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Topics - Mads Barnkob

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1
The pulse discharge videos posted in this thread is a part of a series of explosive videos of old phones and electronics. The high voltage pulse capacitor bank, charger and trigger mechanism can be found with pictures, more videos and schematics here: https://kaizerpowerelectronics.dk/pulse-power/4000-joule-capacitor-bank/

A pulse discharge with a peak current of 50,000 Ampere is send through a Nokia 6230 mobile phone. A mobile phone from the era of indestructible handsets, a piece of electronics that would never let you down and yet here it is to die in a fiery explosion of hot-as-the-sun plasma discharge!


2
The video of the teardown and reverse engineering

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The teardown of a Fujifilm FCR XG-1 X-ray image scanner for computed radiography became the basis for this reverse engineering project. You can see the teardown of the entire Fujifilm FCR XG-1 machine here and the teardown of the polygon laser scanner module here.



A short introduction, computed radiography is based on reusable phosphor imaging plates, the plate is used instead of film. The x-ray exposed imaging plate is scanned with a red laser timed to a photomultiplier tube to read out the single pixels on the imaging plate. The returned light from the scanning laser has a different intensity dependent on the amount of absorbed x-ray energy and thus the photomultiplier tube can translate this into a 12-bit grey scale resolution.



The photomultiplier assembly is mounted on a sheet metal holder with the tube going out through a grounded layer of mu-metal for shielding the tube from electrostatic interference. The PCB has a output amplifier and power supply part on the left side of the socket and a high voltage power supply module on the right side. The Fujifilm PMT12A board has two connectors, which both went to the SCN12A card in the main computer of the Fujifilm FCR XG-1 scanner. CN1 is a 34-pin flatband pin header and CN2 is a coaxial output signal from the output amplifier.



The output amplifier is shielded, the differential amplifiers on the board is using +12/-12VDC from a LM2940CT and LM2990T regulators, as the +15/-15VDC input goes directly to the HV module. The Hamamatsu C7775 from 2007 does not have any datasheets available online, but browsing through the newest modules shows that they still make a C-series 5 pin HV module, that turns out to use the same pin layout as its earlier modules.



From the pin 5 of the C7775 comes the negative high voltage supply for the photomultiplier tube. The cathode of the tube is connected to the 4 blue capacitors that is tied to ground, to ensure a stable voltage at the start of the high voltage chain.

As more electrons are accelerated from the first dynode to the next and so on, less current is needed to drive them on, this is done with a pure resistive divider network between the dynodes, but it has its drawbacks with loss of linearity and output deviation in the region of 10-20% at high output current. A improved divider network uses capacitors to insure stable supply voltage at peaks and even individual power supplies for each dynode can be used to do the same.

From the photomultiplier tube handbooks from Hamamatsu, the requirements to a PMT high voltage power supply reveals that quality control is needed to achieve a line/load regulation at +/- 0.2% and ripple noise/temperature drift at 0.05%. The Hamamatsu R1848-07 photomultiplier tube is a 10-stage 14-pin version that can use up to -2500V dynode supply.

It took a great deal of cutting with a new sharp box cutter, to get in-between the acrylic light guide and the blue glass filter window of the photomultiplier tube. It took about an hour to free the two parts from each-other, without harming tube or light guide.



Schematic from the service manual. I marked the needed pins for the module to run without the computer/scanner analog-to-digital conversion modules.



After having seen the connection diagrams in the manual, I was confident to test the module with power on. I was using a power supply with +15 VDC, -15 VDC and GND. I shielded the window of the PMT with aluminium foil to block out any light. A powered up photomultiplier tube that is flooded with light risk burning holes in its dynodes! Protect and treat your PMT with great care.

Judging from the computer power supply of +5 VDC and the datasheet for the Hamamatsu C9619 high voltage power supply, I tried my luck with putting +5 VDC on the input pins I had located. It was also mentioned in the manual that the module has a "high voltage hardware ok" and "high voltage software ok " signal, that both had to be high for the high voltage to get active. It turns out that the input pin 5, labelled HVSH is "High Voltage Software High". When +5 VDC is applied to pin 5 the high voltage supply is generating -510 VDC.

