OHAI: Open Hardware Assembly Instructions

1 Gather tools and components for assembly

Components Required

Electrical cover
Power supply
Power switch
Power cord receptacle
80 mm fan
4 Pos plug, 200 mm length
Green ground wire w/ spade and ground lug, 80 mm length
Green ground wire w/ two ground lugs, 50 mm length
White and black wires, 250 mm length
White and black wires, 320 mm length
Zip tie bases
Zip ties
M3x6 Flat head screw
M3x20 Flat head screw
M3 Nyloc nut
M3 washer
M3 star washer

Tools Required

2 mm Allen driver
5.5 mm wrench
Phillips screw driver
Cutters

Tools

2 Install power switch

Install the power switch, noting the orientation. FYI, switch may be hard to press in.

Power switch installed, note orientation

3 Install Zip tie bases

Install the zip tie bases as shown by peeling the backing off. The middle of the base should be centered about 5 mm from the bolt holes.

2 bases

Tie base template.

Bases installed, note orientation

4 Add power cable receptacle

Install the power cable receptacle with 2x M3x6 flat head screws as shown.

Receptacle and screws

Receptacle installed

5 Install green ground wires

Attach the two ground wires to the case. Place the wires onto the post using this order: M3 star washer, 50 mm green wire, M3 star washer, 80 mm green wire, then M3 nyloc nut. Plug the spade connector onto the receptacle as shown.

Wires and hardware

Wires attached, spade connector attached to receptacle

6 Prep power supply for installation

Attach the 4 Pos connector to the power supply by removing the four screws. Place the wires in the correct position as shown.

Take the black and white(260 mm length) wires and attach them to the power supply as shown.

Power supply and wires

Orientation of 4 pos connector

Orientation of 250 mm black and white wires

7 Install power supply

Install the power supply using 4x M3x6 flat head screws as shown.

Hook up the green ground wire to the power supply as shown.

Attach the black and white wires to the power switch as shown.

Components

View of screws installed from back

Power supply mounted

Green ground wire attached

Black and white wires attached, note orientation

Zip down ferrite.

8 Install plug to switch wires

Connect the black and white(560 mm length) wires with the spade connectors from the switch to the plug as shown.

Make sure to wrap the wires four times around the ferrite alternating the wires as shown.

Wrap wires bottom to top.

Next, zip tie the four black and white wires to the zip tie bases making sure the slack is pulled and the wires aren't touching the bottom of the case and all the slack is towards the top as shown.

560 mm length wires