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Repair and Repla cement Procedures ProM aster 25 00 User Manua l 7-21 Replacing the Labeler Power Supply If the labeler power supply fails, f ollow the steps below to replace it. Be sure to note the direction of rotatio …

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Repair and Replacement Procedures
7-20 ProMaster 2500 User Manual
Replacing the PE
Power Supply
If the programming electronics power supply fails, follow the steps below
to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the two cable connectors.
3. Remove the four 1/4-inch hex nuts at the corners of the assembly.
4. Carefully lift out the PE power supply assembly.
5. Install the new PE power supply and reconnect the cables.
Replacing the Toroid
Transformer
If the Toroid transformer fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the two cable connectors J1 and J3.
3. Remove the single 3/16-inch hex mounting screw.
4. The Toroid transformer is heavy; lift it out carefully.
5. Install the new Toroid transformer and reconnect the cables.
Replacing the Toroid
PCB
If the Toroid PCB fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the four cables in connectors J-1 through J-4.
3. Remove the four 1/4-inch hex nuts at the corners of the board.
4. Hold the edges of the board, do not touch the capacitors, and lift the
board straight up. You may damage the capacitors if you apply
pressure to them.
5. Install the new Toroid PCB power supply board and reconnect the
cables.
6. Check the voltage selection switch.
Replacing the
Controller Power
Supply
If the controller power supply fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the two cable connectors.
3. Remove the four 1/4-inch hex nuts at the corners of the board.
4. Carefully lift out the controller power supply board.
5. Install the new controller power supply and reconnect the cables.
6. Check the voltage selection jumper.
Repair and Replacement Procedures
ProMaster 2500 User Manual 7-21
Replacing the Labeler
Power Supply
If the labeler power supply fails, follow the steps below to replace it. Be
sure to note the direction of rotation before you remove the fan so that
you can reinstall it correctly.
1. Turn off the 2500 and remove the power cord.
2. Disconnect the three AC input cables on the right side of the power
supply assembly.
3. Disconnect the two output cables on the left side of the power supply
assembly.
4. Use a 3/32-inch hex wrench to remove the two mounting screws
from the back panel of the 2500.
5. Carefully lift out the labeler power supply assembly.
6. Install the new labeler power supply assembly, reconnect the cables,
and reinstall the mounting screws.
System Fan Replacement
This procedure describes the steps required to remove and replace the
system fan.
Replacing the
System Fan
If the system fan fails, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Remove the four 7/64-inch hex screws.
3. Carefully lift out the system fan.
4. Install the new system fan and reconnect the power cable.
Controller Board Replacement
This procedure describes the steps required to remove and replace the
controller board.
Replacing the
Controller Board
If the controller board fails, follow the steps below to replace it. Make sure
you observe all static safety precautions.
1. Turn off the 2500 and remove the power cord.
2. Note the positions and polarities of all of the cables connected to the
controller board before you disconnect any of the cable connectors.
3. Disconnect all of the cable connectors.
Repair and Replacement Procedures
7-22 ProMaster 2500 User Manual
CAUTION: Cover the power supply assemblies in the base of the 2500
with a large sheet of paper to catch any mounting hardware
(screws, washers, and nuts) that might otherwise fall onto
the power supply assemblies as you work. If a piece of
mounting hardware is not accounted for when you install
the new controller board, do not turn on the 2500 until you
have located the missing piece of mounting hardware. If a
screw, washer, or nut contacts one of the 2500’s base
assemblies, an electrical short could occur when you turn on
the 2500, resulting in severe damage to the 2500.
4. Use a 1/4-inch hex nut driver to remove the ten nuts holding the
controller board to the front inner wall of the base of the 2500.
5. Lift the controller board straight up.
Note: Each of the mounting screws under the controller board has a nylon spacer
on it. Do not remove these spacers from the mounting studs.
6. Place the controller board on an antistatic mat or bag.
7. Transfer the firmware from U15 and U43 (unless new firmware is
specifically issued), as well as the U16 EEPROM, to the new
controller board.
8. Install the new controller board.
Note: Refer to the controller board wiring diagram in Appendix C.
Beam Assembly Component Replacement
These procedures describe the steps required to remove and replace the
beam assembly components.
Replacing the Flex
Coupler
If the flex coupler is damaged, follow the steps below to replace it.
1. Turn off the 2500 and remove the power cord.
2. Remove the beam traverse motor as described on page 7-15, but do
not remove the cables.
3. Use a 7/64-inch hex wrench to remove the set screw on the left side of
the flex coupler. (The flex coupler is attached to the end of the lead
screw.)
4. Remove the flex coupler.
5. Attach the new flex coupler to the beam traverse motor shaft. Tighten
with a torque wrench and a right-side screw using 24 inch-pounds of
torque.
CAUTION: Over-tightening the set screw can damage the flex coupler.