HP, Got any grapes?

Hp I say that's funny even though I say doesn't fit me! Cuz it's exactly like a lot of irritating posters all over the web! They ask their questions they get answers and leave only to return again with same questions again and again! Also like duck they aren't fazed when ppl get angry with them and they don't defend themselves against abuse and accusations its like ok, cool! Then back at it all over again later on!

 

Point being: How many times need I advise you to hire another ISP for your personal use - before you either observe my advice -or- realize that same is the extent of my ability to assist you in this matter!? --- While I am sensitive to your clients' security concerns, 'notebooks' are all of; inexpensive, abundant and available! - So why not dedicate a new machine to your personal use through another ISP?

HP when Steve did just like that he was accused of trying to pull a _Hilly_ so I'd be big hypocrite if I did it after being party to bringing him up on charges HP you think I have no boss but clients are boss is not just lip service! They're jumpy about security and I understand that! So I am saying that some sites work with VPN and other sites hardly work at all any more so maybe there is browser setting that can help?

 

HP I'm so happy you are back to working on tutorial! Now I have suggestion, where you are explaining about advantages of using lopt I say you should be using totally separate paragraph for addressing faq about why ignition coils are inadequate for hv power supplies, just saying cuz change of tack in same breath maybe hard for ppl reading tutorial? Obtw I like use of headings and sub headings! HP plz surprise me with major progress for when I return

 

Hp I say that's funny even though I say doesn't fit me! Cuz it's exactly like a lot of irritating posters all over the web! They ask their questions they get answers and leave only to return again with same questions again and again! Also like duck they aren't fazed when ppl get angry with them and they don't defend themselves against abuse and accusations its like ok, cool! Then back at it all over again later on!

And the truly confounding fact of the matter is that it's nearly impossible to determine whether members of 'that caste' are merely 'challenged' in some way -or- playing the 'how far can I push it' game --- Granting that their 'antics' aren't entirely without their 'humorous side' -- it gets old quicklike!!!

HP when Steve did just like that he was accused of trying to pull a _Hilly_ so I'd be big hypocrite if I did it after being party to bringing him up on charges HP you think I have no boss but clients are boss is not just lip service! They're jumpy about security and I understand that! So I am saying that some sites work with VPN and other sites hardly work at all any more so maybe there is browser setting that can help?

First off please refrain from (even veiled) references to specific politicians - negative, positive or otherwise! -- No point in 'polarizing' folks who may otherwise be interested in our topics! --- That said, I know you weren't intentionally casting aspersions, and I hope I'm not coming across as 'scolding you' -- It seems 90% of the acrimony on these fora (when it occurs) is political in nature -- I merely wish to keep it off 'our' thread...K?

But to continue - I must confess that I cannot see the objection to use of a physically distinct device containing NO 'work' related data whatever??? --- Baring that, inasmuch as the difficulty began after an FF update, perhaps you might try another browser? Are extensions for your VPN available for other browsers?

Now I have suggestion, where you are explaining about advantages of using lopt I say you should be using totally separate paragraph for addressing faq about why ignition coils are inadequate for hv power supplies, just saying cuz change of tack in same breath maybe hard for ppl reading tutorial?

Believe it or not I was thinking along those lines also -- it would certainly 'de-clunk' that paragraph! --- many thanks for 'validating' my 'visceral feeling' in that regard -- and please keep the suggestions coming!!!

HP plz surprise me with major progress for when I return

Inasmuch as the gentleman I was assisting (with CRO troubleshooting) over on the 'General Chat' forum has gone on a few week's holiday -- I'll have more leisure time than anticipated! -- So... You might not be disappointed!

Have a safe and productive trip!

All the best Best
HP

 

Now I have suggestion, where you are explaining about advantages of using lopt I say you should be using totally separate paragraph...

I thought so too, however...

Having tried several 'approaches', I've found that merely deleting the digressions (into, for instance, the rationale back of application of 'flyback' topologies to certain specific applications, etc...) and general re-wording of the paragraph for concision seems to address its former issues, and, indeed, achieves something approaching cogency?--- Regarding the excised, tangential content - it is my stance that, among the 'boons' of 'interactive publication', is the fact the 'lines of communication' remain open beyond 'deadline', as it were -- IOW: if they have questions, we have answers! (Yikes! Who am I quoting!?)

Please let me know what you think

And again, best wishes for a safe and productive 'junket'

All the best
HP

 

And the truly confounding fact of the matter is that it's nearly impossible to determine whether members of 'that caste' are merely 'challenged' in some way -or- playing the 'how far can I push it' game --- Granting that their 'antics' aren't entirely without their 'humorous side' -- it gets old quicklike!!!

Does that remind you of some one you interacted with quite a lot on this forum?

 

Does that remind you of some one you interacted with quite a lot on this forum?

Sadly, it reminds me (to varying degrees) of at least 5% of discussion fora participants - Internet wide! -- Perhaps most annoying is their refusal to explain/defend themselves (as per @Aleph(0) 's observation) -- Thus relagating any attempt at confrontation to the futility of 'fighting a cloud'!

For all that, IMNSHO, the foulest 'species' of 'problem poster' is the 'nube' who wastes everyone's time via an ostensible request for assistance only to rudely dismiss all advice and proceed with their 'original plan' regardless!!!

