Ramsey Electronics PG13 Instruction Manual

PG13 1
Ramsey Electronics Model No. PG13
Have you ever wanted to play with a controlled substance? Now you can! It is called plasma, and it is easily generated by this nifty high voltage kit. This is the same though more powerful supply that is used in Plasma Balls and neon art, and can be used for all sorts of high voltage experiments! Turn a standard light bulb into a plasma sphere!
Perfect for driving a Jacob’s ladder. See plasma at work!
Can light many feet of neon tubing
Perfect for driving plasma balls, even make a standard light bulb into a plasma sphere!
Optional 12VAC transformer and this kit are all you need to begin experimenting!
Can generate sparks up to 2 inches.
Very thorough manual on high voltage safety, many neat experiments, and lessons learned along the way.
Can produce many of the same effects as Tesla Coil, on a smaller scale.
Great for science fairs!
DANGER
HIGH VOLTAGE
See instruction manual before operation
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RAMSEY TRANSMITTER KITS
FM100B Professional FM Stereo Transmitter
FM25B Synthesized Stereo Transmitter
AM1, AM25 AM Transmitters
TV6 Television Transmitter RAMSEY RECEIVER KITS
FR1 FM Broadcast Receiver
AR1 Aircraft Band Receiver
SR2 Shortwave Receiver
AA7 Active Antenna
SC1 Shortwave Converter RAMSEY HOBBY KITS
SG7 Personal Speed Radar
SS70A Speech Scrambler
SP1 Speakerphone
WCT20 Wiza rd Cable Tracer
ECG1 Heart Monitor
LABC1 Lead Acid Battery Charger
IG7 Ion Generator
CT255 Compu Temp Digital Binary Thermometer
LC1 Inductance-Capacitance Meter RAMSEY AMATEUR RADIO KITS
HR Series HF All Mode Receivers
QRP Series HF CW Transmitters
CW7 CW Keyer
CPO3 Code Practice Oscillator
QRP Power Amplifiers RAMSEY MINI-KITS
Many other kits are available for hobby, school, Scouts and just plain FUN. New kits are always under development. Write or call for our free Ramsey catalog.
PG13 PLASMA G EN ER A TO R KIT MANUAL
Ramsey Electronics publication No. MPG13 Revision 1.1d
First printing: November 2001 MRW
COPYRIGHT 2001 by Ramsey Electronics, Inc. 590 Fishers Station Drive, V ic t or, New York
14564. All rights reserved. No portion of this publication may be copied or duplic ated without the written permission of Ramsey Electronics , I nc. P rinted i n the United Stat es of America.
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PG13 PLASMA
GENERATOR KIT
Ramsey Publication No. MPG13
Price $10.00
TABLE OF CONTENTS
Safety Guidelines .................................4
History ...................................................9
Circuit Operation .................................12
Learn As You Build .............................16
Parts List .............................................18
Assembly .............................................19
Schematic ............................................24
Power Supply ......................................25
Testing .................................................28
Troubleshooting ..................................31
Experiments ........................................32
Component Placem ent ........................42
Warranty ..............................................43
KIT ASSEMBLY
AND INSTRUCTION MANUAL FOR
RAMSEY ELECTRONICS, INC.
590 Fishers Station Drive
Victor, New York 14564
Phone (585) 924-4560
Fax (585) 924-4555
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SAFETY GUIDELINES FOR HIGH VOLTAGE AND/OR LINE POWERED EQUIPMENT
Author: Samuel M. Goldwasser Corrections/suggestions: sam@stdavids.picker.com
Copyright (c) 1994, 1995, 1996, 1997, 1998 All Rights Reserved
Reproduction of this document in whole or in part is permitted if both of the following conditions are satisfied:
1. This notice is includ ed in its ent iret y at the begin ning.
2. There is no charge except to cover the costs of copying.
Introduction
Consumer electronics equipment like TVs, computer monitors, microwave ovens, and electronic flash units, use voltages at power levels that are potentially lethal. Normally, these are safely enclosed to prevent accidental contact. However, during servicing, the cabinet will likely be open and safety interlocks may be defeated. Depending on overall conditions and your general state of health, there is a wide variation of voltage, current, and total energy levels that can kill.
