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SERVICE TRAINING MANUAL
14.1 REV 11/19/04
RELAY REPLACEMENT CONTINUED
Page 2
RELAY INSTALLATION
1. Inspect the orientation of the new relays, wiring and metal
adapter plate in its shipping cardboard. The relays will be
installed in the control box with the same orientation. Remove
the new relays, wiring and metal adapter place from its packing
material. Take care to keep the orientation of the new relays as
packed to avoid twisting the wires. Locate the metal adapter
plate; it will be installed first.
2. Install the metal relay adapter plate in the control box using 3 of
the old relay screws. The silver colored spacers on the adapter
plate should be placed directly against the metal chassis and
screwed down lightly. Use the bottom set of existing holes in the
metal chassis for mounting the adapter plate. Refer to photo #2
for the proper orientation of the metal adapter plate.
3. Place the 3 new relays and wiring harnesses in place on the
metal chasses. Slide the bottom lip of each relay in its proper place. The plastic lip of
the relays should slide underneath the top notched portion of the metal relay adapter
plate.
4. Using the remaining 3 old relay screws, fasten down the remaining lips of the new
relays using the existing holes in the metal chassis. Lightly tighten down all six screws
holding the relays in place. Do not overtighten the screws as they may strip out.
5. Locate the two large silver ring tongue connectors that contain 3 white wires and one
small red wire each and fasten to the terminal block securely. It makes no difference
if the ring tongue connectors are switched in position on the terminal block. Tighten
these screws VERY tight.
6. Locate the two small red wires mentioned above in step #5. Plug one red wire into the
vacant bottom tab of the transformer and the other red wire into the fuse holder.
7. Locate the two long red wires attached to the black relays. One wire will have a double
end. Plug the wire with the double lead into the circuit board in the position labeled
center tap. Plug the loose end of this wire into the top center tab of the transformer.
Plug the other single long red wire into the circuit board on the tab labeled output 2.
8. Find the six, white, ten inch long wires attached to the relays. Attach these six wires
to the heat baffle terminal strip using the old screws. Attach wire #1 (wires designa-
tions are labled on each relay) to position #1 on the terminal strip. Ensure that these
connectors are lined up nicely and securely tightened. Refer to the numbered strip on
the other side of the heat baffle for proper wire position. Reconnect the red and yellow
thermocouple wire if necessary. Make sure the red thermocouple wire is connected to
the negative position of the terminal strip. This would be the end (or bottom) connec-
tor on the terminal strip. It is labeled “-” on the other side.
9. All of the wiring should be connected now. Check all wiring for any loose ends or
unattached connectors. Refer to the photo #3, finished wiring, if necessary to determine
proper connection points. Ensure that all wiring is neatly routed around components
such as the transformer. Reroute the wiring as necessary to eliminate kinks or pinch
