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Flashlight to Flashing Light August 2014

I have a small LED flashlight that I mount on my handlebars while riding my bike at night. I've seen some people put a flashing white light on the front of their bikes. Is there a circuit to convert my "regular" flashlight to a "flashing" flashlight?

#8144
Sandy McCain
Fullerton, CA



Answers

When I read the question, I remembered that RadioShack sold a blinking LED but in red (part 276-0036). I bought the LED, and testing the current flow while it was blinking, I discovered that the IC inside reduces the current to less than 0.03 mA (30 µA) when off, and conducts over 40 mA when on. So you can buy the blinking LED and add it in series to your LED flashlight. When you turn the flashlight on, the red LED will blink, and make the main LED blink, too.


You will have to open the bicycle flashlight to wire the blinking LED in series to the white LED. This LED can handle up to 5 volts and up to 80 mA (as printed on the package) with no additional components. If you do a web search on the part number, you can find other bicycle projects using the same blinking red LED to flash an array of nine red LEDs for the rear light.

Raymond Ramirez
via email

There are a number of different multi-mode LED flashlight driver modules available, many of which include flashing modes. Check out the selection at dx.com. Make sure to get one that supplies a current appropriate for the LED in your light. They also carry complete lights based around similar modules which might be easier than trying to modify your existing flashlight.

James Sweet
via email


iPod Battery Reconditioning August 2014

My son has gifted me with his cast-off iPod Classic 30gb player. Unfortunately, the battery life is only about 15-20 minutes of playing before it goes dead. Does anyone know of a way to recondition the battery?

#8143
Wendal Haynes
Memphis, TN



Answers

I had one of those (30 GB Classic iPod) and the best thing you can do is simply buy a new battery for $5 - $10 on eBay. You can even get a kit with tools to help you take it apart (that's the $10 end). It's easy to take apart that iPod, there are several YouTube videos to help you do it.

Steve Jacob
Tucson, AZ

The first iPods were famous for the irreplaceable battery, and they are extremely hard to open. IFixit considers the iPod Classic battery replacement "Very difficult", and you can find some YouTube videos on opening and replacing the battery if you dare to do it yourself.


If you wish to continue using your son's iPod Classic as a portable music player but don't want to risk damaging it, consider attaching a portable external battery. If your iPod Classic uses a USB cable to charge, then buy an external USB battery which can supply 5 volts and at least 0.85 Amps (850 milliAmps). Some are as large as the iPod, so just tape it back-to-back, and use the shortest USB cable between them. They are rechargeable from any other USB port, and will be useable with smartphones if you desire to retire that iPod.

Raymond J. Ramirez
Bayamon, PR

Forget the old battery and buy a new Lenmar Replacement Battery for iPod Classic 5 G (30 Gb) This battery replaces 616-0230 and EC008-2. Amazon carries them for around $15. The Portable Rechargeable Battery Association (PRBA) highly recommends against using reconditioned lithium ion batteries and I would assume this also applies to lithium polymer batteries due to their propensity for catching fire. I found one web site that advocated a repeated freeze and charge process but for $15 i would buy a new, known battery versus trying to resurrect a possibly defective unit.

Tim Brown PhD EE, PE
Honea Path, SC


Help Identifying an Old Robot August 2014

I picked up an old robot chassis at an estate sale for $25. I have taken some pictures in the hope someone might be able to identify the make/model for me.

#8142
Jaime Smithers
Las Vegas, NV



Answers

You have an RB5X from RB Robotics. These have been around since the early 80's and were designed for use in the classroom. They do sell parts for your robot at their website - Check out http://www.rbrobotics.com/parts_dept.htm I also have one of this same model, which I want to re-fit with updated microcontroller hardware, as the original control system is very dated. With a few new body parts you could have your RB5X looking like it should and then begin incorporating some of the great projects in Nuts & Volts or Servo to get it animated and doing something fun! Best of luck to you as you resurrect this classic robot!

