Opitec 110.693 User manual

1
D110693#2
Necessary materials
Fretsaw with metalworking blade
drills. dia. 3, 5, 6, 7, 10
Machine vice with soft jaws
Soldering iron, solder
Side cutters
Wire strippers
Combination pliers
Mole grips
Screwdriver
Spanner 5,5
Rivet gun
Centre punch
Sharp pencil
Ruler
Set square
Insulation tape
110.693
Solar Trike
w i t h A C C U b a t t e r y d r i v e a n d
LED lighting
Please Note
The OPITEC range of projects is not intended as play
toys for young children.They are teaching aids for young
people learning the skills of Craft, Design and Technolo-
gy.These projects should only be undertaken and tested
with the guidance of a fully qualified adult.
The finished projects are not suitable to give to children
under 3 years old. Some parts can be swallowed. Dan-
ger of suffocation!

2D110693#1
INSTRUCTIONS
PARTS LIST
Quantity Size Descripton Part
Aluminium sheet 1 200x200x1 Metal part 1
Aluminium section 1 100x16,5x10x1,5 Fork 2
Welding rod 1 200x2 Rear axle 3
Welding rod 1 200x4 Steering 4
Wooden wheel /tyre 1 ø 43mm dia Front wheel 5
Wooden wheel /tyre 2 ø 63mm dia Rear wheel 6
Solar cell 1 80x60 Power source 7
Gear box 1 Gears 8
Solar motor 1 RF300 motor 9
Minature switch 1 Switch 10
LED red 2 ø 5 Rear light 11
LED Super bright 1 ø 5 Front light 12
Battery holder 1 Accu holder 13
Rechargeable Battery 1 Rechargeable battery 14
Voltage regulator 1 Component 15
Schottky diode 1 Diode 16
Cable –black 1 500 Circuit 17
Cable-red 1 500 Circuit 18
Machine screw 2 10x3 Fixing 19
Machine screw 8 8x3 Fixing 20
Machine screw 1 20x4 Front axle 21
Nuts 2 M4 Fixing 22
Lock nut 9 M3 Fixing 23
Cap nut 1 M4 Fixing 24
Cable tie 2 100x2,5 Fixing 25
Sticky pads 2 Fixing solar cell 26
Rivets 7 6x3 Fixing 27
Reducers 4 4/2 Rear wheel 28
Shrink tube 1 Cover for joint 29
Sawing out the metal parts
Step 1
Trace the plan ( Page 15) on to the aluminium sheet
(1)
( see dia.1 ) Cente punch and drill the holes
Note:
Trace the parts one after the other then cut them out
a
b
ef
ghc
d

3
D110693#2
90°
135°
90°
45°
135° 135°
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50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
INSTRUCTIONS
Step 2
Saw out all the aluminium metal parts according to the plan.
Remove the burr from the rough edges with a le
Centre punch all the holes to be drilled.
Step 3
Use a pair of mole grips to hold the individual parts when
drilling ( Drills 3,5,6,7,10 mm) Finally countersink the holes
lightly to remove any burr.
Tape the two support strips together when drilling.
Please Note! There are two holes that are not drilled all
the way through !!! SEE DIAGRAM ( Step 4)
Fixing the metal sheet parts for boring part a
General
Use a machine vice with soft jaws to hold the parts for bending.
Base plate
Cover
Supports
Spoiler
Cable cover
Motor xing
Step 5:
Use a pencil and ruler to draw the lines for bending on all the aluminium parts ( Base,cover,supports, cable cover, motor
xing) See page 7. Bend the two supports ( sellotaped together) at the same time !
Use a set square to check the angles.
Do not drill these
holes all the way
through !!
Step 4:
Take the seating part and turn it over and then sellotape it to the base. Use a ruler to make sure that it lines up. Make sure all
the burr is removed from the holes.
Dia. a Dia. b Dia. c
Please Note !:
When bending angles of over 90 degrees, carefully
use a piece of wood to make the bend
( See photo underneath ).
a
bc
d
e
f
gh
down
up
Fix together with
sellotape ( Top &
bottom )
c
b
d
gh
a
e
f
a
d
g
h
c
eb