Microwave ovens in particular are probably THE most dangerous household appliance to service. There is high voltage - up to 5,000 V or more - at high current - more than an amp may be available momentarily. This is an instantly lethal combination.
TVs and monitors may have up to 35 KV on the CRT but the current is low—a couple of milliamps. However, the CRT capacitance can hold a painful charge for a long time. In addition, portions of the circuitry of TVs and monitors - as well as all other devices that plug into the wall socket - are line connected. This is actually more dangerous than the high voltage due to the greater current available - and a few hundred volts can make you just as dead as 35 KV!
Electronic flash units and strobelights have large energy storage capacitors which alone can deliver a lethal charge - long after the power has been removed. This applies to some extent even to those little disposable pocket cameras with flash!
Even some portions of apparently harmless devices like VCRs and CD players or vacuum cleaners and toasters - can be hazardous (though the live parts may be insulated or protected - but don't count on it!
This information also applies when working on other high voltage or line
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connected devices like Tesla Coils, Jacobs Ladders, plasma spheres, gigawatt lasers, fusion generators, and other popular hobby type projects.
In addition read the relevant sections of the document for your particular equipment. Specific safety considerations have been included where appropriate.
Safety guidelines
These guidelines are to protect you from potentially deadly electrical shock hazards as well as the equipment from accidental damage.
Note that the danger to you is not only in your body providing a conducting path, particularly through your heart. An y involuntary muscle contractions caused by a shock, while perhaps harmless in themselves, may cause collateral damage - there are many sharp edges inside this type of equipment as well as other electrically live parts you may contact accidentally.
The purpose of this set of guidelines is not to frighten you but rather to make you aware of the appropriate precautions. Repair of TVs, monitors, microwave ovens, and other consumer and industrial equipment can be both rewarding and economical. Just be sure that it is also safe!
Don't work alone - in the event of an emergency another person's presence may be essential.
Always keep one hand in your pocket when anywhere around a powered line-connected or high vo lta ge system.
Wear rubber bottom shoes or sneakers.
Wear eye protection - large plastic lens eyeglasses or safety goggles.
Don't wear any jewelry or other articles that could accidentally contact circuitry and conduct current, or get caught in moving parts.
Set up your work area away from possible grounds that you may accidentally contact.
Know your equipment: TVs and monitors may use parts of the metal chassis as ground return yet the chassis may be electrically live with respect to the earth ground of the AC line. Microwave ovens use the chassis as ground return for the high voltage. In addition, do not assume that the chassis is a suitable ground for your test equipment!
If circuit boards need to be removed from their mountings, put insulating material between the boards and anything they may short to. Hold them in place with string or electrical tape. Prop them up with insulation sticks plastic or wood.
If you need to probe, solder, or otherwise touch circuits with power off, discharge (across) large power supply filter capacitors with a 2 W or
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greater resistor of 100-500 ohms/V approximate value (e.g., for a 200 V capacitor, use a 20K-100K ohm resistor). Monitor while discharging and/ or verify that there is no residual charge with a suitable voltmeter. In a TV or monitor, if you are removing the high voltage connection to the CRT (to replace the flyback transformer for example) first discharge the CRT contact (under the insulating cup at the end of the fat red wire). Use a 1M-10M ohm 1W or greater wattage resistor on the end of an insulating stick or the probe of a high voltage meter. Discharge to the metal frame which is connected to the outside of the CRT.
For TVs and monitors in particular, there is the additional danger of CRT implosion - take care not to bang the CRT envelope with your tools. An implosion will scatter shards of glass at high velocity in every direction. There is several tons of force attempting to crush the typical CRT. Always wear eye protection.
Connect/disconnect any test leads with the equipment unpowered and unplugged. Use clip leads or solder temporary wires to reach cramped locations or difficult to access locations.
If you must probe live, put electrical tape over all but the last 1/16" of the test probes to avoid the possibility of an accidental short which could cause damage to various components. Clip the reference end of the meter or scope to the appropriate ground return so that you need to only probe with one hand.
Perform as many tests as possible with power off and the equipment unplugged. For example, the semiconductors in the power supply section of a TV or monitor can be tested for short circuits with an ohmmeter.
