P a r t   R e p l a c e m e n t   I n s t r u c t i o n

Product: SUPERSTAR 2

Part Replaced: 5/12VDC Power Supply

Required Tools:

	5/32 Allen Wrench
	#2 Phillips head screw driver
	Small Slotted screw driver
	Digital Voltmeter

Procedure:

Physical Replacement:

1. Turn the machine off and unplug the Power Cord from the machine and the wall socket.
2. The rear Circuit Breaker Panel (Figure 1-A) must be free before removal of the Main Power Supply. This is done by removing the two Phillips head screws (Figure 1-B) at the top of the Circuit Breaker Panel. Once the screws are removed, carefully lay the entire Panel inside the Power Supply Unit.
3. Disconnect the 2 power plugs (Figure 2-C) on the Main Power Supply, located under the center and to the rear of the MACHINE.

WARNING! THE POWER SUPPLY UNIT IS VERY HEAVY. REMOVING AND REPLACING THE POWER SUPPLY REQUIRES TWO PEOPLE, ONE TO HOLD THE UNIT AND ONE TO REMOVE AND REPLACE THE RETAINING NUTS.

4. While holding the Power Supply Unit firmly in place, unscrew the four retaining screws (Figure 2-D) holding the Power Supply Unit to the machine.
5. Carefully lower the Power Supply Unit and take it out from under the machine.
6. Unplug the 2 white connectors (Figure 3-E) on the 5/12 VDC Power Supply Printed Circuit Board.
7. Remove the four Phillips head screws (Figure 3-F) holding the 5/12VDC Power Supply into the Main Power Unit.
8. Remove the 5/12VDC Power Supply from the Power Supply Unit.
9. Install new 5/12VDC Power Supply with the 4 Phillips head screws removed in step 7.
10. Reinstall the 2 white connectors onto the 5/12VDC Power Supply.
11. Reinstall the Main Power Supply into the machine using the four retaining screws removed in step 4.
12. Reconnect the 2 power plugs to the Main Power Supply.
13. Pull the Circuit Breaker Panel to the outside of the machine Chassis and secure the bottom of the Panel in the latch bracket at the bottom of the opening so that the Panel is held parallel to the ground.

Voltage Adjustment:

14. Look through the Circuit Breaker Panel opening and locate the Blue Wheel, marked R-24, on the 5/12VDC Power Supply. This is the voltage adjustment potentiometer for the 5 volts DC.
15. Remove the locking screw holding the Right Shroud Arm in place and raise the Arm to its full up (locked) position.
16. Look to the right rear of the Mother Board (This is the Circuit Board laying on the chassis that was just exposed by raising the Shroud Arm) and locate the voltage test points, TP1 (Gnd) and TP2 (+5v).
17. At this time plug the Power Cord into the machine and the wall socket. (Use extreme caution not to touch the circuit breaker wires or allow the wires to touch the machine. These wires carry 110 VAC).
18. Place the probes from the Digital Voltmeter into TP1 and & TP2 (Black to TP1 and Red to TP2). Use caution that the probes only touch TP1 & TP2.
19. Turn on the machine.

WARNING! POTENTIALLY DANGEROUS VOLTAGES EXIST INSIDE THE POWER SUPPLY UNIT. DO NOT TOUCH ANY COMPONENTS WHILE ADJUSTING THE VOLTAGE.

20. Using a small Slotted screw driver, adjust the potentiometer (R-24) so that the voltage indicated on the Digital Voltmeter reads 5.10 volts DC, +/- 0.02 volts.
21. After voltage adjustment, turn the machine off, unplug the Power Cord from the Circuit Breaker Panel and reinstall the Panel to the rear of the machine using the screws removed in step 2.
22. Lower the Shroud Arm and secure in place.
23. Plug the Power Cord into the machine, turn it on, and perform a test sew out.

Figure 1

Figure 2

Figure 3