VERSION 1.
REVISIONS Revision Author Date Changes 1.
TABLE OF CONTENTS Revisions ................................................................................................................................................... 1 Abbreviations ............................................................................................................................................ 1 Tools and Materials ................................................................................................................................... 4 Enclosure Assembly ....
Final Test Pass Criteria ......................................................................................................................... 28 Label Application procedure ................................................................................................................... 29 Component List ................................................................................................................................... 29 Procedure .......................................................
TOOLS AND MATERIALS Phillips #2 Screwdriver T6 Torx Screwdriver Black Decker Ratchat Screwdriver UniFlash Software Texas Instruments CC2652R1 Development kit Micro USB Cable Black Decker 18V Drill JTAG Cable FEBRUARY 11, 2022 CLS-4-420-th 4
DC Electric Load Digital Multimeter DC Power Supply P-touch P700 Label Maker Tweezers DROK Signal Generator USB type-B Cable FTDI Program FEBRUARY 11, 2022 CLS-4-420-th 5
EV2400 Interface Adapter Battery Management Studio GTW-BL100 Tera Term Serial Terminal Alligator Cable Clips Gateway Visualizer FEBRUARY 11, 2022 CLS-4-420-th 6
ENCLOSURE ASSEMBLY COMPONENT LIST Description Manufacture Part Number / Revision X-Lab CLS-4-420-TH Right Side Housing Electronics4All Rev. 1.0 X-Lab CLS-4-420-TH Left Side Housing Electronics4All Rev. 1.0 X-Lab CLS-4-420-TH Battery Door Electronics4All Rev. 1.0 X-Lab CLS-4-420-TH Rear Housing Electronics4All Rev. 1.0 X-Lab CLS-4-420-TH Membrane Memtronik Inc. Rev. 2.0 X-Lab CLS-4-420-TH Rotary Encoder CCA Electronics4All Rev. 1.0 Screw M2.
ENCLOSURE ASSEMBLEY PROCEDURE 1 Remove the adhesive backing on the membrane. Do not touch the exposed adhesive after backing removal. 2 Feed the membrane tail through the right housing membrane slot. 3 Align the bottom edge of the membrane with the edge of the membrane cavity in the left housing. 4 Press the membrane down onto the housing. 5 Place the Rotary Encoder Daughter CCA in the housing. 6 Ensure the screw holes in the CCA are aligned with the screw holes in the housing.
7 Install two (2) M2.2*4mm Screws using a T6 torx Screwdriver. Fingers tighten the screws. 8 9 Install the antenna connector in the housing opening. The flat edge of the connector should face away from the membrane. 10 Loosely install the lock washer and nut supplied with the connector. Tighten the connector nut to 15 in-lbs using torque screwdriver. 12 Ensure the DIN mount is aligned correctly: The spring clip should be positioned opposite to the top of the housing.
13 Install the rear housing into the slot in the rear of the left housing. The TOP direction arrow should face towards the antenna connector. 14 Install one (1) 4-40*0.375” screw using a #1 Phillips bit. Finger tighten the screw. 15 Install the right housing into the left housing assembly. Install four (4) 3*35mm torx screw using Black Decker Drill. Finger tighten the screw. 16 Screw the antenna onto the antenna jack using a clockwise rotation. Hand tightens only.
MAIN CIRCUIT CARD PROGRAMMING PROCEDURE PRECAUTION This procedure involves the handling of ESD sensitive components. ESD protection measures should be employed. COMPONENT LIST Description Manufacture Part Number / Revision X-Lab CLS-4-420-TH Main CCA Electronics4All Rev. 1.0 CLS-4-420-TH Test Firmware Electronics4All Rev. 1.0 Serial Number List Electronics4All NA TOOLS AND MATERIAL LIST 1. Computer 2. Texas Instruments UniFlash Software 3.
3 Start the Texas Instruments UniFlash software. The program should automatically detect and display the JTAG programmer. Select the start button. 4 Under the Program tab, select the Browse button to the right of Flash Image(s). Navigate and select the firmware image to load into the CCA. 5 When the file is selected, the Load Image button will be enabled. Select the Load Image button. 6 Once the firmware has been loaded, a SUCCESS message will appear in the console window.
9 Affix the label to the Main CCA. Record the BLE address for corresponding Main CCA serial number in the master spreadsheet. FEBRUARY 11, 2022 10 CLS-4-420-th Provide the updated master spreadsheet to Electronics4all. Case labels with the serial number and BLE address will be printed and provided to the manufacture for final assembly.
GAS GAUGE PROGRAMMING PROCEDURE PRECAUTION This procedure involves the handling of ESD sensitive components. ESD protection measures should be employed. COMPONENT LIST Description Manufacture Part Number / Revision X-Lab CLS-4-420-TH Main CCA Electronics4All Rev. 1.0 AC/DC Adapter CUI Inc. SWI24-12-N Serial Number List Electronics4All NA Battery Configuration File Electronics4All Rev. 2.1 TOOLS AND MATERIAL LIST 1. Computer 2.
3 Set the DC power supply to 4.00VDC, 1.3A. Observing correct polarity, connect the power supply to the BAT+ and BATterminals. 4 Connect the PACK+ test clip to the DC active load positive terminal. Connect the DC load negative terminal to ether the GND test clip or BAT- terminal. 5 Turn on the DC active load. The Load should read 0.00 VDC. 6 Activate gas gauge by temporarily shorting BAT+ and PACK+ terminals using conductive tweezers.
9 Select programming from the Top menu, select the appropriate gas gauge image file, and then select Program. A progress bar dialog will display the programming status. After that successful message will appear at left bottom corner. 10 Select Calibration from the top menu. The calibration controls will be displayed in the main window. 11 Select the CC Offset and Board Offset checkboxes. Ensure no other boxes are checked. Select the Calibrate Gas Gauge button.
