AquaBot Controller Build Guide

What's in Your Kit?

Complete Kit Contents

PCB Assembly Parts

Parts Checklist

Printed circuit board (PCB)

Push button switches and caps x2 (Up/Down)

3-position toggle switches x2 (Left/Right)

RJ45 connector

7.5A fuse and fuse holder

Wire for battery connection 1m

Croc clips and insulators x2

Battery spade connectors and insulators x2

Cable ties x2

3D printed case

M3 x 6mm screws x8

Let's Build It!

Install Push Button Switches

VERY IMPORTANT→ Make sure the C NO NC labels stamped into the switches are facing upwards! Check twice before moving to the next step!

Push the two push button switches into the PCB slots next to the UP and DOWN labels on the PCB.

Place PCB in Case

Gently place the PCB into the 3D printed case, with the push buttons sliding through the front holes in the case.

Check Alignment

Check that everything lines up correctly and the buttons are straight. You may want to put some screws in to hold the PCB in place.

Solder Push Button Switches

Double Check→ Make sure the C NO NC labels are facing upwards one more time!

Solder the switches in place. Remove the PCB from the case when you have finished.

Install Toggle Switches

Place the two 3-position toggle switches into the PCB slots next to the PORT and STBD labels on the PCB. It doesn't matter which way around they go for the toggle switches.

Position Case Lid

Place the case lid on top of the two toggle switches to hold them in the right place, then flip the PCB and lid over and place it on top of the case with the lid facing down.

Solder Toggle Switches

Holding the PCB flat (you might want a friend to help you), solder in the toggle switches. Sometimes it helps to just solder one leg of the switch and then lift the board up to check that it is straight.

Install RJ45 and Fuse Holder

Snap in the RJ45 connector and the fuse holder, they should stay in place by themselves.

Solder RJ45 and Fuse Holder

Flip the board over and solder in the RJ45 connector and the fuse holder.

Prepare Battery Wires

Strip about 5mm of insulation from the ends of the wire for the battery connection, twist the ends of the wire if you need to get all of the wire strands straight. Carefully push the wires into the PCB holes.

Insert Battery Wires

Carefully flip the PCB over, holding the wires in place, you may want to put them in one at a time if they keep slipping out.

Solder and Trim Wires

Solder the wires in place and trim the ends back if they are sticking out a long way.

Secure Wires with Cable Tie

Zip up a cable tie around the wires about 25mm from where they are soldered into the PCB. This will stop the wires from pulling against the soldered joint so that they don't break off while you are winning the competition!

Install Fuse

Push the fuse into place in the fuse holder.

Secure PCB in Case

Place the PCB back into the 3D printed case, and secure it with 4 screws.

Close the Case

Make sure the wires are sitting over the slot in the top of the case, put the lid on and secure it with 4 screws.

Choose Your Battery Connection

You can choose between two types of battery connections. Pick the one that works best for your setup!

Spade Connectors

More permanent and secure connection

Croc Clips

Easy to connect and disconnect

Spade Connector Steps

Tin Spade Connector

Using a clip to hold a spade terminal connector, tin the wire connection by heating it up with the soldering iron and adding solder.

Prepare and Tin Wire

Strip about 5mm of insulation from the ends of the wire for the battery connection and tin the end of the wire with a little solder.

Solder Wire to Spade Connector

Slide the insulated sleeve onto the wire first, then solder the wire to the spade terminal connector by heating up the solder again and holding the wire in place until all of the solder is melted. Remove the heat and hold the wire in place for at least 5 seconds, or until the solder has solidified.

Step 19: Soldering wire to spade connector

Crimp Wire Tabs

Using a pair of needle-nose pliers, bend the wire crimp tabs on the spade terminal down so they squish the wire insulation a little bit.

Install Insulated Sleeve

Slide the insulated sleeve over the spade terminal connector and crimp tabs, then you can repeat steps 17-21 for the other wire.

Croc Clip Steps

Tin Croc Clip

Using a clip to hold a croc clip, tin the wire connection by heating it up with the soldering iron and adding solder.

Prepare Wire for Croc Clip

Strip about 5mm of insulation from the ends of the wire for the battery connection and tin the end of the wire with a little solder.

Crimp Wire to Croc Clip

Slide the insulated croc clip sleeve onto the wire first, then holding the wire in place squeeze the wire crimp tabs down so they squish the wire insulation a little bit.

Solder Croc Clip Connection

Solder the wire to the croc clip by heating up the solder again and holding the wire in place until all of the solder is melted.

Finish Croc Clip Assembly

Slide the insulated croc clip sleeve over the wire crimp tabs, then you can repeat steps 22-26 for the other wire.

Testing Your Controller

Now let's test your controller to make sure everything works perfectly!

Set Up Multimeter

Using a digital multimeter, set the measurement to continuity (the Ω symbol). Touch the leads of the multimeter together and check that the reading goes to 0 (or close to 0).

Test Controller Leads

Connect the two multimeter leads to the controller leads, the reading should go to infinity (sometimes shown as OC on the multimeter).

Test Buttons and Switches

Press both of the buttons, one at a time, then the switches one at a time. The meter should not change reading.

Test with AquaBot

Connect the controller to your AquaBot and complete the same check again. This time the reading should be infinite when no buttons are pressed, and when you press a button the reading should go to about 5 ohms.

Troubleshooting

Don't worry! Let's fix the issue and get your controller working perfectly.

Check Your Soldering

First - check your soldering, make sure none of the soldered joints are blobbed across other solder joints. If you find a short, heat up the soldered joint with a clean iron and let it draw away some of the extra solder until the joint is not connecting another joint anymore.

Check Switch Orientation

Check that the C NO NC labels stamped into the push button switches are facing upwards, if they are not then carefully melt the solder on the three legs of the switch and flip it up the other way. You may need a friend and a second soldering iron to help you with this.

Check Your AquaBot

Check your AquaBot to make sure no wires are broken, and that the bare copper wire ends are not touching each other or the motor casing.

Additional Resources

Download 3D models for printing your case and access the schematic files!

3D Printable Cases

Basic Enclosure

Simple, easy-to-print case design perfect for beginners.

Case (.3mf) Lid (.3mf) STEP File

Angled Enclosure

Ergonomic angled design for comfortable controller handling.