Opitec 105.026 User manual

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E105026#1
Safe with
Secret Code
105.026
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!

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1. Product information:
Article: Useable product;
Suitability: Key Stage 3 11-14 years;
2. Material information:
2.1. Material: Insulated wire;
Multi strand, insulated wire (0,14 mm2);
Working: Cut and remove insulation with electronic snips/stripper
2.2. Material: Gearbox( factory finished)
Working: Assembling, screwing
2.3. Material: Plywood, multi layered;
Each layer set in the opposite direction;
Working: Plywood can be sawn with a fret saw, shaped and sanded;
Mark out using a pattern or measurements;
Joining: Use PVA wood glue, screws;
Finish: Use wax, fluid or solid
Wood paint (undercoat/top coat)
Wood stain ( coloured and water soluable-finish with varnish);
2.4. Material: Pine, softwood
Working: Pine can sawn, shaped, drilled and sanded.
Mark out using a pattern or measurements.
Joining: See plywood
Finish: See plywood
2.5. Material: Bronze band (an alloy of copper and tin)
Hard, good conductor
Working: Cut with tin snips, remove burr with a file.
Joining: Soldering
2.6. Material: Relay
Electromagnetic switch
2.7. Material: Holed metal strip (pre-made)
Zinc plated
Working: Cut with tin snips, remove burr with a file
Joining: Soldering, screws

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3. Tools:
Soldering: For the soldering in this project use a 15-30 Watt
Soldering iron. Use a 'helping hands' clamp or a small vice to hold the
circuit board so that you have both hands free.
Using a file/rasp: Choose the grade according to the work in hand.
Use a needle file for small slots and holes.
Saws: Use a fret saw for all rounded shapes and a straight backed
saw for other work.
Note! Fret saw blades must be inserted with the teeth facing
forward.
Hold the work securely on a sawing board. The Puk-saws in our
catalogue, are ideal for sawing dowel and small strips.
Note! Werkstück einspannen;
Sanding: Use a block and glasspaper for finishing all flat surfaces.
Drilling: Use a handrill or pillar drill;
Note! Take note of the safety precautions when drilling.
(all long hair to be tied back, no loose clothing or jewelry
to be worn and wear safety glasses)
Holding: We recommend clamping the work
G clamps or similar are best for holding the parts whilst the glue
is drying.;
Cutting: Use electronic snips/cutters for the insulated wire and tin snips for
metal strip.;
Note! Be careful not to leave sharp edges as these cause cuts.

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4. Parts list:
Part Value/type/size Quant. Diagram/Part-N°
Pine strip 20 x 20 x 75 mm 2
Pine strip 10 x 20 x 250 mm 1
Plywood 8 x 75 x 120 mm 1
Plywood 8 x 100 x 120 mm 1
Plywood 8 x 115 x 165 mm 1
Plywood 8 x 120 x 120 mm 2
Plywood 8 x 120 x 244 mm 1
Plywood 8 x 120 x 260 mm 2
Welding rod ø 1 x 500 mm 1
Holed metal 0,7 x 10 x 165 mm 1
Bronze strip 0,2 x 5,5 x 250 mm 2
Double gear 10/50 Zähne, rot 2
Double gear 10/50 Zähne, weiß 3
Motor drive gear 1
Angle plates 2
Distance pieces 2
Distance tubes 25 mm 2
Motor R 20 1
Threaded rod 3 x 20 mm 2
Threaded rod 3 x 35 mm 2
Wood screws 3 x 16 mm 4
Nuts M3 6
Shafts ø 3 x 70 mm 2
Brass tube ø 4 x 5 mm 1
Spade connector 6,3 mm 1
Screw eye 10 mm 1
Domed nut M3 1
Drawing pins 24
Relay 12V, 1x um 1
Split pins 24
Hinges 15 x 25 mm 2
Insulated wire ca. 1 m 1
Screws 2 x 6 mm 8
E105026#1
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24
25
26
27
28
29
30
31
32
33
23a 23b

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20
83
8
8
100
5. Planning and making overview:
5.1 Assembling the hinges, sides and door.
5.2 Planning and making the case
5.3 Soldering the metal strip on the drive shaft and adding the motor connections.
5.4 Assembling the gearbox
5.5 Mounting the gearbox and mechanism
5.6 Planning and making the switches
5.7 Making the switch panel
5.8 Wiring the circuit
5.9 Testing
5.10 Gluing the shelf in position
5.1. Assembling the hinges, sides and door:
• Screw (33) the hinges (31) on the door (5) according to the measurements as shown.
• Insert the screw eye (26) in the door as shown.( use a bradawl to start the hole)
• Mark out and glue the supports (2) and (4) where indicated by the shaded lines on to one of the
side parts (8). Finally mount the door on to the side.
40
10
10 10
side part
Door
33
26
5
33
31
8