Oh, well... Life goes on...

Very best regards
HP

 

@Aleph(0)
In case you have a chance to look in here - please note that, although the intro is yet in need of a little 'work', I am now 'putting the shine' on the content...

Principal goals are as follows:

--- Achieve coherency via consistency of nomenclature, presentation, and formatting...

--- Achieve formality/clarity via 'editing out' 'smilies' idiomatic expressions and other 'culture specific' modes of expression - It is my desire that this be as near 'universally accessible' to all English 'speakers' as practical -- That said, I will not and can not corrupt the tutorial nor insult the reader via a 'dumbed down', condescending, presentation...

--- Enhance comprehensibility of complex procedures/descriptions via quasi-redundant framing of perspective as well as 'deference' to images.

--- Enhance readability via refraining from over/unnecessary use of "scare quotes", multiply nested parenthetic structures, and otherwise (especially) egregious punctuation -- that said, if you're expecting 'Neustadt material', expect to be sadly disappointed!

For all that, I envision having the current tutorial ready for transfer to 'Projects' upon your return

Best regards
HP

 

Note: Draft moved here for convenience
Revision in progress: Last action @ Feb 24 2016

--------Tutorial moved down-thread-------



Scope of series:

Central topics:
This tutorial is one in a (prospective) series with focus upon low ripple, relatively high current/power PSU solutions for radiography and other modest photon energy (≤ 2 MeV) particle accelerator applications - and, to a lesser extent, exploration of certain 'current intensive' electrostatic phenomena (e.g. electret photography, electret formation, electrokinesis, establishment of electrostatically 'cordoned' (atmospheric) pressure gradients, high volume ion-flow systems, etc...

Peripheral and extraneous topics:
While everyone is welcome to view and post questions (within the confines of this site's TOS/UA) - Please be advised that those having interests confined to the following topics/applications will not likely find this series particularly useful (owing to the availability of significantly less 'labor-intensive' solutions to same):

--'Pedestrian' and 'Quasi'/'Peri'-EHT applications:
CRTs, PMTs/Image tubes, Gas discharge devices, LASERs, 'negative ion air purifiers', TC primary drivers, GM tubes, etc...
--Low current demonstration topics (e.g. 'Lifters', 'Jacob's Ladders', 'Plasma Spheres', 'Kirlian photography', 'Ion Motors', etc...)
--Capacitor discharge demonstration: (e.g. 'Quarter Shrinkers'/'Can Crushers', 'Rail/Coil Guns', 'EMP generators', electrical weapons, etc...)

Please be advised that site policy prohibits my response to most inquiries coming under the latter category...
=================================================

Scope of this tutorial
Provision of a minute, 'step by step' procedure for modification of 'heavy duty'
AC LOPTs for serious EHT application/research...

Said procedure having the following principal goals:
-- Improvement of insulation integrity via removal of auxiliary windings coaxial to the EHT winding.
-- Enhancement of versatility via electrical 'floating' of the EHT winding.
-- Appropriate adjustment of reluctance gaps.


The desirability of LOPTs:
Of the commonly available magnetic components applicable to low through medium power EHT 'generation', the LOPT offers the advantages of relatively high power intermittent operation (several hundred Watts per transformer) and useful continuous power operation (to Ca. 150 Watts each transformer under forced air cooling). Moreover, LOPTs' amenability to resonant (and, hence, sinusoidal) drive permits development of systems productive of highly desirable mean output EMFs (≈70% peak) as opposed to the rather low (1% to 5% 'spike' EMF) characteristic of flyback and similar pulse driven/energy storage topologies. Additionally, the inherent output symmetry attending resonant drive topologies facilitates implementation of effective external EMF 'multiplication' schemes.

Prominent among the LOPT's disadvantages are the common expedient of integral rectification/EMF multiplication circuity and 'end point' grounding schemes --- While the former objection is readily addressed via judicious transformer selection, the latter requires minor 'reconstruction', said procedure being the topic of this tutorial.

A few words regarding the unsuitability DSTs and their ilk:
Principally
1) Integral components electrically unsuited to general application.
2) Practical impossibility of modification for improved EHT winding to core insulation.

Re: point 1 (above) Although asymmetric drive may permit peak forward (and hence output) EMFs well in excess of the internal rectifiers' PIVs - such is, of course, inapplicable to 'filtered' or otherwise capacitively loaded schemes sans additional external rectifiers - moreover internal rectification greatly complicates cascading of multiple LOPTs for increased EMF and/or development of balanced output schemes...

Re: Point 2 (above)
'DC' LOPTs are constructed as indivisible units sans margin for modification -- moreover (in the case of DSTs) the rectifiers are 'distributed' throughout the winding...

LOPT Selection:
The most desirable transformers are those intended for direct 'generation' of (pre-rectified) accelerating potential for large CRTs -- Contrary to common belief such units are yet readily available from long-established electronics supply houses (whom, in my experience, are only too happy to wave 'minimum purchase' and 'wholesale only' policies at the prospect of disposal of what they regard as dead stock) --- That said, one should expect to size their purchase so as to offset the supplier's 'invoicing costs'... Prices as low as $20 (USD) per transformer (in reasonable quantities) are not uncommon...