Use an isolation transformer if there is any chance of contacting line connected circuits. A Variac(tm) (variable autotransformer) is not an isolation transformer! However, the combination of a Variac and isolation transformer maintains the safety benefits and is a very versatile device. See the document "Repair Briefs, An Introduction", av ail ab le at this site, for more details.
The use of a GFCI (Ground Fault Circuit Interrupter) protected outlet is a good idea but will not protect you from shock from many points in a line connected TV or monitor, or the high voltage side of a microwave oven, for example. (Note however, that, a GFCI may nuisance trip at power-on or at other random times due to leakage paths (like your scope probe ground) or the highly capacitive or inductive input characteristics of line powered equipment.) A fuse or circuit breaker is too slow and insensitive to provide any protection for you or in many cases, your equipment. However, these devices may save your scope probe ground wire should you accidentally connect it to a live chassis.
When handling static sensitive components, an anti-static wrist strap is recommended. However, it should be constructed of high resistance
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materials with a high resistance path between you and the chassis (greater than 100K ohms). Never use metallic conductors as you would then become an excellent path to ground for line current or risk amputating your hand at the wrist when you accidentally contacted that 1000 A welder supply!
Don't attempt repair work when you are tired. Not only will you be more careless, but your primary diagnostic tool - deductive reasoning - will not be operating at full capacity.
Finally, never assume anything without checking it out for yourself! Don't take shortcuts!
Safety tests for leakage current on repaired equipment
It is always essential to test AFTER any repairs to assure that no accessible parts of the equipment have inadvertently been shorted to a Hot wire or live point in the power supply. In addition to incorrect rewiring, this could result from a faulty part, solder splash, or kinked wire insulation.
There are two sets of tests:
DC leakage: Use a multimeter on the highest ohms range to measure the resistance between the Hot/Neutral prongs of the wall plug (shorted together and with the power switch on where one exists) to ALL exposed metal parts of the equipment including metallic trim, knobs, connector shells and shields, VHF and UHF antenna connections, etc.
This resistance must not be less than 1M ohm.
AC leakage: Connect a 1.5K ohm, 10 Watt resistor in parallel with a 0.15 uF, 150 V capacitor. With your multimeter set on ACV across this combination and the equipment powered up, touch between a known earth ground and each exposed metal part of the equipment as above.
WARNING: Take care not to touch anything until you have confirmed that the leakage is acceptable - you could have a shocking experience! The potential measured for any exposed metal surface must not exceed 0.75 V.
If the equipment fails either of these tests, the fault MUST be found and corrected before putting it back in service (even if you are doing this for your in-laws!).
Some notes regarding the above safety information
While the PG13 falls under the high voltage category, many of the safety recommendations do not apply due to the nature of high frequency high
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voltage. This is only true if you do not modify the kit in any way. Here is the reason why, which is very interes ting:
So here is the abridged answer to your question: Sodium channels are responsible for the initiation and propagation of action
potentials. Action potentials are those electrical signals that carry messages throughout the body whether they be neuronal or cardiac in nature. Sodium channels go through a basic gating scheme. Upon membrane depolarization, sodium channels open, or activate, then quickly inactivate or close. Upon repolarization, sodium channels will go back to the resting state at which time they are capable of opening again. Channels require a certain amount of time to recover from inactivation or return to this available resting state. This recovery from inactivation requires on the order of 15 ms. The frequency at which action potentials fire is governed by this recovery. So action potentials can fire about 60 times per second. Stimulation at higher frequencies would for all intents and purposes drive those sodium channels near the point of the stimulation into a long lived inactivated state from which no action potentials could fire. So thus the reason why lower frequency stimulation would be more deleterious than a 2 kHz frequency.
Larry E. Wagner II Technical Associate II Dept. of Anesthesiolo gy P.O. Box 604 University of Rochester Medical Center
Simply put, your nerves are not fast enough to respond! Does this mean you are not getting electrocuted? No, but current flow is harmless at these frequencies. The real danger comes from RF burns, and that is what you will become aware of the most when you touch the wrong things. Burning flesh smells awful by the way. When you feel a “tickle” from the PG13 it is either from a lower frequency component like 60 Hz, or the “tickle” of a nice RF burn. Yes, they HURT!