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5.2. Planning and making the case:
• Cut two pieces 10 x 20 x 120mm from the pine strip (2) 10 x 20 x 250 mm
• Assemble all the parts as shown and glue them together.
5.3. Soldering the metal strip on the drive shaft, and adding the motor connectons:
• Cut a length 4 holes long from the holed metal strip (10) as shown in diagram. Remove any burr with a
file. See diagram 1
• Using a pair of side cutters make a series of cuts/identations in the drive shafts (23a 23b) as shown in
dia 2. These cuts are to ensure that the red gears (12) are a very tight fit on the shafts.
• Clean up any burr on the end of the shaft.
• Mount the holed metal strip on the end of the shaft (23a) and solder it about 3 mm from the end.
See diagram 3.
• Cut two lengths of insulated wire (32) each 150 mm long and remove the insulation from the ends.
• Solder one length to each connector on the motor (18)
• Finally mount the red gears (12) on the shafts where the cuts/indentations have been made ensuring
that they are both a tight fit, use a two component glue if necessary.
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7
2
8
6
6
107
37
23a
23a
23a
23b
23b
18
32
10
10
dia. 1
dia. 2
dis. 5 dia. 3
dia. 4

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5.4. Assembling the gearbox:
Make up the gear box as shown.
5.5. Mounting the gearbox and mechanism:
• Glue the two strips (1) in the case as shown
• Screw (21) the gearbox centrally on to the two strips
•
Take the remaining holed metal strip (10) and shorten it to 11 holes long (approx 93mm) remove burr
and round the ends.
• Finally use the machine screw(19) nuts(22) and domed nut (27) to join the 10 holed strp to the screw
eye on the door and the holed metal on the shaft ensuring that it moves freely. See page 8
18
20
17
17
24
14 13
13
12
12
32
15
15
22
16
22
7
52

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5.6. Making the switches:
• Cut the bronze band (11) into 24 strips each 18mm long and bend as shown.
5.7. Making the switch panel
• Mark out the position of the switches using the pattern on page 11 on the switch panel (3)
8 x 75 x 120 mm. Mark out and drill the holes, 3 mm dia for the split pins, 3 mm dia for the screws and
2 mm for the wire.
• Cut three lengths, 100 mm long from the welding rod (9)
• Insert the drawing pins (28) into the panel. Push the split pins (30) through the holes and bend.
Tin the drawing pin heads.
Note: use a multicore solder with flux.
• Solder the switches to the drawing pin heads.
• Solder the bridging rods in position. (welding rod)
6 9
3
Bend
the split pins
Snip off the excess legs from the lower row of split
pins with side cutters
27
22
19
19
26

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5.8. Wiring the circuit:
• Cut three 100mm long lengths from the insulated wire and tin the ends. Insert one wire through the hole
in the switch panel and solder the end to the first row of drawing pins. The rest of the wiring is carried out
as shown in the diagram.
• The code for the door opening is 4 -6- 3. Of course another code can be 'wired' up.
• Screw the shelf (21) on the pine strips (2) (Use two roundhead screws)
5.9. Testing:
The safe can be opened only when the correct code is entered. The door is opened by the action of the
gearbox and mechanism, which in turn is operated by the relay and motor. The code is made up from the
action of three switches. We have chosen the code 4-6-3. To open the door you must press the fourth
switch in the top row and the sixth switch in the middle row at the same time. The relay is now activated
and you only have to press the third switch in the bottom row and the door should open. The motor will
only work as long as the switch 3 is pressed. If an incorrect switch in the bottom row is pressed a short
circuit is made and the relay is de-activated. The switches in rows 1 and 2 must
then be re-pressed.
Note: Do not press a switch in the bottom row when the door is closed, otherwise the contact
in the relay will activate and the battery will run down.
Relay (29)
Motor
Rear of the switch panel
+ Battery
- Battery
Insert the wires through
the holes and solder to
each row.
Front of the switch panel
Rear of the switch panel
1 2 3 4 5 6 7 8
8 7 6 5 4 3 2 1
wiring diagram + Battery
Relay
- Battery
M

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5.10. Gluing the shelf in position:

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Pattern - Switch panel scale 1 .1
fixing screw
fixing screw
cable
drawing pins
split pins