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[TowerTalk] Control Cable protection

To: towertalk@contesting.com
Subject: [TowerTalk] Control Cable protection
From: CubexCo@aol.com
Date: Mon, 13 Sep 2004 23:39:51 EDT
List-post: <mailto:towertalk@contesting.com>
excerpts of comments on the subject -
--------------------------------------------
I am quite sure that you cannot easily manufacture the required
grounding blocs yourself????
----------------
Affraid if you are not going to set-up a production line, you even wont
find the different elements needed in small qnt.
( And if.......At what price ?....) 
-------------------------------------------------------

I was surprised to see the range of comments and particularly to two above 
regarding the problem of lightning protection for rotor control cables.  
Clearly 
they must be protected, and there are at least two commercial sources 
manufacturing packages that handle up to 8 conductors.  But there are 
alternative 
solutions that permit some customization as well.  

My problem for rotator control was protecting the 9 lines for DC power and 
direction indication.  Using 110volt selsyns for direction indication was a 
problem for the standard commercial products as they are limited to the lower 
voltage of most rotators - I think the peak voltage was less then 80volts.  
Okay 
for 24 vac sources, but not higher voltage.

The first thing to do is find out what the commercial guys use to make their 
devices.  Disassembly of one revealed low inductance ground strip foil, and 
short leaded devices looking like disc capacitors.  These turned out to be 
radial lead Varistors.   Checking one of the components sources (Jameco) a 
whole 
series of varistors is listed with various voltage ratings and peak current 
ratings.  The cost is nominal less then $0.60 each in packs of 10.  They can be 
mixed allowing me to make 5 terminals for 110v and 4 for 24volts.  The housing 
may take a little creativity depending on the the requirements (indoor or 
outdoor).  These devices can be added at both ends of the cable which might be 
useful in protecting the intermal circuitry of the rotor itself.

There usually is no "magic" in these types of electronic products, but there 
are some rules.  low inductance common ground termination for each device, and 
short leads to the "hot" terminals.  Good mechanical connections first, then 
secure with solder.  Of course the package has to be connected to a low 
inductance ground system as well.  In my case it is the SPG entry to the shack.

Jameco also carrys a line of diecast boxes that work well for this 
application. www.jameco.com    

Regards,
Norm W4QN 

 
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