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HOW I ARRIVED AT THE PG13.
(A little history, if you please!)
Let me introduce myself. I am an engineer at Ramsey Electronics, and have been so for over 12 years now. Who said anything about company faithfulness being dead? Anyhow since I was in high school I have been messing around with high voltage, becaus e it is a challe nge , a bit risky, and is simply fascinating. I suppose the fixation on high voltage stems from an earlier fascination with fire, but I won’t get into that. The connection is that fire and a good spark are both made of the same stuff: Plasma.
This kit is NOT a Tesla Coil by any means, in fact it exhibits very little of the effects that Tesla Coils use to achieve a very high output voltage. Tesla coils use a completely different effect from turns ratios to achieve a high voltage output, which involves transmission line theory, magnetic fields, and a lot of power. Tesla coil’s output voltages are dependant upon factors such at secondary Q factors, and not as much on turns ratios. My PG13 is completely dependant upon turns ratios because the Q factor is too low to exhibit Tesla effects.
This project was conceived due to an inability to find those old flyback transformers that do not contain diodes. Diodes convert the output of a television flyback transformer to DC, preventing them from working for many AC experiments. I searched long and hard, and finally found a manufacturer of a perfect experimenter’s coil. No more stopping at the side of the road at an old console TV to see if the flyback is usable!
So, what the heck is plasma, you may ask? No, it’s not the plasma in your blood, swimming along with the red blood cells. Plasma is matter in an extremely excited state. Basically it is molecules being repeatedly stripped of their electrons, and then electrons falling back into place. The process of electrons falling into place is what gives sparks and fire (plasma) its characteristic colors. These colors are dependant upon the mixture of gases that the plasma is made up of, and how excited the gases are. Our atmosphere is mostly Nitrogen, with Oxygen and other gases thrown in as an afterthought. Nitrogen emits blues and violets mostly in a low excitement state, and that is why sparks appear violet at low currents, and blue as the current increases. Why is fire orange and yellow? Because particles such as carbon and ash in the plasma are heated to incandescence, like the filament of a light bulb. If not for the particles the flames would be blue, like Natural Gas burning.
Aurora Borealis is another example of plasma In this case upper atmosphere molecules are excited by high energy particles from the sun. Auroras vary from green to red, depending on intensity and elevation in the atmosphere. At higher elevations and low atmospheric pressures found in the upper atmosphere, Nitrogen will emit quite a bit of green. Down a few dozen kilometers closer to earth, Oxygen ionizes (turns to plasma) much more easily and Oxygen tends to emit red. That is why you see different colors in aurora.
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To see an aurora closely, we can use Plasma balls. Plasma balls operate by applying a high AC voltage to an electrode in the center of a glass sphere. This high voltage must be high frequency AC in order for any current to get through the glass of the globe and surrounding air by capacitive coupling to your hand or the air. The current actually doesn’t go through the glass, but is induced on either side. Typical voltages are around a few thousand volts for most commercial plasma globes, sometimes around 10,000 volts for some homebrew ones. Typical frequencies are from a few kilohertz to a few tens of kilohertz.
Plasma balls will usually employ unusual gases such as helium, neon, xenon, krypton, and argon to achieve different colors and spark types. Since gases usually ionize more easily at low air pressures, a plasma ball’s air is first sucked out with a vacuum pump, and then replaced with a mixture of the above gases at about 1/10 to 1/20 of an atmosphere. These gases are noble gases, also meaning inert, which means that they don’t readily react with other molecules and create dangerous results. There have been reports of Plasma balls working at atmospheric pressure, and we may try that experiment here.
I used a small water-controlled vacuum pump at home when I was a kid and a large, green wine bottle. The best I ever got was 4” streamers at the very bottom, which were white due to the quantity of water vapor coming back through my hose. When your budget is $20 a month, you simply can’t afford a vacuum pump.
Now that I have a job, I can get all of those toys I always wanted as a kid (if my wife lets me!), but now I needed to make a new supply. My old one looked like a rat’s nest of wires, and the television flyback wouldn’t fit in any plastic case that I could find. It was time to make a new one that looked nice, and didn’t periodically shock me. I decided to use my resources here at work to make a new kit as well as a new toy for me. (The wife won’t stop me if the boss is paying!)
