All About the Battery Kits

02/20/2000

Mini Table of Contents

  1. What is in the Kits
  2. Component Assembly
  3. Tool Reference
  4. Ordering of Supplies Reference

A. What is in the Kits?

QuantityItem

1Set of User Instructions & Packing List – ¼ sheet

1Pigtail – Set of red & black wires with receptacle attached

1Wall Brick – Plugs into the wall to recharge battery

112V Rechargeable Battery – Receptacle locks shaved off

B. Component Assembly

User Instructions & Packing List:

The original sheet with four sets of instructions should be in the box of supplies.

 Copy them in ME copy room across from ME125

 Cut with the paper cutter next to the copy machine.

Pigtail:

 Measure and cut around a foot and a half of red wire, and a slightly

shorter piece of black with the wire stripper/cutter Shown in Figure TOOL-1.

 Strip approximately ½ in or less off one end of both colored wires with the same wire

stripper/cutter.

 Attach crimp terminals labeled as male on the bag to stripped ends with the larger

opening from the crimp tool TOOL-2.

 Insert these terminals into a female housing making sure the black wire is nearest the

square end as shown in Figure PT-1.

Figure PT-1: Housing Setup for Pigtails

Wall Brick:

These will generally come in a box with a single end connector already on them. If the ends are already off skip to the appropriate step.

 Cut off the entire single plug with the wire cutter/stripper.

 Cut a small slit down the middle of the wire to aid in separating the two

halves of the wire about one foot in length.

 If you look closely at the two halves, one will have a brown or gray stripe

along its length. Cut this half approximately 8 inches from the end farthest the wall plug. Steps to assembly are shown in Figure WB-1.

 Strip approximately ½ in or less off all ends you have cut for a total of 4 ends.

 Cut each wire protrusion coming from the resistor until they are approx ½ in

long.

 Take the shorter end of the wire still connected to the plug (with the

stripe on it) and squish the end into one side of a red butt with the SuperChamp

tool in Figure TOOL-3.

 Squish the left (or right, doesn’t matter) resistor protrusion into the other end of the red

butt.

 Squish the opposing resistor protrusion into a new red butt.

 The opposite end of the red butt will now be squished into the extra wire

we cut off earlier (should be the spare piece cut with a stripe on it).

 Crimp male-looking terminals onto the two free ends.

 Pop these terminals into a female housing making sure the non-striped

wire is nearest the square end.

Figure WB-1: Wall Brick Assembly Drawing

Batteries:

These come pretty much the way we use them. The only that needs to be done is to shave off the locking bumps shown in Figure BT-1 with a utility knife shown in TOOL-4.

Figure BT-1: Where to Find Locking Bumps

Kits:
Place one Set of Instructions, Pigtail, Wall Brick, and Battery into a Hefty OneZip Freezer Bag.

C. Tool Reference

Figure TOOL-1: Wire Stripper/Cutter Tool

Figure TOOL-2: Crimp Tool

Figure TOOL-3: SuperChamp Tool

Figure TOOL-4: Utility Knife

D. Ordering of Supplies Reference:

Digi-Key

701 Brooks Ave S

Thief River Falls, MN 56701

1-800-344-4539

Description

Red Wire, 18G C2064-R-1000

Black Wire, 18G C2064-B-1000

Brown Wire, 18G C2064-W-1000

Resistor, 30W, 10W 30W-10-ND

Male Housing (Recepticle) WM1220-ND

Male Crimp Terminal (Corresponding Plug) WM1000-ND

Female Housing (Plug)WM1230-ND

Female Crimp Terminal (Corresponding Recepticle)WM1001-ND

Jameco Electronics

1355 Shoreway Road

Belmont, CA 94002

1-800-831-4242

Acct #: 559908

Description

Wall Brick131300

All Electronics Corporation

P.O. Box 567
Van Nuys, CA 91408-0567

1-888-826-5432

Description

Butt Splice5100

dc Battery Products

2708 Summer St NE
Minneapolis, MN 55413

(612) 623-8894

Description

12V NiCd, 6 cell battery with connectorsdc2064

Target

various locations

Description

Hefty One Zip Freezer Bags