCE SPECIFICATIONS ............................42...

  • Page 5: Sr-150 Refurbishing And Repairing

    1. SR-150 REFURBISHING AND REPAIRING SO YOU JUST GOT AN SR-150 FROM E-BAY OR SOMEONE THAT SAID “IT WORKED FINE THE LAST TIME I TURNED IT ON”. NOW WHERE DO YOU START? THE FOLLOWING PROCESS HAS EVOLVED OVER YEARS OF REFURBISHING THE SR-150.

  • Page 6: Factory Up-Grades

    3 amp normal delay fuse. It is not necessary to start with a low AC voltage and increase the voltage over time to cook the rig. There are no domino circuits in the SR-150. If you have a short somewhere, you may cook a resistor and it will smell bad but it will lead you straight to the problem.

  • Page 7: Carrier Oscillator

    SR-150 REFURBISHING AND REPAIRING CONTINUED: 1-6-1. CARRIER OSCILLATOR: The carrier oscillator is comprised of V10 and its associated circuitry. First thing is to check the output of the carrier osc in both USB and LSB modes. After warm up you should have approximately 30 Vpp on pin 7 of V6.

  • Page 8: Vfo: The Vfo Is Comprised Of V9 And Associated Circuitry, Vfo Correction Circuitry And The Rit/Cal Circuitry

    3 KHz from spec knifing of C32A is indicated (I use 1 KHz for my shop spec). Knifing should never be attempted on the SR-150 unless you are very skilled at knifing. C32A is fragile and can be destroyed very easily.

  • Page 9: Receiver Testing

    ISOLATION section. The Hallicrafters spec states the receiver sensitivity as 1uv signal in for 20db signal plus noise to noise. The gain is specified at 1uv in for ½ watt audio output. It is quite common for the SR-150 to meet both of these specs at 0.5uv.

  • Page 10: Receiver Troubleshooting Table

    SR-150 REFURBISHING AND REPAIRING CONTINUED: 1-8-2-1 RECEIVER TROUBLESHOOTING TABLE. Injection Injection Injection Audio If OK go to next step. If not level** point signal check suggestions below V13 and associated circuitry, Pin 1 V13 1KHz 15vpp watt check K1 switching...

  • Page 11: Final Receiver Test

    SR-150 REFURBISHING AND REPAIRING CONTINUED: 1-8-2-2 Final receiver test. With the ground still connected to the AGC line. With the equipment set up as in step 12 in the table; 1, remove the gnd from the AGC line. If the audio output decreases more than 2db or goes away you have a fault in the AGC and this fault must be cleared before continuing.

  • Page 12: Transmitter Testing

    SR-150 REFURBISHING AND REPAIRING CONTINUED: 1-9. TRANSMITTER TESTING 1-9-1. TRANSMITTER TESTING EQUIPMENT REQUIRED Wattmeter/load 50 ohm 250 watts full scale Scope 100 MHz bandwidth Microphone dynamic 600 ohm Multimeter 2 VDC full scale and 10 VDC full scale recommended Optional telegraph key 1-9-2.

  • Page 13: Tx Drive Fault Isolation

    TECHNICAL INFORMATION section of this document. There are still a few ckts you have not proven. A full alignment will proof the rest of the system. Go to Section 8 of your Hallicrafters INSTALLATION AND OPERATING INSTRUCTIONS manual for the complete alignment procedure. You may check but need not perform the procedures in subsections 8-3, 8-10, 8-12, 8-14, 8-16 and 8-17.

  • Page 14: Tx Bias Fault

    SR-150 REFURBISHING AND REPAIRING CONTINUED: Unkey the transmitter and power down. If the signal is not correct and given that we have already demonstrated nominal receiver operation the possible faults have been narrowed. These possibilities are: relay K1, T6 and its diode switching and the FUNCTION and OPERATION switches wiring.

