Depth Sensor Node Enclosure Assembly Repair Guide

Difficulty

Moderate

Steps

Time Required

                          30 minutes - 2 hours

Sections

Depth Sensor Node Enclosure Assembly
29 steps

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What you need

Step 1

              Running Node Builder Web App

open Anaconda Navigator
launch Spyder
click ‘Open File’ and select “node_builder.py” under “\Documents\anvil”
click the ‘Run’ button
visit this link to get started: Node Builder

open Anaconda Navigator

launch Spyder

click ‘Open File’ and select “node_builder.py” under “\Documents\anvil”

click the ‘Run’ button

visit this link to get started: Node Builder

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Step 2

              Outside Structure

Obtain a solar panel with the appropriate metal plate.
Obtain the correctly bend metal plate.
The enclosure is the box where the sensor board, and wires are kept to protect from the environment.
Obtain the enclosure with the predrilled holes.

Obtain a solar panel with the appropriate metal plate.

Obtain the correctly bend metal plate.

The enclosure is the box where the sensor board, and wires are kept to protect from the environment.

Obtain the enclosure with the predrilled holes.

Step 3

              Extending the Solar Panel Wire

Obtain the solar panel extension cable
Obtain heat-shrink tubing and place it around the cable
Cover the connection between the solar panel wire and the extension cable with the heat-shrink tubing. Then, use a heat gun to shrink the tubing, creating a water-tight seal around the connection

Obtain the solar panel extension cable

Obtain heat-shrink tubing and place it around the cable

Cover the connection between the solar panel wire and the extension cable with the heat-shrink tubing. Then, use a heat gun to shrink the tubing, creating a water-tight seal around the connection

Step 4

              Preparing Solar Panel Wire

Trim the solar panel extension wire so there is approximately 20 inches of wire from the connection point
Strip the wires as shown in the image
Twist the ends of the wires

Trim the solar panel extension wire so there is approximately 20 inches of wire from the connection point

Strip the wires as shown in the image

Twist the ends of the wires

Step 5

              Attaching The Solar Panel

Attach the solar panel onto the metal plate.
Using screws and a screw driver, screw the solar panel into these holes. Now that the solar panel is attached to the metal plate, attach the metal plate onto the lid of the enclosure
Note: the tall side of the metal plate should be on the same side of the enclosure as the holes for the ultrasonic sensor and cable glands.
The screws and nuts should be screwed in this matter in the holes on the sides of the box lid (meaning the nut is on the outside)

Attach the solar panel onto the metal plate.

Using screws and a screw driver, screw the solar panel into these holes. Now that the solar panel is attached to the metal plate, attach the metal plate onto the lid of the enclosure

Note: the tall side of the metal plate should be on the same side of the enclosure as the holes for the ultrasonic sensor and cable glands.

The screws and nuts should be screwed in this matter in the holes on the sides of the box lid (meaning the nut is on the outside)

Step 6

              Adding The Velcro

Obtain velcro
Add velcro with soft side inside the enclosure in the following places

Obtain velcro

Add velcro with soft side inside the enclosure in the following places

Step 7

              Solar Panel Wire

Now we need to insert the red extension wire from the solar panel into the enclosure box
Obtain a cable gland
Screw the cable gland into the wall of the enclosure, through the small hole, as shown
Place an o-ring between the cable gland and outer-wall of the enclosure
Insert the solar panel extension wire into the cable gland as shown, leaving approximately 8 inches of wire inside the enclosure

Now we need to insert the red extension wire from the solar panel into the enclosure box

Obtain a cable gland

Screw the cable gland into the wall of the enclosure, through the small hole, as shown

Place an o-ring between the cable gland and outer-wall of the enclosure

Insert the solar panel extension wire into the cable gland as shown, leaving approximately 8 inches of wire inside the enclosure

Step 8

              Solar Panel Wire Pt. 2

Obtain a plugable header and ensure the ends of the wires are twisted
Screw the wires into the plugable header as shown in the picture
Note: hand tight is just right.

