Autosampler Battery Enclosure Assembly For Old New Versions Repair Guide

Difficulty

Moderate

Steps

Time Required

                          2 hours

Sections

Autosampler Battery Enclosure Assembly (For Old & New Versions)
17 steps

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What you need

Step 1

              Drill the holes into the enclosure.

1. Drill a hole in the top right corner 16.5 mm from the top and 30.3 mm from the side using a 13/16 inch drill bit.
1. Drill two holes in the side 30 mm from the short sides and 27 mm from the long side using a 1/2 inch drill bit.
1. Screw in two waterproof cable gland connectors to the side holes.
Put in a button in the rocker switch in the other hole.

Drill a hole in the top right corner 16.5 mm from the top and 30.3 mm from the side using a 13/16 inch drill bit.
Drill two holes in the side 30 mm from the short sides and 27 mm from the long side using a 1/2 inch drill bit.
Screw in two waterproof cable gland connectors to the side holes.

Put in a button in the rocker switch in the other hole.

1024

Step 2

              Prepare the battery wires.

1. Cut the purple wire and the inline fuse holder wire 10 inches long.
1. Attach a 10A, 12VDC fuse.

Cut the purple wire and the inline fuse holder wire 10 inches long.
Attach a 10A, 12VDC fuse.

Step 3

              Prepare the wires for the batteries.

1. Strip both wires about 1/2 inch
1. using the 16 gauge slot of the wire stripper
1. Get 3 pink and 3 blue fully insulated heat-shrink quick-disconnect terminals.

Strip both wires about 1/2 inch
using the 16 gauge slot of the wire stripper
Get 3 pink and 3 blue fully insulated heat-shrink quick-disconnect terminals.

Step 4

              Attach heat-shrinking terminals.

1. Crimp the fully insulated heat-shrink quick-disconnect terminal onto the end of the wire.
1. Use the heat shrink gun to heat shrink the ends of the crimps.
1. Repeat for both ends of both wires.

Crimp the fully insulated heat-shrink quick-disconnect terminal onto the end of the wire.
Use the heat shrink gun to heat shrink the ends of the crimps.
Repeat for both ends of both wires.

Step 5

              Prepare the battery connector wire.

1. Cut two feet of red and black 16G wire (grey insulated wire) and then strip 2 inches off of the grey insulation.
1. Strip 1/2 inch of both the black and red wires.

Cut two feet of red and black 16G wire (grey insulated wire) and then strip 2 inches off of the grey insulation.
Strip 1/2 inch of both the black and red wires.

Step 6

              Prepare the battery connector wire.

1. Place two metal contacts on both the red and black wires.
You should see copper wire through the little pin hole. If not, strip more insulation.
1. Crimp the contacts into place.
1. Thread the contacts into the Amphenol connector.

Place two metal contacts on both the red and black wires.

You should see copper wire through the little pin hole. If not, strip more insulation.

Crimp the contacts into place.
Thread the contacts into the Amphenol connector.

Step 7

              Prepare the battery connector wire.

1. Attach the green wedge to the connector.
1. Cut 1.5 inches of 2:1 0.25" diameter heat shrink tubing.
1. Use the heat shrink gun to shrink the heat shrink tubing.

Attach the green wedge to the connector.
Cut 1.5 inches of 2:1 0.25" diameter heat shrink tubing.
Use the heat shrink gun to shrink the heat shrink tubing.

Step 8

              final battery connector.

1. This is what the final battery connector looks like.

This is what the final battery connector looks like.

Step 9

              Creating a 2-pin amphenol connector.

1. Cut 30 inches of red and black 16G wire (grey insulated wire). Strip 2 inches of the grey rubber coating from both ends.
1. Strip 0.5 inches from both the red and black wires from both ends.
1. Obtain a 2-pin amphenol connector.

