Interesting theory Brett. I own two Sixpaks and I've had similar problems
with each, especially when using a Top Ten band decoder to control them. I
felt the problem was there was not enough voltage at the coil to pull in the
relay. In one case I solved the problem by stretching the relay spring
slightly and in the other with a long (350') control wire I increased the
voltage using an external relay after the band decoder. My guess is the
rotor brake is putting enough vibration to the relay to pull in the contact.
Voltage drop could be an issue for some, but I have short cable run to the
A slightly stronger spring might help. What I did after cleaning all the
contacts is to slightly bend the frame to apply more pressure on the
contacts when the relay isn't energized.
I have also noticed the arm of the relay sometimes moves to one side,
causing the contacts to not line up.
Failure of the relays to operate for me appears to be due to bad contact
on the opposite port's relay, which is used for the lock out. Sounds
like W9GE is experiencing the same thing & I reckon might be
contributing to your problem, too. I only recently had a good look at it,
after putting up with it for far too long - a tap or squeeze on the one relay,
or running the unused port back & forth through the bands will usually
cause it to work.
Stretching of the springs may have added this problem, based on what
I see here - when energized, the relays seem to break through the gunge
that builds up on everything here & is often the culprit.
See: http://www.mscomputer.com for "Self Supporting Towers", "Wireless Weather Stations", and lot's more. Call Toll Free, 1-800-333-9041 with any questions and ask for Sherman, W2FLA.
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