WARS Powerpole kit Alignment JIG hints

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V2-19Sept2020

1. After soldering the resistors and fuse leds onto the main board, insert the powerpole contacts (with their copper wire extensions) into the red and black housings, and place fuses in the spade sockets (as per main instructions).

2. Check that the powerpole connector contacts are properly inserted, by inspection and joining together, should make good connection and positive click.

3. Place Fuses in spade sockets into the board, and Powerpole connectors in their positions as shown.

4. Position jig over parts so that they are aligned properly (several minutes of fiddling)!

5. Flip over and push fuse connectors down. They should be almost flush with the main board.

Tack solder the Fuse socket contacts to the board (but not the Powerpole connectors).

Tack each Fuse contact closest to the middle of the board, i.e. those on the small copper islands, as they will soak away far less heat. Next, do all the outer connections and then come back and properly solder the inner ones. Note that with the jig the bottom side only provides a good electrical connection for the fuse, not enough mechanical support. You need to at least solder the sides of the legs as well on the top.

Flip board over to drop off all the Powerpole connectors (because it will be much easier for access) and properly solder both sides of fuse sockets onto the board. Then reassemble the jig with Powerpole connectors and continue the main instructions.

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