Network LTC Plus: (Video) Power Supply Assembly & Wiring Harness Troubleshooting Guide

695 June 1, 2023

Video Text Summary

LESSON SUMMARY: This lesson is designed to assist the user in troubleshooting a variety of issues that can occur within the Power Supply Assembly and Wiring Harness that could also lead to further functionality issues in the satellite.

Special Tools Needed: Digital Multimeter, Phillips Screwdriver

⚠ CAUTION: THIS LESSON MAY INCLUDE INSTRUCTIONS TO TEST HAZARDOUS VOLTAGES (120V-240V) THAT CAN CAUSE SERIOUS INJURY OR DEATH. IT IS RECOMMENDED THAT A LICENSED ELECTRICIAN BE CONTRACTED TO PERFORM SUCH TESTS.

🛑 STOP: ALWAYS TURN OFF THE POWER TO THE SATELLITE BEFORE REMOVING OR INSTALLING COMPONENTS.

The Power Supply Assembly and Satellite Wiring Harness in a Network LTC® Plus satellite are responsible for supplying and distributing power to components throughout the satellite. If the Power Supply Assembly or Satellite Wiring Harness are damaged, or are not functioning properly, there will be a disruption in the functionality of components throughout the satellite. To determine if your Power Supply Assembly and Satellite Wiring Harness are functioning properly, follow the guided steps below.

*Note: Before you begin testing the Satellite Wiring Harness or the Power Supply Assembly, verify that the red Voltage Selector Switch located on the front of the Power Supply Assembly is set to the correct utility voltage for your course: 115V or 230V. If the Voltage Selector Switch is set to the incorrect utility voltage, power your satellite OFF using the On/Off rocker switch located on the front of the Power Supply Assembly and proceed to switch the Voltage Selector Switch to the correct utility voltage for your course.

Network LTC® Plus Wiring Harness Voltages:

The Satellite Wiring Harness in a Network LTC® Plus satellite supplies power from the Power Supply Assembly to the Power Distribution Board. The Satellite Wiring Harness and Power Supply Assembly are located in the lower right-hand corner of the satellite.

The Satellite Wiring Harness has four wires: red, white, green and black. It also has two plugs: one 9-position plug and one 4-position plug.

The 9-position plug contains all four wires and should be plugged into the back of the Power Supply Assembly.

The 4-position plug, which also contains all four wires, plugs into the 4-position connector located on the Power Distribution Board.

To measure the voltages for the Satellite Wiring Harness, proceed with the following steps:

Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Next, unplug the 4-position plug on the Satellite Wiring Harness from the Power Distribution Board.

Power the satellite back on.

Using a digital multimeter or voltmeter set to the AC Voltage setting, measure the voltage where the wires enter the back of the 4-position plug by placing one probe of your digital multimeter or voltmeter on the red wire and one probe on the white wire.

Your digital multimeter or voltmeter should display a reading of 12VAC; up to 16VAC is acceptable.

After measuring the voltage for the red and white wires, proceed to measure the voltage for the green and black wires.

Your digital multimeter or voltmeter should display a reading of 24VAC; up to 30VAC is acceptable.

If the voltage readings for the red and white wires or the black and green wires are 0, or very close to 0, there is an issue with the Satellite Wiring Harness or the Power Supply Assembly. Proceed to test the Power Supply Assembly using the instructions outlined below.

Measuring Power Supply Assembly Output Voltages:

Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Next, disconnect the 9-position plug for the Satellite Wiring Harness from the back of the Power Supply Assembly by squeezing the two tabs on each side of the connector to release the 9-position plug.

Power the satellite back on.

Using a digital multimeter or voltmeter set to the AC Voltage setting, refer to the following diagram and measure the voltages between the indicated pins on the 9-position connector located on the back of the Power Supply Assembly.

If the voltage measured between the 12VAC pair of pins is 12-16VAC and the voltage measured between the 24VAC pair of pins is 24-30VAC, the Power Supply Assembly is functioning properly.

If the Power Supply Assembly is found to be functioning properly but the voltage readings recorded when testing the 4-position plug on the Satellite Wiring Harness were 0,or very close to 0, the Satellite Wiring Harness is damaged and needs to be replaced.

Power Supply Assembly Troubleshooting:

Testing the 4A Reset Breaker:

Start by checking the 4A Reset Breaker and the 3.2A Slow Blow Fuse located on the front of the Power Supply Assembly.

The 4A Reset Breaker has a small rocker-style plunger that pops out when the breaker is tripped. The rocker-style plunger can be pressed to reset the breaker. If the 4A Reset Breaker is tripped and the rocker-style plunger fails to stay in the reset position while power to the satellite is off, the 4A Reset Breaker is damaged and needs to be replaced.

If the 4A Reset Breaker is found to be functioning properly, proceed to test the 3.2A Slow Blow Fuse.

Testing the 3.2A Slow Blow Fuse:

*Note: Visually inspecting a fuse is never a trustworthy method to determine the failure or functionality of the fuse.

Start by removing the 3.2A Slow Blow Fuse from its holder.

Use a digital multimeter on the resistance setting or continuity setting with an audible beep. If using the resistance setting, touch the two multimeter probes together and note the reading on the display; it should be 0 or very close to 0. *Note: Different multimeters will vary slightly.

Proceed to place one probe on each end of the fuse.

