Edit Step 9
— Install temperature sensor jumper
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Slip the bent, soldered ring terminals at the end of the temperature sensor jumper cable you prepared in Step 1 over the binding post screws.
Add an additional hex nut to each binding post to secure the ring terminals in place.
Tighten the hex nuts down with a small socket, as shown.
Edit Step 10
— Install switch-side A/C leads
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Cut two lengths of copper wire about 4" long, and strip the ends.
Insert the end of each length of wire into one of the two binding posts on the inward side of the A/C outlet.
Secure the leads in the A/C outlet by tightening the binding screws with a flat-head screwdriver, as shown.
Edit Step 11
— Install STC-1000
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Slip the STC-1000 in from the front of the panel until the bezel is flush with the surface.
Slip the orange plastic panel clips onto the guide rails on either side of the STC-1000.
Compress the clips against the panel face from the inside, securing the STC-1000 in place.
Edit Step 12
— Prepare power harnesses
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Strip about 3/4" from each end of each of three 5" lengths of white 18 AWG stranded copper wire.
Twist the stripped ends of all three wires together into a bundle.
Slip the bundle into a yellow crimp-on .25" female disconnect, as shown. Crimp the connector in place with a crimp tool.
Slide a ~50mm length of 20mm heat shrink tubing over the end of the bundle, positioning it so that it overlaps the end of the disconnect by a bit.
Shrink the tubing in place over the flame from a cigarette lighter or a candle.
Cut the end of the tubing flush with the end of the disconnect. The result should be a fully-insulated connector.
Repeat this entire step using three 5" lengths of black 18 AWG stranded copper wire.
Edit Step 13
— Prepare ground lead
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Strip about 3/4" from each end of a 5" length of green 18 AWG stranded wire.
Insert one end of the stripped wire into a red crimp-on 0.25" female disconnect.
Crimp the connector.
Slip a ~50mm length of 10mm heat shrink tubing over the connector, as above, and shrink it using a lighter.
As above, trim the heat shrink flush with the end of the connector.
Edit Step 14
— Connect sensor, switched leads
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Insert the free ends of the temperature sensor cable into the appropriate terminal block on the back of the STC-1000. Secure the leads in place by tightening the screws with a small flat-head screwdriver.
Route the sensor cable around the back side of the STC-1000 housing, as shown, and secure with a piece of electrical tape. The idea is to keep the sensor leads well apart from the power leads when the case is closed.
Note, at this point, which of the two outlets will control cooling and which heating. Go ahead and mark them on the front of the panel now, if you like. (See step 17.)
Insert the free end of each of the switch-side A/C outlet leads from Step 10 into one of the two heating/cooling binding posts. Secure the leads in place with a small flat-head screwdriver.
Edit Step 15
— Connect power harnesses and ground lead
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Connect a "black" lead to the open side of each heating/cooling terminal block on the STC-1000. Connect the third "black" lead to either side of the STC-1000's operating power terminal block.
Connect a "white" lead to the free bus of each A/C socket. Connect the third "white" lead to the open side of the STC-1000's operating power terminal block.
Connect the free end of the "green" lead to the grounding post on the A/C outlet.
Edit Step 16
— Final assembly
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Hold the front panel in one hand, as shown, and with your free hand reach into the junction box and attach the female disconnects for the black and white power harnesses, and the ground lead, to the appropriate tabs on the C14 power jack. They should slip on with a bit of force. Careful not to bend the tabs.
Slip the gasket into place on the junction box lid, and lower the junction box lid onto the junction box body.
Secure the lid to the junction box body using the screws that came with it.
Page 2 of 3
Suggestion: add an extra inch on the power harnesses. When I got to Step 16, I was barely able to get the disconnects onto the power jack.