Self-Contained "67.5 volt B Battery" for
©Tony Maher 2001 - presented here with the permission of the author.
article was first published in the April 2001 edition of
'Radio Waves', the magazine of the Historical Radio
Society of Australia.
This article describes the
construction of an AA battery powered 67 1/2 volt "battery".
This new rechargeable "B battery" is slightly
smaller than the original Eveready 467 battery and is the
same weight. The substitute battery can be made in
different voltages and can be powered from a wide variety
this unit generates voltages which can in some
circumstances be lethal.Take
The immediate forerunner of today's
transistor portable was the Personal Portable of the late
1940's and early 1950's. Many of these were very
attractive sets. They used miniature 7 pin valves and
were powered by small 'Eveready' 67 1/2 volt batteries,
but they were expensive to buy and to run. With the
advent of the transistor radio in the late 1950's they
disappeared from common usage and sight.
Today the small 67 1/2 volt batteries that powered
these sets are no longer available and the collector has
the choice of soldering together seven or eight 9 volt
batteries or making a mains powered power supply. Neither
choice is a good one.The first at about $30 to $40 a time
is expensive, and the second takes away the portability
which was one of the major attractions of these, the
smallest valve receivers ever made.
A year ago, during a visit to the hills around
Melbourne, the writer obtained a small cream AWA Personal
Portable Model 450-P made in 1948. This radio uses two D
flashlight cells for its filament supply and a small 67 1/2
volt Eveready 467 battery for the B supply. D batteries
are, of course, readily available but not so the B
This focused the author's mind on a suitable B battery
replacement. I sought out on the internet a suitable
design.I found many mains powered battery eliminator
designs and a few suitable battery powered ones for
portable use, but none that fitted inside the set in the
place occupied by the original battery. The final effort
was to design my own. This was not a simple task.
I wanted a simple solution that did not involve
metalwork or shielding, that was easy to make, cheap to
build and run, and could of course happily coexist with
and within a small valve portable radio. Switching
regulators could be used but the author's experience of
these in the past had shown him they were a potent source
of Radio Frequency Interference (RFI). Cast aluminium
boxes, filter chokes and miniature metalwork loomed on
Luckily the space requirement ruled out this approach.Once
the switching regulator approach had been discarded a 50
hertz inverter was considered. The lower frequency would
make RFI problems much more manageable and ordinary power
transformers could possibly be used. Serendipity then
entered the scene in the form of a magazine advertisement
for "on special" 10VA toroidal power
transformers . These were cheap at $10 and they had two 6
volt, and two 120 volt, windings. Toroids are efficient,
small, and have very low external fields. I ordered two.
Oh how I wish I'd ordered more....
This toroidal transformer forms the
basis of the final design. Power is supplied from 4 or
more AA NiMH batteries, depending on the output voltage
required.Other power ources that can be, and have been,used
include AA alkaline batteries, AA NiCad batteries, lead
acid batteries, non regulated voltage adjustable power
packs, and regulated voltage adjustable power packs.
Personal Portable radios were designed to operate over a
wide B battery voltage range. Batteries were expensive
and the radios were designed to extract the aximum amount
from the battery before it was discarded. Typically
radios were designed to continue operating with B battery
voltages 30% or more below their nominal voltage. This
unit will continue to operate when the individual AA
cells are below 1.0 volt. This
corresponds to an output voltage of 40 volts. A set of
four AA NiMH 1600maH rechargeable batteries will supply
the B battery needs of the authors AWA 450-P Personal
Portable (67 1/2 volts at 8.0ma) for nearly 10 hours at a
B battery cost approaching zero (assuming of course you
already have the batteries).
The unit will give 15 hours or more of operation from a $2.50
set of Chinese made AA Alkaline batteries. The unit can
be used with extra AAs as a 90 volt battery or as a 108
volt supply. With a switchable 1 amp plug pack it can be
used as a variable bench supply.
