RE: [TCML] RE: Splicing wires - Secondary Coil

["McCauley, Daniel H" <daniel.h.mccauley@xxxxxxxx>]

- Ouch if it was the manufacturer.  I wasn't responsible for the poor workmanship.  All were replaced at no charge. 


Ouch if it involves 100 coils.

Peter
www.tesladownunder.com

----- Original Message -----
From: "McCauley, Daniel H" <daniel.h.mccauley@xxxxxxxx>
> Steve,
>  .....
> And I don't have any measurements handy, but I have plenty of bad 
> experience with splices.  Just last year, I had a magnetics house down 
> in Mexico wind 100 small coils for a customer of mine.  These were for 
> a small self-tuning SSTC coil.  After having each of the first (5) 
> coils I tested fail about 85% up the coil, i began to suspect that 
> something was amuck.  Upon close inspection of the coils, i noticed a splice point.
> After some discussions with the manufacturer, it was determined that 
> the coils were all wound initially, but too short, so they decided to 
> splice and continue winding the coil to spec.
>
> Now electrically (with LCR meter), these spliced secondaries measured 
> just fine, and from visual inspection, you would never even notice the 
> splice unless you used a magnifying instrument.  But when connected to 
> a self-tuning driver, they all failed at that splice point.
>
> Now I certaintly don't claim to know all the theoretical and 
> mathematical explanations to why this occurred, and I'm *certaintly* 
> open to suggestions from other people regarding this, but I do know 
> that they were all failing at this point, and the only thing I can 
> think of is some sort of impedance discontinuity due to the splicing causing this problem.
>
> So again, its my opinion that if you have a self-resonant system, i 
> don't recommend splicing your secondaries.
>
> Daniel McCauley
> http://www.easternvoltageresearch.com
> DRSSTC, SSTC, Flyback Kits and Components!


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