The output signal is sine wave like waveform with 1, 2 or 3 peaks, depending on the signal strength. The highest peak was up to 70V, but I am not sure that the scaling was correct from these measurements. I unfortunately lost all my oscilloscope screenshots  to a defective USB stick :(



A photomultiplier tube can be a very sensitive instrument, depending on the negative supply voltage for the dynodes. From the PMT handbooks graphs show that common PMT behavior the amplification is highly dependent on the high voltage supply. The -510 VDC this module uses gives a mere amplification of 40.000 times. This level of amplification is sufficient for the computed radiography, but for a more interesting task like radiation detection with a scintillation crystal, it is suggested that -1 to -2 kV is needed for a amplification of 20.000.000 times and up towards 1.000.000.000 times.





3
Part 1: Teardown of a Fujifilm FCR XG-1 x-ray image scanner / digitizer. Also known as Computerized Radiography (CR), it fulfills the job of scanning a x-ray exposed image plate with a laser beam and extract each pixel illumination with a photo multiplier tube setup. It can scan 72 plate per hour with a maximum resolution of 7080 X 9480 in 12 bits per pixel gray scale.

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All pictures can be found here: https://kaizerpowerelectronics.dk/teardown/fujifilm-fcr-xg-1-x-ray-image-scanner-teardown-part-1-of-3/

The scanner is normally delivered as a standalone system with a single PC for operation.



The unit I found was stripped for all outer plastic parts, user interfaces and the computer compartment was empty of cards, leaving only bare bus mainboard behind. Teardown and reverse engineering of the PMT assembly will be covered in part 3.



The mainboard or bus backplane has board names printed on to it. I was able to find out that the CPU12A board uses two Altera Flex FPGAs in a main (machine control) / sub (image handling) CPU setup and has a SMSC Feast FD LAN91C100FDQFP Ethernet controller for 100 Mbit networking. It uses a VxWorks RTOS with a default login cr-ir346 and password is cr-ir346 as well. Great security there!  Default IP address 172.16.1.10 which seems a little unusual.



Here is closeup pictures of stepper motor driver boards, mechanical parts, power supply for the photomultiplier tube and belt driven casette feeder. It also features a few badly translated warning labels, half of them does not make any sense.



The power supply is a Lambda / Densei-Lambda model Alpha 4000 with model name MA4000256J. It is a modular power supply with 5 output slots and this particular configuration has outputs at 5V, 15V and 24V at different current ratings. Each power supply module is isolated from the others.



The scanning laser is packaged inside a black plastic enclosure and will be covered in part 2. There seems to be a external power supply /conditioning board for a stable power supply near the laser module itself.



4
This is a teardown of a Thermo Scientific Dionex TCC-3000SD Standard Thermostatted Column which has a temperature range from 5° to 80°C. It is used in liquid chromatography to supply 5° to 80°C ±0.5°C at a stability of ±0.1°C


5
I got hold of a large Merlin Gerin Masterpact M16N1 circuit breaker, from 1997, from a low voltage distribution drawout system. In the video you get a inspection of the various parts of the breaker and I have some fun making it work and test it!

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It was a deal to get it now or miss it, so I had to transport the damn thing of around 50kg home on my bicycle, good thing I only had to balance it for a 2 km walk :)



Some product series data:
Quote
The Masterpact M series circuit breaker is used to protect and control low voltage distribution systems. It can be installed in main LV switchboards (incoming units, main and secondary outgoers).
Nominal current: 800 to 6300A AC
Breaking capacity from 40 to 150 kA rms
Voltage rating: up to 690 V
Versions: 3 and 4-pole. Fixed or drawout.

The front of the unit had a crank for charging the internal spring, ON/OFF buttons, short-circuit curve settings, indicators and a hidden timer setting PCB. The undervoltage- and remote operation coils can be seen as the two cylindrical parts at the top.


Underneath the large and dangerously powerful spring can be seen.


This version also has a motor assisted charging mechanism, that can be used for remote closing of the breaker.