Obtain a plugable header and ensure the ends of the wires are twisted

Screw the wires into the plugable header as shown in the picture

Note: hand tight is just right.

Step 9

              Depth Sensor Assembly

Solder a 3-prong terminal block to the ground, power, and data (#5) through-holes on the depth sensor
For organization, bind three wires (red, white, and black) with a small piece of shrink wrap
Connect the wires as shown in the picture (black to ground, red to power, white for data)

Solder a 3-prong terminal block to the ground, power, and data (#5) through-holes on the depth sensor

For organization, bind three wires (red, white, and black) with a small piece of shrink wrap

Connect the wires as shown in the picture (black to ground, red to power, white for data)

Step 10

              Depth Sensor Installation

Assemble the depth sensor by adding the o-rings, and the connective wires in the order pictured, leaving the nut ring to the side
Note that the connective wires connect the depth sensor to the sensor node board. Remember, red wire is responsible for power, black is for ground, and white is for data
Place the depth sensor through the larger hole, and secure it firmly by tightening the nut ring
Make sure the nut ring is tightened securely as it will keep the enclosure water-tight

Assemble the depth sensor by adding the o-rings, and the connective wires in the order pictured, leaving the nut ring to the side

Note that the connective wires connect the depth sensor to the sensor node board. Remember, red wire is responsible for power, black is for ground, and white is for data

Place the depth sensor through the larger hole, and secure it firmly by tightening the nut ring

Make sure the nut ring is tightened securely as it will keep the enclosure water-tight

Step 11

              Attaching GPS and Antenna to Modem

Obtain the cell module (modem), GPS, and antenna
Insert Super SIM card into cell module
Attach the GPS to the connection shown (grey wire)
Attach the antenna to the connection shown (black wire)

Obtain the cell module (modem), GPS, and antenna

Insert Super SIM card into cell module

Attach the GPS to the connection shown (grey wire)

Attach the antenna to the connection shown (black wire)

Step 12

              Adding Velcro to GPS and Antenna

Attach rough-sided velcro on the antenna and GPS as shown in the picture.

Attach rough-sided velcro on the antenna and GPS as shown in the picture.

Step 13

              Adding Velcro and Block Plug  to Battery

Obtain velcro and lithium ion 3.7V battery. Attach rough side of velcro on battery
Be very careful not to short the battery by touching the two wires together.
Obtain a block plug.
Twist the wires of the battery so they fit nicely in the plugable-header block
Screw the wires into the block plug
Note: hand tight is just right.

Obtain velcro and lithium ion 3.7V battery. Attach rough side of velcro on battery

Be very careful not to short the battery by touching the two wires together.

Obtain a block plug.

Twist the wires of the battery so they fit nicely in the plugable-header block

Screw the wires into the block plug

Step 14

              Preparing Battery for Enclosure

Obtain one battery, 4 zip ties, foam, and a pair of scissors
Cut out two battery-sized pieces of foam
Sandwich the battery between the two pieces of foam and secure it using the zip-ties. Connect the zip-ties to make two extra long zip-ties

Obtain one battery, 4 zip ties, foam, and a pair of scissors

Cut out two battery-sized pieces of foam

Sandwich the battery between the two pieces of foam and secure it using the zip-ties. Connect the zip-ties to make two extra long zip-ties

Step 15

              Adding Standoffs and Battery to Enclosure

Obtain eight 1.5-inch long standoffs. Screw the standoffs together as shown, to make four 3-inch long standoffs
Screw the standoffs into the enclosure
Insert battery into the enclosure. Make sure the wire is on the sensor-side of the enclosure

Obtain eight 1.5-inch long standoffs. Screw the standoffs together as shown, to make four 3-inch long standoffs

Screw the standoffs into the enclosure

Insert battery into the enclosure. Make sure the wire is on the sensor-side of the enclosure

Step 16

              Connecting Jumpers, SD card, and Modem on Sensor Node Board

Obtain Open-Storm board and place 4 jumpers in the spots shown
Insert microSD card into board
Attach the cellular module onto the sensor node board in the appropriate place

