Re: Caton connectors + Re: HV connectors needed!

To: tesla-at-pupman-dot-com
Subject: Re: Caton connectors + Re: HV connectors needed!
From: "Jim Lux" <jimlux-at-jpl.nasa.gov> (by way of Terry Fritz <twftesla-at-uswest-dot-net>)
Date: Thu, 30 Dec 1999 10:54:23 -0700
Approved: twftesla-at-uswest-dot-net
Delivered-To: fixup-tesla-at-pupman-dot-com-at-fixme


> 
> 
> Tesla List <tesla-at-pupman-dot-com> on 29.12.99 21:09:40
> 
> To:   tesla-at-pupman-dot-com
> cc:    (bcc: Marco Denicolai/MARTIS)
> Subject:  Re: HV connectors needed!
> 
> 
> 
> >Original Poster: "Jim Lux" <jimlux-at-jpl.nasa.gov>
> 
> >Do you need shielded connectors?
> 
> No shield needed, 1 pole only
> 
> >Is it DC or AC or RF?
> 
> It is the current charging the primary tank capacitor: max 20 kVDC,
oscillating
> there between 0 and 20 kV.
> 
> >Modified PL-259/SO-239's ("UHF" connectors) are popular and inexpensive.
> >Drill out the phenolic and replace with a length of acrylic or
> >polycarbonate rod.
> 
> And I do I manage with the central conductor pin? Can you specify,
please?
Banana jack/plug... 

The male side (made from the PL-259) is a rod/tube about 10 cm long (tube
is easier to work with unless you have a lathe to drill the hole, but
harder to find). Epoxy or silicone the banana plug into the end of the
tube. Force fit, or epoxy, the tube/rod into the drilled out plug. All you
keep from the PL259 is the outer shell and the threaded coupling. 

The female side is much the same. You drill out the phenolic insulator (or
hit it with a hammer and drift). Get a piece of tubing (or a block) that is
the same outside diameter as the mounting flange of the SO239. Drill it out
to match the OD of the male plug you just built. Drill/tap 4 holes into the
top of the block to mount the flange on (the panel you are mounting on
sandwiches in between the plastic and the mounting flange). Epoxy/silicone
the female banana jack in the end of the tube where it nicely engages the
plug. (I.e. do a trial assembly).

Once you get the dimensions worked out for your particular materials and
parts, you can crank out a whole bunch of these with a drill press in a
short time.

I've also just used PVC pipe for making "deep" banana plugs/jacks.  A piece
of 1/2" PVC nests nicely inside a piece of 3/4" Sch 40 PVC. The banana jack
mounts in a 3/4" cap.The other end of the 3/4" PVC is glued to a standard
PVC electrical conduit "terminal adapter" (i.e. a slip/Male thread), which
is mounted to the panel with a standard conduit nut. For the Plug end, you
need to find one of the 1/2" plugs that slides INSIDE the pipe (which is a
bit trickier). You trim this down with a file or sandpaper so it doesn't
hang over the edge of the 1/2" pipe, mount the banana plug into it with the
wire fed back up the tube. 

If you want a fancy shrouded jack/plug, find yet another size that nests
outside the 3/4"..

You can make this as long as you want to increase the creepage distance at
will.  
> 
>
The Caton connectors are very nice, and resonably priced, if you put any
sort of rational price on your labor.