CEB Press/Manufacturing Instructions/Case

Tools

• Screwdriver with the following bits: Quarter Inch Flathead, Half Inch Flathead, Number 1 Philips, and Number 2 Philips

• Hammer

• Centre Punch

• Crimper

• Cordless Drill with the following twist drill bits: 9 by 64 inch, 1 by 8 inch, 3 by 16 inch

• Needlenose Pliers

• Electrical Tape

• Tap Wrench with 8-32 Tap

Materials

• Outdoor Main Lug Box

• [2] Wire Clamps

• Toggle Switch

• [2] 3.2cm OD, 1.27cm ID Washers

• Fuse Holder

• Male Insulated Connector for 10-12 Gauge Wire

• Ring Insulated Connecter with Small Hole for 10-12 Gauge Wire

• 10 Amp Buss Fuse

• Ring Insulated Connector for 10-12 Gauge Wire

• [2] 12cm by 7.5cm by 0.4cm high density polyethylene plate

• [4] M3 machine screws of 20mm length

• [4] M3 nylon-threaded lock nuts

• [4] 8-32 machine screws of 3/4 inch length

• [7] 8-32 machine screws of 3/8 inch length

• Arduino Uno Microcontroller

Arduino Uno Serial Issue Solution, Replies 2 and 4 Note: for Arduino Uno Version R2, the contact point for entering DFU mode is the top-left male pin instead of the top-left pad. You'll need to perform this solution method if initial serial communication tests prove buggy. You cannot perform this after mounting the microcontroller inside the case.

• Linked Extension Cord Manufacturing Instructions

Steps

• Open the lug box

• Using the screwdriver and the half inch flathead bit, unscrew and remove the terminal components inside the lug box

• Using the safety glasses, hammer and the centre punch, remove the inner lids at the bottom-left, bottom-middle, bottom-right, and right-bottom of the lug box

• Mount the two wire clamps onto the bottom-left and right-bottom holes of the lug box

• Mount the toggle switch onto the bottom-right hole of the lug box; in the process, put the 3.2cm OD washers on both sides of the lug wall.

• Using the crimper, crimp the small ring connector and the male connector onto the two ends of the fuse holder; then insert the buss fuse.

• Using the crimper, crimp the ring connector to the black wire of the male end of the linked extension cord.

• Using the safety glasses, cordless drill and the 9 by 64 inch drill bit, drill holes on the first plastic plate such that 5 terminal holes are approximately evenly spaced along an axis near the top edge, and such that 2 terminal holes are located near the bottom corners.

• Using the safety glasses, cordless drill and the 1 by 8 inch drill bit, position the Arduino microcontroller board on a second plastic plate then drill through the board mounting holes through the plastic such that the holes of the board and those of the plastic align. Use M3 Machine Screws to help align the drilled holes during the process. Be careful not to excessively ream the Arduino board.

• Using the safety glasses, cordless drill, and the 3 by 16 inch drill bit, drill 2 mounting holes near the far edges of the first and second plastic plates.

• Using the safety glasses, cordless drill, and the 9 by 64 inch drill bit, drill holes on the back of the lug box such that they align with the mounting holes of the first and second plastic platforms. The Arduino platform should be positioned closer to the top than the terminal platform. Leave enough room surrounding the edges of the platforms to facilitate assembly, disassembly, and wiring.

• Using the metal file, deburr the lug box's platform mounting holes.

• Using the tap wrench and the 8-32 tap, tap the 7 terminal holes of the terminal platform and the 4 platform mounting holes of the lug box.

• Using the screwdriver with the number 1 philips bit and pliers, mount the Arduino microcontroller board onto the Arduino platform through the 4 mounting holes with the 20mm M3 machine screws and the 4 M3 nylon-threaded lock nuts.

• Using the screwdriver with the number 2 philips bit, mount the Arduino platform and the terminal platform onto the back of the lug box by screwing the 3 by 4 inch length 8-32 machine screws through the 4 mounting holes. Use 1/2-13 nuts to act as spacers between the platforms and the back of the lug box. The arduino platform should be mounted closer to the top of the lug box than the terminal platform.

• Insert the non-clip end of the linked extension cord into the lug box through the bottom-left hole, then connect the black wire's female connector to the fuse holder's male connector. Wrap electrical tape around the exposed male-female connection and put a small fold at the end of the tape piece for ease of disassembly.

• Using the screwdriver with the number 2 philips bit, connect the fuse holder's ring connector to one terminal of the toggle switch. Then connect the linked extension cord's black wire ring connector to the bottom-right screw terminal on the terminal platform.

• Using the screwdriver with the number 2 philips bit, tighten the screws of the wire clamp at the bottom-left of the lug box.

See Also

• Different Version (old/new?)