Happy experimenting, and I hope you enjoy playing with high voltage as much as I do! Oh, here is a little reference I pulled from the Internet on gases and the colors they make. Pretty neat!
Colors and Effects of Various Gases (by Don Klipstein) Helium - In spectrum tubes it glows a brilliant whitish yellow-orange color,
somewhat like that of a high pressure sodium lamp. I have heard that this sometimes varies with pressure, current, and container dimensions.
Neon - Usually produces dim red blurry streamers with brighter orange "pads" at the ends. If neon is mixed with another gas (other than helium), the streamer color and character is often dominated by the other gas, but the ends of the streamer are orange or pink "pads".
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Carbon Dioxide - Glows a whitish or blue-white color. It is probably good to have no direct contact with metal electrodes for long life with gases that are not completely inert. Carbon dioxide probably requires more voltage than the noble gases. Generally, gases and vapors with monoatomic molecules work with less voltage than others.
Nitrogen - Streamers are usually a whitish or grayish pink or light orange. The color may be more gray or lavender at very low currents. The apparent color varies with what kind of lighting it is in contrast with. Requires somewhat higher voltage than noble gases .
Air, Oxygen, Water Vapor - These require more voltage than the noble gases and do not glow brightly. I do not recommend these. If you must use any of these, you may also want no direct contact of gas or vapor to metal in order to avoid corrosion problems.
Argon - Streamers are violet-lavender. The ends are blue-violet-lavender. Argon and neon. A mixture of around 99.5 percent neon, .5 percent argon has
the lowest voltage requirement, but may not look as good as other gases. Argon-Nitrogen mixture (as found in many light bulbs) - Streamers are whitish
or grayish pink or orange, but more lavender at low currents. The ends are blue-violet-lavender. Requires a bit more voltage than pure argon.
Krypton - Generally lightning-like and close to white or light gray, sometimes purplish or pinkish, depending on background lighting. Sometimes fuzzier and/ or gray-greenish, especially if the pressure and/or peak current are low.
Xenon - Usually lightning-like and bluish white or bluish gray. May get fuzzier and more gray or lavenderish gray at lower pressure and lower peak current. Peak currents over a few milliamps favor a more lightning-like appearance even if the RMS current is less than a milliamp.
Don Klipstein's web site with plenty of great information on HV and plasma: http://www.misty.com/people/don/index.html
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CIRCUIT OPERATION
What is going on with this board may look simple at first, but it is actually quite a difficult design to get working properly and reliably. A lot has to be considered with magnet ic s when deali ng wit h high vo lt age, hi gh freque ncy transformers. Unlike power transformers like the one powering the entire kit, high voltage transformers have a “sweet spot”, or a resonant frequency where they operate the most efficiently. The goal of the design is to get it working above human hearing, otherwise the screech of high frequency from a plasma discharge is deafening. When choosing the transformer for this design, I wanted the best of everything: High Voltage output, High Current, High Resonant Frequency, and the ability to generate this from a relatively low voltage.
The transformer company we found delivered four different transformers to us to experiment with, and a bunch of plastic spacers of varying widths. The four transformers had increasing numbers of secondary windings, but all other factors similar. The problem is that the more windings there are on the secondary, the more inductance there is, meaning the resonant frequency would be lower. The largest transformer which had 6500 turns in the secondary would have been perfect to get 12 volts up to 25kV using a low number of turns on the primary, but the resonance was around 13kHz. The sound this emits is intolerable for any length of time. The coil also had the problem of having very thin wire resulting in a low current output. They have to use fine wire to make it fit in the transformer’s plastic case.
The smallest coil had 2000 turns on the secondary, which isn’t quite enough to get 25kV from 12V, even in a push-pull configuration. The problem here is we really need more than one turn of wire on the primary to make an effective output. An advantage would be that the transformer oscillated around 35kHz, well above hearing, but almost too high for some effects we would like to make.
The transformer we wound up using was the third size, which has 4000 windings on the secondary, which gives us plenty of high voltage output. It also has the larger sized wire, and with the proper spacers would oscillate right around 18kHz. This frequency is above most people’s hearing, but your dog won’t like this too much.
