5V PS32 is bigger than the 5V board - mounting problem

Yes to all of the questions.  I've mounted a number of them on their sides, and for a couple I had to actually remove the plastic holder and just wrap them in Kapton tape for insulation.  The ones I wrapped in Kapton, I used double-sided foam tape to hold them in place.

Moving it to the tender will be messy.

It also depends on the engine.  Some are not going to work and you do not want to crush wires, not heat sink it, or have metal shell contact exposed parts of the board.  G

@GGG posted:

It also depends on the engine.  Some are not going to work and you do not want to crush wires, not heat sink it, or have metal shell contact exposed parts of the board.  G

Obviously true as well!  I hoped that would go without saying, but smart to say it anyway!

My engine has a clear plastic sleeve that is molded to the interior of the shell so the shorting to the casting won't be an issue.  I had to remove the plastic carrier for the two PS32 boards so they would fit into the boiler without mounting them sideways.  Now I'm looking at how to make sure the boards don't sag towards each other and the component leads from the top board don't poke into the electrolytic caps on the lower board. I know the heatshrink on the caps is durable, but I'd rather not take that chance of a puncture or wear through after years of vibration.  I think some RTV dots on a cap or two might end up being used to keep the spacing between boards.  The heatsink is under construction and nearly finished.

Dale

I've also had to extend some wires to get to the placement on the newer boards.

Premiere FEF I recall is one of those that is a tight fit.

Jim

If the top board has leads that will poke into the caps on the bottom board, trim them off!  I got a bunch of these boards with that issue.  Once you trim these flush, you can then use something like Kapton tape to secure the two boards together.  This is the only two places that the projecting pins endanger something on the lower board.

Also, for many (all) of these the board goes in upside down. G

Yep, which also means you'll probably be making a custom heatsink.  Not a difficult task, just a little bending and cutting of 1/16" aluminum.

I'm ready to transfer the wiring connectors to the new 5v PS32 board.  So just to recap before I do anything, there's no connection on the new board for the two pin connector near the diode bridge on the old board with red and black wires, and I should remove the BCS since the new board has a supercap.  Is this correct?

Thanks everyone for your help!

Dale

Yes, do NOT connect to the 2-pin connector!  The PS32 board has a supercap and needs no external battery.