Wiring Panel

This is a wiring panel.

Supplies

These are all of the tools, wiring pieces, and other components you need.

List of tools: battery powered screwdriver, wire cutters, hexagonal screw driver, wire crimper, needle nose pliers, small socket wrench, warning label, black sharpie, and finally a guide for the terminal strip.

List of other deviced needed: black & red wires, wiring harness, FENWAL, terminal strip, time delay relay, ground screw, normal screw, tiny screws, one long screw, zip-ties, grommet, toggle switch, and an aqua-stat.

Step 1: Figure Out What You're Making

Once you are able to decipher the cereal code for the part that you will be making, you can begin the building process.

Step 2: Starting the Panel

Using the needle nose pliers, bend the panel located towards the side up at 90 deg., and then use the socket wrench to tighten on the toggle switch.

Step 3: Installing the Aqua-Stat

Use the needle nose pliers to take out the knock-out hole on the bottom of the aqua-stat, put a grommet in the hold and then thread the blue and red wires with the plastic encasing around it through the grommet. Set the aqua-stat to 120 and put the blue wire on the top and the red wire on the bottom of the two connectors. Screw the aqua-stat in with top left and bottom right screw holes.

Step 4: Installing the Aqua-stat Con.

Put the top back onto the aqua-stat and take the copper coil connected to it and put it through the rectangle directly next to the aqua-stat. Bring the coil upfront next to the aqua-stat and store it in the little pocket on the right - secure with zip-tie. Next, through that same rectangular opening put the wires coming out of the aqua stat through but leave the two red wires that are connected. One is a single red with a fork, and the other is a double red with a ground strip and a fork.

Step 5: Installing the FENWAL and Wire Terminal

Now on this step it is time to install the wiring terminal and the FENWAL system. For both of these you use the short tinier screws, with the FENWAL you install the screws on the top left and bottom right, and for the wire terminal you install both on the left. Then, with the two wires you left on the same side as the aqua-stat, you install them into the field interlock position in the middle.

Step 6: Wiring the Time Delay Relay

On the side of the panel with the toggle switch (opposite of the aqua-stat), you install the time delay relay with the long screw. You then set it to 5 minutes with blue switch (which I failed to do but I did go back to fix later on) and the wires you pulled the through the rectangle opening in the aqua-stat get installed like so: the double red wire goes on terminal one (1), the yellow wire goes on terminal three (3), and the double red wire goes on terminal six (6).

You must also install the red and black wires with the female push-on on the two elevated terminals, black on bottom and red on top.

Step 7: Setting the Large Wire Harness Up

Now that you have the majority of the components installed, you can get the large wiring harness, straighten it out and find the wires group as shown. There are three groups of wires with grommets, now, only two will be used, the very colorful one, and the one with two large adapters. You put the wires through the holes on there respective sides and put the grommets inside the holes.

Step 8: Wiring the FENWAL

With this step you will be installing the wires that are connected to the FENWAL. So first, with the wires you brought through the hole with the grommet, you will see the wires on the bottom that line up with the labels on the wire connectors and plug them in. Next you will connect the two wires on the top - same deal with them being labeled - and then you will neatly organise the wires with the zip-ties on the left side of the FENWAL system.

Step 9: Wiring the Terminal Strip

With this step there is 'room' for error. By that I mean since there are the wires connected through a jumper, they can be interchanged but preferably they are put in place correctly. As you can see from the picture, the ground wire with two wires gets installed with the ground screw, followed by the blue wire (pos1), the red wire (pos2), and then the already installed wires from the aqua-stat, then the double yellow with NO ground strip (pos5), and then finally on the last set of the wire terminal, the second single ground wire is installed on the bottom along with the double yellow with the ground strip.

Step 10: Wiring the Toggle Switch

For this step with the rats nest of wires (the large wire harness), you will find two wires labeled 'PSS Top', and 'PSS Load'. As shown in the picture PSS Top goes on the top left of the toggle switch, and PSS Load goes in-between that wire and the red one.

Next for the finally wiring bit of the aqua-stat you find the two wiring sections with the plastic adapter and connect them with the corresponding wires - red on red, blue on blue, yellow on yellow, and black will be an outlier by itself.

Step 11: The Final Piece of Wiring

You will want the find this tiny black wire very close to where that plastic adapter is, and you'll strip off the plastic coating (sometimes already stripped), and put on a female push-on. Next from the black wire with the red male push-on connected to the time delay relay, you will want to connect those together.

Step 12: Tidying Up

When you are organizing the wires at the end, you want the wires along the top to be as flush and flat with the top of the panel as possible - by doing this you will want to attach the farthest zip-tie on the right side and pull all of the slack to the left. You'll also connect another bundle of wires on top of it. Those wires would normally go into the relay but for this specific model they are unnecessary as of now.

Once those are completed the final step is to neatly organize the remaining wires by taking two zip-ties to make one large one, bundling up the wires and securing them tightly with the zip-ties. Then your wiring panel is mint!