Work Instructions: Light Module Assembly
Work Instructions: Light Module Assembly
Each step number includes corresponding pictures. Numbered parts are depicted on the technical drawing on page 3. Assembly instructions include a pre-populated printed circuit board (#6) as well as CREE LED light (#4) affixed with heat sink (#3). Operator should be qualified in soldering procedures and basic tools.
Steps:
1.)Assemble Cover
- Insert two hex screws (#9) into likesized holes on opposite sides of the top cap (#1); Fasten top cap with one hex nut (#2) on each screw; Insert two washers (#12) and one more hex nut on each screw;
- Insert DC Power jack (#7) into fit hole in the top cap so that wires are facing the inside of the assembly - tighten on the bottom end of the cap; Insert DPDT switch (#11) into remaining hole - tighten from top end of cap,
2.)Place LED
- Slide Heat Sink (#3) onto Cover Assembly using the two hex screws (#9); the attached CREE LED (#4) should face the Top Cap (#1). Make sure the heat sink fits properly with the shortened end facing the DPDT Switch (#11) – if applied incorrectly the heat sink will not be level with the top cap.
3.)Insert Patter Pack
- Insert 4 NMH Batteries into battery pack.
- Slide battery pack (#5) between hex screws – battery pack may need to be filed down where in contact with hex screws to fit properly.
- Make sure that connection wiring from DC Jack (#7), CREE LED (#4), and Battery Pack (#5) are exposed, they will be connected in the next step.
- Tighten batter pack in place using one hex nut (#2) on each hex screw.
4.)Connect PCB
- Slide populated PCB (#6) half way onto hex screws without fastening so that the component side is facing the top of the assembly.
- Solder component wires to corresponding PCB pins accordingly:
Wire / PCB pin
- Black CREE LED wire - LED –
- Red CREE LED wire -LED +
- Black Battery Wire - Vin –
- Red Battery Wire -Vin +
- Black Switch Wire -SW3
- Green Switch Wire -SW2
- Red Switch Wire -SW1
- Black DC Jack Wire -J –
- Red DC Jack Wire -J +
- When all wires are correctly connected, carefully slide the PCB on to the assembly completely; apply a hex nut onto each hex screw to fasten PCB in place – be sure not to damage the PCB when tightening hex nuts.
5.)Fasten Can Housing
- Place component assembly inside can housing (#10), inserting the hex screws into the holes in the bottom of the can; be careful not pull out any wire connections in this process.
- Insert Lamp Hanger (#8) onto the length of hex screw at the bottom of the can housing; screw on a hex nut on each hex screw – securely tighten.
- Apply silicone waterproofing sealant to the edge of the Top Cap where it meets the Can Housing.
