MANUFACTURING ENGINEERING INSTRUCTION

PROCEDURE MEI

PRODUCT LINE Back-Ups

PRODUCT SKU BK500

CREATED BY: A.M. Arayon DATE: 8/14/00 MEI DOC. # 991

TITLEPG6-98.XLS

REVISION CONTROL CHART MEI DOC. # 991

Revision Date Page(s) ECO # / MCO # - Description of Change(s) Initials1 14-Aug-00 All New Release MEI AMA

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYMEC1 Assy Left Panel 500VA McKinley OM-205 1 Manufacturing Engineering Instruction

Product: Operation:

BK500

Assembly:

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 3 of 10

Prep'd by: Rev'd by: App'd by:

filename:Network drive where electronic copy resides

Rear Panel Assembly

Final Assembly

Andrew Chase Ted SolgotAmor Mia Arayon

Place the OP2032 in the MEC1, in the red square as shown. Make sure that the main PCB is securely fastened in all retainer points.

Detach the Display PCB and the Telnet board from the main PCB (OP2030). Break it on the red dotted line as shown.

Make sure that the main PCB is securely fastened to the MEC1 as shown, with the red circle.(rear panel side)

Make sure that the main PCB is securely fastened to the MEC1 as shown, with red box.(bezel side)

MEC 1

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYXFMR 1 XFMR 500VA 120/12V w/ BST UL 430-2061 1 Manufacturing Engineering InstructionMEC 2 Assy PNL RR Dom Nemas-15 1

Product: Operation:

BK500

Assembly:

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 4 of 10

Prep'd by: Rev'd by: App'd by:

filename:Network drive where electronic copy resides

Amor Mia Arayon

0M-202

Final Assembly

Andrew Chase Ted Solgot

Rear Panel Assembly

Attach the PCB display to the bezel. Make sure it is securely fastened to the bezel

Place XFMR 1 in the designated position of the chassis.

Black Secondary wire of XFMR 1 at J11.

Red wire of XFMR 1 at J14.

White secondary wire of XFMR 1 at J13.

Brown wire of XFMR 1 at J10.

Blue wire of XFMR 1 at J12.

White primary wire of XFMR 1 at J5.

Black primary wire of XFMR 1 at J4.

Green bundled wire (long green ground wire) of MEC 2 at J7.

Attach rear panel to the Main PCB as shown.

Red bundled wire of MEC 2 at J9.

Yellow bundled wire of MEC 2 at J3.

Black bundled wire of MEC 2 at J2.

White bundled wire of MEC 2 at J8.

Short Green wire (ground wire) of MEC 2 at J17 of Telnet Board.

Insert telnet board into the rear panel assembly. Make sure it is securely fastened at the retainer clips as shown (with dotted circle).

XFMR 1

MEC 2

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYBEZ 1 Printed Right Panel MK 0B285 1 Manufacturing Engineering InstructionWIR 1 Harness #12 Battery Wire 1

LBL 1 Label Model / Serial # 1 Product: Operation:

RFET 1 Feet Rubber Strip 1mm thick 2 BK500

Assembly:

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 5 of 10

Prep'd by: Rev'd by: App'd by:

filename:Network drive where electronic copy resides

Right Panel Assembly

0W209A

885-7015B

825-0016

Final Assembly

Ted SolgotAndrew ChaseAmor Mia Arayon

(+) Red battery wire of the WIR 1 at J15

(-) Black battery wire of the WIR 1 at J16.

RFET 1 should be centered and within the circle area of the left panel (MEC 1).

LBL 1 should be centered and within the square area of the right panel.

Insert the WIR 1 properly in the right panel assembly. Make sure that the battery harness is locked as shown.

The bottom side of the right panel assembly.

The inner side of the right panel assembly.

BEZ 1

RFET 1

LBL 1

WIR 1

BEZ 1

1st end side of the WIR 1

This is the portion that will lock the end sides of the WIR 1 and do not allow the battery wire harness to go althroughout the hole of the right panel (BEZ 1).

2nd end side of the WIR 1

Make sure that the red (+) and black (-) battery wire are properly inserted into the respective tabs. Battery housing must be locked upon insertion into the tabs.

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYSCR 1 Screw M4 X 12 Plastite PH 803-0492 2 Manufacturing Engineering Instruction

Product: Operation:

BK500

Assembly:

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 6 of 10

Prep'd by: Rev'd by: App'd by:

filename:Network drive where electronic copy resides

Amor Mia Arayon

Final Assembly

Left and Rear Panel Assembly

Andrew Chase Ted Solgot

Mount first the top end of the right panel, BEZ 1. Make sure the panel hooks properly in the main assembly.

Make sure it is properly hook on this portion.

bottom end of the rear panel

Mount bottom end of the rear panel, MEC 2. Make sure that it is properly hook in the main assembly.

Push downward the bottom end of the rear panel

Fasten the rear panel with two (2) screws, SCR 1. Use 4~6 in lbs. torque driver setting in screwing.Mount the BEZ 1 by pushing it first towards

the MEC 1 (see left red arrow). Then push it downward, see red arrow down. Make sure there will be no gap between the MEC 1 and BEZ 1.

