Mains Power Converter 220 to 110 VAC Creation

From Aeon HACS Wiki
  1. Take off the 12 screws that hold the outer panel and place to the side in a separate small box.
    Mains converter with screws removed.
  2. Loosen larger nut that holds the power cord in place.
  3. Remove all glue from the power cord and the ground connection.
  4. Remove the power cord.
    1. Unscrew green (ground) wire from terminal lug, put the nut in the box with the 12 screws.
    2. Remove heatshrink from red and black bundle (Bundle laying on top of huge coil, that connects power cord) + the white wire connecting to the inside back face of the panel.
    3. Cut connection between power supply and long black wire, as well as the white wire where it connects to the panel.
    4. Pull out the entire power cord from its hole.
    5. Take the larger nut that held the power cord and reattach to the panel.
  5. Take an inch long piece of 3/8 OD silicone tubing and slide up the replacement power cord to fill the gap between the panel hole and the new power supply cord.
  6. Cut across the seam of the crimp holding the black cables inside of the power supply box.
  7. Cut off the end of the replacement power supply (The one that doesn't plug into the wall) and strip back wires leaving enough room for each wire to be soldered
  8. Cut an inch piece of 2:1 black dual wall heatshrink both 1/2 inch and 1/4 inch. Put the 1/4 inch heathsrink at the base of the brown (Line) wire, and the 1/2 inch piece at the base of the blue (Neutral) wire.
  9. Tin the line wire and bend (fishhook) it around the 26A Breaker connection. Squeeze wire tight with pliers around connection. Solder the connection and move the heatshrink over it.
  10. Connect the neutral and two black wires together in a crimp.
    1. Push the stripped wires through to opposite sides of the crimp. i.e. The black wire ends should be poking out of the crimp where the blue side enters and vise-versa.
    2. Solder inside of crimp until both sides of the crimp are starting to ooze out solder.
  11. Use heatgun to heatshrink both the line and neutral wire connections.
  12. Strip the ground wire, and crimp a #8-10 blue fork terminal.
    1. Use the yellow/black crimper to crimp the connection and use the color coding on it.
      Use the blue crimp space.
    2. Align the edge of the blue cover, where the fork starts, with the crimp and squeeze down part way. Move the stripped ground wire so the edge aligns with the start of the fork and fully crimp down.
  13. Put a <nowiki>#<nowiki>8 washer down over the original ground connection point, then attach the fork from the ground wire, and then put another washer over the fork, and tighten the smaller nut from the original ground connection.
    Loop the ground wire back and around in such a way that it leaves more room for the wrench to tighten the bolt.
  14. Change the back panel red switch from 115 to 230V.
  15. Attach the 3 Mains detect stickers on the front panel:
    1. 230 sticker goes over Output AC 220V.
    2. 115 CEGS Up goes over the left Output AC 110V.
    3. 115 Do Not Use goes over the right Output AC 110V.
  16. Inspect the inside of the entire system and blow out any loose scraps or dust.
  17. Reassemble with 12 screws.
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