Bob Chadwick
Lompoc, CA

It appears that you have the bottom portion of the RB Robotics RB5X Robot. The domed top, top portion of the body cover and programmer are missing (check eBay for parts for sale). See the web site [url=http://www.theoldrobots.com/rb5x.html]http://www.theoldrobots.com/rb5x.html[/url] for more information.

Tim Brown PhD EE, PE
Honea Path, SC

I am SO jealous! That is the RB5X robot made by RB Robotics in 1982. You can read more about this awesome robot on my web site here - www.robotsandcomputers.com/robots/rb5x.htm - or this other great site here - www.theoldrobots.com/rb5x.html ... I hope you enjoy your very impressive find! I'm still looking for one of my own...

Derek Tombrello
via email


Audio Mixer Question August 2014

I have a rather old audio mixer that has 1/4" inputs for microphones. The inputs are labeled "HiZ." I have microphones I'd like to use, but they have a three-pin "XLR" style connector. Do I need a some kind of matching transformer, or can I just use a 1/4" male plug wired to some of the contacts on the XLR jack?

#8141
Andre La Tores
Birmingham, AL



Answers

There are many transformers, less than $15 that are available to match low impedance microphones to a high impedance input. Some can be permanently wired while others like the Audio Technica  CP8201 are adapters that simply plug in.


Google for 'microphone transformer' to see what's available. You might also raid old audio gear. Many times, depending on your needs , exact values are not so critical and there's no risk in trying them!

Len Powell
via email

I am going to go against the two prior answers. I have directly wired devices with XLR connectors to ones with phone plugs. And have wired balanced to unbalanced and vice versa. I have done this in the professional environment of broadcast TV stations where any technical problems would be instantly noticed and can not be tolerated. You just have to know what you are doing.


First, the type of circuit used, balanced or unbalanced, and the impedance of the circuit do not necessarily directly correlate to each other. Nor do either of these directly correlate to the type of connector used. Although the XLR style of connectors are generally used for balanced, low impedance (600 Ohm) circuits and phone plugs are generally used for unbalanced circuits, I have seen the opposite successfully used in many cases. Connectors are connectors and do not care about impedance or balanced/unbalanced. If they have the correct number of pins and the required quality level, they will work.


OK, now your question. Your XLR terminated microphones have an equivalent circuit something like this:


It functions as an AC Voltage source in series with a resistance. The shield connection is not connected to anything in the microphone cable or in the microphone itself except the outer case. It is for shielding only. You did not say what the impedance or signal level of the microphone is so there are two main possibilities, high impedance or low impedance (Rs). Either of these can have a number of different signal levels (Vac). This is the ideal way of wiring any microphone as it can be used with any type of input, as I will show below. If it were wired as an unbalanced device, then it would be OK for an unbalanced input but not well suited for a balanced one.


The other side of your circuit is the amplifier input. The only thing you say about this is that it is a high impedance connection that uses a telephone style jack. This could be either a two pin or a three pin telephone jack. You should look inside the amplifier to determine which it is. As for the "high" input impedance, the most common value used is 10 Kohms, but some amplifiers may differ. But it really makes little difference. 


If it is a two pin (T&S - Tip and Sleeve), then it is definitely an unbalanced input and the equivalent circuit will look like this:

 

 

 

 

 

 

 

 

 

 

 

 

Your microphone and amplifier could then be connected as follows:

Notice that the ground is not connected to the XLR pin 3 at the microphone. The two resistors form a Voltage divider so the signal delivered to the input stage of the amplifier will be a simple fraction of Vac. If Rs is low, almost the full value of Vac will be delivered to the input stage. If Rs is higher, then this will be reduced, depending on the exact values. There should not be a lot of reactance in the amplifier input stage so there should not be any high frequency roll off. In any case, the connection should work with no expected problems unless the amplifier has too little gain. If gain is a problem, you will need to use another microphone or a pre-amplifier.