BEZ 1

BEZ 1

SCR 1

MEC 1

MEC 2

Make sure that there is no gap between the MEC 1, BEZ 1 and MEC 2.

top end of the rear panel

Note : Follow the green arrow for the sequence of the process.

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYFAS 1 Foam Strip Adhesive Back BA 824-0018 1 Manufacturing Engineering InstructionLBL 2 Label Battery WRLD INST 1

BAT 1 Battery 12V, 7-7.2AH, High-Rate 1 Product: Operation:

MTL 1 Housing Battery Terminal 1 BK500

Assembly:

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 7 of 10

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filename:Network drive where electronic copy resides

Battery Insertion

885-2229

910-8011

870-3219

Final Assembly

Andrew Chase Ted SolgotAmor Mia Arayon

Attach the FAS 1 to the other end of the BAT 1.

Attach the LBL 2 on the front end of the battery. The portion with an arrow sign should hang over the edge of the BAT 1 from the line of the text box (dotted line as shown).

Insert the BAT 1 by pushing into the panel assembly. The bottom end of the BAT1 (with FAS 1) must come in first into the panel assembly ( as shown).

Black battery wire should be connected to the terminal.

Make sure red battery wire is disconnected to the battery terminal.

FAS 1

LBL 2

BAT 1

(+)

(-)

(+)(-)

BAT 1

Make sure WIR 1, battery wire harness, is properly push into the panel assembly with black battery wire properly connected to the (-) terminal.

Make sure red battery wire(+) must not touching the terminal of the battery.

Bottom edge of the battery must not cover the three square holes (dotted square as shown) that lock the battery door.

Bottom edge of the battery

MTL 1

Attach battery housing terminal (MTL 1) on the positive (+) terminal of the battery.

Align the edge of the battery clip (MTL 1) to this edge of the battery

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYMTL 2 Door Battery Mckinley 870-3335 1 Manufacturing Engineering InstructionLBL 3 Label Battery Disconnect 1

Product: Operation:

BK500

Assembly:

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 8 of 10

Prep'd by: Rev'd by: App'd by:

filename:Network drive where electronic copy resides

Amor Mia Arayon

Final Assembly

Label Application

Andrew Chase Ted Solgot

885-2123B

Cut this section

Cut this section

Leave this section uncut

Back side of the LBL 3, cut the sections with the red box as shown. Then leave the green section uncut.

Make sure that there will be no gapbetween the battery door and the right and left panel assembly.

With the unit's battery door open and the unit on its side, peel off the three (3) inches backing strip on the bottom of the label and attach it to the side of the battery as shown. Then install the battery door.

Install the battery door (MTL 2) by sliding downward on the bottom side of the unit. Follow the arrow as shown. Make sure it is locked.

Make sure that these portions allow the battery door to be locked in the right panel of the unit.

Wrap the label (LBL3) around to the top of the unit, peel off the top two (2) inches backing strip and secure to the cover as shown.

LBL 3

MTL 2

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYPCK 1 Foam Insert BK McKinley 871-0488 2 Manufacturing Engineering InstructionPCK 2 Carton BK / MK 1

LBL 4 Label, blank 4 X 2.5, Therm XSF 1 Product: Operation:

PCK 3 Bag Plastic 18 X 6.75 X 4" BK 1 BK500

LIT 1 Lit Kit BK/MK USB Domestic 1 Assembly:

CBL 1 MOD Tele CBL 6ft 2 Wire Blk 1

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 9 of 10

Prep'd by: Rev'd by: App'd by:

filename:Network drive where electronic copy resides

Packaging

871-0490

885-0611

872-0097

Final Assembly

Andrew Chase Ted SolgotAmor Mia Arayon

0L219

607-0038

Place the unit in the plastic bag (PCK 3).

CBL 1

PCK 1

PCK 1

PCK 3

LIT 1

LBL 4

PCK 2

Insert the foam (PCK 1) on the top and bottom side of the unit.

Place the cable (CBL 1) on the top portion of the unit and in the center of the hole of the foam (PCK 1).

Place the lit kit (LIT 1) inside the box (PCK 2).

Place the label (LBL 4) on the box (within the red square as shown).

Lit kit (LIT 1) should be place in the red box portion.

Arrange the Power Cord properly in the red box portion of the drawing.

Push the flaps of the box inwards (PCK 2).

NO. PART NAME PART NO. QTY NO. PART NAME PART NO. QTYPCK 4 Carton RS Master 2X BK 871-0489 1 Manufacturing Engineering InstructionLBL 5 Box Label 4.4 X 12 1

Product: Operation:

BK500

Assembly:

Doc. No. 991 Rev. 1

Date Created / Revised : August 14, 2000 Page 10 of 10

Prep'd by: Rev'd by: App'd by:

filename:Network drive where electronic copy resides

Packaging

885-0635

Final Assembly

Andrew Chase Ted SolgotAmor Mia Arayon

Place the label (LBL 5)on edge of carton, making sure that the edge of the carton falls between the printed guidelines on the label. (See red box as shown)

Push the flaps of the master box (PCK 4) inwards.

Place two (2) units in one master box (PCK4)

PCK 4

LBL 5