One of the Arc suppressors/chimneys


Inside the switching chamber where the arc suppressor mounts down into. The 10 copper arms that can be seen are not the main contact points, these are silvery and can be sen lower down and fits with the 10 dark square marks that can be seen in the wear-surface of the output terminal.


I could not find a manual for this rather old unit, so I had to find some manuals from the more modern versions and it did share the same schematics, I just had to find the right terminals.



The hidden timer settings PCB is a configuration of the maximum permissible time between undervoltage coil activation (MN) and closing release (XF) activation, if this time is passed, the breaker will not close. I properly need some other conditions to keep it closed, but for the tests I want to do, a closing and opening with a 3 second time is perfect!


6
I got hold of two electrical panels with a bad wiring job, worst documentation and completely out of code (racing fast for illegal).

The did however turn out to contain a gem of lost times. A "Speed Commander", which is a Danish designed and produced 4 kW motor drive with a very simplistic interface consisting of only 16 settings. The manufacturer still exists ( https://speed-tech.dk/ ) but does not seem like they are selling motor drives anymore, there is a only a trace after it in the manuals section with refences to a V4 and V5. This is most likely the version 4.


7
Contests and Events / Keysight University Live giveaways
« on: March 15, 2021, 09:52:06 PM »
Keysight is giving away a lot of instruments, get into the daily/weekly draws throughout April here: https://kulive.keysight.com or give me a few more entries in draw https://kulive.keysight.com/?ref=9LsUQqkwtfWsrteQ

Dave on EEVBlog is also giving some Keysight instruments away, multiply chances to win:
Comment "I'm in!" on
youtube video:
/>odysee video: https://odysee.com/@eevblog:7/keysight-university-live-test-gear:4

There is also a instrument being given away to a eevblog forum user, link will be announced here: https://www.eevblog.com/forum/blog/keysight-university-live-test-gear-giveaway!/


8
The stock cooler for my i7-4970K CPU fell off due to a broken plastic holder, I am not sure when it happened, but my PC had been really slow for a couple of weeks and I was contemplating an upgrade as this PC is from 2009!

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I think I have upgraded the graphics card, added more RAM and a SSD since it was first built. So as today it still sports a 4GHz i7-4970K, 16 GB RAM, MSI Z97 motherboard and a NVIDIA GeForce GTX 970. 250GB SSD boot drive, 1TB backup and 2TB storage. Corsair RM550 Watt PSU. All installed in a nice sound-reducing Antec cabinet as well as the TB drives are installed in noise reducing blue drive bays seen at top.

Please do leave suggestions for a new PC build :) Good performance on a budget!


9
I am building a Tesla coil show controller that can control up to 6 Tesla coils at once. It will feature individual interrupters, touch screen controlled MIDI interrupter, safety features to ensure a safe method of working with the Tesla coils before a show, under a show and after a show. It will all be housed in a transportable 19" rack mount flight case for ease of transportation and to protect the electronics.

The 6 channel MIDI interrupter is the feature rich Syntherrupter made by Max as he shares all the plans, documentation, code and schematics.

The users and readers that know about my Tesla coils will know that I "only" have a small Tesla coil, a medium Tesla coil and a large Tesla coil. So how does this correspond with building a show controller that can take up to 6 coils at once? Well, I just have to build some more Tesla coils :)

Due to time constraints due to things like life, work, education and more or less sleep, this project is split into some smaller phases.

Part 1 - The parts
Part 2 - Programming Syntherrupter
Part 3 - 6 outputs build
Part 4 - Syntherrupter and MIDI
Part 5 - Interrupters
Part 6 - Power supply and safety

Part 1 - The parts
I bought 19" transportation rack, panels, power bar and some other parts for the previously released video about flight case construction. I bought it from the German company Adam Hall that is a supplier to many smaller retailing companies of disco, event and show business equipment like audio, light and transportation gear.

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The plan


The plan is not set in stone, so feel free to chime in with suggestions and questions about the possibilities :)

10
Building large flight cases and transport boxes is easy and much cheaper than buying them. Hinges, locks, fittings and aluminum rails is readily available at almost all audio / light retailers of equipment for disco, clubs and festivals. I share the tips on how to construct it in a simple way and make sure you get parallel edges that looks good when the boxes are locked together. With so many different rails, hinges and locking mechanisms it is easy to make a mistake and mount something off-center or with distances that does not take aluminum rail thickness into account.

