TelePost Incorporated LP-200 User manual

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LP-200
DummyLoad / Wattmeter
EnclosureRetrofit AssemblyInstructions
March2009
TelePost Incorporated
LP-200 isatrademarkofTelePostInc.Material inthisdocumentcopyrighted ©2009 TelePost Inc.

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Introduction
Theseinstructionswill gude youthroughtheinstallationof the LP-200enclosure. Thereisreallymore
dissassemblythan assemblyinvolved,but it’sastraightforwardprocess andshouldonlytakeaboutanhourto
do.Beforestarting, you shouldinventorytheparts. Hereisapictureof all thepartsexcepttheenclosuretop,
bottom,andsixsheetmetalscrewsthatholdthetoptothebottom.
PartsList- Subject tochange without notice.
Quantity Designation Description
3SW1,2,3 Right angletactileswitchesw/keycaps
1SW4 Toggleswitchand hardware
21x8ribbon cables
4 4-40 x¼” threaded standoffs
42-56 x3/8”threaded standoffs
84-40 x3/16”machine screws
8 2-56 x3/16”machine screws
1Enclosuretop
1Enclosurebottom
6#4 sheet metalscrews
4Rubberfeet

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Assembly
Pre-assemblyoverview.
Assemblywill followthisbasicorder…
Removalofpowerswitch.
Removalofdisplayconnector
Installation ofnewtactileswitches(oldswitchescanremain)
Installation ofnewpowerswitch
Installation ofnewdisplaycables
Thefollowingtoolsarerecommendedtocompleteassembly…
Adjustablesolderingiron–800degreesmaximum
Solder
Solderwickorsoldersucker
Needle-nosepliers
Wirecutters
SmallPhillipshead screwdriver
Smallflatscrewdriver
Alcoholandoldtoothbrush
Electricaltape
Step-by-step assemblyinstructions.
Itisrecommendedthat you print thismanualtoallowforeasy referencewhilebuilding, and toallowyoutocheck offthestepsasyou
completethem. Makesureyourworkareaisstatic-free toavoiddamagetotheinstalledparts.It isalsoadvisabletowearananti-static
wristbandandgroundedsoldering iron.
qRemovethePCBfromthemounting plate.
qCarefullyunsolderand removethepowerswitch.
qCarefullyunsolderand removethedisplayconnector.Iusedsolderwick toclearthepinsofsolder.Ithengentlypriedupthe
connectorhousingtoexposethepins.Takecareifyoudothistonotplaceyourscrewdriverbladeoveracircuittrace.Ithenpulled
theremaining pinsonebyone. Alittleheatmightberequiredonapinifithasanyresidualsolderleft.Hereisapictureofthe
exposedpins

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AssemblyCont’d
qUsingthealcoholandtoothbrush,carefullyclean awayexcess fluxfromthedissassemblyprocedures. Hereisapictureof whatthe
displayconnectorholesshouldlooklikeafterunsoldering and cleaning…
qInstall thethree rightangletactileswitchesnext totheexistingthree mallerones.Donotinstallthekeycapsyet. Youmayhaveto
slightlyenlargetheholeswheretheplastictabsfit,orfiledowntheplastictabssothattheyfitsnugly. DO NOTmodifytheholes
wherethemetalcontactsaresoldered.
qSolderacoupleof 1”long wiresfromtothebottomtwopinsof thepowerswitch.Soldertheotherendsofthewirestothemiddle
twoholesoftheremovedswitch,asshown…

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AssemblyCont’d
qPreparethetworibbon cablesasshownbelow.Youshouldplaceapieceofelectricaltapeovertheexposedmetaledgeswhere
thepinsarecrimped,becausethetwocableswill beclosetoeachotherwheninstalled.Forclarity,Iusedthedarkcoloredwirein
eachasareferencetodeterminewhichsideofthecableisup,but thisdoesn’t reallymatteraslongasthetwoarekeptparallelto
eachother.
qSolderthecablestothedisplayconnectorholessothattheyaresidebysidewiththetapedportionsfacingeachother. Itis
probablysmarttoalsoseparatethemalittlesothattheydon’ttouch,asshown…

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AssemblyCont’d
qInstall thefourshortstandoffstotheundersideofthePCBusingthe4-40x3/16”screws. Leavethescrewsalittleloosesothatthe
boardcanbeadjustedwhenit’sinstalled.
qInstall thefourrubberfeet on thebottomof theenclosure.
qSlidethePCBintotheenclosure, and insertthefourremaining4-40x3/16”screwsonthebottomofthechassis.Onceallscrews
arestarted,position theboardasfarbackasit willgointheenclosure, and tightenalleightscrews.
qInstall thelongstandoffsonthefront ofthedisplay, using the2-56x3/16”screws.
qMountthedisplaytothefrontoftheenclosureusingtheremainingfour2-56x3/16”screws.
qInstall theribbon cableconnectorson thebackofthedisplayasshown…
qInstall thepowerswitch,usingthelockwasherandnutsupplied.
qInstall thefourswitchkeycaps.
Beforeinstallingtheenclosuretop,itisnecessarytodeterminethefan direction.Theoriginalunitshadthefanblowing downward,as
thisprovidesthemostventilation.Withthenewenclosure,thiswillblowalotofhotairontowhateversitsbelowtheLP-200.Youmay
wishtophysicallyflipthefantoblowupwards.It willreducecoolingefficiency,anddecreasethelengthoftimeyoucantransmitatfull
power, butit willstillworkwiththislimitation.
qInstall theenclosuretopusingthesixsheetmetalscrews. Positiontheventslotstothebackoftheenclosure.