The following images are offered as an aid to recognition of the desired form factor:

Assorted LOPTs typical of the desired geometry
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/lopts-jpg.101773/

Detail - Axial view
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/lopt2-jpg.101772/

Detail - Transverse view
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/nos_tyre_lopt-jpg.101774/


The modification procedure:


--Please do not commence disassembly of the transformer prior to reading and comprehension of the entire tutorial...

To Begin:
Disassembly of the LOPT unit

Tasks:
1) Remove any tape, looped conductors, ground leads, etc... bonding the frame to the form.

2) Free each end of the frame ligature -- note that said fastener will take the form of a metallic strap or bolt running from one side of the frame, along the top 'facet' of the form, through the center of the EHT winding assembly, to the opposite side of the frame.
2A) In the case of a cylindrical bolt, remove the burr then carefully withdraw the bolt from the assembly
2B) In the case of a strap, straighten each fastening 'tab' then splay the frame such that the frame 'ears' clear the ligature tabs -- Do not attempt to withdraw a non-cylindrical ligature from the EHT winding assembly at this point!

3) Draw the frame rails 'back' such that the transformer may readily be be removed from same.

Remove transformer (i.e. core and winding assembly) from the frame -- please retain frame, ligature and any lose mounting components.

=================================================
Removal auxiliary windings from 'lower leg':
==== This installment under composition in another post (Feb 12 2016) ===


For these purposes we will consider four (coaxial) features of the EHT winding assembly:

To Wit:

(Distal to medial).
1) The EHT 'tyre' (comprised of the EHT winding proper, potting material and bunting).
2) The Auxiliary shell (a paperboard or polymer 'collar' intervening the medial aspect of the EHT winding and the distal aspect of the Aux winding...
3) The Aux Winding{s}.
4) The form sleeve (intervening the medial aspect of the Aux winding and the ferrite form).

Please note said features in the image below:

Image of intact EHT winding assembly.
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/i1_1-jpg.101749/


Step 1) Locate the lug carrying the EHT return:
The EHT return generally emerges with one or more AUX leads from the distal circumference of the AUX winding whence they are tied to a shell lug...

In this instance, said lug occupies the 2-o'clock postilion -- The image below shows said leads emerging from the Aux winding immediately below the CCW edge of the lug (as indicated by the ball-point pen) -- of special significance is the extreme peripheral position of the break-out point.

Image of the bundle containing the EHT return.
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/i1_2-jpg.101750/

Step 2) Separate and identify the EHT return:

Tasks:
1) Carefully unsolder all leads from the lug identified in Step 1 (above).
2) 'Untwist' and otherwise separate said leads.
3) Using a resistance indicator, check each lead for continuity to the EHT output contact --- the return lead will show a resistance of between 400Ω and 1000Ω All other leads should show infinite resistance (i.e. no continuity).

In the case of the demonstration transformer, three leads were tied to the lug -- the continuity examination identified the 38 AWG lead as the EHT return (said lead indicated by the pen in the attached image).

Image of separated EHT return --- Note that the associated lug was broken out of the way.
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/i1_3-jpg.101751/

Step 3) Remove the form sleeve:

Please note: Far and away the most significant challenges attending this procedure owe to the 'gossamer' nature of #38 and #40 AWG conductors... From this point onward it will behoove the reader to remain alert to the location of the EHT return whenever handling the assembly - while a severed or broken return lead is not necessarily 'fatal to the cause' - such will greatly complicate matters via the requirement of 'teaseling out' the end of a #40 or even #42 (AWG) lead from the lacquered winding!

Tasks:
1) Carefully dress the return lead out of 'harm's way'.
2) Twist, pry and/or break the form sleeve out from the center of the Aux winding.

Image of EHT winding following removal of the form sleeve. Note the EHT return at ~ "2 O'clock"
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/i1_4-jpg.101752/

Step 4) Remove the AUX winding:

Precautions:
A) While 'unraveling' the Aux winding, apply counter-thrust only to the shell --
as opposed to the tyre!
B) While debriding residue from the 'medial gap' following removal of the Aux Shell - great care must be exercised is damage to the medial layer{s} of the EHT winding to be avoided!

Tasks:
1) Cut all leads attached to all remaining lugs.
2) Using a surgical pick or similar instrument, pry a few 'layers' of the Aux winding into the center such that they may be grasped with forceps.
Image of Aux winding prepared for removal.
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/i1_5-jpg.101753/

3) Grasp the the loosened layers and begin withdrawing ('unraveling') the Aux winding -- Taking great care to avoid application of tension to the return lead as you progress toward the periphery.

Image of Aux winding in an intermediate stage of removal.
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/i1_6-jpg.101754/

Note: The EHT return will typically be 'laminated' between the penultimate and ultimate layers of the auxiliary winding bunting
4) Cautiously break (not tear!) the bunting material away from the return lead.

In the image below you may observe the end of the EHT return (as per the pen) and its emergence from the bunting in the gap intervening the shell and the deflected bunting medial to the remaining lug at 4 O'clock

Image of EHT return embedded in peripheral Aux winding bunting.
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i1_7-jpg.101755/


Image of EHT winding following complete removal of Aux winding
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/i1_7-jpg.101755/

Step 5) Remove the AUX Shell:

Tasks:
1) Carefully break, crumble and/or fold the auxiliary shell into the 'medial gap' via symmetrical application of force to the distal labra of same at quadrature to the plane of the return.