In this video I show you how I built 3 boxes in total at a cost of around 500$, they are meant for transportation of my large Tesla coil with two very large flight cases for my secondary coil and topload. The third box is a cable and equipment box that is just made from the leftover plywood from the two large cases.

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My first draft drawings on the sizes of the boxes


Later I put it all in a spreadsheet (attached at the bottom) to get a precise calculation on the weight of the boxes when trying out different layouts or panel thickness. As it can be seen from the calculations, it is the panels that make up almost all of the weight, there is certainly not much to gain by skipping on the aluminum rails, hinges, handles or locks.

I bought handles, locks and rails from Adam Hall in Germany


The laminated plywood panels is cheapest to find at your local hardware store


Some details of the riveting and me next to the topload flight case for size reference, its huge!



How To Make a Stencil For Spray Paint With Cheap Hand Tools


11
2000 kg (4395 lb) would be the weight of the AC motor that this 630 A / 440 kW contactor can turn on and off. This also explains the shear size of this contactor, a almost solid piece of metals, copper coil, iron core, copper terminals, platinum contact points and aluminium enclosure.


12
General Chat / Merry Christmas and a Happy New Year!
« on: December 23, 2020, 01:00:09 PM »
Thank you all members and visitors to High Voltage Forum!

2020 has been another good year where the steady organic growth of the forum brings in many new exciting projects, experiments and a wealth of knowledge being shared!

Carol of the Bells! The 4th and final seasonal greetings from High Voltage Forum and Kaizer Power Electronics! May the lightning be with you and your IGBTs be unexploded!


13
Hi all

The background for this idea is to discuss the implementation of a standard industrial safety relay in a Tesla coil power supply. However with the twist of obtaining galvanic isolation between the power electronics and control panel.

A regular safety category 3/4 relay has 2 channels with surveillance between them. The emergency push buttons goes through these two channels, output signal is sent to power electronics mains contactors, a contact set from this mains contactor is sent back to safety relay as part of the reset push button circuit.



I could be single channel, double channel, with one or two mains contactors and with- or without the reset switch going through the mains contactors feedback, its all about what safety category you want to design for.

Here is a generic schematic of a two channel relay with feedback through reset.


To obtain galvanic isolation, I want to run a fiber with either a just on signal or a pulse train that has to change every x seconds in order to keep the mains contactors on. I figured the most correct way to implement this is to put the safety relay in the control panel where the reset/emergency buttons are and only run that single fiber to the power electronics, that does however present me with a components that needs 24VDC in a 5VDC environment. The other way around with safety relay at the power electronics gives me a problem of needing to run two fibers back to control panel to maintain two channels, here the deviation could be to just use a single channel relay or use a single contact to activate both channels of a 2 channel relay.


Please give me your best ideas and suggestions on how to implement this in a way most practical and cheapest. If money was not an issue I would just go out and buy a approved wireless safety relay :)

14
X-ray / AGFA ADC 5155 X-ray Scanner Teardown (4 part series)
« on: November 18, 2020, 08:47:27 PM »
Part 1: AGFA ADC 5155 System teardown
Teardown of a AGFA ADC 5155 x-ray image scanner / digitizer. Also known as Computerized Radiography (CR) it fulfills the job of scanning a x-ray exposed image plate with a laser beam and extract each pixel illumination with a photo multiplier tube setup.

This particular unit has a very interesting computer that runs on VME framework developed for the Motorola 68000 series CPUs.

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Coming soon, part 2: Computer teardown and reverse engineering
Coming soon, part 3: Laser scanner module teardown
Coming soon, part 4: Photomultiplier tube teardown and reverse engineering

15
Teardown of the Agilent Markes UNITY Thermal Desorber which contains a cold trap (Peltier) and some very fine fluid mechanical parts, a thermal desorber is used as a part in the chain of machines used in Gas Chromatography.