Obtain Open-Storm board and place 4 jumpers in the spots shown

Insert microSD card into board

Attach the cellular module onto the sensor node board in the appropriate place

Step 17

              Connecting Sensors, Solar Panel to Node Board

Put the board on top of the standoffs in the enclosure, and screw it in using a screw driver
Connect the depth sensor wire as shown
Connect the solar panel wire to the board as shown
Connect the battery wire to the board as shown

Put the board on top of the standoffs in the enclosure, and screw it in using a screw driver

Connect the depth sensor wire as shown

Connect the solar panel wire to the board as shown

Connect the battery wire to the board as shown

Step 18

              Securing Antenna, GPS, and Battery

Attach the antenna, and the GPS on the velcro to the closest wall on the inside of the enclosure

Attach the antenna, and the GPS on the velcro to the closest wall on the inside of the enclosure

Step 19

              Applying Open-Storm and Node ID stickers

apply the open-storm sticker to the side of the enclosure as shown
apply the unique node ID sticker to the two spots shown
print a label with the unique node ID that appears on the sticker using the label maker
apply the label to the board as shown

apply the open-storm sticker to the side of the enclosure as shown

apply the unique node ID sticker to the two spots shown

print a label with the unique node ID that appears on the sticker using the label maker

apply the label to the board as shown

Step 20

              Securing the Solar Panel Wire

Fold wire over itself so that the portion above the hose clamp won’t have slack when the black wire section is pressed against the inside of the panel
Obtain a hose clamp, and secure the red part of the wire to the black section using a drill fitted with the drill bit
Wrap a zip tie around the wire as shown.
Use a second zip tie to connect the ends of the first one

Fold wire over itself so that the portion above the hose clamp won’t have slack when the black wire section is pressed against the inside of the panel

Obtain a hose clamp, and secure the red part of the wire to the black section using a drill fitted with the drill bit

Wrap a zip tie around the wire as shown.

Use a second zip tie to connect the ends of the first one

Step 21

              Securing the Solar Panel Wire-continued

Use a clamp to tighten the zip tie
Position each zip tie head as shown while tightening
Clip excess zip tie as close as possible

Use a clamp to tighten the zip tie

Position each zip tie head as shown while tightening

Clip excess zip tie as close as possible

Step 22

              Adjusting Solar Charger Potentiometer

Obtain USB power supply, plug into a laptop, and set output to 5.9V
Check the voltage with a voltmeter (you may have to set the power supply to ~5.8V for the voltmeter to read 5.9V)
Plug in the green terminal block from the power supply into the Open-Storm board solar port.
Confirm the solar charge LED is off.
Plug in a dead battery to the battery port. This step will not work with a charged battery
CAREFULLY turn the silver potentiometer next to the charge controller IC with a small flathead screw driver until the charge light turns on.
Although the screw has a phillip screw head, using a phillip screwdriver may damage the potentiometer. The hole in the center is too shallow for most screwdrivers. It is easier to use a flathead screwdriver!
Resource: 1. How to Select MPP Voltage on a Solar Charge Controller 2. Sunny Buddy Solar Charger V13 Hookup Guide

Obtain USB power supply, plug into a laptop, and set output to 5.9V

Check the voltage with a voltmeter (you may have to set the power supply to ~5.8V for the voltmeter to read 5.9V)

Plug in the green terminal block from the power supply into the Open-Storm board solar port.

Confirm the solar charge LED is off.

Plug in a dead battery to the battery port. This step will not work with a charged battery

CAREFULLY turn the silver potentiometer next to the charge controller IC with a small flathead screw driver until the charge light turns on.

Although the screw has a phillip screw head, using a phillip screwdriver may damage the potentiometer. The hole in the center is too shallow for most screwdrivers. It is easier to use a flathead screwdriver!