4D110693#1
25
25
50
150°
150°
7
12
17
27
70
100
5
Ø 5
Ø 3
Ø 4
R5
R0,5
Ø 5
4
Assembling the solar trike
INSTRUCTIONS
Step 7:
Cut the welding rod (4) handlebars to 100mm
Bend to shape as shown. See the pattern on
page 7
Step 6:
Mark 30mm with a pencil on the aluminium
on the U section (2).
Carefully saw the section as shown in the dra-
wing as shown so that the left side
is left . File any sawn edges smooth.
Constructing the front axle and steering
8. Mount the fork on the base frame
using to machine screws (19) from the
top.
Insert the steering from the side and
clamp it in position.
Add the aluminium part (f ) under-
neath and x with two stop nuts (23)
9. Set the battery holder (13) dia.9 in the
basic frame so that the red cable faces
the fork and the black faces the rear of
the trike . Line up the holes and rivet
the holder in place.
10. Fix the motor holder (e) to the back
of the gearbox using a machine
screw (20) and nut (23) Drill the
second hole 3mm dia. and insert a
screw (20) and nut (23).
Dia. 8
Dia. 9
Dia. 10
vor dem Bohren die Mitte markieren!!
Mark out with a pencil the holes in the top. Use sellotape to hold the
fork on the
Frame. Drill the rst 3mm hole and then insert a machine screw (19)
and nut (23)
Then drill the remaining holes. Remove the sellotape and remove any
burr from the holes
Note 1:
Before cabling the solar trike cut the cables to length according to the plan. Remove about 10mm insulation from the
ends and twist wire strand together. Tin all the ends with solder and then trim the ends to 8mm long.
Flat side of rivet on top
To x the battery holder
3mm hole
Drill through
Note 2:
Before connecting the voltage block tin the connections The solder on the black and red cables as shown.
Note 3:
On the plan shown ( See page 7 the points are shown with ( 0 ) where the shrink cover must be added before making the
cable connection
a
f

5
D110693#2
Dia.13
INSTRUCTIONS
13. Rivet the spoiler in place as shown
in Dia.13.
Note! The direction of the spoiler
14. Place two sticky pads (26) on the
spoiler.
Dia.14
Dia.15
15. Screw the tabs on the solar cell. Set
the solar cell (7) in place Make sure the
xings line up with the holes and the
cell is held in place by pressing it on the
pads.
16. Connect a 60mm length of red cable
(18) to an outside connection on the
switch. And a 60mm long length of
cable(18) to the middle connection on
the switch Insert the switch in place as
shown in dia. 16 .
Dia.16
17. Guide the cable from the switch and
the battery holder through the 7mm
hole in the base
Fix the cover (6) in place with 2
machine screws (20) and 2 lock nuts
( 23) see diagram 17.
Dia.17
18. Pass the cables from the motor
through the holes as shown dia.18
Then insert the white LED (12) in the
hole in 5mm hole the front fork.
Dia.18
Dia.12
11.Shorten the welding rod (3) to 95mm and
remove burr from the ends.
Assemble the gear box (8) using the above
welding rod ( rear axle ).
Use two machine screws (20) and two nuts
(22) to hold it together See dia 11a.
Note: the rear axle protrudes about 50mm
Dia.11a
12. Rivet the two supports in place on
the back of the trike.
Note!
Place this gears
carefully
as it can break !
Dia.11
50mm

