KEPCO Kit 219-0425 User Manual

INSTRUCTION SHEET

KEPCO

An ISO 9001 Company.

KIT

DRIVER ASSEMBLY KIT

1. DESCRIPTION

This kit provides a replacement pass assembly A3 for the Model ATE 325-0.6M power supply, two resistors for the chassis
and three components for modification of PCB Assembly A1 required to accommodate the new pass assembly. This man­ual provides detailed instructions for removal of the existing A3 assembly, and replacing it with the pass assembly supplied
in this kit, and adding and replacing components on the chassis and on PCB Assembly A1, as well as adding wires to the
existing harness.

2. MATERIAL SUPPLIED (SEE TABLE 1.)

Table 1 lists the contents of this kit and a description of each component.

TABLE 1. MATERIAL SUPPLIED

ITEM DESCRIPTION

Pass Assembly A3 Replaces existing A3 driver assembly 113-0415 1

Resistor, 270 ohm, 2W, 5% Add component R3 to A1 board 115-0872 1

Capacitor, 1UF 100V, 10% Add component C32 to A1 board 117-1087 1

Resistor, 20K ohm, 20W, 5% Add component R206 to chassis 115-0853 1

219-0425

KEPCO

PART N O .

QUANTITY

Resistor, 10 ohm, 1W, 5% Replace R205 115-0052 1

Shunt Add component at CR12 location to A1 board 172-0298 1

Cable tie Secure added wires in harness 138-0076 10

Wires Add wires to harness

#24, 25 (twisted pair with connector on one end, 2 lugs on other end)
#44 (lug on each end
#45 (lug on one end, insulation stripped on other end)
Jumper (insulation stripped on both ends)

Sleeving Insulates leads of R205 197-0121 2

Speed Nut, Clip-on 6-32 Attaches R206 to bracket 102-0116 2

Hex Nut, 4-40 Secure R206 to speed nut 102-0003 2

Screw, 4-40, x 0.75, ST FLPO Secure R206 to speed nut 101-0417 2

Washer, Int. Lock, No. 4 Secure R206 to speed nut 103-0014 2

Instruction Sheet Contains instructions for installing KIT 219-0425 components 228-1482 1

n/a 4

3. INSTALLATION

1. Disconnect unit from power source and remove wrap-around cover by removing 5 screws from each side. Be careful not
to damage ground strap attached to cover. For convenience the ground strap can be removed from the cover by remov­ing one nut and two washers (save hardware for reassembly).

2. Referring to Figure 1, tag and disconnect connectors J204 and J205 on A3 assembly.

3. Remove terminal strip from pass assembly A3 (with L301 and wire attached) by removing one screw and install on new
pass assembly A3 using same screw.

KEPCO, INC. " 131-38 SANFORD AVENUE " FLUSHING, NY. 11352 U.S.A. " TEL [phone] "

http://www.kepcopower.com " email: [e-mail]

©2004, KEPCO, INC 052804
Data subject to change without notice 228-1482 REV 1

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4. Remove pass assembly A3 from chassis by removing four screws (save screws for reassembly).

5. Install new pass assembly A3 P/N 113-0415 on chassis and secure with four screws previously removed.

FIGURE 1. CHASSIS COMPONENT LOCATION

6. Remove PCB Assembly A1 from chassis by removing four screws (save screws for reassembly), then tag and
remove connectors J201, J202 and J203 from A1 Assembly.

7. On A1 assembly, refer to Figure 2 and install three new parts supplied in Kit (see Table 1).

FIGURE 2. ADDING COMPONENTS TO A1 BOARD

KEPCO, INC. " 131-38 SANFORD AVENUE " FLUSHING, NY. 11352 U.S.A. " TEL [phone] "

2

http://www.kepcopower.com " email: [e-mail]

228-1482 REV 1 052804

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8. At rear panel, remove R205 from terminal block TB201 (see Figure 1). Install sleeving provided over leads of new
R205 and install across terminals 4 and 9 of TB201 at rear panel.

9. Referring to Figure 3, step 1, assemble new R206 onto two speed nuts and secure using screws, washers and nuts
provided in this kit (see Figure 3). Then press clip-on speed nuts (with R206 assembled) onto the bracket as shown in
step 2.

FIGURE 3. INSTALLATION OF R206

10. Refer to Figure 4 and disconnect orange wire (1-O) from connector J204 pin 4 and connect to J205 pin 3.

11. Route wire #44 (Green) along harness and connect one end to connector J204 pin 4, and the other end to connector
J205 pin 4.

12. Disconnect red wire (2-R) from connector J204 pin 1. Route wire #45 (Red) along harness and connect one end to
connector J204 pin 1. Connect the other end, together with red wire previously disconnected from J204 pin 1, to R206
terminal 1.

13. Connect one end of jumper (wire #18) to R206, terminal 2, and the other end to R203, terminal C1.

14. Route wire #24, 25 along harness and plug connector into A3 pass assembly at one end. At the other end connect
wire #24 (White-Yellow) to J202 pin 17 and wire #25 (White-Purple) to J202 pin 19.

15. Reattach connectors J201, J202 and J203 on A1 Assembly (see Figure 1), then secure PCB to chassis using four
screws previously removed.

16. Reconnect connectors J204 and J205 on A3 assembly.

17. Secure wires to harness using cable ties as needed.

18. If removed, reattach ground strap to cover using nut, flat washer and lockwasher previously removed. Reinstall cover
using 10 screws previously removed.

KEPCO, INC. " 131-38 SANFORD AVENUE " FLUSHING, NY. 11352 U.S.A. " TEL [phone] "

http://www.kepcopower.com " email: [e-mail]

052804 228-1482 REV 1

FAX [phone]

3

FIGURE 4. WIRING CHANGES

KEPCO, INC. " 131-38 SANFORD AVENUE " FLUSHING, NY. 11352 U.S.A. " TEL [phone] "

4

http://www.kepcopower.com " email: [e-mail]

228-1482 REV 1 052804

FAX [phone]