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@ -84,24 +84,25 @@ Motherboard is a separate PCB connected to the grip (with 4-wire cable), to the
![Motherboard_assembly](img_motherboard_assembly.png)<br> ![Motherboard_assembly](img_motherboard_assembly.png)<br>
All components of the motherboard except step-up transformer are available on the market. The step-up transformer must be assembled per specifications.<br> All components of the motherboard except step-up transformer are available on the market. The step-up transformer must be assembled per specifications.<br>
![Trafo_assembly](img_trafo_assembly.png)<br> ![Trafo_assembly](img_trafo_assembly.png)<br>
The transformer has the following roles The transformer has the following roles<br>
* to accumulate energy while the switching transistor is in the on state and release that energy to the high-voltage cascade when the switching transistor goes to the off state (a) to accumulate energy while the switching transistor is in the on state and release that energy to the high-voltage cascade when the switching transistor goes to the off state<br>
* to provide step-up voltage transformation from the low-voltage input to the high-voltage cascade and (b) to provide step-up voltage transformation from the low-voltage input to the high-voltage cascade and<br>
* to provide galvanic insulation between the low-voltage input and the high-voltage cascade. (c) to provide galvanic insulation between the low-voltage input and the high-voltage cascade.<br>
<br>Windings:<br> <br>Windings:<br>
(1) The primary and the secondary are to be wound on the coil former.<br> (1) The primary and the secondary are to be wound on the coil former.<br>
(2) The total number of turns for the primary winding is 4.<br> (2) The total number of turns for the primary winding is 4.<br>
(3) The total number of turns for the secondary winding is 1860, i.e., about 155 per layer, 12 layer in total.<br> (3) The total number of turns for the secondary winding is 1860, i.e., about 155 per layer, 12 layer in total.<br>
(4) The sense (direction) of the windings should be the same.<br> (4) The sense (direction) of the windings should be the same.<br>
(5) The high voltage (secondary) winding shall be wound first. The low voltage (primary) winding shall be wound on top of it.<br> (5) The high voltage (secondary) winding shall be wound first. The low voltage (primary) winding shall be wound on top of it.<br>
![Trafo_ends](img_trafo_ends.png)<br> ![Trafo_ends](img_trafo_ends.png)<br><br>
Winding can be performed using a winding machine or produced manually, with care. The number of turns per layer of the secondary winding can be counted or can be estimated from the inside length of the coil former and the wire AWG.<br> Winding can be performed using a winding machine or produced manually, with care. The number of turns per layer of the secondary winding can be counted or can be estimated from the inside length of the coil former and the wire AWG.<br>
Regardless of the winding method, the beginning of the high voltage coil, which comes closest to the ferrite core, shall be inserted in heat shrink tubing and the tubing shall be heated to its final dimensions. The tubing is used to improve the insulation between the wire at the beginning of the coil and other wire layers.<br> Regardless of the winding method, the beginning of the high voltage coil, which comes closest to the ferrite core, shall be inserted in heat shrink tubing and the tubing shall be heated to its final dimensions. The tubing is used to improve the insulation between the wire at the beginning of the coil and other wire layers.<br>
Once a winding layer is completed, it shall be fully covered by layers of insulation paper. The total thickness of the insulating layer must be at least 0.2 mm. The first role of this insulation is to reduce the parasitic capacitances between adjacent wire layers. The second role is to increase the breakdown voltage between adjacent wire layers.<br>
<br>Once a winding layer is completed, it shall be fully covered by layers of insulation paper. The total thickness of the insulating layer must be at least 0.2 mm. The first role of this insulation is to reduce the parasitic capacitances between adjacent wire layers. The second role is to increase the breakdown voltage between adjacent wire layers.<br>
The completed secondary winding shall be covered by layers of insulation paper either fully or only in the area where the primary winding is going to be placed. The main role of this insulation is to increase the breakdown voltage between the two windings.<br> The completed secondary winding shall be covered by layers of insulation paper either fully or only in the area where the primary winding is going to be placed. The main role of this insulation is to increase the breakdown voltage between the two windings.<br>
Once both windings are completed, the insulation from all wire ends shall be removed. Solder the terminals of the primary and secondary windings according to raster view. The beginning of the secondary winding (which is covered by the heat shrink tubing) shall be soldered to the pin denoted by the red circle in raster view.<br> <br>Once both windings are completed, the insulation from all wire ends shall be removed. Solder the terminals of the primary and secondary windings according to raster view. The beginning of the secondary winding (which is covered by the heat shrink tubing) shall be soldered to the pin denoted by the red circle in raster view.<br>
Insert the two halves of the ferrite core into the coil former shown in assembly of the step-up transformer. The cross sections of the core in the areas denoted by green ellipses should have gaps of 0.25mm to 0.3mm. Cut three pieces of the standard printing paper (80 GSM) paper per gap, and stack pieces to form the gap. It is not necessary to place the paper in the central column of the core.<br> Insert the two halves of the ferrite core into the coil former shown in assembly of the step-up transformer. The cross sections of the core in the areas denoted by green ellipses should have gaps of 0.25mm to 0.3mm. Cut three pieces of the standard printing paper (80 GSM) paper per gap, and stack pieces to form the gap. It is not necessary to place the paper in the central column of the core.<br>
![Trafo_core_clips](img_trafo_core_clips.png)<br> ![Trafo_core_clips](img_trafo_core_clips.png)<br><br>
Secure the transformer by two clips. One clip is shown in Sketch of a clip. The location of the clips can be seen in assembled step-up transformer.<br> Secure the transformer by two clips. One clip is shown in Sketch of a clip. The location of the clips can be seen in assembled step-up transformer.<br>
## Use-case scenarios for testing and demonstration ## Use-case scenarios for testing and demonstration