If the telephone jack on the amplifier is a three pin type (RTS - Ring, Tip, and Sleeve), then the circuit will most likely look like this:


I said "most likely" because I have seen microphone inputs that used the three pin telephone jacks for other purposes, like selecting between a line and a microphone input. Also, it could still be an unbalanced input, just with the extra pin. In that case, the R and S contacts would probably be connected together and you are just back to the unbalanced situation above and you still use the hookup shown below. But let's assume that your amplifier's input is strictly a balanced, microphone input and the above circuit is correct.


For a three pin telephone jack your connection should look like this:


If you look at it carefully, you will see that there is no difference in the signal loop. Only that the ground is not connected to it so both sides are floating, as opposed to one side being grounded in the unbalanced connection. This configuration is less susceptible to picking up noise from the environment, but does not operate any differently as far as the signal is concerned. So all my comments for the signal in the unbalanced connection still apply to this balanced one.


One more thing, if a three pin telephone jack is used with an unbalanced amplifier input, the above circuit is still valid except that the bottom end of Ri is connected to ground at that amplifier connector and the lower arrow to the input stage is not present.


In short you should simply use a shielded pair for your microphone cable. Connect one wire of that pair to the T (Tip) connection at the amplifier. Connect the shield to the S (Sleeve) connection and the other wire of the pair is connected to the R (Ring) terminal if it exists and to the S (Sleeve) if it does not. This covers all cases.


A transformer may help if the microphone level is too low for the amplifier input. But that will introduce inductance and it will have it's own frequency response curve which may not be very good. Good audio transformers need a lot of steel and copper and are expensive. As I said above, a far better way to do this would be with a pre-amplifier. Even an inexpensive pre-amp will have better specs. than almost any transformer, hands down. Or get higher level microphones, but that can also be expensive.

E. Paul Alciatore III
Beaumont, Texas

Andre, yes you can connect an XLR microphone to a 1/4" TS (or TRS) jack. I'm 67 and am a retired studio chief engineer for a major studio in Hollywood, and it works no matter what some people might tell you.


Connect the XLR pin 1 (ground) and pin 3 (low) to the 1/4" sleeve (TS jack) or ring and sleeve (TRS jack), and connect the XLR pin 2 (high) to the 1/4" tip. Those who haven't done this get confused because, theoretically, you then have "unbalanced" the microphone, but the signal still exists. The less obvious problem is that an impedance matching transformer gives you 10-20 dB of noiseless gain so your signal-to-noise ratio is a bit better (the noise includes hum, of course, plus electronic thermal noise with a floor of -131dBm).


Finally, good transformers are EXPENSIVE (I like Jensens, jensen-transformers.com). All transformers need RC compensation on the secondary; send a square wave through one if you don't believe me and look at the ringing (ask if you want more info on this). HERE'S THE BOTTOM LINE: Connect the XLR to the 1/4" jack (use a NO-transformer adapter or wire one yourself) and see if you're happy; if not, then (and only then) think about using a transformer (and don't use a cheap one, they have more distortion). Heck, even a lot of today's semipro equipment runs XLR "unbalanced" (look at the schematics). Call me at 818-951-8646 (desk line, daytime Los Angeles) if you or anybody else wants further info.

Peter Skye
Los Angeles, CA

Yes Andre, you need an adapter to mate that "Unbalanced" (Hi-Z) microphone input to a "Balanced" (Low-Z) microphone. Here are three ideas:


RadioShack sells item #274-016 (you'll need cables to connect the two ends). Here's the link: www.radioshack.com/product/index.jsp?productId=2062443.  Chances are your local Shack has it in stock.


Parts Express (www.partsexpress.com) sells a similar adapter: www.parts-express.com/pyle-ppmjl15-1-4-male-to-xlr-female-mic-cable-15-ft--248-4614.


If you're handy with a soldering iron, here's a DIY idea: www.mediacollege.com/audio/connection/xlr-jack-mono.html (all necessary parts are available at RadioShack).
All three methods will do what you need — just pick the option that's easiest for you to implement.

