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PB110/PB205 Booster Ground Issue

Normally NCE Boosters have the case serve as a Booster Ground (AKA Booster Common) connection point using the case screws.  This connection becomes very important when dealing with multiple boosters and is covered in the booster manuals.  The booster common is establish by running a large wire connecting all the metal chassis of all the boosters involved on the layout electrical together.  It existence eliminates engine stalls and intermittent power loses as a given engine crosses over from one booster power district to another booster power district.

(NOTE: One would be attempted to think the above wire connection would be called a "Chassis Ground" or Earth Ground connection but that would be incorrect.  This connection never goes to Earth Ground.)

HOWEVER, there are 4 older and discontinued Booster products that do NOT support a Booster Common using the case screw connections.
  

UNLESS OTHERWISE STATED, THIS SECTION ONLY APPLIES TO THESE 4 DISCONTINUED PRODUCTS.

IN THIS SECTION ARE:

1) DISCONTINUE BOOSTERS THAT NEED MODIFICATION
2) NCE PB110/PB205 & SYS1 PSR11 MODIFICATION OVERVIEW  (NCE/SYS1 10Amp & NCE Dual 5Amp)
3) NCE PB110/PB205 & SYS1 PSR11 MODIFICATION STEPS 
4) SYS1 PSR01/SBR01 (SYS1 Dual 5Amp) MODIFICATION STEPS

To learn more about Wangrow's System One (SYS1) go here: System One/Wangrow


1) DISCONTINUE BOOSTERS THAT NEED MODIFICATION

There are 4 old and discontinued Boosters that are compatible with NCE and they all have booster common/ground support issues.  There is no provision inside the box to allow the case to be grounded to the booster's ground point.  To allow this booster to function with other boosters, you must modify the booster internally to add this missing connection.  This section talks about the modifications.They are:

1) NCE PB110 single 10Amp booster.  Discontinued.  (NOT THE PB110a) Most if not all have the "Master Series" label on the front.  The key is the "PB110" shown for the model number.  No "a" suffix.  It is shown here in the very top left corner of the front panel but in hard to see being under the lip of the cover.  Another unique indication is "Meter" connection located on center 2 terminals of the connector on the left bottom side.

(NOTE: The current production 10 amp booster is called the NCE PB110a.  The "a" suffix is very significant.  This PB110a booster does NOT NEED any of these modifications.  However there is an internal ground screw connection that does need to be check to see if it is in the correct position. To learn more go here: PB110a Booster Grounding)

2) NCE PB205 dual 5A booster.  Discontinued.  Most if not all have the "Master Series" label on the front.  The key is the "PB205" shown for the model number.  No "a" suffix.  It is shown here in the very top left corner of the front panel but in hard to see.  Another unique indication it has 2 track connections in the connector on the left bottom side.





3) SYS1 Wangrow PSR01/SBR01 dual 5 Amp booster. Discontinued.  This booster is unique to System One.  Although it looks like the PB205 on the outside, it is very different on the inside.  The only thing common between the two is the metal case and front panel.







4) SYS1 Wangrow PSR11/SBR11 single 10Amp booster.  Discontinued.  The booster is 100% identical to the NCE PB110 booster.  In fact NCE made the PSR11 for SYS1.  All the was done was a applying a different "SYSTEM ONE" label to the front panel.






2) NCE PB110/PB205 & SYS1 PSR11 MODIFICATION OVERVIEW




The picture on the left shows the insides of the PB110.  The PB205 looks exactly the same inside since the same parts and PCB layout are used to be both versions.

The power supply is on the left side using the big large tall parts.  The big blue (case color can vary) round items are the capacitors used to filter the power.

The input full wave bridge rectifier is the big square box on the far center left side of the PCB board surrounded by the big blue capacitors.  The part is mounted upside down and bolted to the chassis for heat sinking reasons.  This electrical part converts any incoming AC to DC.  (It also fixes the DC input polarity issue too if a DC power supply is used.)





 


The picture on the left shows close up of the left side of the PCB board.  The bridge rectifier, BR1, can now be seen peaking out from under the PCB board.  You can see the mounting nut/bolt in the open hole in the board.

The modification requires one to run about a 3" long solid 18 AWG wire between the negative (-) terminal to metal screw the holds the PCB to the chassis.  The exact length of the wire is not critical.  It just has to be long enough to fit. Note the use of a screw terminal lug for the screw end. This gives one a clean connection on the screw end.  Check your local electronics store for parts.

For clarity sake.  The (-) terminal your soldering to is DIAGONAL from the (+) terminal.  The (+) terminal is marked by the beveled corner for the square box showing the bridge rectifiers outline.   Looking from the front of the booster, the negative terminal would be the top left corner terminal closest to the edge of the board.  It is also the terminal that is closest to the BR1 label.





3) NCE PB110/PB205 & SYS1 PSR11 MODIFICATION STEPS

PBB110 = NCE MASTER SERIES 10Amp Booster.
PB205 = NCE MASTER SERIES dual 5 amp booster.
PSR11 = SYS1 10 Amp Booster made by NCE.  Identical to PB110.

1) Remove the screw.

2) Soldering the lug to the wire first and then trim off any excess wire.  

3) Pre-bend the solid wire into the shape shown so that it lines up with were it going to go between the bridge rectifier (-) terminal and the screw hold.  This may take sever tries to get it to fit.

4) Next solder the wire to the bridge rectifier at the (-) terminal.  

5) Orient the lug as shown.  Then screw down the lug end to the PCB board mounting screw on the left bottom corner of the photo.  When securing the lug with the screw, the lug should not touch any other parts on the PCB.    It is not critical that the lug avoid touching the very small brown capacitor labeled C5 (shown just underneath the bent portion of the lug) for it happens to be part of the same circuit).  However, try to avoid touching it anyway.  BTW: C1 is the big blue cap.   Once the lug is screwed in place, the wire will not move.


4) SYS1 PSR01/SBR01 MODIFICATION STEPS

PSR01/SBR01 = SYS1 Dual 5 Amp booster.

The modification steps are identical to the 10Amp booster PSR11 above.  Follow them with understanding there are some minor differences regarding the locations of the bridge rectifier and the grounding screw.

The Bridge Rectifier is located up front (front panel) right behind the AC and Track power connector J1 on the PCB.  You can see a hole with a nut exposed and the square white markings with a "+" sign on the left bottom corner.  That is the bridge rectifier.  The unmarked negative (-) terminal of the bridge rectifier is located diagonally from the "+" in the top right corner right next the part labeled "L2".  Soldering the jumper wire to the "-" terminal is going to be very physically tight since the big round black or blue capacitor C6 is right next to the terminal.   Of course you do not want to burn the cover of the big capacitor or heat up the capacitors itself with the soldering iron.  However accidentally and momentarily doing so will not harm the capacitor since there is a metal can behind the plastic cover of the capacitor.  Just be careful.

The ground screw is on the left side of power connector J1 right next to the capacitor labeled C5.  Its in corner of the PCB acting as a PCB mounting screw.  You can see the silver square metal PCB pad the screw is secured to.  That is the screw you need to complete the connection.

The jumper wire will be very short.

Updated 7/27/2015