15 Wait for few seconds for the Gauge box to display the load current. For previously uncalibrated gauges, current will read approximately -1000 ± 5mA. Select the Calibrate Gas Gauge button. 16 When calibration is complete, a green checkmark will appear beside the Calibrate Gas Gauge button. Confirm that the reported current in the gauge box is approximately -1000 ± 5mA. Disable the active load. 17 Using a multimeter, measure the voltage between the BAT+ and BATterminals.
21 At the top menu, select Data memory. In the top right corner, select Read All. After a few seconds, all data loaded into the gas gauge will be displayed. FEBRUARY 11, 2022 22 CLS-4-420-th Select the Export button and save the file using CCA board serial number as the filename.
INTERMEDIATE ASSEMBLY PROCEDURE PRECAUTION This procedure involves the handling of ESD sensitive components. ESD protection measures should be employed. COMPONENT LIST Description Manufacture Part Number / Revision X-Lab CLS-4-420-TH Main CCA Electronics4All Rev. 1.0 X-Lab CLS-4-420-TH Enclosure Assembly Electronics4All Rev.
3 Install the washer and nut removed in step 1 back on to the DC input connector. 4 Tighten the DC input nut to 15 in-lbs. using a 10 mm socket and a torque driver. 5 Install the membrane tail into the membrane connector on the main CCA. 6 Carefully guide the main CCA into position. The membrane tail should loop as shown in the image, and the antenna connector tail should be located above the CCA.
Ensure that the wires coming off the DC input jack are not in contact with the main CCA. 10 Install four (4) 4-20 x 5/16 screws using a #1 Phillips bit and driver. Finger tighten the screws. 11 Connect the antenna cable to P300 on the main CCA. The connection should snap once seated correctly. Note that both the connector and cable are delicate, should be manipulated with care. 12 The coaxial cable from the antenna should form a gentle loop as shown in the above image.
15 Install the USB Daughter CCA into J502. Ensure the connection pins are aligned before pressing the board down into place. FEBRUARY 11, 2022 16 CLS-4-420-th Install one (1) M3 x 8mm screw into the left housing to hold the USB Daughter CCA in place. Use a #1 Phillips bit and driver. Finger tighten the screw.
ASSEMBLY TEST PROCEDURE PRECAUTION This procedure involves the handling of ESD sensitive components. ESD protection measures should be employed. COMPONENT LIST Description Manufacture Part Number / Revision X-Lab CLS-4-420-TH Intermediate Assembly Electronics4All Rev. 1.0 AC/DC Adapter CUI Inc. SWI24-12-N TOOLS AND MATERIAL LIST 1. Computer 2. FTDI FT Prog Software 3. USB Type-B Cable 4. Multimeter 5. Tera Term Serial Terminal Software PROCEDURE 1 Connect a USB type-B cable to the UUT.
3 Select the search icon at the top of the window. The program should automatically locate the UUT and display default parameters. 4 Right Click the Device 0 ID in the tree (1), Highlight Apply Template (2), then select From File (3). Select the appropriate template file in the window dialog. The file will automatically be applied once selected. 5 LEFT click USB String Descriptors in the tree. A default serial number will be displayed. Change this serial number to the serial number of the UUT.
FINAL TEST PROCEDURE PRECAUTION This procedure involves the handling of ESD sensitive components. ESD protection measures should be employed. COMPONENT LIST Description Manufacture Part Number / Revision X-Lab CLS-4-420-TH Final Assembly Electronics4All Rev. 1.0 TOOLS AND MATERIAL LIST 1. Computer 2. X-LAB GTW-BL100 Wireless Gateway 3. Gateway Visualizer 4. DROK Signal Generator 5. Tera Term Serial Terminal Software PROCEDURE 1 Connect a USB type-B cable to the UUT, Turn ON the device.
3 Find a Port (1), Set a speed to 115200. Select a New Open (2). 4 Press and hold PB1 and PB2 button together for 6 seconds, after 6 seconds let go PB2 button and hold PB1 button until the line appears on tera term terminal. 5 Line appears on tera term terminal. It says type ‘h’ for menu option. 6 Type ‘h’ and press Enter. It will give you option. In Tera Term, type the following letters: “p, g, k” to check the cell current, cell SOC, provision. After the test type ‘r’ to reset the device.
9 Press and Hold PB1 button until the green COM LED on the gateway turn OFF. 10 CLS-4-420-TH broadcast the data packets to the gateway at 20 seconds intervals, which in turn will forward the data to electronics4all. The green COM LED both on UUT and gateway will flash one 11 Connect DROK Signal Generator to four (4) channels of UUT. 12 Turn the knob of DROK Signal generator in anticlockwise direction to set the output to 4mA current.
15 The Gateway Visualizer will show 20 mA current reading on all the four (4) channels. Set the DROK Signal Generator to different current reading and check the gateway visualizer for results. 16 If the any of four channel is not showing current value according to DROK signal generator display, change the resistance on potentiometer until it is similar to DROK signal generator display.
LABEL APPLICATION PROCEDURE COMPONENT LIST Description Manufacture Part Number / Revision X-Lab CLS-4-420-TH Final Assembly Electronics4All Rev. 1.0 X-Lab CLS-4-420-TH Label 1 Electronics4All Rev. 1.0 X-Lab CLS-4-420-TH Label 2 Electronics4All Rev. 1.0 PROCEDURE 1 Labels will be provided by Electronics4All once the serial number and MAC address list is received, and the gas gauge calibration file and final test data has been reviewed for the UUT.