If using a digital multimeter on the resistance setting, a working fuse will display a reading close to the reading that was displayed when the two probes were touched together: 0 or very close to 0.

If using a digital multimeter on the continuity setting, a working fuse will create an audible beep.

If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the fuse is damaged and should be replaced.

If the 4A Reset Breaker and the 3.2A Slow Blow Fuse have been tested and are known to be working properly, you will need to verify that the utility voltage coming into the satellite is adequate.

Testing the Incoming Utility Voltage:

Using a Phillips screwdriver, unscrew the single screw on the back of the Power Supply Assembly and remove the metal cover.

After removing the metal cover you will see a white connector containing the utility power wires and three different colored wires going into the Power Supply Assembly: two blue wires, two brown wires, and one green wire.

Using a digital multimeter or voltmeter on the AC Voltage setting, place one probe of the multimeter on the screw containing the blue wires and one probe on the screw containing the brown wires. The multimeter should display a reading 115V or 230V, depending on the utility voltage at your course. If your utility voltage at your course is 115V, a reading within the range of 105-130VAC is acceptable. If your utility voltage at your course is 230V, a reading within the range of 210-260VAC is acceptable.

If the voltage reading is outside of the acceptable range, the main utility power feeding the satellite has an issue that needs to be addressed.

If the voltage reading is within the acceptable range, the Power Supply Switch will need to be tested.

Testing the Power Supply Switch:

The Power Supply Switch is the On/Off rocker switch located on the front of the Power Supply Assembly to the left of the Voltage Selector Switch.

To test the Power Supply Switch, start by shutting off the utility voltage going into the satellite. To shut off the utility voltage, locate the panel housing your circuit breakers that control power to the course. Switch the utility voltage that supplies power to the satellites off.

Using a Phillips screwdriver, unscrew the single screw on the front of the Power Supply Assembly that holds the front metal cover in place. Proceed to remove the front metal cover from the Power Supply Assembly.

Next, disconnect the four blade-style wire connectors from the Power Supply Switch, making sure to mark them for proper reinstallation.

Carefully press the tabs on the Power Supply Switch to release it from the Power Supply Assembly.

Set the Power Supply Switch to the ON position and place one probe of your digital multimeter on the terminal labeled “LINE 11” and one probe on the terminal labeled “12(K)”.

When using the resistance setting on a digital multimeter, a working Power Supply Switch will cause the multimeter to display a reading that is very close to the reading displayed when touching the two probes directly together: 0 or close to 0.

If using the continuity setting on a digital multimeter, a working Power Supply Switch will create an audible beep.

If the digital multimeter displays a reading of Over Limit (“OL”) on the resistance setting, or no audible beep is heard if using the continuity setting, the Power Supply Switch is damaged and should be replaced.

If the test of the terminals labeled “LINE 11” and “12(K)” resulted in a reading of 0 or close to zero, or an audible beep, proceed to test the remaining two terminals.

With the Power Supply Switch still set to the ON position, place one probe of your digital multimeter on the terminal labeled “LINE 21” and one probe on the terminal labeled “22(K)”.

If using the continuity setting on a digital multimeter, a working Power Supply Switch will create an audible beep.

If the test of the terminals labeled “LINE 21” and “22(K)” resulted in a reading of 0 or close to zero, or an audible beep, the Power Supply Switch is working and can be reinstalled in the satellite.

If the Power Supply Switch has been tested and is working properly, the Power Transformer will need to be tested.

Replacement Power Supply Switches can be purchased here.

Testing the Power Transformer:

The Power Transformer is located within the Power Supply Assembly on the right-hand side.

If the metal cover on the front of the Power Supply Assembly is installed, use a Phillips screwdriver to unscrew the single screw on the front of the Power Supply Assembly. Remove the metal cover.

Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Next, unplug the 4-position plug and both 2-position plugs on the Satellite Wiring Harness from the Power Distribution Board and both 24VAC Connector Groups, leaving the Satellite Wiring Harness plugged into the rear of the Power Supply Assembly.

Using a digital multimeter set to the resistance setting, place one probe of the multimeter on the red wire and one probe on the white wire. The resistance reading should be less than 1 OHM.

Proceed to place one probe of your multimeter on the black wire and one probe on the green wire. The resistance reading should be less than 1 OHM.

If your digital multimeter displays a reading of Over Limit (“OL”) for either set of wires, the Power Transformer is damaged and should be replaced.

If the Power Transformer has been tested and is working properly, the resistance of the brown and blue wires that the utility power connects to on the rear of the Power Supply Assembly will need to be tested.

Replacement Power Transformers can be purchased here.

*WARNING!*

The following troubleshooting step should only be performed with the utility power to the satellite turned OFF and the utility wires completely removed from the back of the Power Supply Assembly.

Start by powering on the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Using a digital multimeter set to the resistance setting, place one probe of the multimeter on the blue wires and one probe on the brown wires. The resistance reading should be 3 OHMs.

If your digital multimeter displays a reading of Over Limit (“OL”), the Power Transformer is bad and should be replaced.

If it appears that the Power Supply Assembly has sustained significant damage as a result of a lightning strike or other surge-related event, the Power Supply Assembly should be replaced.

Replacement Power Supply Assemblies for Network LTC® Plus can be purchased here.

Lesson tags: toro, network ltc plus, power supply assembly, power supply switch, wiring harness, repair, replacement, exchange, boardtronics

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