Outback Power Systems FX Series Circuit Board Replacement Instruction - Manual (Page 8)

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 8
Rev 2.0 10/26/04 Tel 360 435 6030 Fax 360 435 6019
Board”, curl the “Bend” in the ribbon cable towards the inside of the FX. This
will pull the ribbon cable inward and then it will be less likely to be pinched
between the chassis and the top cover when you put on the top cover. This is a
major source of problems, pinching the ribbon cable will destroy the boards!
Make sure the ribbon cables are pushed all the way in and then tape the ribbon
cable to the clear relay if necessary. Again, be sure the boards are all in their
respective card guides. The AC board especially likes to go off to one side or
the other if you are not careful.
AC GASKET: Between the AC assembly and the top cover is a gasket that
keeps water from entering and also functions as isolation. Some AC assemblies
have this AC gasket permanently attached while some don’t. If you have
received a new AC assembly chances are it will come with a separate AC
gasket. This gasket has six holes for screws to pass through. Place the AC
gasket on the AC assembly so that the holes in the gasket line up with the holes
in the AC assembly.
O-RINGS: There are two small O-rings that need to be placed in the slots on the
FET board battery terminals. They may be stuck to the underside of the top
cover or they may have stayed in the FET board itself. These O-rings are
necessary if you have a “Sealed” FX that is in a corrosive environment. If not
then you may lose them and not feel too stressed out. There is also a very large
O-ring that fits in the slot that travels the perimeter of the chassis. It also may be
stuck to the top cover or it may be in the slot already. Same deal applies to your
stress level.
STEP 10:
Test: Now that the unit is electrically back together, it should be tested on a
bench power supply or a series of 9-volt batteries prior to applying battery
power. For 12-volt and 24-volt FX’s use three 9-volt batteries in series
(alligator clips work nicely) but for 48 volt FX’s use at least five maybe six 9-
volt batteries in series. These batteries will probably be toast afterwards but it’s
cheaper than blowing up another FX board. Batteries and power supplies are
current limited and therefore forgiving of assembly errors. Large battery banks
are not forgiving at all and can turn all of your hard work into a lot of smoke
due to a simple assembly error.
Hook up your bench supply (Or your 9 volt batteries) to the battery terminals
making sure the battery voltage is set according to the unit under test. The
inverter should go through a boot up routine. The red “Low” battery LED will
go on and then change to the yellow “OK” LED and then it may change to the
green “Full” LED. The fan will also come on if plugged in (if the fan isn’t
plugged in, the “Error” LED will blink, no big deal. After about 5 seconds the