  • Page 15: Production Run Up-Grades

    R85 and the ground lug of the same strip. boating when sidebands are switched. Change C113 (0.01uf) to 0.005uf, 500v, ceramic disc. Removes transmitted “click” from SR-150 when switching from See section 2-2 for details of click mod transmit to receive.

  • Page 16: Key Click Mod

    2-2. KEY CLICK MOD Key click modification instructions The following procedures outline the modifications necessary to remove the transmitter “click” from the SR-150 Transceiver, when switching from transmit to receive. Remove white/green wire from terminal 4 of terminal strip near tubes V1 and V7.

  • Page 17: Subsystem Technical Information

    3. SUBSYSTEM TECHNICAL INFORMATION 3-1. RIG CLEANING 3-1-1. CHASSIS CLEANING Step 1: I have found all forms of foreign matter in rigs emerging from long term storage. My favorite of cleaning method is the bathtub, Scrubbing Bubbles bathroom cleaner, and the shower hand wand. I set the rig in the tub, back side down, front panel up.
  • Page 18 By Walter Cates WD0GOF (UPDATE 10/30/2013)
  • Page 19 BEFORE CLEANING CLEAN CHASSIS By Walter Cates WD0GOF (UPDATE 10/30/2013)

  • Page 20: Tube Socket Cleaning Kit

    3-1-2. TUBE SOCKET CLEANING KIT By Walter Cates WD0GOF (UPDATE 10/30/2013)

  • Page 21: Air Variable Cleaning

    3-1-3. AIR VARIABLE CLEANING By Walter Cates WD0GOF (UPDATE 10/30/2013)

  • Page 22: Microphone Selection

    2. Most of the Dynamic mics were specified to be operated into a 100k or higher load. Assumptions: The Hallicrafters specs state: The microphone preamp in each rig is hi-Z, either 48K or 100K. They preferred a dynamic mic. Documentation also uses either 4 millivolts or 5 millivolts (RMS) as the standard mic signal.

  • Page 23: 3-3.Vfo Drift

    3-3.VFO DRIFT 3-3-1. VFO DRIFT TEST To eliminate outside effects it is recommended to disconnect the VFO correction ckt and replace the RIT/CAL input with a 9Vbattery. Remove the VFO can cover from the bottom side of the VFO. Locate CR 3 and with a low wattage iron lift one end of the diode.

  • Page 24: Sr Series Rit/Cal Adj Discussion

    3-4. SR SERIES RIT/CAL ADJ DISCUSSION The RIT/CAL ckt is virtually the same for the SR series gear from the SR-150 thru the SR-2000 The CAL function is needed primarily to offset the slight errors in the xtal oscillators. During assembly and test at the factory xtals were hand selected for minimum error.

  • Page 25: Cw Rit Operation & The Sr-150

    3-4-2. CW RIT OPERATION & THE SR-150. I have received these questions many times. “Why is it that the only way I can get satisfactory operation in CW mode is when the RIT is turned on?” Also “I don’t seem to have enough tuning range on the RIT” or “I have to turn the RIT CONTROL almost to its limit to copy code”.

  • Page 26: Relays K2 & K3

    3-5. RELAYS K2 & K3 The design of the SR-150 uses the V13 cathode current in receive mode to do four things. 1: In receive mode to reverse bias CR9 to block the output of T6 which feeds V17 in the TX mode.

  • Page 27: K2 K3 Cleaning

    3-5-2. K2 K3 CLEANING: Spray strip of paper with DeOxit, insert it between the NO contacts, compress the armature and pull the paper, repeat several times. Spray strip of paper with DeOxit, Insert it between the NC contacts, pull the paper and repeat several times. 3-5-3.
  • Page 28 (see drawing below). There is one thing to check before considering this approach. Some K1 relays do not have that contact. The contacts are stacked. So if you have a junk box full of relays and can find a similar relay, you can add the needed contact.