Under no circumstances attempt to pry the shell from the interstices!!! Doing so will almost certainly damage the EHT winding beyond repair!

2) having thus loosened the shell, carefully remove the fragments being ever mindful of the return...

Images of the EHT winding following removal of the auxiliary shell...
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_1-jpg.101757/

∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_2-jpg.101758/

∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_3-jpg.101759/



Image of EHT winding and debris following removal of Form sleeve, Aux winding, and Aux shell:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_4-jpg.101760/


Note: Should the reader's EHT winding be potted in silicone (as opposed to merely 'jacketed' as in the case of the demonstration transformer) it will be desirable to arrive at this juncture sans disruption of the potting material -- Should a breach occur, prompt repair via application of electronics grade RTV is advisable...

Step 6) Prepare The Dummy Shell:

Note: Owing to the 'brittleness' of 'Purell' grade polypropylene, use of a sharp instrument is recommended!

Tasks:
1) Excise the the base of the pharmaceutical vial.
2) Section the (resulting) cylinder longitudinal to its axis.
3) Temporarily mount the dummy shell on the ferrite form -- Verify end-clearance ≥ 5mm (form pieces in firm apposition) If end-clearance < 5 mm, trim the dummy shell to 'compliance' but try to keep end-clearence < 1 cm

Image of prepared dummy shell:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_5-jpg.101761/


Image of correctly 'trimmed' dummy shell on leg of LOPT ferrite form:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_6-jpg.101762/

Step 7) Prepare Return Lug:
Tasks:
1) Form a #4 solder lug such that the 'tab' is at a right angle to the plane of the fastener surface.
2) Drill a #66 (~0.83mm) hole through the lug immediately above the bend.

Image of properly prepared lug -- Notice the small (#66) hole near the fastener angle.
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_7-jpg.101763/

Step 8) Installation of the dummy shell:

Image of EHT winding at this juncture - note return lead:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_8-jpg.101764/

Tasks:
1) Furl the dummy shell, then position it in the medial gap from the side of the winding opposite the return lead such that the 'cut' faces opposite the output 'tower'.
2) Using a stylus, etc, mark the dummy shell at the point axial to the emergence of the return and 5 mm back from the edge of the dummy shell.
3) Carefully remove the dummy shell.
4) Using a drill bit commensurate with a #4 bolt, bore through the dummy shell at the point marked in task #2.
5) Liberally coat the dummy shell and gap surfaces with electronics grade RTV. -- Avoid application of RTV to the return lead!
6) Reinstall the shell as described in task #1, taking care to position the cut opposite to the output 'tower', and the bolt hole axial to the emergence of the return lead.
7) Mount the EHT winding/Dummy Shell assembly on the ferrite form.
8) Adjust the (linear) position of the winding tyre on the shell such that the former is equidistant from the form piece angles while the end of the shell emerging from the 'return lead side' of the winding tyre extends as far as possible from the winding sans contact with the form piece.
9) Remove the form from the assembly taking care not to alter the relative position of the shell/winding.
10) Manually expand the shell as much as possible -- smooth and 'touch-up' the silicone... --- Again keep the return lead free of adhesive!
11) Allow RTV to cure for at least 72 hours at temps of 45°F through 60°F -OR- for at least 48 hours at temps > 60°F

Step 9) Installation of the Lug and connection of the return:
Tasks:
1) Carefully insert the #4 bolt from inside the shell.
2) Secure the lug to the top of the shell as shown in the images below.
3) Solder-tin the end of the return lead.
4) Insert ~ 2 mm of the return lead into the #66 hole near the base of the lug then secure it with solder.

Note: It is imperative that you neither trim nor glue the return lead at this point! - Please loop any slack as shown in the images.

Images of the assembly; Dummy shell & Lug installed, return connected:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_9-jpg.101765/

∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i2_10-jpg.101766/

5) Verify that the DC resistance (lug to output tower connector) -- is that measured in step #2, task#3


Anticipated FAQs
Note: the following questions approximate the 'mean' of copious feedback received at this 'stage' during composition of the original draft...

Q) The lug screw head will short the EHT return to the form -- and anyway, who wants the winding rattling around on the form like that?
A) We're not done yet! --- Patience!

Q) One centimetre is insufficient spacing of lug and winding for 50kV operation!?
A) That's why we're going to intervene lug and tyre with a thickness of PTFE in a subsequent step.

Q) Why not trim the return lead to length or at least glue it to the shell?
A) Prior to complete curing of the shell-to-tyre adhesive, and robust securing of the lug, provision for 'immunity' to relative motion of the parts makes good sense.

Q) What do spools of solder and capacitors have to do with rebuilding an LOPT?
A) The extraneous items in the images assist to achieve optimal focus -- especially as regards diminutive objects (IOW I'm using an inexpensive camera).

Step 10) Prepare the CPVC Form sleeve:
Tasks:
1) Cut a length of 3/4" (id) CPVC tubing equal to the total length of the form-leg on which it will be placed (In this case of this demonstration 8.5 cm) See the two images immediately below...