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http://kaizerpowerelectronics.dk/teardown/agilent-markes-unity-thermal-desorber-teardown-gas-chromatography/


16
During corona isolation back in March/April, I did two videos on variacs/variable transformers on day 28 and day 30, this is the reverse engineered schematic of the 3A electronic fuse found inside the Impo Electronics Skillevario type 11.36



The old videos

Day 28
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Day 30

17
This is a teardown video of a 5 zone induction stove with a total power consumption of about 10 kW.

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The induction stove is built up on standard 2-zone modules that are likely used in their 1,2,3,4 and 5 zone models, so just mix and match to get the number of zones needed. For a single zone induction zone, a 2-zone PCB is used and only one of the power electronics sections are populated, all control electronics is still in place.





ATMEGA controllers are widely used throughout all the boards and they also maintain the network connection between the boards, presumably over CAN bus.



Two IXYS IXGR40N60 IGBTs in a TO247 package is used, 600V / 65A (200A Icm) for each zone and two zones share a GBJ2510 full bridge rectifier, 1000V / 25A.



Each zone is controlled by a NXP MC56F8322 controller that is a DSP / MCU hybrid with a wide range of I/O, busses and memory options to make it tailored for low cost implementations of many different parts, but few I/O count, applications.


18
Turn your old compact Canon camera into a high speed photography camera with Canon Hack Development Kit

I bypass the battery pack and make the camera run on a power supply, as the CHDK software takes a lot of CPU power, I also add a fan to cool down the CPU and optics.

CHDK: https://chdk.fandom.com/wiki/CHDK

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Hacking the battery pack into power supply requires a 10K resistor between negative and middle contact point of the battery connector.



Temperature measurements to locate the DIGIC2 processor heating and it actually turns out that the optics heat up even more and will often be the limiting factor.




19
A guide on how to make the, EMC2 API4SG10 (Dell# 071-000-482) , server power supply run outside of its server enclosure. A simple bridge between control pins next to the 230VAC GND pins is required.

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Schematic for the modification

http://kaizerpowerelectronics.dk/electronics/server-psu-hack-emc2-api4sg10-12vdc-300w-from-a-dell-poweredge-m1000e/

Additional information on where it came from is available in the server teardown video, follow the link below
*Dell PowerEdge M1000E Blade Server Teardown*
I came by a discarded full size Dell PowerEdge M1000E server rack. Full SAN, 2 large blade servers, 4 or 6 backbone switches, all power supplies and fans. This is a system that is about 8-10 years old and had a new price of around 1000000 DKR (166666 $US).
It was all unloaded in a big mess into a container and I only had time/space to take a blade server, all power supplies and fans with me. Hard disks all go to destruction and backbone switches and the M1000E cabinet itself is too big and clumsy to have any real value in the work shop.

Discussion of the teardown: https://highvoltageforum.net/index.php?topic=1151.0

20
This is 9! 12V/7A server fans built into a fan cluster with handles! It is time to wreck some havoc and play with fire and smoke!

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Deciding on what looks best or gives the best airflow, but eventually went with the arrangement that gave the easiest soldering and routing job for the wires at the back.



Modified all fans with new wires and removed all excessive plastic parts, grills and connectors. Maximum air flow please!



I did not realize just how much fire was sucked through the fans until after I saw the photage. As seen in the pictures on the forum link there was some bad damage to the fan blade and wiring. It actually short circuited the DC rails from the fence melting through the insulation. It is also very good at cleaning the work shop floor.



The teardown there came from: *Dell PowerEdge M1000E Blade Server Teardown*
I came by a discarded full size Dell PowerEdge M1000E server rack. Full SAN, 2 large blade servers, 4 or 6 backbone switches, all power supplies and fans. This is a system that is about 8-10 years old and had a new price of around 1000000 DKR (166666 $US).
It was all unloaded in a big mess into a container and I only had time/space to take a blade server, all power supplies and fans with me. Hard disks all go to destruction and backbone switches and the M1000E cabinet itself is too big and clumsy to have any real value in the work shop.

Discussion of the teardown: https://highvoltageforum.net/index.php?topic=1151.0

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