Gen2 Power cord replacement

Warning : Before you start: Turn off the chiller and unplug the unit from the wall. Do not work on it while plugged in. If you’re unfamiliar with electrical wiring, have a qualified technician complete the replacement.

Tools Required

• 2.5mm hex driver

• Zip ties

• Utility knife or snips (for cutting zip ties)

• Protective gloves

• Adjustable wrench

• Pliers

Replacing the Power Cord/Fuse Holder

1. Take a picture of the wiring. Photograph the connections and the order of the nuts and washers so you can put everything back the same way.
2. Unplug the A/C input connector. Find the connector marked “Remove A/C input connector.” Release its clip, if present, and gently pull on the plastic plug—not the wires.
3. Disconnect wires 1, 2, and 3. Label the wires before removing them. Loosen the screws holding them at the bottom of the power supply: #1 is ground, #2 is neutral, marked AC(N), and #3 is power, marked AC(L).
4. Disconnect the ground wires at #4 and #5. The ground from the A/C input connector attaches at #4. The ground from the fuse holder attaches at #5, along with a second ground wire that runs to #1. Remove the retaining nuts and keep all washers and hardware in their original order.
5. Remove the old cord assembly. Remove the two fasteners marked “Remove bolts.” Carefully remove any zip ties holding the cord’s wires, then free the assembly without pulling on nearby wiring.

6. Install the replacement assembly and position the cord. Use the correct replacement supplied or approved by Plunge. Position it like the original and reinstall the mounting fasteners. Guide the power cord into the notch on the edge of the electrical box, following the red arrow below. Make sure it sits fully in the notch so the cover will not pinch it.

    

7. Reconnect the ground wires first. Attach the ground from the A/C input connector to #4. Attach the ground from the fuse holder to #5, and reconnect the separate ground wire between #5 and #1. Both ground wires must be secured at #5. Reinstall the washers and nuts in their original order and secure them to Plunge’s specifications.
8. Reconnect the remaining wires. Reconnect #2 to AC(N) and #3 to AC(L). Push the A/C input connector into its socket until fully seated and its clip, if present, locks.
9. Check your work. Compare every connection with your original photo. Make sure no wires are loose, pinched, or damaged. Replace the zip ties without over-tightening them. 
10. Place the cord in the notch. Guide the power cord into the notch on the edge of the electrical box, shown by the red arrow. Make sure the cord sits fully inside the notch so it will not be pinched when you reinstall the cover.
11. Close the enclosure and test. Confirm the cord remains seated in the notch as you reinstall the cover. Plug the unit in, follow the GFCI’s TEST and RESET instructions, and confirm normal operation. If it trips repeatedly or does not work correctly, unplug it and contact Plunge Support.