Ken Simmons
Auburn, WA

For starters you CANNOT use a 1/4" male plug wired to a XLR jack. The 1/4" line is unbalanced meaning there is one signal line and a ground. The XLR line has two signal lines with opposite and equal signals plus the ground. Use a RadioShack Model; 274-016 (or equivalent) A3F XLR jack to 1/4" plug adapter. This adapter contains a balance-to-unbalance (balun) transformer to match the two lines properly. The balanced line and High Impedance (HiZ) are both used to reduce interference on low level signal lines like microphones.

Tim Brown PhD EE, PE
Honea Path, SC


Renewing Permanent Magnets June 2014

I have an old style hand crank telephone generator. It works, but output voltage is low due to the four horseshoe magnets it uses being weak. What is the best way to revitalize these magnets to bring the generator back to like-new operating condition?

Also, how can I tell when — as a result of the revitalization process — the magnets have achieved maximum strength and won't get any stronger?

#6145
David LeFevre
Ontario, NY


Call Blocker June 2014

Telemarketing has gotten both ultra sophisticated and out of control. Do Not Call listings are a waste.


I'd like to stop all incoming calls short at the point of entry, unless the caller — on receiving a prompt — dials an additional pass code to access my stand-alone answering machine and simultaneously ring any phones on which the ringer is turned on.


Is a DIY circuit available? Is anything off-the-shelf available? I checked with AT&T marketing and all they offer is blocking of all calls where no telephone number or caller name is available. That's not what I want.

#6144
Robert Wheaton
San Antonio, TX



Answers

Telemarketers are harassing millions of people every day which is a major problem. In 2012 the FTC offered a $50,000 reward for a solution. A couple of solutions are available:


#1 Some telephone carriers will put a telemarketer blocker on your phone service. Check with your provider who may have a charge for the service.

#2 The Telebouncer Blocker TB1000 is advertised to block 100 percent of robo-calls and 99 percent of solicitor calls. I have never tried this and it’s pricey at around $120.

#3 I just hang up, but if you have caller ID you may just not answer calls with numbers you do not know. This still does not help the telemarketers loading up your voice mail.

Tim Brown PhD EE, PE
Honea Path, SC


Battery Charging Indicator June 2014

My truck only has a voltmeter for battery condition indication. I don't have room for an ammeter. Is there a circuit I could build with a red and green LED to indicate if the battery is charging or discharging?

#6143
Ray
via email



Answers

If you want to know if the charging circuit is working, note the voltage with the switch on, motor off, then start the motor; the voltage should go up about 1 volt. If it goes into the red, the regulator is defective.

Russell Kincaid
Milford, NH

I suspect that your truck already has the circuit installed. If it is less than 20 years old it almost certainly does. It is called the "battery indicator light". That light does exactly what you want, except it is dark when you want an illuminated  green LED.


Put the keys in the ignition and switch to the ON position without starting the engine. All the warning lights on the dash should light up (this is a bulb check routine to identify burned out indicator bulbs or LEDs). After a couple seconds most of the warning lights will go off, except probably 2. One is the oil pressure warning light. The engine isn't running, so the oil pressure is zero, so the light is on. The other light still on will be the battery light. The engine isn't running so the battery is supplying all the power to the truck’s electrics.


Now start the engine. Those two lights should go off. The battery light is off which means the alternator is supplying all the power to the trucks electrical systems. That little indicator light basically just looks at the electrical system's voltage. A good, fully charged car lead acid battery will read 12.6V without any load. The charging system of a car runs at about 13.5V to 14V.


You can check the voltages with a voltmeter at the battery posts with the engine on and off. If the electrical system is at a voltage of 12.6V or less than the battery is carrying the electrical load. If the electrical system is at more than about 13V then the alternator is supplying all the electrical power.


If the battery needs charging then the alternator is doing so, as long as the battery indicator light is off. If the battery is not charging because it doesn’t need to be, then the light is also off. What the battery light won’t tell is the charge/discharge rate, which you would need an ammeter for.