Image illustrating desired sleeve dimension
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i3_1-jpg.101767/

Image of form and adjacent CPVC section cut as per step #10
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i3_2-jpg.101768/

2) Cut shoulder stirrups in CPVC Sleeve:
Note: the stirrups must be sufficiently deep as to allow a slight amount of end-clearance when mounted upon the form (such that form-piece apposition is assured).

Image of form pieces and 'prepared' CPVC sleeve
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i3_3-jpg.101769/

Image of form and CPVC sleeve in an intermediate state of assembly
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i3_4-jpg.101770/



Image of (temporary) fully assembled form and CPVC assembly
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/i3_5-jpg.101771/

Step 11) Install CPVC form sleeve in EHT winding assembly:

Image of components referenced in this step:
(L to R) CPVC sleeve, EHT winding assembly, Form [core] pieces
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/1-jpg.101711/


Tasks:
1) Assemble EHT winding, CPVC sleeve and form as shown (below).
2) Using PTFE shims, center EHT winding assembly about CPVC sleeve (both sides).
Note: While the adhesive does not bond PTFE it is, nonetheless, essential that the shims be so formed as to preclude (interlocked) captivity therein!

Images of mounted and centered EHT winding as seen from 'EHT return side':
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/2-jpg.101712/

∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/3-jpg.101714/

∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/5-jpg.101717/

4) Using acrylic-based 'hot-melt' adhesive, tack the CPVC sleeve to the polypropylene shell at several points each side.
5) Remove form pieces.
6) Fill the space intervening the CPVC sleeve and the PP shell with acrylic-based 'hot-melt' adhesive taking care not to disturb the relative positions of said structures!
7) Allow the adhesive at least 60 Minutes to cool/cure.
8) Withdraw the shims.

Image of assembly immediately following withdrawal of shims as seen from EHT return side.
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/7-jpg.101719/

9) Fill the 'shim gaps' with acrylic-based 'hot-melt' adhesive.

Image of EHT winding assembly following completed installation of CPVC sleeve.
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http://forum.allaboutcircuits.com/attachments/8-jpg.101721/


Identification of components referenced in steps #12 through #15 (inclusive):
1) PTFE insulator.
2) EHT Winding assembly.
3) Form pieces.
4) LOPT Frame.
5) Polyolefin (heat shrink) sleeves.
6) Elastic cushions.
7) Frame ligature.
8) Form standoffs.
9) Reluctance gap spacers (see text).
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/lopt_partsnum-jpg.101730/

Step 12) Prepare form guides

Prior to proceeding, it is imperative that the form pieces are absolutely free of adhesive residue, etc...!

Tasks:
1) Trim two pieces of polyolefin tubing such that they extend the full inside length of each 'winding leg' of the assembled frame (as shown below).
2) With the sleeves in place on the form, clamp or otherwise place form pieces in firm apposition with close attention to alignment of same.
3) 'Heat-shrink' the polyolefin tubing -- Note: expeditious completion of this step will significantly reduce liability to ferrite breakage (secondary to uneven application of heat) and/or permanent shift of magnetic properties (secondary to excessive temperature)...
4) Allow at least 20 Minute 'cool down' period then carefully disassemble the form such that the heat-processed polyolefin tubes remain installed on each 'half-leg of a single piece.
5) Trim another sleeve then repeat the above procedure such that one leg is bound by a double layer of polyolefin.

Image of assembled form 'sporting' the unprocessed polyolefin sleeves (Post task #1)
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/preshrink-jpg.101742/

Image of form piece following processing of sleeves (Post task #4)
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/separated1-jpg.101743/

Image of form piece following processing of second sleeve on (arbitrarily chosen) EHT winding 'leg' (Post task #5)
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/separated2-jpg.101744/

Step 13) Fashion and place reluctance gap spacers

Note: Reluctance gaps will be incorporated to reduce liability to saturation (in all cases) and to leave the transformer compatable with 'flyback' drive topology should same be desired... --- That said, this series prefers forward transfer paradigms (as explained in the introduction to this tutorial).

Note: The (.95mm) reluctance gap spacers salvaged from the disassembly process are shown in the "component identification image" for completeness of presentation only --- Based upon core material properties and desired output current, optimal operation requires development of reluctance gaps consistent with the inequality: 0.25mm < Gap < .5mm -- To this end 0.4mm (nominal) PTFE sheet stock will be used.

Tasks:
1) Cut two small disks of PTFE having maximum diameters (as a practical matter, major axises) slightly less than that of the form piece 'ends'...
2) Check actual spacer thickness with a caliper -- then verify with a mechanical micrometer.
3) Very lightly smear one side of each spacer with electronics grade RTV.
4) Place each spacer ('siliconed' side down) flat upon each form piece end (inside each polyolefin sleeve).
5) Via firm tamping with a pencil eraser or similar implement assure that the RTV film 'tacks' the spacers to the form piece ends...

