On Wed, 29 Dec 2004 19:06:12 +0000 (UTC),
(E-Mail Removed) wrote:
>The intermittent contact from a wrong sized plug might be more of
>a problem than anything else.
Once upon a time, a manufactory of remote serial terminal servers
decided to replace their defective wall warts, which tended to catch
fire, with a more substantial equivalent. Unfortunately, they weren't
very careful about the selection of power connectors. The center pin
on the terminal server was 1.6mm, while the plugs were 2.1mm or 2.5mm
(I forgot which). They would sorta fit and worked as long as one
didn't touch anything, move anything, slam the door, breathe, etc.
Intermittent would be an understatement.
Faced with the task of replaceing connectors on 15 terminal servers in
5 different locations, in 3 states, I elected to take a short cut. I
found some suitable brass shim stock and rolled it around a mandrel to
form something that resembled a roll pin. I used a Dremel tool to cut
the tube to size. I then crammed it into the power plug. No more
intermittents. I mailed a supply of adapter tubes to the various
locations, which were successfully installed by office personnel.
When I informed the manufactory of the problem, I was immediately
innundated with phone calls from corporate hindquarters and their
legal office. Apparently, they were worried that they had compounded
a hazzard and was hunting for litigatory relief. After I assured them
that this was not the case, and that my fix was satisfactory, I was
again innundated by phone calls from their field service and
engineering departments asking how I had done it, what thickness, what
size mandrel, what cut length, etc. I ended up making a drawing
suitable for manufacturing and faxed them a copy. I hadn't seen any,
but I was told that they shipped their available stock of power
supplies with oversized connectors and shims, until someone gave them
a clue that the UL certification might be "affected" by the change.
I still carry some shim stock around for the purpose.
--
Jeff Liebermann
(E-Mail Removed)
150 Felker St #D
http://www.LearnByDestroying.com
Santa Cruz CA 95060 AE6KS 831-336-2558