Thermal Dynamics PakMaster 50 XL Plus, Service Manual

Page: 41 / 74

Manual 0-2745 35 SECTION 5: REPLACEMENT PROCEDURES
5.09 Right Side Internal Component
Parts Replacement
NOTE
Refer to Section 6.08 for parts list and overall de-
tail drawing.
A. Pilot/Output PC Board Assembly
Replacement
1. Remove the Right Side Panel per Section 5.04-C.
NOTES
Before removing any connection mark each wire
with the connection designation. When reassem-
bling this makes sure the wires go to the proper
terminals.
Note the routing of wires and make sure the wires
are put back in the same place when reassembling
the unit.
2. Disconnect all the wiring connections to the Pilot/
Output PC Board Assembly.
3. Remove the four screws and washers securing the
PC Board to the standoffs.
4. Install the replacement Pilot/Output PC Board As-
sembly by reversing the above procedure.
B. CD PC Board Assembly Replacement
1. Remove the Right Side Panel per Section 5.04-C.
NOTES
Before removing any connection mark each wire
with the connection designation. When reassem-
bling this makes sure the wires go to the proper
terminals.
Note the routing of wires and make sure the wires
are put back in the same place when reassembling
the unit.
2. Disconnect all the wiring connections to the CD
PC Board Assembly.
3. Remove the four screws and washers securing the
PC Board to the standoffs.
4. Install the replacement CD PC Board Assembly by
reversing the above procedure.
C. Relay Replacement
1. Remove the Right Side Panel per Section 5.04-C.
NOTES
Before removing any connection mark each wire
with the connection designation. When reassem-
bling this makes sure the wires go to the proper
terminals.
Note the routing of wires and make sure the wires
are put back in the same place when reassembling
the unit.
2. Disconnect all the wiring connections to the Relay
Assembly.
3. Remove the two screws securing the Relay Assem-
bly to the Pilot Panel.
4. Install the replacement Relay Assembly by revers-
ing the above procedure.
D. Main Transformer Assembly Replacement
1. Remove the Left Side Panel per Section 5.04-B.
2. Remove the Right Side Panel per Section 5.04-C.
3. Remove the following terminal connections from
the two FET/Heatsink Assemblies noting the lo-
cation of each wire:
C o n n e c t io n D e sc rip t io n
E 1 4 M A I N X F M R P R I
E 1 5 X F M R P R I
E 1 6 M A I N X F M R S E C
E 1 9 X F M R S E C
4. Remove the four screws which hold the mounting
plate to the bottom chassis.
5. Carefully remove the mounting plate with the Main
Transformer Assembly from the unit.
6. Install the replacement Main Transformer Assem-
bly by reversing the above procedure (see NOTE).
NOTE
The four screws securing the mounting plate to
the chassis should have a maximum of 2 to 5 threads
protruding through the left side of the chassis.
E. Output Inductor Assembly Replacement
1. Remove the Left Side Panel per Section 5.04-B.
2. Remove the Right Side Panel per Section 5.04-C.
3. Disconnect the lead wire on terminal E7 of the Pi-
lot Output PC Board.