Images showing representative spacer and measurement of thickness:
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/airgapcal-jpg.101725/

http://forum.allaboutcircuits.com/attachments/airgapmic-jpg.101728/

Image showing correct pre-assembly placement of spacers:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/airgapinplace-jpg.101727/


Step 14) Assemble LOPT

Tasks:
1) Tack elastic cushions and form standoffs to frame then position as shown:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/loptframechoks-jpg.101732/


2) Verify that the reluctance gap spacers are fast to the form piece.
3) Hold the frame ligature in lengthwise apposition with the utmost facet of the form's EHT winding leg. (i.e. the leg carrying a double thickness of polyolefin).
4) Carefully place the EHT winding assembly over the form piece leg and ligature such that the shoulder stirrup engages the the form piece as shown below:

Form ligature in pre-assembly position:
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/asm1-jpg.101729/

Views of EHT winding, form piece and form ligature in intermediate state of assembly.
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/lopt_preasmby-jpg.101731/

vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/loptpartialasmby-jpg.101735/

Slowly press opposite form piece into place allowing time for displacement of air from the polyolefin tubes.
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/loptpreframe-jpg.101737/


5) Install transformer assembly into frame such that the ligature strap ends extend through the 'ears' of the frame.
6) Very carefully but firmly clamp assembly preparatory to fastening...
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/loptpresoldered-jpg.101739/


7) Solder ligature ends to frame
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/loptpostsoldered-jpg.101736/

Step 15) Install lateral insulator

Tasks:
1) Form a carotid of 0.093" (AKA "93/1000'ths") PTFE sheet stock as per item #1 in the image (immediately below):
∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨∨
http://forum.allaboutcircuits.com/attachments/lopt_partsnum-jpg.101730/

2) Size, shape and fit the insulator to the EHT winding assembly in a manner consistent with the following images but do not apply adhesive at this time.
Note that the insulator must trimmed to closely fit the shell and extend beyond the distal aspect of the EHT winding by at least 1 cm.

νννννννννννννννννννννννννννν
http://forum.allaboutcircuits.com/attachments/final-jpg.101745/

vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv
http://forum.allaboutcircuits.com/attachments/strikeshldside-jpg.101748/

3) Having properly formed the insulator, 'de-gloss' one side of same using '00' grit emery cloth/paper.
4) Apply liberal quantities of electronics grade RTV silicone to the appropriate surfaces of the EHT winding assembly and the entirety of the 'sanded' side of the insulator.

5) Attach the insulator to the EHT winding assembly as shown in the above images
6) Apply an excess of electronics grade RTV to the exposed side of the insulator and adjacent areas of the EHT winding assembly...
7) Distribute the RTV over the insulator and EHT winding assembly surfaces such that an interlocking bond is established.
8) Position the LOPT 'insulator up' then allow at least 48 hours curing time.



To be continued/refined via edit...

Best regards
HP

 

@Aleph(0)

Inasmuch as this thread contains considerable technical content of potential interest to others (and in connection with the tutorial series) -- I feel a conscientious review of same is 'in order' --- To said end Please review your posts on this thread, with an eye to error detection/correction -- No need to concern yourself with spelling, grammar, etc... Please focus only upon disparity of meaning vs intent...

In the event that I 'quoted' erroneous content from any of your posts, please advise me such that I may re-quote the revised version --- Similarly, should you have quoted any of my errors please advise me such that I may correct the 'original'

I will do likewise with my posts shortly...

No need to review our off-topic content!

By the time you read this, the tutorial should be ready for transfer to 'Projects ---' So... Please give it a through, multi-pass, 'proofreading'!!!

All the best
HP

 

HP under heading of _central topics_ I say you should include endothermic anomalies to list cuz they are so common with anything to do with atmospheric ion streams! I know maybe you're afraid ppl with think it's _fringe_ but references to contrary anyhow you aren't claiming paranormal manifestation! I say it is ion motion manifestation of Wirbelror principle but defined apart from stupidly over simplified Hilsh principle because conditions preventing ASWs also prevent the effects, DUH! I have ragey feelings about fools who prefer citing and reference to research that they don't even understand to thinking on their own! I know science and all scholarship depends on passing along knowledge so each generation doesn't have to always reinvent the wheel, but it's getting so that idiots who are afraid to think and happy to just compiling and misinterpreting results of others are claiming to be scientists! Now I'm saying that's just wrong! Idiots are bad enough but I agree with you that followers and fans and devotees are the worst of the worst and the embarrassment of the human species!

Inasmuch as this thread contains considerable technical content of potential interest to others (and in connection with the tutorial series) -- I feel a conscientious review of same is 'in order' --- To said end Please review your posts on this thread, with an eye to error detection/correction -- No need to concern yourself with spelling, grammar, etc... Please focus only upon disparity of meaning vs intent...

Good idea! I'll do that when back to regular schedule!

@Aleph(0)
In case you have a chance to look in here - please note that, although the intro is yet in need of a little 'work', I am now 'putting the shine' on the content...

Principal goals are as follows:

--- Achieve coherency via consistency of nomenclature, presentation, and formatting...

--- Achieve formality/clarity via 'editing out' 'smilies' idiomatic expressions and other 'culture specific' modes of expression - It is my desire that this be as near 'universally accessible' to all English 'speakers' as practical -- That said, I will not and can not corrupt the tutorial nor insult the reader via a 'dumbed down', condescending, presentation...

--- Enhance comprehensibility of complex procedures/descriptions via quasi-redundant framing of perspective as well as 'deference' to images.

--- Enhance readability via refraining from over/unnecessary use of "scare quotes", multiply nested parenthetic structures, and otherwise (especially) egregious punctuation -- that said, if you're expecting 'Neustadt material', expect to be sadly disappointed!

