MANUFACTURING ENGINEERING INSTRUCTION

PROCEDURE MEI

PRODUCT LINE PRODUCT SKU CREATED BY:

Back-Ups BK500 A.M. Arayon

DATE: 8/14/00 MEI DOC. # 991

TITLEPG6-98.XLS

REVISION CONTROL CHART Revision

1

MEI DOC. # ECO # / MCO # - Description of Change(s)

New Release MEI

991 Initials
AMA

Date
14-Aug-00

Page(s)
All

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.

MEC 1

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)

NO.

PART NAME

PART NO. OM-205

QTY 1

NO.

PART NAME

PART NO.

QTY

MEC1 Assy Left Panel 500VA McKinley

Manufacturing Engineering Instruction

Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 3 of 10 App'd by: Operation: Rear Panel Assembly

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot

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

Attach rear panel to the Main PCB as shown. Place XFMR 1 in the designated position of the chassis.

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

MEC 2 XFMR 1

Black Secondary wire of XFMR 1 at J11.

Brown wire of XFMR 1 at J10.

Green bundled wire (long green ground wire) of MEC 2 at J7. Black bundled wire of MEC 2 at J2. Black primary wire of XFMR 1 at J4.

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

White bundled wire of MEC 2 at J8.

Red wire of XFMR 1 at J14.

White secondary wire of XFMR 1 at J13.

PART NAME

Blue wire of XFMR 1 at J12.

White primary wire of XFMR 1 at J5.

Red bundled wire of MEC 2 at J9.

Yellow bundled wire of MEC 2 at J3.

NO.

PART NO. 430-2061 0M-202

QTY 1 1

NO.

PART NAME

PART NO.

QTY

XFMR 1 XFMR 500VA 120/12V w/ BST UL MEC 2 Assy PNL RR Dom Nemas-15

Manufacturing Engineering Instruction

Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 4 of 10 App'd by: Operation: Rear Panel Assembly

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot

The bottom side of the right panel assembly.

The inner side of the right panel assembly.

2nd end side of the WIR 1

BEZ 1 WIR 1 BEZ 1 1st end side of the WIR 1

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

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).

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

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

NO.

PART NAME

PART NO. 0B285 0W209A 885-7015B 825-0016

QTY 1 1 1 2

NO.

PART NAME

PART NO.

QTY

BEZ 1 Printed Right Panel MK WIR 1 Harness #12 Battery Wire LBL 1 Label Model / Serial # RFET 1 Feet Rubber Strip 1mm thick

Manufacturing Engineering Instruction

Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 5 of 10 App'd by: Operation: Right Panel Assembly

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot

BEZ 1

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

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.

Fasten the rear panel with two (2) screws, SCR 1. Use 4~6 in lbs. torque driver setting in screwing.

MEC 2 SCR 1 BEZ 1

top end of the rear panel Push downward the bottom end of the rear panel bottom end of the rear panel

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

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

NO.

PART NAME

PART NO. 803-0492

QTY 2

NO.

PART NAME

PART NO.

QTY

SCR 1 Screw M4 X 12 Plastite PH

Manufacturing Engineering Instruction

Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 6 of 10 App'd by: Operation: Left and Rear Panel Assembly

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot

(-) (+)

Attach battery housing terminal (MTL 1) on the positive (+) terminal of the battery. MTL 1 Align the edge of the battery clip (MTL 1) to this edge of the battery

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

FAS 1 LBL 2 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).

(+)

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

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

BAT 1

(-)
Black battery wire should be connected to the terminal. Bottom edge of the battery Bottom edge of the battery must not cover the three square holes (dotted square as shown) that lock the battery door. NO. PART NAME BAT 1

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

NO.

PART NAME

PART NO. 824-0018 885-2229 910-8011 870-3219

QTY 1 1 1 1

PART NO.

QTY

FAS 1 Foam Strip Adhesive Back BA LBL 2 Label Battery WRLD INST BAT 1 Battery 12V, 7-7.2AH, High-Rate MTL 1 Housing Battery Terminal

Manufacturing Engineering Instruction

Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 7 of 10 App'd by: Operation: Battery Insertion

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot

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

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

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

Cut this section

Leave this section uncut

Cut this section

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.
NO. PART NAME PART NO. 870-3335 885-2123B QTY 1 1 Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 8 of 10 App'd by: Operation: Label Application

NO.

PART NAME

PART NO.

QTY

MTL 2 Door Battery Mckinley LBL 3 Label Battery Disconnect

Manufacturing Engineering Instruction

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot

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

CBL 1

PCK 1

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

PCK 3

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

PCK 1 Lit kit (LIT 1) should be place in the red box portion. Place the lit kit (LIT 1) inside the box (PCK 2). Push the flaps of the box inwards (PCK 2).

LIT 1

LBL 4

Place the label (LBL 4) on the box (within the red square as shown). PCK 2

NO.

PART NAME

PART NO. 871-0488 871-0490 885-0611 872-0097 0L219 607-0038

QTY 2 1 1 1 1 1

NO.

PART NAME

PART NO.

QTY

PCK 1 Foam Insert BK McKinley PCK 2 Carton BK / MK LBL 4 Label, blank 4 X 2.5, Therm XSF PCK 3 Bag Plastic 18 X 6.75 X 4" BK LIT 1 Lit Kit BK/MK USB Domestic

Manufacturing Engineering Instruction

Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 9 of 10 App'd by: Operation: Packaging

CBL 1 MOD Tele CBL 6ft 2 Wire Blk

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot

PCK 4

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

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

LBL 5

NO.

PART NAME

PART NO. 871-0489 885-0635

QTY 1 1

NO.

PART NAME

PART NO.

QTY

PCK 4 Carton RS Master 2X BK LBL 5 Box Label 4.4 X 12

Manufacturing Engineering Instruction

Product: BK500 Assembly: Final Assembly Doc. No. 991 Date Created / Revised : August 14, 2000 Prep'd by: Rev'd by: Rev. 1 Page 10 of 10 App'd by: Operation: Packaging

Amor Mia Arayon

filename:Network drive where electronic copy resides

Andrew Chase

Ted Solgot