Hypertherm Powermax65 Manual de referencia

Powermax65®

Powermax85®

Power Board Replacement

Remplacement du circuit imprimé

Field Service Bulletin

Bulletin de service sur le terrain

806780 – Revision1 – December, 2012

Révision1–Décembre, 2012

Powermax65/85 Power board rePlacement

Field Service Bulletin 1

Introduction

Purpose

This Field Service Bulletin describes the procedure for replacing a Powermax65 or Powermax85 power board.

Materials and tools

• #2 Phillips screwdriver

• #3 Phillips screwdriver

• T15 TORX screwdriver (preferred) or a blade screwdriver

• T20 Torx screwdriver (preferred) or a blade screwdriver

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance. See the

Safety and Compliance Manual included with your system for more safety

precautions.

Caution: Static electricity can damage circuit boards.

• Use proper precautions when handling printed circuit boards.

– Store PC boards in anti-static containers.

– Wear a grounded wrist strap when handling PC boards.

Part number Description Quantity

075534* #6 x 5/16 Phillips pan head screw 4

141103 65A CSA Power board 1

Kit 228659 contents

Part number Description Quantity

075534* #6 x 5/16 Phillips pan head screw 4

141076 85A CSA Power board 1

Kit 228662 contents

Powermax65/85 Power board rePlacement

2Field Service Bulletin

Part number Description Quantity

075534* #6 x 5/16 Phillips pan head screw 4

141079 85A CE Power board 1

Kit 228672 contents

Part number Description Quantity

075534* #6 x 5/16 Phillips pan head screw 4

141106 65A CE Power board 1

Kit 228708 contents

* 075534 - screws included with kits as spares if needed.

Powermax65/85 Power board rePlacement

Field Service Bulletin 3

Remove the power supply cover, Mylar®barrier, and end panel bracket

1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.

2. Using a T15 TORX or blade screwdriver, remove the 8 small screws (2) from the power supply cover.

3. Using a T20 TORX or blade screwdriver, remove the 8 large screws (1) from the power supply cover.

4. Lift the cover (3) off the power supply.

1 1

5. Remove the Mylar barrier from the power-board side of the power supply. The Mylar barrier is flexible and can be

bent slightly for removal.

6. Remove the metal end panel bracket located on top of the center panel by pulling it straight up.

Powermax65/85 Power board rePlacement

4Field Service Bulletin

Remove the DSP board

1. Disconnect the DSP connector (1) from the top of the DSP board (3).

Note: This step is only required on systems that have an RS485 communication board installed.

Systems without an RS485 communication board installed will not have a connector plugged

into the top of the DSP board.

2. Use a #2 Phillips screwdriver to remove the 2 screws (2) from the DSP board.

Two rows of connector pins (4) are located on the back of the DSP board (3) as shown in the figures below. The

dashed rectangle identifies the location of the pins on the back of the board.

3. Carefully pull the DSP board (3) straight out from the power board (5). Do not bend the pins.

Note: Instructions for removing the DSP board are the same for both CE and CSA models. The power

board (5) shown below is a CSA model.

4. Disconnect the ribbon cable from the ribbon cable connector (6) on the back of the DSP board. Set the DSP board

aside.

If the power supply is a 380/400V CE model, continue to the next page.

If the power supply is a 200-600V CSA model, proceed to page 8.

DSP back viewDSP front view

Powermax65/85 Power board rePlacement

Field Service Bulletin 5

Replace the power board (380/400V CE)

Please refer to Figure 1 on the next page when performing the following procedure.

Remove the power board

1. Unplug the five wire connectors located at the J3, J4, J5, J6, and J7 headers on the heat sink side of the power

board.

2. Disconnect the two gate drive wire connectors (J18, J19) from the power board.

3. Remove the 3uF capacitor and the two transformer wires below it using a #3 Phillips screwdriver to remove the

three inverter IGBT screws and the screw at J30.

4. Disconnect the work lead wire using a #3 Phillips screwdriver to remove the screw at J27.

5. Disconnect the AC input wires and PFC inductor wires using a #2 Phillips screwdriver to remove the screws at J1,

J2, J13, J23, and J24.