For all that, I envision having the current tutorial ready for transfer to 'Projects' upon your return

HP it's looking real good! Sry I've got to go for now See you in March

 

HP I was thinking how you are starting tutorial with fb totally disassembled to core, hv tire, and frame so I had to come back on here now to say you should start by walking them through dismantling from beginning! I say if they don't have whys and wherefores about that they'll break ferrite core for sure I know that's tall order cuz you didn't take pics for that (which is my fault) but you can show them with another transformer for reference and just explain if not wanting to dissect it just yet. Simple part is to take out of frame and cut non coaxial windings off lower leg, but separating form halves is tricky part! Now I say don't overwhelm them with inductive core heating to soften glue! I know it works best but that means teaching them about drivers straightaway so like putting carriage before horse! Anyhow if they soak the lower half in acetone until epoxy is degraded there and afterwards gently heat form with heat gun so heat transfer to top joint under hv winding without enough intensity to alter ferrite properties or damage hv winding that can work if they have the patience!

Sorry to assign work and run I already had tons on myself but now I'm doing IT dept's work for them too! We need to roll back OS on all semidedicated servers cuz FW caught out Edge as a security pipeline so Win10 is non HIPAA compliant (I'm saying what was their first clue!) But silver lining is that at least we'll be rid of Clippys evil big Sis Cortana I wish there was third party package to fix win10's built in spyware and corporate control ware! As for me, I'll stick with XP cuz no security updates is safer than what MS has going now!

HP I hope you see what I mean about tutorial, I'm very sorry about this cuz I was one who told you to start with winding when we weren't thinking ahead! I will be very happy to see you in person in a few weeks!

 

HP under heading of _central topics_ I say you should include endothermic anomalies to list cuz they are so common with anything to do with atmospheric ion streams!

As you suggest -- Said area is subsumed by the topic 'Ion Flow' --- Interested parties will recognize this - others won't likely care --- no need to (further?) 'swamp' the intro with a ponderous litany of sub-categories/related subjects...

I say it is ion motion manifestation of Wirbelror principle but defined apart from stupidly over simplified Hilsh principle because conditions preventing ASWs also prevent the effects, DUH!

In my considered option they are distinct phenomena -- One need merely consider that manifestation attending acoustic standing waves (or, similarly, 'symmetrical' odd order requiting 'fronts') readily yield minimum temps <100°K whereas 'Hilsh tube' effects scarcely reduce the temp more than ~15°C/K below ambient... -- IOW Point taken, but with qualification!

I have ragey feelings about fools who prefer citing and reference to research that they don't even understand to thinking on their own! I know science and all scholarship depends on passing along knowledge so each generation doesn't have to always reinvent the wheel, but it's getting so that idiots who are afraid to think and happy to just compiling and misinterpreting results of others are claiming to be scientists! Now I'm saying that's just wrong! Idiots are bad enough but I agree with you that followers and fans and devotees are the worst of the worst and the embarrassment of the human species!

I think most intelligent, motivated and emotionally mature people share your (our) abhorrence of mindless deference and 'hero worship' for the sloth and cowardice it represents! -- That said, let's save our ire for the 'condition' as opposed its 'patients' --- 'Typhoid Marys' though they may be --- Please don't get me wrong! - Your stance makes me very proud! Yet I'm given to wonder why (intelligent) young folk are often so angry? -- Perhaps same is a manifestation of impatience?...

Good idea! I'll do that when back to regular schedule!

Thanks! --- My long-term plan is to 'condense' the on-topic portions of this thread for presentation as a 'supplement' to the tutorial series --- Thoughts?

All the best
HP

PS --- Response to post #333 pending careful consideration of your proposals...

 

HP I was thinking how you are starting tutorial with fb totally disassembled to core, hv tire, and frame so I had to come back on here now to say you should start by walking them through dismantling from beginning! I say if they don't have whys and wherefores about that they'll break ferrite core for sure

Agreed! --- I've begun composition of the suggested initial steps --- New images will be modeled by a similar transformer...

I say don't overwhelm them with inductive core heating to soften glue! I know it works best but that means teaching them about drivers straightaway so like putting carriage before horse! Anyhow if they soak the lower half in acetone until epoxy is degraded there and afterwards gently heat form with heat gun so heat transfer to top joint under hv winding without enough intensity to alter ferrite properties or damage hv winding that can work if they have the patience!

Agreed and 'WILCO' --- Though I'm bound to say the cost of maintaining 'universal accessibility' is fast approaching its limit!

We need to roll back OS on all semidedicated servers cuz FW caught out Edge as a security pipeline so Win10 is non HIPAA compliant (I'm saying what was their first clue!)

---Emphasis added---
What indeed!?!? --- Sounds to me as if you've a personnel problem to sort --- Stat!

at least we'll be rid of Clippys evil big Sis Cortana

Oh! That! I find it a bit unfortunate, really --- "Point of origin vs. point of return" and all that --- MS started out writing games (TRS-80, Atari, etc...?) and, so it seems, is 'bowing out' with Halo -- A four decade journey from Nowhere to Nowhere by way of the arcade --- Embarrassingly, Cortana isn't even impressive as chatbots go -- It is drably reminiscent of certain antique toys equipped with 'pull strings' - Canned responses in this day and age? Come-on MS! You can do better than that!? --- That said, I must confess to some amusement at its propensity for 'back talk' and rejoinders

I wish there was third party package to fix win10's built in spyware and corporate control ware!