Jim Sluka
Greenwood, IN


Delay Circuit Needed June 2014

I need a little help with an automatic above ground pool filler circuit I constructed. It’s nothing complicated — a water level switch with a power supply. When the water level drops below the set point of the float switch, it completes the circuit which applies 12 VDC to a solenoid which activates and allows the water to flow.


When the water level comes up and the float switch raises up to the preset point, the reverse happens and the water stops flowing.


My problem is I need some sort of delay before the power supply sends 12 VDC to the water relay. The float switch — due to motion by the wind or vibration — normally keeps the water level switch bouncing. This, in turn, keeps the water constantly turning on and off. If there was a 15 to 30 second delay until the float switch stabilized in one condition — either on or off — it would prevent the water switch from constantly going on and off.


Anyone out there with a circuit that can do this? It would be even better if the same timer also supplied the voltage for the water relay. Thanks in advance.

#6142
Gary Lichtenstein
Las Vegas, NV



Answers

The input to the circuit has an RC filter so the water valve doesn't turn on immediately when the switch closes.  When the water level falls and the switch on time exceeds the off time, the opamp will turn on Q1 which powers the solonoid valve.  As the water rises and the switch off time exceed the on time, Q1 turns off.

Russ Kincaid
Milford, NH

You asked for a circuit that would provide about 15 to 30 seconds delay before sending 12 volts to your water relay, because the float switch bounces which keeps the water constantly turning on and off. The on delay timer circuit in figure 1 will give you that delay.


25 to 30 seconds after the float switch closes (and stops bouncing), the output on pin 3 of the 555 will go positive and the MJE3055 NPN power transistor will conduct to turn on the existing water relay. The 555 will keep the MJE3055 conducting until the float switch opens.


However, I think there is a better approach to your problem. Even with the delay you wanted, the water will still turn on and off constantly as the water level raises and lowers at the set point, closing and opening the float switch. It is better to use two level switches, set to transfer at an upper limit to turn the water off and a lower limit switch set to turn the water on. When the lower switch transfers, water will flow and continue until the upper switch transfers. The float switch circuit in figure 2 will do that. The vertical distance between the switches will determine how often the water runs and how long it takes to raise the water in the pool from the low level to the high.

Ed Schick
Harrison, NY

I solved this problem many times over the years by using 2 floats in a simple start/stop pushbutton configuration. This comes from the common push button controls used by major motor control systems. One float needs a N.C. contact and the other needs a N.O. contact. Many floats have both. In your application, the top level float should operate N.C. contacts as the Stop button. The lower level float, which starts the pump, would use the N.O. contacts as the Start button.


The power relay needs an extra N.O. contact to serve as a holding contact and is wired in parallel with the N.O. contact of the Start float.


In operation, with a dropping water level, the Stop button contacts would be closed. As the water level continues to fall, the Start float N.O. contact would close and start the pump. The holding contact in parallel then holds the motor drive relay in the energized condition with no regard for any bouncing by the Start float. The pump would continue to run until the level rose sufficiently to trip the Stop float and stop the pump motor. Falling water level will then reset the Stop float.


The water level will continue to fall again until the Start float again closes and the cycle repeats. Run time of the pump is determined by the vertical distance between the Stop and Start floats and the flow rate of the pump.

Ed Farver
Green Valley, AZ

The easiest solution is to use a time delay relay. If the relay is on for 30 seconds straight, then the contact will close for the relay. So wire the float switch in series with the time delay relay COIL. Then wire power thru the relay contact to the water valve. So the water valve will come on when the float is low for 30 continuous seconds - until the float switch opens up. They have a 30 sec and a 60 sec time delay relay with socket at www.mpja.com for $9.95. You should probly put a reverse diode across the time delay relay - so you don't burn out the contacts on the water float switch. If you need a schematic - email me at jimsATruralhostDOTcom and I should be able to come up with one for ya......

