Front Enclosure Replacement
Service Manual 12-11
13. Install the AC power inlet in the new enclosure as follows (Figure 12-3 on
page 12-4):
a. Position the AC power inlet assembly as shown in Figure 12-3.
b. Attach the AC power inlet to the enclosure with the two screws. Tighten the
screws to 0.4 to 0.6 N-m (3.5 to 5.3 lb-in).
c. Connect the 6-pin connector of the AC power inlet wire assembly to P112 on
the Power PCBA. Make sure that the connector is oriented as shown in
Figure 12-3, and that it is fully seated.
d. Connect the 3-pin connector of the wire assembly to CON1 on the power
supply. Make sure that the connector latch engages.
Note: If a cable tie previously secured the AC power inlet wire assembly to the
power supply mounting boss (see page 12-4), install a new cable tie at the same
position. The cable tie should cause the wires connected to CON1 to form an arch
approximately 4 cm (1.5 in) above the connector. Trim off the end of the cable tie.
14. Install the equipotential stud in the new enclosure as follows (Figure 12-2 on
page 12-3):
a. From the bottom of the enclosure, insert the threaded end of the stud, with
the ground washer attached, into the hole.
b. Place the AC power inlet ground cable terminal on the threaded end of the
stud. See Figure 12-2 for the order of items on the stud.
c. Place a lock washer on top of the terminal.
d. Place a nut on top of the lock washer. Tighten the nut to 3.2 to 3.8 N-m (28.3
to 33.6 lb-in).
e. Place the power supply ground cable terminal on top of the nut.
f. Place a lock washer on top of the terminal.
g. Place a nut on top of the lock washer. Tighten the nut to 3.2 to 3.8 N-m (28.3
to 33.6 lb-in).
15. Follow the procedure Rejoining the Front and Rear Enclosures on page 9-5.
16. Perform the following tests:
a. Keypad Test on page 7-5.
b. Display Test on page 7-7.
c. Temperature Accuracy Test on page 7-8.
d. Flow Test on page 7-10.
e. Thermostat Test on page 7-11.
f. Electrical Safety Tests on page 7-14.
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