6D110693#1
+-
ANODE long
leg = + plus
CATHODE short
leg = - minus
Cabling – For the lengths see the plan on page 7 :
INSTRUCTIONS
21.Solder one end of 150mm long black
cable (17) to the back (minus) con-
nection on the solar cell . The solder
a 150mm long red cable to the plus
connection on the solar cell.
Insert both cable through the 7mm
hole in the rear of the trike. Connect
( solder the free end of the red cable
to the Schottky diode(16). Don’t for-
get to use the insulating shrink tube
on the joints !
22. Place a piece of shrink tube over the
red cable where it joins the Schott-
ky-diode. Solder the black cable
from the solar cell with the black
cable from the battery holder.
23. Connect a 60mm piece of black cable
(17) with the black cable motor, battery
and solar cell. Solder the free end of
the black cable to the minus pole on
the voltage regulator.
A red 60mm cable is soldered to the
plus + connction on the voltage regu-
lator (15) Solder the middle cable of
the switch (10) with the Schottky diode
(Shrink tube ).
24. Solder a 60mm red cable (18) to the
Anode of the LED (12) in the fork .
The other end is connected to the
voltage regulator (15) + output ).
Solder a 120mm piece of red cable
from the Cathode on the LED (12)
and guide it through the hole in
the rear of the trike . Solder it to the
Anode on the left hand side of the
rear light ( LED red,11) ( Use shrink
tube insulation ).
25. Solder a 100mm length to the volta-
ge regulator to the free connection
on the voltage regulator. The other
end is soldered to the Cathode on
the left hand rear light.
Insulate the joist with insulation tape
! Check the circuit .
26. Tie all the loose cable together with
a clip(25) Add the cable cover using a
machine screw(20) and a stop nut (23).
19. The rear lights ( Led red, 11 ) are inserted through the 5mm hole
in the rear of the frame.
Please note !
If its dicult to solder the LED in place the gearbox can be mo-
ved. Insulate the solder joints with insulation tape.
Dia. 19
20. Insert a machine screw (21) through the axle in the front fork.
Add a nut (22) and tighten. Add a wooden wheel (5) and nish
with a capped nut (24) The fork should be able to turn See dia.19
27. Insert a reducer (28) in each of the rear
wheels. Push the two wooden wheels
(6) on the rear axle . Finally mount the
top cable cover using two machine
screws (20) and 2 stop nuts (23).
++
--
input
output

7
D110693#2
M
Spannungs-�
wandler
+
-
+
+
-
+
-
+
-
-
LED�
weiß
LED�
rot LED�
rot
Schottky�
Diode
Schalter
Akku
Solar-�
zelle
+
-
++
--
100
60 60
140
150 70
110
60
120
60
60
70
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135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
90°
135°
90°
45°
135° 135°
135°
135°
50°
45°
140°
140°
90°
90°
90°
Anode =
Long =+
Cathode=
Short = -
Circuit diagram
Schottky
Diode
Solder connection with
shrink tube tape.
Voltage
regulator
LED
white
LED
red
Solar
cell Akku
INSTRUCTIONS
Bending pattern
M 1:1
Base frame
cover
supports 1 and 2
Motor xing
Spoiler
cable cover
LED
red
switch
Soldering point Solder covered with insulation
M
+
+
-
-
+
-
b
a
d
g+h
e
c
Motor cable
Motor cable

8D110693#1

9
D110693#2
5
10
45
55
5
20
5
45
60
93
55
130
150
155
162
200
10
20
30
30
5 8
Ø 5
Ø 3
Ø 7
Ø 3
Ø 3
Ø 5
25
R 12,5
Ø 7
10
Ø 3
5 5
35
INSTRUCTIONS
Pattern for the base frame(a)
Scale 1:1

10 D110693#1

11
D110693#2
28
Ø 6
120
35
4
25
35
10
5
35
Ø 3
17,5
7
12
17
27
70
100
5
Ø 5
Ø 3
Ø 4
R5
R0,5
Ø 5
4
10
20
10
R 2
10
20
10 20
Ø 3
Ø 3
INSRUCTIONS
Pattern for cover (b)
Scale 1: 1
Pattern for the forks
Scale 1: 1
Pattern for the clip and motor xing ( f+e)
Scale 1: 1

12 D110693#1

13
D110693#2
25
25
50
150°
150°
5
20
25
4
10
110
Ø 3
R 2
10
12
20
33
78
98
110
20
40
60
R 5
Ø 3
Ø 10
25
55
27,5
5
10
18
40
45
R5
Ø 3
INSTRUCTIONS
Pattern for the supports ( g+h)
Scale 1:1
Pattern for the spoiler
Scale 1:1
Pattern for the steering
Scale 1:1
Pattern for the cover (d)
Scale 1:1

14 D110693#1

15
D110693#2
a
b
e
f
g h
c
d
Cutting pattern
Scale 1:1
INSTRUCTIONS