Task 4: Battery

Preparation

Assembly time

10 minutes

Tools needed

• T10 torx screwdriver
• 3mm hex-head key
• Philips cross-headed screwdriver

Step 1: Plastic cover

Prepare:

• 1x battery cover (3D-printed)
• 1x battery metal plate (aluminum, painted grey)
• 2x M4x8 torx screws
• 2x M4 square nuts
• T10 torx key

As in the Task 5, insert the M4 square nuts in the battery cover grooves, insert m4x8 torx screws and tighten them.

Step 2: Battery button

Prepare:

• 1x battery box
• 1x battery button
• 1x button nut
• 1x button o-ring

Assemble the o-ring to the button.

Insert the button in a corresponding hole in the battery box.

Screw the button nut on the other side. Push the button with one hand and screw the nut with your fingers. It will be enough

Check if the o-ring under the button sits properly (is not seen from the outside).

Step 3: Box to cover

Prepare:

• Step 1 assembly
• Step 2 assembly
• 4x M4x16 inner hex head screw
• 4mm hex key

Position the battery box on the battery metal plate. Align the both assemblies holes. Insert each of the M4x16 screws in the box holes.

Tighten the screws using a 4mm hex key.

Make sure each of the screws protrudes equally on the other side.

Step 4: Power connector and battery cover

Prepare:

• 1x power cable (3pin female socket with a green wire and push connectors)
• 1x power cable nut (needs to be detached from the cable beforehand)
• 4x plastic screw (big, fitting the battery cover)
• 1x battery cover

Push each of the plastic screws in the corresponding holes of the battery cover.

Insert the power cable to the hole in the cover. Thread the cables.

Push the power cable socket with one hand.

Tighten the socket nut with the other hand.

Step 5: Cable connection

Prepare:

• Step 3 assembly
• Step 4 assembly
• 1x battery pack

List of connections:

• power connector green wire to (+) pin on the button
• power connector black-with-white-stripe wire to NO pin on the button
• power connector black wire to (-) pin on the button
• battery red wire to C pin on the button
• batter black wire to power connector black wire

info

The button terminals may look different depending on a batch of components we get. When there's no marking on the left and right terminals, connect green LED wire to the left (number 1) terminal and the black negative wire to the right (number 2). There is a photo lower on the site showing the correct connections for the other type of button commonly used in our Leo Rover.

Connect the green cable from the battery cover to the + pin of the button.

Connect the white-and-black cable from the battery cover to the NO pin of the button.

Connect the black cable (female connector) from the battery cover to the - pin of the button.

Position the battery pack in the box.

Connect the battery pack red cable to the C pin of the button.

Connect the battery pack black cable (female connector) to the power cable black cable (male connector). Slide the rubber cover to make the connection tight.

Here's a photo showing cable connections for the other button type commonly used in our rover:

List of connections:

• Green wire connected to the leftmost pin (pin "1"),
• black and white wire connected to middle pin (pin "NO"),
• black wire connected to the rightmost pin (pin"2") and to the black battery cable.
• Red battery cable connected to the bottom pin (pin "C")

Step 6: Battery box cover

Prepare:

• Step 5 assembly
• 1x foam
• Philips cross-headed screwdriver

Cover the battery pack with the foam.

Push the battery pack into the battery box. Push the remaining cables in the box. Make sure nothing is protruding over the box outline, so it won't be pressed between the box and the box cover in the next step.

Close the box cover.

Tighten the cover screws with a cross-headed screwdriver.

Nice and tidy. Now it's time to put everything together.

After this Task you'll end up with 3x M5x10 inner hex head screws that will be used to mount the battery pack to the Rover in the Task 8.