  • Page 29: K2 Wiring And Pin Out

    SUBSYSTEM TECHNICAL INFORMATION CONTINUED 3-5-4 K2 WIRING AND PIN OUT By Walter Cates WD0GOF (UPDATE 10/30/2013)

  • Page 30: K3 Wiring And Pin Out

    3-5-5 K3 WIRING AND PIN OUT By Walter Cates WD0GOF (UPDATE 10/30/2013)

  • Page 31: Pa Loading Coil L32

    150 with exceptional power out on 15 and 10 meters I thought it was time to look seriously into the problem. Not having had any real problems in the output ckt of the SR-150 in the past I have not paid it any close attention.

  • Page 32: Receiver Gain Improvement

    3-8. RX GAIN ANOMALY I had a particularly troublesome SR-150 in the shop. No matter what I did I could not get the gain up to norm. The spec states that a 1uv sig at the antenna shall produce 500mw or better audio output. However the norm for the SR-150 receivers is 500mw or better with 0.5uv or less at the antenna.
  • Page 33 RX GAIN ANOMALY CONT. Now it's back to the initial SR-150. I pulled the control, a rather fun chore. Got on the internet and found that 10kX500K ganged controls aren’t readily available. So I disassembled the pot and painted the landing area for the wiper at both ends of the pot with three thin coats silver paint.

  • Page 34: Mic Gain And Audio Oscillations In The Sr-150

    Recent discoveries indicate it should not be done on the SR-150. This has been the year for the SR-150 in my shop. I have noted a recurring problem. In the RX mode with the audio gain turned fully CCW there will be a faint 2500 Hz to 4500 Hz tone in the speaker.

  • Page 35: Pa Neutralization

    THIS PROCESS. IT IS A PROVEN PROCESS THAT HAS BEEN IN USE FOR OVER 50 YEARS. ALL I HAVE DONE IS SPECIFICALLY ADAPTED IT TO THE SR-150. BEFORE STARTING THE PROCESS, YOU NEED TO TUNE THE TX AS BEST AS YOU CAN AT 21.3 MHZ. AFTER TUNE UP TURN THE POWER OFF AND DO NOT RE-ADJUST THE PRESELECTOR OR FINAL TUNE THROUGHOUT THIS PROCESS.

  • Page 36: Sr-150 Filter Pass Band Email Discussion

    Hi Jim, I have been playing around with the filter and balanced modulator in the SR-150. The specs on the SR-150 state that SSB transmit audio response is 2100 Hz wide. That is, the -3db voltage points are 600 Hz and 2700 Hz respectively.
  • Page 37 This makes good sense for better performance. My only question now is what effect will it have on carrier suppression in SSB? I'll have to test that. Carrier suppression in the SR-150 just does make spec now. However some of that is from not using match diodes in the balanced mod ckt.

  • Page 38: Data Sheets

    4. DATA SHEETS By Walter Cates WD0GOF (UPDATE 10/30/2013)

  • Page 39: Vfo Frequency Correction

    4-1. VFO FREQUENCY CORRECTION BLACK DIAL SPEC MHz TEST 1 TEST 2 TEST 3 TEST 4 TEST 5 TEST 6 4.8519 4.7519 4.6519 4.5519 4.4519 4.3519 By Walter Cates WD0GOF (UPDATE 6/5/2013)

  • Page 40: Receiver Performance

    4-2. RECEIVER PERFORMANCE: Sensitivity The receiver will produce 500 mw audio out with 1.5 uv RF signal at the antenna terminal on the 80 and 40 meter bands. All other bands will produce 500 mw with 1.0 uv or less BAND TEST FREQ SIG REQ FOR 500mw...

  • Page 41: Transmitter Performance

    SR-150 4-3. TRANSMITTER PERFORMANCE: Tests performed with 50ohm resistive load. Measurements made with BIRD avg power and PEP power meter. Hi voltage __vdc B+ __vdc Bias -__vdc Final amplifier bias set to 70 ma SSB mode zero drive. _________ Neutralization performed @ 21.3 MHZ. _______ Carrier balance null (>...