Cut 30 inches of red and black 16G wire (grey insulated wire). Strip 2 inches of the grey rubber coating from both ends.
Strip 0.5 inches from both the red and black wires from both ends.
Obtain a 2-pin amphenol connector.

Step 10

              Creating a 2-pin amphenol connector.

1. Disconnect the 2-pin amphenol connector into its individual parts.
1. Loosen the screws on the amphenol connector. Thread the stripped wire through the end of the amphenol connector and through the middle piece of the amphenol connector.
The black GND wire should be in the “A” port and the red PWR wire should be in the “B” port.
1. Solder the wires to the other end of the amphenol connector.

Disconnect the 2-pin amphenol connector into its individual parts.
Loosen the screws on the amphenol connector. Thread the stripped wire through the end of the amphenol connector and through the middle piece of the amphenol connector.

The black GND wire should be in the “A” port and the red PWR wire should be in the “B” port.

Solder the wires to the other end of the amphenol connector.

Step 11

              Creating a 2-pin amphenol connector.

1. Obtain a Flux Remover Pen, 99 % Isopropyl Alcohol, and a Q-Tip.
1. Use the pen to remove the flux from the soldered pins.
1. Dip the q-tip in the alcohol. Use the q-tip to remove the flux remover.

Obtain a Flux Remover Pen, 99 % Isopropyl Alcohol, and a Q-Tip.
Use the pen to remove the flux from the soldered pins.
Dip the q-tip in the alcohol. Use the q-tip to remove the flux remover.

Step 12

              Creating a 2-pin amphenol connector.

1. Screw the amphenol pieces back together. Then tighten the external screws.
1. This is what a final 2-pin amphenol connector looks like.
1. Thread the 2-pin amphenol autosampler wire through the top hole and the battery connector wire through the bottom hole of the enclosure box. Leave about a foot of each on the outside of the box. Tighten the glands.

Screw the amphenol pieces back together. Then tighten the external screws.
This is what a final 2-pin amphenol connector looks like.
Thread the 2-pin amphenol autosampler wire through the top hole and the battery connector wire through the bottom hole of the enclosure box. Leave about a foot of each on the outside of the box. Tighten the glands.

Step 13

              Add quick-disconnect terminals to ends of 2-pin and battery wires.

Once 2 pin and battery wires constructed and threaded into box, strip opposite ends and add heat-shrinking quick disconnect terminals.

Once 2 pin and battery wires constructed and threaded into box, strip opposite ends and add heat-shrinking quick disconnect terminals.

Step 14

              Connecting wires to the rocker switch.

1. This is what the wires look like threaded through the glands in the box.
1. Connect the battery wire to the first two prongs of the rocker switch.
1. Connect the 2-pin amphenol autosampler wire to the last two prongs of the rocker switch.

This is what the wires look like threaded through the glands in the box.
Connect the battery wire to the first two prongs of the rocker switch.
Connect the 2-pin amphenol autosampler wire to the last two prongs of the rocker switch.

Step 15

              Connecting the battery in the enclosure.

1. Connect the purple wire and fuse wire to the middle two prongs of the rocker switch.
1. Connect the other side of the purple wire and fuse wire to a 12 volt battery.
1. A light goes on if the fuse is blown!

Connect the purple wire and fuse wire to the middle two prongs of the rocker switch.
Connect the other side of the purple wire and fuse wire to a 12 volt battery.
A light goes on if the fuse is blown!

Step 16

              Completing the enclosure.

1. Place the 12V battery and all the wires into the enclosure.
1. Screw the lid onto the enclosure.
1. This is what the completed battery enclosure looks like.

Place the 12V battery and all the wires into the enclosure.
Screw the lid onto the enclosure.
This is what the completed battery enclosure looks like.

Step 17

              Label the switch

Label the switch with the label maker.
<– Manual Mode
–> Node Trigger Mode

Label the switch with the label maker.

<– Manual Mode

–> Node Trigger Mode

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                    Brooke Mason

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