Note 1: An Eveready Type 467 MiniMax 67 1/2 volt
battery is 94 x 71 x 35mm.
An Eveready Type 482 MiniMax 45 volt battery is 140 x 89
2 parts of a CMOS 4011 quad Nand gate U1a and U1b are
used as a square wave oscillator. The frequency of the
oscillator is not critical and is set by the capacitor C1
and the resistor R1. Another Nand gate U1c is used as a
buffer between the oscillator and the gate of a Mosfet Q2.
The last Nand gate of the 4011 U1d is used to supply an
inverted signal to the gate of another Mosfet Q1. When
its gate is driven positive by the buffered output of the
oscillator, each Mosfet in turn passes current through it's
portion of the primary of transformer T1. The transformer
steps up the voltage and supplies it to a bridge
rectifier D1- D4 and filter capacitor C2. Because the
voltage from the transformer is a square wave, with only
a small time between each half cycle, there is little
ripple on the output and only a small filter capacitor C1
is required. R4 discharges the capacitor C1 in the event
of there being no load connected.
The toroidal transformer has two 6 volt windings which
are connected in series. These are driven by the Mosfets.
It also has two 120 volt windings which are connected in
parallel. Resistors R2 and R3 perform a number of roles
and should be located as close as possible to the gates
of their respective Mosfets. Their first role is ensure
that one Mosfet is off before the other turns on. They do
this in conjunction with the gate to source capacitance
of each Mosfet by slowing the rise and fall times of the
square wave which is fed to each Mosfet. They also
minimize the amount of RFI generated and prevent high
frequency oscillations from occuring in the gate circuit.
Resistor R5 prevents destruction of the 4011 IC in the
event of the battery being connected the wrong way around.
R6 and D6 provide a Power on light for the unit. Q3 acts
as an on/off switch. It enables the unit to be turned on
and off by a small current. A normal toggle switch can be
used in its place but it is often desirable to have
switching performed by small low current contacts. Low
current reed switches can be fitted to doors lids etc. so
that the unit turns on automatically when a door or lid
is opened. Reed switches would stick if used to directly
switch the current required by the unit. D5 and R7 are
used to protect the gate of the Mosfet from being damaged
Experienced readers will have noted that this circuit is
very similar to that of the vibrator power supplies long
used for battery operated radios and car radios. The
plugin vibrator unit is replaced by the 4011 and the two
Mosfets. The 4011 oscillator acts as a replacement for
the vibrator's reed and the 2 Mosfets act as the vibrator's
contacts. The author is currently adapting this design to
act as a plugin vibrator replacement.
C1 Capacitor 330nfd MKT type
C2 Capacitor 100mfd 160 volt small or
Capacitor 47mfd 250 volt small
D1 - D4 Diode 1N4007
D5 Zener Diode 1N965 15 volt
D6 5mm Red led of reasonable brightness
Q1 - Q3 Mosfet MTP3055E
R1 Resistor 15k ohm 1/4 watt
R2 - R3 Resistor 100k ohm1/4 watt
R4 Resistor 470k ohm1/4 watt
R5 Resistor 100 ohm 1/4 watt
R6 Resistor 1k ohm 1/4 watt
R7 Resistor 10k ohm 1/4 watt
SW1 Reed switch normally closed type (used
as an on/off switch for the unit)
NB: An existing B battery switch on the radio can also be
rewired to perform the function, in which case the
existing B battery wire from the switch should be
directly connected to the +ve output of the unit.
Take care when rewiring an existing switch! Do not under
any circumstances connect the output of the unit to the A
battery or filament circuit. Valves will be
destroyed if this occurs.
T1 Toroidal Transformer 10VA Powertran M4312
Two 6 volt windings plus two 120 volt windings.
U1 CMOS Integrated Circuit 4011BP
Also the following hardware:
Battery holder suitable for 4 AA batteries (or more if
higher voltages are required.)
Doublesided tape or suitable glue for mounting the
battery holder to the transformer.