  • Page 42: Performance Specifications

    SR-150 must function between 105v and 125v AC line input. All tests marked with double asterisk (**) are for type test purposes only. Using the PS-150-12 power supply the SR-150 must function between 11.5v and 16.0v DC RECEIVER PERFORMANCE Unless otherwise specified control settings shall apply as follows: RF and AF gain set at maximum.
  • Page 43 PERFORMANCE SPECIFICATION FOR THE SR-150 Standard audio output 500 milliwatts into 3.2 ohm load. Antenna input impedance - 50 ohms (nominal). Audio output impedance 3.2 and 500 ohms. Measurements made with Hewlett-Packard Model HP-606A Test signal – unmodulated CW signal.
  • Page 44 PERFORMANCE SPECIFICATION FOR THE SR-150 **J. Image and Spurious Responses All frequencies other than the fundamental shall be down at least 55 dB on all bands (except I.F. rejection). I.F. Rejection Ratio (6.0 to 6.5 mc) Band Minimum Rejection 3.5 mc 50 dB (300 X) 7.0 mc...
  • Page 45 PERFORMANCE SPECIFICATION FOR THE SR-150 0. Calibration Adj. Limits (RIT control at OFF) The total range of each control shall be at least 3 KC. Clockwise rotation shall increase frequency. Dial Calibration (LSB) The error between adjacent 100 KC check points shall not exceed 1.0 KC With the dial calibration set to zero at the high frequency end of the dial, the error at any point shall not exceed + or - 3.0 KC.
  • Page 46 PERFORMANCE SPECIFICATION FOR THE SR-150 Sideband Switching Frequency Error Limits. The test shall be performed at 14.3 mc. The VFO sideband corrector capacitor shall be set for no more than 15 cps change in carrier frequency between sidebands. Mechanical Stability There shall be no evidence of instability or microphonics under any condition of normal use.
  • Page 47 PERFORMANCE SPECIFICATION FOR THE SR-150 Carrier Balance Limits 1. Carrier balance adjustment shall be capable of at least -50 dB below maximum output level on either sideband on any band. **2. Carrier level shall not exceed -40 dB below maximum output level for one hour after a 15 minute warm-up from start with equipment at room temperature (25 C).
  • Page 48 PERFORMANCE SPECIFICATION FOR THE SR-150 RF Power Output Limits (CW operation) The keying envelope shall be smooth with no sharp peaks in leading edge or training edge transients. With the RF LEVEL control set at minimum, there shall be no more than 2 watts output on any band.
  • Page 49 PERFORMANCE SPECIFICATION FOR THE SR-150 Operation of VOX Delay Control. VOX relay delay shall increase with clockwise rotation of the DELAY control set at approximately ½ rotation. Output Level Meter Check Test at 50 watts output on any band. The S meter shall indicate no less than S-8 or more than 50 dB over S-9...
  • Page 50 The holes for the FINAL TUNING and PRESELECTOR shafts are to be hand reamed to 0.587 min. I.D. All cores in RF coils are to be lubricated and locked after final adjustment using a wax bearing Hallicrafters part number 034-000422 (Biwax #7022 manufactured by Biwax Corporation, Skokie, Illinois.) By Walter Cates WD0GOF (UPDATE 10/30/2013)
  • Page 51 LUBRICATION VFO Assembly Light oil (3 in 1 type) Four nyliners, 077-202301, located in bushings 077-002851. Two nyliners, 077-202301, located in pinion of dial disc, 026-001087. Grease (093-000542) Spur gear, 026-001088 and 026-00089 Gear Bushings 077-002850 Gear pinion 026-001087 Chassis Assembly Grease (093-000542) Rear end of preselector outer shaft, 074-002791-02, and preselector inner shaft, 074-002756-03...

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