SERVICE
BULLETIN
PN: 21467120

RELEASE DATE:
September 5, 2019
REVISION DATES(S): July 1, 2020
MODEL:

Onyx 5L and 10L (Ultra) Models

ISSUE:Onyx 5L and 10L (Ultra) Main Circuit Board Retrofit Instructions

NOTES:

This instruction is intended to guide technicians through replacing circuit board
item CB154 / CB160 (or older circuit boards) with circuit board CB200.

Table 1. Available Kit Options
Kit PartMain Board
NumberIncluded in Kit
KI611-4
CB200-4
KI611-3
CB200-3
KI611-2
CB200-2
KI611-1
CB200-1

ModelOnyx 5L (220 V, 50Hz)
Onyx 5L (120V, 60Hz)
Onyx 10L (220V, 50Hz)
Onyx 10L (120V, 60Hz)

Tools Required:x Flat-Head Screwdriverx Phillips-Head Screwdriverx ESD Electrostatic Protection
x Wire Cuttersx 5/16 wrench

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Table 2. Parts Included with KI611
Part Number
Description

Qty

CB200-*

Main Circuit Baord, programmed(* see Table 1 for details)

1

WH147-1

Wire Harness Main New Life

1

WH146-1

Power Switch Wire Harness

1

WH097-1

Wire Harness, Power Switch/

1TW001-4

Tie Wrap, 4”221467120

Instruction Bulletin for Board Retrofit

1CD004-1

Cord, Power, 3-Prong, 12ft

1CD006-1

Cord, Power, Strain Relief

1CN001-3

Connector, Push-On, Straight2

CN049-5

Connector, Terminal Ring

1CA007-11

Cabinet, Recepticle

1CD007-1

Cord, Power, 2-Prong, 8ft

1

Procedure:
1. Turn off the unit and disconnect the power cord.
2. Remove the side panels with a flat head screwdriver.
3. Disconnect the main power 10-pin connector from the circuit board.
See Figure 1
Important Note: It is strongly recommended to use standard electrostatic discharge(ESD) protection when handling any circuit boards. Damage to boards may result if ESD
procedures are not properly followed.
Note: If working on the Onyx 10L 220V unit, the 2-pin compressor connector will need tobe disconnected as well. This is located directly to the left of the main power 10-pin
connector. (Red & White Wires)

Figure 1. Main board harness
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4. Cut the tie-wrap at the circuit board pressure transducer and disconnect thegreen tube from the transducer.
See Figure 2Figure 2. Pressure transducer zip tie5. Push in on the circuit board support tabs while you lift each area of the circuitboard to remove the circuit board from the control panel.
See Figure 3

Figure 3. Board supports

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6. Remove main wire harness from the main control board, terminal block, valve
block, EQ valve, and fan.You will also need to disconnect the two white plugs andthen cut the light blue and brown wire from the power cord to remove the harness
from the Superstructure. Discard the wire harness.
See Figures 4 and 5.

Figure 4. Disconnected white plugs and cut light blue and brown wires frompower cord.

Figure 5. Main wire harness removed from the unit.

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7. Leave only the brown and blue wires coming up from the compressor on theterminal block.
See Figure 6

Figure 6. Terminal block with only
blue and brown compressor wires.
8. Remove the grounding wire from the front panel by removing the nut andpulling green wire off of screw.
See Figure 7

Figure 7. Ground wire and nut is located.

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9. Cut the zip tie mounted on the unit that secures the power cord.
See Figure 8

Figure 8. Zip tie holding the power cord
10. Remove the power cord completely from the superstructure by untwisting two
plastic ties that hold the cord, beside fan.
See Figure 9

Figure 9. Power cord removed from twist ties.

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11. Lay unit down horizontily with compressor side of the superstructer towards
the table. Remove the power cord housing from the base of unit which is securedby 2 Philips head screws. Re-install your new power cord/power cord housing andfeed power cord back up through twist ties.
See Figure 10

Figure 10. Location of two Philips head screws on the bottom of
the base of the unit.
12. Remove the 4 nuts holding the front panel on the unit with a 5/16” wrench.
These will be located at the top and bottom corners of the left and right sides of thefront panel.
See Figure 11

Figure 11. Shows the screw on the front panel once the nut is removed.

