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[Amps] electrolytic strings ++

To: <amps@contesting.com>
Subject: [Amps] electrolytic strings ++
From: W8JI@contesting.com (Tom Rauch)
Date: Tue, 11 Jun 2002 10:39:43 -0400
> If your design constrains allow for a relatively high PS output
> internal resistance (5 - 100OHM) it will be wise to insert in SERIES
> with every capacitor a limiting resistor/fuse. A thyristor crossbar

In a series circuit, one fuse or one resistor is enough. One at the 
each component would do absolutely no good at all. 

The real problem with this suggestion, however, is that peak current 
in a capacitor input supply is very very high during ever cycle while 
the supply is under load. Any fuse that would be low enough current 
rating to protect the capacitors would quickly undergo metallurgical 
changes (often called fatigue) and fail. Any series resistance would 
increase ESR and have a deleterious effect on supply regulation and 
performance. Of course any fuse would also have to be a high-voltage 
type fuse, and cost several dollars!  
 
> can then be triggered by the failure of the cap, thus the other caps
> will be protected.

Average MTBF of a typical electrolytic operated at full voltage is 7-
10 years.

It makes little sense to use a cost>$500 circuit with considerably 
less MTBF to protect $5 components.

That's why no one bothers with such overly complex and unreliable 
schemes.

The real problems are easy to correct, and inexpensive to correct. 

The primary reason most series electrolytic strings fail after 
abnormally short time periods is use of carbon-based equalizing 
resistors that are not low enough in resistance value. For some odd 
reason, many people just blindly use 100k equalizers, and worse yet 
some use carbon resistors. Carbon should NEVER be used in a critical 
equalizing system.

You would have to take the worse-case leakage current differential 
and calculate the safe equalizing resistor value based on that worse-
case condition and allowable voltage tolerances. Many times required 
resistance is much lower than 100k ohms.  

Compounding the problem, "technicians" often never bother checking or 
replacing the resistors that often cause the initial failures. They 
change the capacitors, while ignoring the root-cause of the 
failure!73, Tom W8JI
W8JI@contesting.com 


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