Power Relay System
Installation Instructions (PMTR2037) for "Silver Series" Controllers
Step 1 - With a Dremel cut through the
circuit board trace as noted in #1 in the picture below - Do this on BOTH sides of the circuit
board. Make sure all the copper is removed between the
vertical black lines inside the gold colored circle. If
using the controller with high power supply voltages between 14 and 20 volts
then the enclosed resistor must be installed in-line in the small lead wire that
goes to the relay circuit #85 (failure to do this can cause the relay to
fail !).
Step 2 - Using the lead wire provided in
the kit, strip and solder the wire to the location as noted in #2 in the picture
below. For best results the wire should be on the back face of the circuit
board with only the bare copper extending through the front side of the circuit
board in the location indicated. Solder the wire in using a good grade of
rosin core electrical solder & use lighter fluid & a Qtip to clean up
any flux residue after soldering. Do not use
acid flux or solder with acid flux core.
Step 3 - Route the lead wire out the
bottom of the controller handle through a notch cut with a Dremel. You can then
close up the handle and tighten the screws.
Step 4 - Trim the relay brass tabs with a
Dremel to make them about 3/16" high. Solder the relay supplied into
the controller wires using the circuit numbers as marked on the relay as noted
below. Again, be sure to only use rosin core electrical solder for these
connections. Ideally the relay should be located about 4-6" from the
end of the wire alligator clips. Wire per the relay circuit numbers and
wires : Lead wire from controller (& resistor if used) - #85, Black - #87
(either one), White - #30, Red - #86.
Step 5 - Cover the relay with the heat
shrink tubing and shrink in place using a heat gun. When complete it
should look like the picture below.