Schneids
Redgranite, WI

Debouncing might fix the problem. Adding hysteresis into the circuit might also work. But you might consider fixing the problem the way the problem of float switches in a fluid is usually fixed: use two switches (which both debounces and adds hysteresis). A lower float switch turns on the water supply when the level falls below the lower limit. The supply then runs until the water level rises above the upper float switch, where it turns off. Look up the circuitry used for septic tank and sump pump controllers that use two float switches.

Jim Sluka
Greenwood, IN

The pool-filler setup can use a low-pass filter, but not the electronic kind.


Take a piece of large-diameter PVC pipe (see figure) and glue a cap on one end (the bottom). Drill a small hole near the bottom below the level at which you want to start the pump. Drill a large hole above the level at which the the pump or valve should stop the flow of water.


This arrangement provides an aquatic low-pass filter. The small hole does not let waves or disturbances in the pool affect the level in the tube. The large failsafe hole lets water get into the pipe quickly in case the the small hole gets plugged and cannot let water fill the tube.


So if the water reaches the failsafe hole it immediately floods the tube and causes the level switch to turn off immediately. Think of the small hole as a high resistance connected in series with a capacitor — the large tube. Attach the tube to the side of the pool with a bracket or a pair of suction cups.

Jon Titus
Herriman, UT

Gary has described what is known as a "switch debouncer." The MC14490 contains six switch debounce circuits which may be cascaded in order to create a longer time delay than a single one will provide. The IC also contains an oscillator circuit whose frequency is controlled via a single external capacitor.  This IC followed by a transistor can be used to power his relay.

Larry Cicchinelli - K3PTO
via email

From your description it looks like the wave motion is exceeding the movement differential or differential gap of your switch. I have a couple of solutions.


#1 Mechanical Solution (easy):  Insert the float in a piece of PVC pipe which is large enough to allow free movement of the float. In industrial applications this is called a stilling well and it works by shielding the float form the wave action of the pool surface.


#2 Electrical Solution (more complicated): By using two Normally Closed (NC) float operated switches and a 12V relay with an extra set of NO contacts, you can build a circuit to turn the solenoid valve on at a "low" level and off at a "high" level. Wire the relay coil, Low float switch and High float switch in series between the +12V Source and Ground. Wire the "extra" relay contact in parallel with the Low float switch and the other relay contact in series with the solenoid valve. This arrangement works as follows:


(a) The two float switches are Open when the float is high, when the level drops to the "Low" level the Low float switch closes and activates the relay which closes the relay contacts.

(b) as water runs into the pool the "Low" float switch opens up but the "Hold In" contact on the relay keeps the relay (and thus the solenoid valve) activated allowing the pool to continue filling.

(c) When the pool level reaches the "High" float, the High float switch activates (opens) and the relay and solenoid valve deactivate stopping the flow of water. You can experiment with the "low level" position to obtain the operation you want.


CAUTION: Water and electricity do not mix. Any electrical devices used around water where humans can contact the electrified water should be fed through a ground fault interrupt device.

Tim Brown PhD EE, PE
Honea Path, SC

An effective method to prevent short-term fluctuations from exercising the float switch is to dampen the frequent rise and fall of the water level by a non-electronic method. Just enclose the float switch in a vessel (such as a one-gallon milk container with the top cut off) and make a very small hole in the bottom of the container. This is the equivalent of adding a large capacitor to a varying dc voltage to smooth out the variations. The float switch will respond to an average level over time. Depending on the size of hole, it will take some time for the water level in the container to rise or fall. I believe this is essentially what lake level monitors use to tune out temporary wave action.

Bryan Carl
Marietta, GA


FM Instead of Wi-Fi June 2014

I would like to use a device such as a Pi or Arduino to connect to an Ethernet. I want to send/receive data wirelessly via digital FM instead of Wi-Fi to communicate with devices where the Wi-Fi/internet connection is unavailable, but still relatively close (suitable for low power FM where FCC regulations would not be an issue).

High speed data transfer such as for streaming video is not a must, but 100-200 kps would be ideal. This would, of course, vary depending on the strength of my signal.

