Board Assembly Steps

To assemble the board, follow these steps:

1. Lay out and identify all the parts and pieces. Verify the separate resistors with the parts list, as they have a color code to determine their value. Colors are indicated on the parts list.

2. Fabricate a piece of.1-inch grid perforated board to a size of 7.2 X 2.6 inches. Locate and drill holes as shown in Figure 1-3. An optional PCB is available from Information Unlimited.

3. Fabricate the metal heat sink for Ql from a piece of.063-inch aluminum at 1.5 X.75 inches, as shown in Figure 1-4.

4. Assemble LI as shown in Figure 1-4.

5. If you are building from a perforated board, insert components starting in the lower left — hand corner, as shown in Figure 1-5 and 1-6. Pay attention to the polarity of the capacitors with polarity signs and all semiconductors. Route leads of components as shown and sol­der as you go, cutting away unused wires. Use certain leads as the wire runs or use pieces of the included #22 bus wire. Follow the dashed lines on the assembly drawing as these indi­cate connection runs on the underside of the assembly board. The heavy dashed lines indi — cate the use of thicker #20 bus wire, as this is a high-current discharge path and common ground connections. See Figures l-7a and l-7b for an expanded view.

6. Attach the external leads as shown. Figure 1-6 shows the construction of the safety spark gap made from pieces of #20 bus wire. This pre­vents high voltages from damaging circuit components when using light or no load con­nections. The circuit is not designed to operate with continual discharging and indicates a fault or too light of a load if it continually fires. See Figures l-7a and l-7b for an expanded view.

7. Double-check the accuracy of the wiring and the quality of the solder joints. Avoid wire

Board Assembly Steps

The assembly board is in two sections attached together by two outer 6-32 nylon screws and nuts. The middle hole is used to fasten the entire assembly to the base of the endosure.

The circuit section is 4.8» x 2.9" .1 x.1 perforeted board. The high-voltage Plexiglas section is 3.6 X 2.9" .063 thickness. Drill eight.063" holes in the perforated section and eleven in the Plexiglas section located as shown.

Drill the three.125" holes in both sections for attaching together.

Drill and drag the.125" slot as shown. This cutout and the enlarged holes are for mounting transformer T1 Using the optionally available printed circuit board will still require fabrication of the Plexiglas board Hole diameters are not critical.

Always use the lower t eft-hand corner of perf board for position reference.

Figure 1-3 Driver board fabrication

Board Assembly Steps

for both sides

Heatsink bracket assembly

HSINK Bracket fabricated as per step 3 from 1/16" aluminium piece. Note hole for attaching tab of Q1.

Board Assembly Steps

Board Assembly Steps

Figure 1-4 LI current feed inductor and heatsink bracket

Board Assembly Steps

Note polarity of C1.C4.C9. D3.D4, D12, and D20A-D20J Note position of 11.12. Q1

Fi g и ге I — 5 Parts iden tifi cat ion

bridges, shorts, and close proximity to other circuit components. If a wire bridge is neces­sary, sleeve some insulation onto the lead to avoid any potential shorts.

8. Fabricate a channel from a piece of ‘/іь-inch plastic material. Add it to the assembly and secure it at its comers using silicon rubber adhesive. You may also enclose it in a suitable plastic box as shown in Figures 1-8 and 1 -9. Figure 1-10 shows the simplified channel enclosure that does not include the meter M1.

Thick dashed lines are direct connection runs beneath board of #20 bus wire (WR20BUSS) and are extended for the spark switch electrodes

Board Assembly Steps

See Figures i-7a and i-7b for enlarged views of this figure.

Figure I-Б Wiring connections and external leads

Board Assembly Steps

Figure l-7a Enlarged view of wiring

Cut and paste 7a and 7b together

Board Assembly Steps

Figure l~7b Enlarged view of wiring

Board Assembly Steps

Figure 1-8 Final assembly showing metered enclosure

Board Assembly Steps

Detail ol end viewing safety vottage breakdown set to 25 to 30 Kv This scheme helps protect lifter craft and power supply from dangerous over-voftage breakdown

Figure 1-9 Final isometric view

Board Assembly Steps

The lower-cost GRA10 is a modular approach where the electronics assembly is secured into a ptastic channel CH1. Input and output leads are the same and R1 is a smaJI trimpot.

Assembly is secured via the center nylon screw

Figure 1-10 Alternate GRAlO assembly module

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