So what do those spacers do? Without getting into magnetics too much, they lower the saturation point of the ferric core. This means the core saturates faster with a larger gap, which also translates to a higher operating frequency. This also means, however, that since the core saturates faster, less energy will be transferred from the primary to the secondary, which reduces power output.
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We have included two 0.25mm spacers for you to do experiments with.
Since the transformer is specific about its “sweet spot”, we couldn’t run the drive circuit directly from a pulse width modulator circuit (PWM). We may have been able to tune it up really close while there was no load applied, but as soon as we would draw a spark, the frequency would change, and our output would drop considerably. For example if the “sweet spot” was 20kHz, and we were driving the circuit with 20kHz, we may have 20kV on the output. Then, if we add a new load on the output that changes the “sweet spot” to 19kHz, but we are still driving it with 20kHz, the output may drop to only a few kilovolts.
Because of this we decided to make the transformer self-resonating. This means as the load changes, so will the frequency, so that the transformer is always running in the sweet spot.
The way this oscillator works is by alternately saturating the core, first in one direction, then the other. R1 and R5 are used as a “kick start” for the oscillator. These resistors provide some current to turn the transistors on. Because no two transistors are perfectly alike, one will turn on before the other, providing an imbalance.
In Figure 1, The transistor that is turned on stays on, forcing the other transistor to turn off by directing current through the feedback winding of the transformer in the direction required to turn the other transistor off, and turn itself on even harder. For this illustration we’ll say that Q3 is turned on while Q4 is turned off. As this is occurring, magnetic flux in the core is building along with the current being drawn through Q3, because of the side of the winding Q3 is attached to. This current is drawn through the center tap of the primary winding through the winding, and finally down through Q3 to ground. This rising magnetic flux in turn is inducing voltage and current in the high voltage secondary, as well as the feedback winding. This current in the feedback winding pushes the transistor on even harder up to the point that the core of the transformer saturates.
Fig 1. Fig 2.
Direction of Flux
+V High Voltage
-V High Voltage
+12V
Direction of Flux
-V High Voltage
+V High Voltage
+12V
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Once saturation occurs, the flux stops increasing in the core, and the current that was induced in the feedback winding abruptly halts and reverses direction due to a “ringing” effect. This reversal in current direction then turns off Q3 and begins to turn on Q4, which quickly ramps up the flux in the core now heading in the other direction. (Fig 2).
This cycle goes back and forth continuously until power is removed.
To control the output voltage we can simply adjust our driving voltage. Here’s why I chose a 12.6VAC transformer instead of a 16VAC transformer to be used with your PG13.
One quirk we have come across is that our high voltage design cannot produce a high current arc directly to ground. For this to actually occur we would need a lot more parts in the circuit, and also it would reduce the safety considerably. We decided to go for safety and stick with a lower power design. Besides, you can pull some pretty hot arcs onto a screwdriver and other objects, no ground needed!
To find out what we have for output voltage is a simple matter of turns ratios. See the chart below to see the transformer secondary windings that were in the different models of transformers that I sampled.
Winding Turns
Wire Diam.
CHT-0126A: 2000 0.1mm CHT-0126B: 2500 0.1mm CHT-0126C: 4000 0.1mm CHT-0126D: 6500 0.06mm
Since we chose the C version of the transformer, we see that we have 4000 windings in the secondary. Now we need to know what is in the primary. Since we were trying to achieve highest poss ible vo lt age out put alo ng with a dec ent current output, I compromised at 9 turns center tapped on the primary. Since we are in a push-pull configuration, this essentially doubles our supply voltage across the primary. So let’s say we have a 12.6 VAC transformer supplying our kit, and we need to know what our output voltage will be. First we have to find what the supply voltage will become after converting the 12.6VAC which is an RMS value to the DC value after rectification. First we convert to peak to peak:
12.6VAC * SQRT(2) = 17.81 Vpk/pk
Then we subtract 1.4 volts for the diode drops in the bridge rectifier.
17.81—1.4 = 16.41 VDC
Now realize that the 12.6VAC rating is at the current rating of the
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