Polycarbonate or similar insulating material for forming
into a U shape to insulate and protect unit.
3/16" screw for mounting same to transformer
Suitable Nickel Metal Hydride, alkaline, Nicad or lead
A printed circuit board for the unit has been designed
and is available from the author .
The unit is built around the toroidal power transformer.
The power transformer is designed for printed circuit
mounting and advantage is taken of this to mount a small
fibreglass matrix or printed circuit board to the pins of
the transformer. All components are in turn mounted on
this board. The battery pack is fastened to the flat side
of the transformer with double sided carpet tape or
Scotch VHB tape or similar. Clear 1.6mm thick
polycarbonate plastic is cold folded into a U to create
the correct size envelope for the "battery" and
to provide insulation. This envelope is held in place
with a 3/16" countersunk screw which passes into the
mounting hole of the transformer. Please refer to the
photo and layout drawing.
A printed circuit board has been designed for the unit.
This is a small board and the tracks on it are likewise
small. You will need a suitable soldering iron with a
suitable tip. A Scope or similar high wattage soldering
iron will not do. A 25 watt or temperature controlled
iron with a small tip is required. Insert components in
the position shown on the drawing. Insert Mosfets last.
Leave Mosfet leads at maximum length. Refer to the photo
as necessary. All diodes and all resistors are mounted
vertically because of limited space. Observe the way each
component is fitted in the photo and copy. Test pins are
fitted on the perimeter of the board and the input,
output and switch leads are soldered to these pins.
Note: One switch lead shares a common pin with the +
input lead. There are four wire links on the board. One
link runs along the top of the IC. The other three links
are on the copper side of the printed circuit board. Join
pads labelled A to A, B to B, C to C and D to D.
Warning: this unit generates voltages which can in some
circumstances be lethal. Take all precautions. Care
should be taken with the wiring to ensure it is as per
the circuit diagram. Great care should be taken to avoid
shorts and dry joints. Buy new glasses if necessary.
Visually check and check again.
Is the polarity of the electrolytic capacitor correct?
Is the IC or one of the Mosfets around the wrong way?
Note the Mosfets. One is reversed in orientation to the
Are the 4 diodes the correct way around?
Does the bar on the zener go to the outer edge of the
Do you have the correct resistors in the correct places?
Check your colour codes.
Make sure the transformer is the right way around. 6 volt
windings should be near the Mosfets.
Make sure each individual AA cell is correctly inserted
in the battery holder.
Make sure the battery pack is connected with the correct
polarity. The unit will withstand polarity reversals of
short duration but don't leave the battery reversed for
minutes rather than seconds.
The author has constructed 6 units and all worked first
up so it's not too hard.
The good news is that it's pretty difficult to
permanently damage any of the parts... but...stand by for
the emails from those who "succeed". If you
have a voltmeter or DVM select the 200 volt range and
connect it across the output. Fit the batteries and
briefly touch the battery connector to the battery pack
terminals. Voltage should immediately appear. If not
inspect and inspect again.
WARNING: If you are
fitting the unit to a battery powered portable take great
care with the battery plugs particularly if you do not
have the original batteries.Many portables had combined A
and B batteries, others had separate plugs. Colour codes
on battery plugs can be different to what one would
Using a DVM on ohms range check the battery plug and
locate the filaments. If the filaments are in a series
chain remove a valve to confirm you have the right leads.
If in doubt don't connect the unit but trace the wiring
instead. The polarity of the A battery is important. If
no sound is heard, or if only a brief burst is heard, try
reversing the two A battery leads.
My hope is that by using this design and future ones
we can wake these beautiful little sets from their long
sleep and once again freely use them as the portables
their designers intended, and at a running cost much
lower than ever before possible.
All correspondence will be entered into - email: firstname.lastname@example.org
or send a stamped self addressed envelope to:
Tony Maher, 31 Barossa Ave,Vermont South, Victoria,