Outback Power Systems FX Series Circuit Board Replacement Instruction - Manual (Page 3)

Installation & Programming Manual FX Circuit Board Replacement Copyright 2003  OutBack Power Systems, Inc.
900-0042-1 19009 62 nd Ave NE, Arlington WA 98223 USA
Page 3
Rev 2.0 10/26/04 Tel 360 435 6030 Fax 360 435 6019
boards. The form of static that is harmful is much less than what actually
makes sparks. 30 volts can damage parts, so don’t take chances and don’t
handle any boards unless static control measures have been taken.
Figure 2
STEP 4:
Pay attention to this one or you’ll hate yourself later! Use a 4mm Allen wrench
(included) to remove the 8 stainless steel socket head cap screws that connect
the top to the bottom casting (Figure 2, Hex). The FX has a fan mounted to the
top cover. It plugs into the FET board. If you pull the top cover off without
thinking, it will rip the wires right out of the connector. (This is where you will
start swearing and your customer will become alarmed!) If this happens, you
have two choices. 1: get new Molex crimp terminals and the special crimp tool
to correctly fix the problem, or 2: solder the wires onto the sockets that are still
attached to the mating connector on the FET board. Hint: cut some of the plastic
away first so you can get to the pins. The red wire goes towards the bottom
casting (the latch side of the connector). Figure 3 gives you an idea how long
the wires are. There are two small O-rings that fit into slots of the battery
terminals. If they aren’t in their slots, they may be stuck to the underside of the
top cover. Remove these small O-rings so they don’t get lost. There is also a
very large O-ring that travels the perimeter of the chassis. This doesn’t need to
be removed but if it comes out it should be reinstalled before the top cover is
put back on. If this O-ring is too small, it can be stretched. The last thing that
should be noted is the square piece of “Nomex” attached to the underside of the
top cover (see Figure 3). Sometimes this piece falls out or is loose. If this is the
case please use some silicone to glue it back in place. Make sure it is fairly dry
before attaching the top cover.
Phillips
Hex