Henry HVC200 Vacuum Cleaner Repair

Having moved house recently I accquired an old Henry vacuum cleaner that had been used for workshop and garage duties so was rather filthy but cleaned up well with soap & water.
However it was in a questionable electrical condition with a broken plug, missing cable strain relief and worst of all, an exploaded mains filter/RFI capacitor of the Rifa brand.

Remove a couple of covers and the electrical connections are revealed. The socket on the left is a passthrough for other domestic tools I think. In the middle is the failed Rifa capacitor and mains cable missing strain relief.

You can see the capacitor casing cracked wide open and there was burn marks/staining on the surrounding plastic. I bet this made quite an unpleasant smell when it went.

Old and new capacitors. The replacement is a modern Rifa capacitor. You can also see a 1 Meg Ohm bleed resistor attached to the old capacitor, I didn’t bother salvaging this and fitted a new one instead.

New capacitor soldered to the original terminals.

Fitted in position and you can also see the outer insulation of the mains cable correctly clamped.

Here it is cleaned up and fitted with a modern ‘turbo’ brush head, this uses the suction to also drive a brush head for a more thorough cleaning on thick carpet.

During my research I discovered this model was significantly older than I thought, being made during the mid 1980’s https://numatic.fandom.com/wiki/Henry#Henry_HVC200_(1983-1987)

Here is to another 30 years service!

New components and completion

The following pictures show the new components and the completed board.

Capacitors

The above image shows the new and old Rifa capacitor. You can see the crazing and discolouring on the left hand side.

TRIAC

There was some difficulty in finding an alternative TRIAC. From the part numbers on the package, TAG D2 450 800 , I took a guess on the typical specifications as I could not find a vintage TAG Semiconductors parts catalogue. I used a ST BTA16-800CW with a blocking voltage of 800V and an RMS current of 16A.

Finished PCB

The motor is now working well unloaded and is surprisingly loud at max speed (28,000 rpm).

Watch this space for a reverse engineered circuit diagram.

Battery Mount

Downtube Battery

The 15Ah battery comes with a rail for mounting on the downtube in place of a bottle cage. However none of the precut slots matched the screw bosses on my frame so I had to drill an additional hole. Due to the tradiational bottle cage bolt spacing this leaves the top of the battery without a firm mounting so I shall 3d print a clamp.

2017 Winter Update

The updates have been sparse but here is a brief list of what I’m working on.

  • Final Year Engineering Project – Building a low cost bicycle power meter.
  • Vintage Bicycles – Restoring an Orbit Gold Medal and a Holdsworth Triath-Elan.
  • Railgun – Still in early design stages, this has taken a backseat.

I hope to write a longer post soon with more details on the low cost power meter.