Resource: 1. How to Select MPP Voltage on a Solar Charge Controller 2. Sunny Buddy Solar Charger V13 Hookup Guide

Step 23

              Preparing Lock

obtain a master lock and a pair of scissors
cut the lock and key out of the packaging
set the lock to the default combination, 0-0-0-0, open the lock
put the key into the lock and twist clockwise 90 degrees
while the key is still twisted, set the combo to 2-2-4-5
remove the key, and the lock is ready to go

obtain a master lock and a pair of scissors

cut the lock and key out of the packaging

set the lock to the default combination, 0-0-0-0, open the lock

put the key into the lock and twist clockwise 90 degrees

while the key is still twisted, set the combo to 2-2-4-5

remove the key, and the lock is ready to go

Step 24

              Preparing Node Handle pt. 1

obtain the materials in the quantities shown
screw the U-bracket onto one of the 8" strut channels, using one of the 1/2" hex bolts and the 1/2" strut channel nut
attach the remaining 8" strut channel piece to the U-bracket, using two 1/2" hex bolts and two 1/2" hex nuts
be sure not to center the strut channel you are attaching the the U-bracket, instead make one side of the U-bracket flush with end of the strut channel (as shown)

obtain the materials in the quantities shown

screw the U-bracket onto one of the 8" strut channels, using one of the 1/2" hex bolts and the 1/2" strut channel nut

attach the remaining 8" strut channel piece to the U-bracket, using two 1/2" hex bolts and two 1/2" hex nuts

be sure not to center the strut channel you are attaching the the U-bracket, instead make one side of the U-bracket flush with end of the strut channel (as shown)

Step 25

              Preparing Node Handle pt. 2

insert the two 5/16" strut channel nuts into the back of the horizontal strut channel as shown

insert the two 5/16" strut channel nuts into the back of the horizontal strut channel as shown

Step 26

              Preparing Node Handle pt. 3

attach the winged strut channel bracket to the 8" telespar using the remaining two hex bolts and hex nuts
when tightening the hex nuts, ensure the edge of the nut points directly outwards (as shown), or else the struct channel piece will not slide inside
confirm the T-shaped strut channel piece slides into the telespar, and the handle is now finished

attach the winged strut channel bracket to the 8" telespar using the remaining two hex bolts and hex nuts

when tightening the hex nuts, ensure the edge of the nut points directly outwards (as shown), or else the struct channel piece will not slide inside

confirm the T-shaped strut channel piece slides into the telespar, and the handle is now finished

Step 27

              Adding Reinforcement Rails

Attach the reinforcement rails to the back of the node using two 5/16" hex bolts, two 5/16" hex bolts, and two 5/16" 1.25" OD washers. Insert the bolts the bottom two holes of the node enclosure, using the bottom holes of the rails as shown in the image.
Line up the top holes of the rails with the top node enclosure holes and then tighten the bottom bolts.

Attach the reinforcement rails to the back of the node using two 5/16" hex bolts, two 5/16" hex bolts, and two 5/16" 1.25" OD washers. Insert the bolts the bottom two holes of the node enclosure, using the bottom holes of the rails as shown in the image.

Line up the top holes of the rails with the top node enclosure holes and then tighten the bottom bolts.

Step 28

              Attaching Enclosure to Handle

screw the node enclosure onto the strut channel using the two 5/16" hex bolts and two 5/16" 1.5"OD washers. Be sure to put bolts through the reinforcement rails.
removing the T-shaped strut channel piece from the telespar makes this step easier
slide the T-shaped piece back into the telespar

screw the node enclosure onto the strut channel using the two 5/16" hex bolts and two 5/16" 1.5"OD washers. Be sure to put bolts through the reinforcement rails.

removing the T-shaped strut channel piece from the telespar makes this step easier

slide the T-shaped piece back into the telespar

Step 29

              Finishing Touches

this is what the node should look like on the inside
make sure the battery is plugged in
attach the lock to the outside of the enclosure
return to Node Builder for instructions on how to drop off the node at the testing rack

this is what the node should look like on the inside

make sure the battery is plugged in

attach the lock to the outside of the enclosure

return to Node Builder for instructions on how to drop off the node at the testing rack

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                    Brooke Mason

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