Ummm... Ever hear of LINUX?

HP I hope you see what I mean about tutorial, I'm very sorry about this cuz I was one who told you to start with winding when we weren't thinking ahead! I will be very happy to see you in person in a few weeks
!

No problem! -- I'm pleased you bring these matters to my attention! -- 'Tis merely that I'm bored of all this mechanical/construction folderol -- I'll be pleased when we're on to drivers, etc...

Looking forward to your visit!
All the best
HP

 

--Relocated--

 

HP I say good job! But you'd be doing faster if you'd spend more time on here than hanging at EDN and always shooting breeze on Doximity! 500 _posts_ in last few months over there is a lot when you say you've sworn off! You are the one who's saying social networks are bad habit! Now you are imagining that trades and professional network are like houses built from tempered glass? HP I can tell installment is still at formative stage so nothing to comment on right now except to say that specialized instruments can be confusing to unfamiliar ppl, just saying.

 

HP I say good job! But you'd be doing faster if you'd spend more time on here than hanging at EDN and always shooting breeze on Doximity! 500 _posts_ in last few months over there is a lot when you say you've sworn off! You are the one who's saying social networks are bad habit! Now you are imagining that trades and professional network are like houses built from tempered glass?

Well... On the subject of 'glass houses' I'm bound to say that my 'base' penchant for the 'scandalous' likes of EDN and Doximity compares quite favorably to your four week's long 'business junkets' which being 10% business and 90% drinking, doping and partying!!!

HP I can tell installment is still at formative stage so nothing to comment on right now except to say that specialized instruments can be confusing to unfamiliar ppl, just saying.

Special instruments? Specifically? --- Perhaps it is fortunate that readers lacking sufficient intellect or motivation to 'look up' unfamiliar tools, etc... via Google (and its ilk) should be thus precluded from 'playing about' with devices capable of overload conditions >900 mA at >800V --- Just tellin!

Ya know @Aleph(0) --- I've had about enough of this! --- I've committed a great deal of time and effort to this project over its course, and, more recently, over the last couple weeks! -- While I genuinely welcome constructive criticism, I resent your intimation that I am somehow 'slacking off'! --- Startling though it must seem - I have interests, responsibilities and, yes! A life beyond this thread! --- Moreover, my annoyance with your impatience is exacerbated --in no small measure-- by the fact that you have flatly refused/ 'ducked out of' my every request that you offer even minimal contribution to this effort! --- Then too is the fact that you continue to offhandedly fail to respect my desire for on-line anonymity/privacy (CIP your citation of other on-line services on which I participate) -- Granting that appreciation (or, lack thereof) of privacy is a 'generational thing' you, nonetheless, know my feelings on the matter!!!

I intend to finish the present tutorial regardless --- After which -- while I would very much like to continue the series, your (at very least, 'nominal') participation will be required!...

Hopefully
HP

 

Seems like RK has rubbed off on Aleph_0.

 

Seems like RK has rubbed off on Aleph_0.

Well... It is certainly true that they share an annoying (and, I might add, self defeating) propensity for 'larking about' --- Unlike RK, however, Aleph has added insult to injury via reversal the blame!

One can but hope...

Best regards
HP

 

On the subject of 'glass houses' I'm bound to say that my 'base' penchant for the 'scandalous' likes of EDN and Doximity compares quite favorably to your four week's long 'business junkets' which being 10% business and 90% drinking, doping and partying!!!

HP if I can live with your asceticism you can sure as heck live with my hedonism! So you are saying I should wait until I'm octogenarian before I enjoy life? Now I am saying I'm guilty of occasional alcohol and other drug use NOT abuse and OMG! Even a bit dalliance from time to time! SO WHAT? But I am not a drunk or other sort of addict and you already said you know that! HP is like I said before! I think to be trapped in corporal form is totally bogus! Since this degrading biological BS is hand fate dealt all of us I say Ok, fine! So that's how I choose play it! HP You fond to say _life is too short_ for this and that but I am saying it's too short to be taken seriously for ANYTHING! So I DON'T! So enough of that!

HP You say I larking about but now I'm saying you're the one larking about by using my bruskqueness in last post as excuse to drag feet on tutorial again? HP I'm very interested for us to be doing entire course of tutorials! EMR and like that are like you say purely beautiful cuz totally independent of material physicality and I am saying those phenomena are more aligned with human mind rather than treacherous filth which is organic corporeality! HP I only bug you about Doximity and like that cuz YOU said is like habit you're trying to kick! Anyhow they're too many subscribers for your anonymity to be jeopardized cuz of me telling that you're member there!

HP I am aware that your disapproval of my excesses is out of concern for my welfare instead of moral censorship and I am very happy you care so much!
HP I owe you apology for post that sounded ungrateful after all the work you did (which was way more than I knew when made post) But plz be fair! All I did was complain that cooling your heels on the _trades_ was distracting you from tutorial and you overreacted by saying my very important and not at all fun business trips are nothing more than orgies! I think you owe me apology too?

HP I am delighted to help with tutorials but I need specific idea of what to do? Plz remember that my connection to site is mostly broken so on list editing is not option.