Can I buy a board with Ethernet and simply I/O data to an FM transceiver? Any suggestions to help me get started would be great.

#6141
Gary McPherson
Wyoming, MI


Pot Cleaning May 2014

I recently purchased a small "pignose" guitar amplifier at a neighborhood garage sale. I put batteries in it and it works, but the volume knob is very "scratchy" and at certain places in its rotation, the sound cuts out entirely. Is this something I could fix by cleaning the potentiometer and if so, what would I use? If it's time for a replacement, does anyone know where I could find a schematic for this unit?

#5145
Emanuel Estrada
Denver, CO



Answers

You didn't say, but I'll presume you have the classic, small (8"x6"x4") model 7-100 that I have. Mine sits for long periods unused and always is scratchy.  But, so far, it always cleans up by rotating the control shaft through its entire range for a minute or so. I usually do this before I turn it on. If that doesn't do it, cleaning is the next step. DeoxIT D5 is a product most used now in the amp repair business. I think RadioShack even carries it. The pot on mine is sealed in the normal opening at the terminals, but I saw a small hole in the side or you might be able to get some cleaner around the back side of the shaft. I don't think I have ever cleaned mine.


I saw  a couple of schematics floating around at Activity Stream - Music Electronics Forum.  But you don't need one to replace the pot. Mine is 50K ohm, but I also saw 10K ohm on a schematic. There are several versions of this amp, updated over the years. I presume these are logarithmic/audio taper. You can check the value and taper with an ohmmeter. The pot is really small and has the power switch included. I haven't seen any replacement parts listed or mentioned. One of the best and cheapest parts sources is Mouser Electronics - Electronic Components Distributor. You would have to remove the battery holders and metal shield to use any larger pot. You could get by without the power switch, since power is removed when the cable is removed from the input jack, like is done on many guitar FX pedals.

Dave DeLeersnyder
Kansas City, MO

You can SAFELY clean a pot with a spray cleaner like "Deoxit D5" (item #64-249 @ RadioShack). Just spray a small amount of it into the pot (typically in the case opening where the solder tabs are), rotate the pot through its' range a few times, then repeat once or twice more.  This should clean up your pot nicely.  NOTE - This stuff is also good for cleaning noisy/intermittent switches (make sure there's NO POWER APPLIED to the switch!).


However, if it doesn't help (a possibility, depending on the age of the pot and its overall use), you can replace it with a similar unit. Just unsolder ONE LEAD from one of the end tabs and use a DMM to measure the resistance between the end tabs - this will give you the resistance value of the pot. In many cases, your local RadioShack will have a similar-value pot in stock - if not, get the next larger value pot that's closest to what you read (i.e., your pot read 7.5K, the next closest value would be 10K). If The Shack doesn't have anything close, order one through DigiKey (www.digikey.com) or Jameco (www.jameco.com).  IMPORTANT: make sure you replace it with an audio taper pot, not a linear taper pot.

Ken Simmons
Auburn, WA

RadioShack may still sell an aerosol can of potentiometer/contact cleaner, just use it sparingly!


If the sounds still cuts out at certain spots, the control is probably bad and needs to be replaced. If you can use a soldering iron this is a simple job.


Connect an ohmmeter across the two outer tabs, you will not get a reading if the control is broken. Now take a reading from the center tab to each of the outer tabs and add them together to get the value of the new one to buy.

Michael Herman
La Quinta, CA

The best fix is to replace the pot. If you don't want to do that, then a spray on cleaner is available at most RadioShack or electronic parts supplies that will supposedly clean these pots. I've never had much success with the spray stuff though. It's supposed to wash away the carbon dust and leave a protective slippery film behind to prevent further ware. My preferred method is to disassemble the pot, clean it thoroughly with alcohol, re-lube it with pot grease, then reassemble it. Even all this doesn't permanently fix the problem, it will return.


The problem is usually caused by the carbon resistance material breaking down. Most pots have their value stamped somewhere on the case, generic replacements are available and are  cheap and easy to install.

Ray
Vancouver, BC

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