6. Remove the four snubber resistor screws and four capacitor screws using a #2 Phillips screwdriver.

7. Disconnect the MOV subassembly from the board using a #2 Phillips screwdriver to remove the two input bridge

screws on the right.

8. Remove the remaining three input bridge screws.

9. Disconnect the output inductor wire by removing the upper left diode screw with a #2 Phillips screwdriver.

10. Remove the three remaining diode screws.

11. Disconnect the nozzle wire (black) using a #2 Phillips screwdriver to remove the pilot arc IGBT screw on the left.

12. Remove the remaining pilot arc IGBT screw.

13. Disconnect the electrode wire (red) using a #2 Phillips screwdriver to remove the screw at J29.

14. Remove the three heat sink mounting screws using a #2 Phillips screwdriver.

Note: It may be necessary to pull the top of the front panel slightly forward to remove the upper left heat

sink mounting screw from the board.

15. Remove the four board mounting screws using a #2 Phillips screwdriver.

16. Pull right hand edge of power board forward, while pushing the gate drive wires through the opening in the board,

until components on back side of board will clear the rear panel.

Note: There is silkscreen print above the opening in the board, denoting the color and orientation of the

gate drive wires, if they are accidently disconnected from the IGBT while removing the board.

17. Slide the board to the right until the wire connectors on the left edge of the board are accessible, approximately 2

inches (5.1 cm).

18. Unplug the wire connectors from the J15 and J20 power board connectors.

19. If the power supply has a CNC interface installed, unplug the wire connectors from the J21 and J33 power board

connectors.

20. Remove the power board from the power supply and set aside.

Powermax65/85 Power board rePlacement

6Field Service Bulletin

WORK

LEAD

J13

J18J19

J27

J30

J23

J24

TP13

J29

TP11

TP12

J7, J6, J5, J4, and J3

Gate drive

connectors

AC input wires

MOV sub-

assembly

Heat sink

mounting

screw

Heat sink

mounting

screw

Pilot arc IGBT

screws (2)

PFC inductor wires

Capacitor screws

Board

mounting

screw

Board

mounting

screw

Board

mounting

screw

Input bridge

screws (5)

Transformer wires

Output inductor wire

Electrode wire

Board

mounting

screw

Work lead

3uF Capacitor

Viewing holes

Snubber

resistor

screws (4)

Diode

screws (4)

Nozzle wire

Inverter

IGBT

screws (3)

Heat sink

mounting screw

(located behind

edge of front

panel)

Figure 1 – 380/400V CE Power Board

Front panel

Rear panel

Powermax65/85 Power board rePlacement

Field Service Bulletin 7

Install new power board

1. Position the left edge of power board on a slight angle toward the front end panel, so the previously removed wire

connectors will reach their intended locations.

2. If the power supply has a CNC interface installed, plug the respective wire connectors into the J21 and J33 power

board connectors.

3. Plug the respective wire connectors into the J3, J4, J5, J6, J7, J15 and J20 power board connectors.

4. Slide the power board into the mounting position while routing the gate drive wires through the opening in the

board.

Note: Make certain all power board connection wires (eleven wires with metal ring terminals) are

positioned in front of the power board.

5. Install the four board mounting screws using a #2 Phillips screwdriver to tighten to 10 in-lbs (11.5 kg cm).

6. Install the three heat sink mounting screws using a #2 Phillips screwdriver to tighten to 15 in-lbs (17.3 kg cm).

Note: It may be necessary to pull the top of the front panel slightly forward to install the upper left heat

sink mounting screw.

7. Connect the electrode wire (black) to J29 using a #2 Phillips screwdriver to tighten the screw to 20 in lbs

(23.0 kg cm).

8. Install the two pilot arc IGBT screws, securing the nozzle wire (red) to the board with the left screw. Use a

#2 Phillips screwdriver to tighten both screws to 20 in-lbs (23.0 kg cm).

Note: All screw mounting holes which secure a wire to the power board, except for J29, have a yellow

silkscreen outline on the board depicting the placement of the ring terminal.

