Posted by krisgel (A) on March 20, 2003 at 18:40:54

I am attemting to install the circuit board and circuit board shelf to the battery cover standoffs. The problem is that the T1 and T2 transformers are about 1/8" to tall. This makes it so that the switches are too short and the battery cover standoffs are too short. The jumper wires below the transformers are as flat against the circuit board as possible. What should I do?

• I think there are two problems here - Ron W 07:55:42 03/21/03 (1)
  In Reply to: Ultrapath construction question posted by krisgel on March 20, 2003 at 18:40:54:

  Yes, the clearance is very close and thus the reason I stated in the manual that you must make sure the transformers are mounted as close to the circuit board as possible. Soldering the jumper wires to the other side of the circuit board may help but their should be enough clearance under the transformers provided the jumpers are short, mounted flat against the circuit board and do not interfere with the transformer placement.

  What may also be happening here is there could be some variation in the height dimension of the transformers. I'm using transformers from two different manufacturers but their spec sheets are identical.

  Ron
  
  

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  • I need the shorter transformers . . . - Jeffm 21:07:54 03/21/03 (0)
    In Reply to: I think there are two problems here posted by Ron W on March 21, 2003 at 07:55:42:

    It would be nice to have the shorter transformers in the kit since the tolerances that we are required to meet are very, very small (at least for people who build kits somewhat infrequently). Sorry. I thought that I had placed everything as low as possible but obviously it did not work out.

    I would not have thought to check the height differences between the manufacturers if the spec sheets show them to be identical.
    
    

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• Re: Ultrapath construction question - CE dweeb 07:31:45 03/21/03 (1)
  In Reply to: Ultrapath construction question posted by krisgel on March 20, 2003 at 18:40:54:

  Me too. I removed the transformers and jumpers (PITA), put the jumpers on teh other side of the circuit board, reinstalled the transformers flush with the circuit board, and put spacers (about 1/16") between the back long metal standoffs and the circuit board shelf. There is enough clearance between the circuit board shelf and the batteries to accommodate the spacers.
  
  

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  • Please excuse the double post. - CE dweeb 07:45:33 03/21/03 (0)
    In Reply to: Re: Ultrapath construction question posted by CE dweeb on March 21, 2003 at 07:31:45:

    Please excuse the double post. I am just learning how to use the forum.
    
    

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• Re: Ultrapath construction question - CE dweeb 07:03:27 03/21/03 (0)
  In Reply to: Ultrapath construction question posted by krisgel on March 20, 2003 at 18:40:54:

  Me too. I removed the transformers (PITA) and reinstalled them flush to the circuit board, changed the jumpers to the other side of the circuit board, and put a small spacer between the long metal standoffs (back ones) and the circuit board shelf. There is enough clearance between the batteries and the bottom of the circuit board shelf.
  
  

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• I had the same problem . . . - Jeffm 19:34:22 03/20/03 (1)
  In Reply to: Ultrapath construction question posted by krisgel on March 20, 2003 at 18:40:54:

  but realized that the jumpers were not absolutely completely flat against the board (just a hair of an air gap) and that the transformers were not pushed completely down on top of the jumpers (again, just a faint hint of an air gap). It looks like there there is no room for error (!!!) and that when the manual says " . . . as short as possible and flat against the board." and "Make sure that you have them mounted as close to the circuit board as possible." you better make sure that this is done.

  I had to desolder the transformers and the jumpers but haven't had time to give it another go just yet. I was lucky in that I gave myself just a bit more length on the switch wires or else I would have had the exact same problem with the switches that you have.

  I wouldn't mind a helpful hint on this as well.
  
  

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  • The easiest fix - Ron W 08:56:52 03/22/03 (0)
    In Reply to: I had the same problem . . . posted by Jeffm on March 20, 2003 at 19:34:22:

    The easiest way to solve the problem will be to get you some 100 grit sand paper and sand down one end of the four plastic standoffs until you achieve the appropriate height.

    Taking a few sample measurements on these transformers shows some of them to be off by as much as 1/16". If your clearance problem is greater than this, then mostly likely you don't have the transformers mounted all of the way flush on the circuit board per the instructions.

    Ron
    
    

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