Stator panel solder connection question

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TheDoge

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I had purchased a used ESL panel and when it arrived I found that 2 of the wires were no longer soldered in place. In looking at my other panel it appears that the solder connection is actually between the panels. Would anyone be able to confirm this and is there a way to solder the wires back in place?
Thanks
Dan
IMG_20250210_174742868.jpg
 
As a follow up. I see where there are solder joints on the front frame for the blue wire and on the back frame for the black wire. It appears that the red wire goes between the frames. Any idea on what this connects to?
 
As a follow up. I see where there are solder joints on the front frame for the blue wire and on the back frame for the black wire. It appears that the red wire goes between the frames. Any idea on what this connects to?

All ESL panels require three power connections:

The two wires connecting to the front & rear stators are from a transformer that steps up your amplifiers AC output to the much higher voltage needed to drive the ESL.

It's important that these wires do not have missing or cracked insulation that might allow exposed bare wire strands to overhang the stator edges, as this could result in damaging arcing to the opposite stator or wire.

There is huge electrical potential (thousands of volts) between all three wires, and you don't want any bare wire strands touching or even close to each other because that much potential can throw a spark across a 3/8" gap.

If you see any bare strands overhanging the stator edge, either replace the faulty wire and connection or at least apply some RTV silicone around the exposed wire strands, as insulation.

The third [red] wire comes from a high-voltage DC bias supply, and [probably] connects to a copper foil periphery charge ring sitting atop the diaphragm, about 1/2" in from the panel edge.

The charge ring extends around the periphery of the panel and conducts the DC biasing voltage onto the diaphragm.

I was going to add that you must be very careful not to pull on this bias supply wire (the red one), as its connection to the foil charge ring is fragile and easily broken--- but I see that someone has already pulled that wire out :-(

Don't despair just yet... there may be an easy fix:

I'm not not sure if all ML models use a full-periphery foil charge ring but that would be my guess.

If so; that red wire would have been connected to a periphery charge ring that sits atop the diaphragm, about 1/2" in from the panel edge.

Here's what I suggest:
You will need a thin, flat copper probe 3/4" to 1" long, to insert between the stators and contact the charge ring. It must be thick enough to resist bending but no thicker than necessary, and its edges must be smooth so it inserts smoothly without tearing the diaphragm.

You could easily make the perfect probe by hammering flat a piece of 10 gauge or 12 gauge single strand electrical wire.

Solder your bias supply wire onto one of end of the probe but splay the wire strands to make the flattest possible solder joint (you don't want a fat gob of solder that could impinge on and arc to a stator).

Also, you might want to wrap the soldered end with a layer of electrical tape to isolate it from the stators. For sure you want to insulate any portion of the probe that protrudes after you've inserted it into the panel.

The charge ring will be on the top surface of the diaphragm, so you will need to insert this probe between the stator spacers and on top of the diaphragm. The "top" surface faces the front stator.

You don't necessarily have to insert the probe in the exact same place that the wire pulled out from-- if there is a periphery charge ring, then anywhere along the periphery will suffice.

You merely need the probe to touch the charge ring to make an electrical connection. It's not as robust as a soldered connection but functional, and the panel should then play.

Once you have the connection, you will want to fold the wire against the stator edge and over-wrap it to the panel with tape so that it doesn't pull out easily.

Good luck with it!
 
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As a follow up. I see where there are solder joints on the front frame for the blue wire and on the back frame for the black wire. It appears that the red wire goes between the frames. Any idea on what this connects to?
I built these panels for many years. There's a graphite tape bias strip that runs down the edge of the panel and halfway across the bottom. The red wire needs to be touching this bias strip. Its what feeds power to the film. The black wire gets soldered to bare metal on the back stater. The blue wire gets soldered to bare metal on the front stator. Make sure there isn't any power to the panel! If there is and you touch the bare metal on the front and back stator at the same time, you'll end up having a really bad day.
 
I built these panels for many years. There's a graphite tape bias strip that runs down the edge of the panel and halfway across the bottom. The red wire needs to be touching this bias strip. Its what feeds power to the film. The black wire gets soldered to bare metal on the back stater. The blue wire gets soldered to bare metal on the front stator. Make sure there isn't any power to the panel! If there is and you touch the bare metal on the front and back stator at the same time, you'll end up having a really bad day.

Well there you have it Mr TheDoge;
One who knows just informed us that the bias strip is graphite but the same solution applies. I think re-inserting the red wire as-is would probably not work so well-- but soldering it to a short copper probe, and inserting the probe to touch the graphite strip should work OK.

I've done this once about five years ago and the panel still plays fine.
 
I did try what Jazzman recommended but no joy. I took a piece of 16 gauge copper from a piece of electrical romax and put it in a clamp to flatten it out. I soldered the red wire to this and then slid it under the front frame about 1/2". No sound from the panel. I will continue to be on the look out for a panel. Thanks for the suggestions.
 
I did try what Jazzman recommended but no joy. I took a piece of 16 gauge copper from a piece of electrical romax and put it in a clamp to flatten it out. I soldered the red wire to this and then slid it under the front frame about 1/2". No sound from the panel. I will continue to be on the look out for a panel. Thanks for the suggestions.
Assuming you have AC power feeding in from the blue & black wires and DC power in the red wire, this leaves only two possibilities to explain why your panel still doesn't play:

1) The probe contacted the charge strip but the diaphragm coating is completely deteriorated and can no longer hold a charge. Normally I would say this is very unlikely, but the prior owner may have been troubleshooting a problem with the panel, and ended up pulling the wire out by mistake (i.e. the panel wasn't playing before the wire was pulled out).

2) The probe you inserted did not make electrical contact with the charge strip. I would definitely give it several more attempts. That charge strip may not run the full width of the panel end, in which case you might have missed it.

You should also rule out a problem with the bias supply and transfomer by connecting the panel to the other speaker's power supply, if you know it's good.
 
To test if you got the red wire inserted in the right place, use a voltmeter to check for conductivity. Place one probe from the voltmeter into the end of the connector where the red wire terminates. Then gently touch anywhere on the film with the other probe. Don't poke through it! (If you do it's ok, it'll still work. You'd have to poke out about 2/3 of the holes to hear a noticeable difference) If the voltmeter beeps then you have conductivity. If not then the red wire still isn't touching the bias strip which is what I'm guessing is happening. When built, the bias strip gets looped around the bare part of the red wire first. The bias likely ripped some when the wire came out so try inserting the red wire a little further down stream on the panel to try to find a solid part of the bias that's still intact. If that makes any sense.
 
I did try what Jazzman recommended but no joy. I took a piece of 16 gauge copper from a piece of electrical romax and put it in a clamp to flatten it out. I soldered the red wire to this and then slid it under the front frame about 1/2". No sound from the panel. I will continue to be on the look out for a panel. Thanks for the suggestions.
Did you also solder the black and blue wire to the bare spot on the front and back of the panel? If not it won't play, even if you got the red wire put back in correctly
 
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