9. Install the four diode screws, securing the output inductor wire to the board with the upper left screw. Use a

#2 Phillips screwdriver to tighten all four screws to 20 in-lbs (23.0 kg cm).

10. Install the five input bridge screws, securing the MOV sub assembly with the two screws on the right. Use a

#2 Phillips screwdriver to tighten all five screws to 20 in-lbs (23.0 kg cm).

11. Install the four snubber resistor screws using a #2 Phillips screwdriver to tighten to 15 in-lbs (17.3 kg cm).

12. Verify that the gray dot on each capacitor is visible through the two viewing holes. Start the four capacitor screws

by hand, then use a #2 Phillips screwdriver to tighten to 20 in-lbs (23.0 kg cm).

13. Connect the AC input wires and PFC inductor wires at J1, J2, J13, J23, and J24 using a #2 Phillips screwdriver.

Tighten all five screws to 20 in lbs (23.0 kg cm).

14. Connect the work lead at J27 and the shorter transformer wire at J30 using a #3 Phillips screwdriver to tighten the

screws to 30 in lbs (34.6 kg cm).

15. Secure the 3uF capacitor and the remaining transformer wire to the board using the three inverter IGBT screws.

Use a #3 Phillips screwdriver to tighten the screws to 30 in-lbs (34.6 kg cm).

16. Plug the gate drive wires into their respective power board connectors (J18, J19). Gently pull on each wire to

ensure that they are fully seated.

Proceed to page 12 for further instructions.

Powermax65/85 Power board rePlacement

8Field Service Bulletin

Replace the power board (200-600V CSA)

Please refer to Figure 2 on the next page when performing the following procedure.

Remove the power board

1. Unplug the five wire connectors located at the J1, J2, J3, J4, and J5 headers on the heatsink side of the power

board.

2. Disconnect the three gate drive wire connectors (J17, J18, and J19) from the power board.

3. Disconnect the PFC temperature sensor connector (J16) from the power board.

4. Remove the 3uF capacitor on the left and the longer transformer wire using a #3 Phillips screwdriver (Powermax85)

to remove the three inverter IGBT screws. Use a #2 Phillips screwdriver to remove the screws on the Powermax65.

5. Disconnect the remaining transformer wire using a #2 Phillips screwdriver to remove the screw at J29.

6. Disconnect the work lead wire using a #3 Phillips screwdriver to remove the screw at J26.

7. Remove the 3uF capacitor on the right and the two PFC inductor wires below it using a #3 Phillips screwdriver to

remove the three PFC IGBT screws and the screw securing the shorter PFC inductor wire.

8. Disconnect the snubber resistor wires using a #2 Phillips screwdriver to remove the screw at J13 and the two input

bridge screws.

9. Remove the six snubber resistor screws and four capacitor screws using a #2 Phillips screwdriver.

10. Disconnect the output inductor wire by removing the upper left diode screw with a #2 Phillips screwdriver.

11. Remove the three remaining diode screws.

12. Disconnect the nozzle wire (black) using a #2 Phillips screwdriver to remove the pilot arc IGBT screw on the left.

13. Remove the remaining pilot arc IGBT screw.

14. Disconnect the electrode wire (red) using a #2 Phillips screwdriver to remove the screw at J28.

15. Remove the three heat sink mounting screws using a #2 Phillips screwdriver.

Note: It may be necessary to pull the top of the front panel slightly forward to remove the upper left heat

sink mounting screw from the power board.

16. Remove the four board mounting screws using a #2 Phillips screwdriver.

17. Pull right hand edge of power board forward, while pushing the gate drive wires through the two openings in the

board, until components on back side of board will clear the rear panel.

Note: There is silkscreen print above the openings in the board, denoting the color and orientation of

the gate drive wires, if they are accidently disconnected from the IGBT while removing the board.

18. Slide the board to the right until the wire connectors on the left edge of the board are accessible, approximately 2

inches (5.1 cm).

19. Unplug the wire connectors from the J12 and J20 power board connectors.

20. If the power supply has a CNC interface installed, unplug the wire connectors from the J21 and J32 power board

connectors.

21. Remove the power board from the power supply and set aside.

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