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13. Once the 4 nuts are taken off front panel screws, gently pull on thefront panel to remove it from the front of the superstructure to expose
wiring to hour meter, power switch, and circuit breaker.
See Figure 12

Figure 12. Front panel disconnected from the front of the unt
14. Once the backside of the front panel is exposed, take all wiring off ofthe hour meter, power switch and circuit breaker.
15. Place circuit board mounts into superstructure. Reconnect the pressure
sensor tubing back onto boards top pressure sensor and secure with a ziptie.
See Figure 13

Figure 13. Pressure sensor tubing reconnected to board with zip tie.
16. Place the circuit board back onto circuit board mounts.
See Figure 14.
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Figure 14. Board reinstalled onto superstructure.
17. Plug main wire harness and AC power into the board.
See Figure 15

Figure 15. Showing AC power and main wire harness on board.

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18. Plug the purple and grey wires into the EQ valve. See Figure 16

Figure 16. Purple and grey wires
connected to the EQ valve.
19. Plug in valve block wire harness.
Note: On each side, the wires that connect to the valves on top will be a shorter inlength than the ones that connect to the valves on the bottom of the block.
See Figure 17

Figure 17. Valve block wire harness connections

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20. Install Fan Wire into the Circuit Board. The Circuit Board is marked “Fan” on
the lower right side where this connection goes.
See Figures 18

Figure 18. Terminals connected to fan.
21. For 120V: Begin plugging wires into the terminal block of thesuperstructure. There is a left side and a right side to this terminal block.
Left Side of Terminal BlockTop Left: Empty Top Right: Double white (Fan),
Bottom Left: Blue (Compressor) Bottom Right: Single White (AC Power)
Right Side of Terminal BlockTop Left: Empty Top Right: Double Black (Fan)
Bottom Left: Brown (Compressor) Bottom Right: Single black (AC)See Figure 19.

LEFT
Right

Figure 19. 120V terminal block connections.
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22. For 220V: Begin plugging wires into the terminal block of thesuperstructure. There is a left side and a righ side to this terminal block.
Figure 20
Left Side of Terminal BlockTop Left: Light Blue (Power Cord)
Top Right: Double white (Hour Meter & AC),
Bottom Left: Dark Blue (Compressor) Bottom Right: Single White (AC)Right Side of Terminal BlockTop Left: Single Black (Power Switch)
Top Right: Double Black (Hour meter & AC)
Bottom Left: Brown (Compressor) Bottom Right: Single black (AC)

Right

LEFT

Figure 20. 5L 220V terminal block connections

Note: If you are working on a 10L 220V unit, the Compressor wires hookdirectly to the board and the terminal block will not have the brown andblue wires, only a light blue wire coming from the power cord on the top
left side of the terminal block.
See Figure 21 and 22

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LEFTRightFigure 21. Onyx 10L (Ultra) 220V unit’s terminal block
will be wired up without the compressor wires.

Figure 22. Blue and brown compressor
wires connect directly to the board on a 10L (Ultra) 220V unit.

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22. Install Circuit Breaker and Power Switch harness.
Circuit BreakerLeft: Brown (from Power Cord),
Right: Black (from Power Switch Wire Harness)
See Figure 23 and 24
Power SwitchTop Left: Black (from Circuit Breaker),
Top Right: Red (from board)
Bottom Left: Black (from Terminal Block),
Bottom Right: Red (from board)
See Figure 23 and 24

Figure 23. Showing how the front panel is wired up.

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Figure 24. Showing a different angle ofhow front panel is wired up.
23. Reinstall the ground wire and 4 nuts that hold the front panel in placewith the 5/16” wrench.
See Figure 25

Figure 25. Showing ground wire and nut re installed.
24. Re-attach case panels and test to ensure purity / flow meets
manufacturing specifications.

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CONTACT:

For technical questions or concerns, contact Technical Service:USA:
800-482-2473
Europe:+44 (0) 118 936 7060
Techservice.global@caireinc.com
For ordering information or general inquires, contact Customer Service:USA:
800-482-2473
Customerservice.usa@caireinc.com
Europe:+44 (0) 118 936 7060

Customerservice.Europe@caireinc.com

Copyright © 2020 CAIRE Inc. CAIRE Inc. reserves the right to discontinue its products, or change theprices, materials, equipment, quality, descriptions, specifications and/or processes to its products at any
time without prior notice and with no further obligation or consequence. All rights not expressly statedherein are reserved by us, as applicable.
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