Hypertherm powermax65 Manual de referencia
Powermax65®
Powermax85®
Power Board Replacement
Remplacement du circuit imprimé
Field Service Bulletin
Bulletin de service sur le terrain
806780 – Revision1 – December, 2012
Révision1–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 1
2
2
1
2
2
1
3
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.
1
4
6
2
3
3
3
5
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
J2
J1
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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