Hypertherm Powermax45 XP Referenzhandbuch

Field Service Bulletin

Bulletin de service sur le terrain

807990 – Revision 1 –September 2016

Révision 1 – Septembre 2016

Powermax45®

and Powermax45 XP

Snubber Resistor

Replacement Kit

Kit de remplacement de transistor

à effet de champ du Powermax45 et

Powermax45 XP

Hypertherm Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)

[email protected] (Main Office Email)

800-643-9878 Tel (Technical Service)

[email protected] (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)

877-371-2876 Fax (Return Materials Authorization)

[email protected] (RMA email)

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,

Colonia Olivar de los Padres

Delegación Álvaro Obregón

México, D.F. C.P. 01780

52 55 5681 8109 Tel

52 55 5683 2127 Fax

Soporte.T[email protected] (Technical Service Email)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5

63452 Hanau

Germany

00 800 33 24 97 37 Tel

00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (Technical Service)

[email protected] (Technical Service Email)

Hypertherm (Singapore) Pte Ltd.

82 Genting Lane

Media Centre

Annexe Block #A01-01

Singapore 349567, Republic of Singapore

65 6841 2489 Tel

65 6841 2490 Fax

[email protected] (Marketing Email)

TechSupportAPA[email protected] (Technical Service Email)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building

2-1-1 Edobori, Nishi-ku

Osaka 550-0002 Japan

81 6 6225 1183 Tel

81 6 6225 1184 Fax

HT[email protected] (Main Office Email)

TechSupportAPA[email protected] (Technical Service Email)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE

Roosendaal, Nederland

31 165 596907 Tel

31 165 596901 Fax

31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (Technical Service)

[email protected]

(Technical Service Email)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road

Shanghai, 200231

PR China

86-21-80231122 Tel

86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

[email protected]

(Technical Service Email)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia

Guarulhos, SP – Brasil

CEP 07115-030

55 11 2409 2636 Tel

[email protected] (Technical Service Email)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.

Korea 48060

82 (0)51 747 0358 Tel

82 (0)51 701 0358 Fax

[email protected] (Marketing Email)

TechSupportAPA[email protected]

(Technical Service Email)

Hypertherm Pty Limited

GPO Box 4836

Sydney NSW 2001, Australia

61 (0) 437 606 995 Tel

61 7 3219 9010 Fax

[email protected] (Main Office Email)

TechSupportAPA[email protected]

(Technical Service Email)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,

Mohan Co-Operative Industrial Estate,

Mathura Road, New Delhi 110044, India

91-11-40521201/ 2/ 3 Tel

91-11 40521204 Fax

HTIndia.info@hypertherm.com (Main Office Email)

TechSupportAPA[email protected]

()

Powermax and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries. All other trademarks

are the property of their respective holders.

Powermax45/45 XP Field Service Bulletin 807990 1

Powermax45/45 XP Snubber Resistor Replacement Kit

Introduction

Purpose

Powermax45 systems: This Field Service Bulletin (FSB) describes the procedure for replacing the snubber resistors

on a Powermax45.

Powermax45 XP systems: Complete instructions for installing this repair kit are included in the Powermax45 XP

(809230) Service Manual. To download the Service Manual, go to www.hypertherm.com and click the “Documents

library” link.

Tools and materials needed

Assorted Phillips®and TORX®screwdrivers

428065 Kit contents

* 075526 – screws included with kits as spares if needed.

DANGER!

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance. See the

Safety and Compliance Manual for more safety precautions.

Part number Description Quantity

075526* M4 X 10 pan head screw 4

109670 10Ω 120W resistor 2

128836 1/8 ounce container of thermal grease 1

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.

2Powermax45/45 XP Field Service Bulletin 807990

Powermax45/45 XP Snubber Resistor Replacement Kit

Remove the power supply cover and component barrier

1. Turn OFF the power, disconnect the power

cord, and disconnect the gas supply.

2. Remove the 2 screws from the handle on the

top of the power supply, as shown in Figure 1.

Gently pull on the end panel nearest the screw

you are removing to keep pressure on the

screw. When the screw is almost out, tilt the

screwdriver slightly to help pull the screw out

of the recessed hole.

3. Tip the end panels back slightly so that you

can get the edges of the handle out from

underneath them. Set the handle and screws

aside. Continue to tilt the end panels outward

to release the fan side of the cover from its

track. Then lift the cover off the power supply.

4. Remove the component barrier from the

power-board side of the power supply. The

component barrier is flexible and can be bent

slightly for removal.

If your power supply is a 200–240 V CSA or a

230 V CE model, continue with the following

procedure.

If your power supply is a 400 V CE or a 480 V CSA model, proceed to page 5 for further instructions.

Remove the power board (200–240 V CSA and 230 V CE)

The following procedure applies to 200–240 V CSA and 230 V CE power boards. Please refer to Figure 2 on page 3

and Figure 3 on page 4 when performing this procedure.

1. Detach the ribbon cable from J7 on the heat sink side of the power board.

2. Remove the connectors at J10, J12, and J22 on the heat sink side of the power board.

3. Remove the connectors at J3, J4, and J5 on the heat sink side of the power board.

4. Remove the connector for the red and black wires from the power switch at J6 from the heat sink side of the power

board. J6 is located about an inch down from the top edge of the board.

5. Remove the wires for the transformers and inductors at J13, J14, J15, J16, J17, J18, J19, and J20.

6. Remove the work lead ring terminal from J21 and the 4 capacitor screws.

7. Remove the 3 retaining screws, the 4 heat sink assembly screws, and the 4 snubber resistor screws.

8. If you have an older 200–240 V CSA or 230 V CE power board that has 2 input bridge diodes (and without the

small slot below the heat sink assembly screw hole), remove the 3 screws that attach the IGBTs and the 2 screws

that attach the input bridge diodes to the heat sink. There are holes in the power board to provide access to them.

If you have a newer 200–240 V CSA or 230 V CE power board that has a single input bridge diode (and has a

small slot below the heat sink assembly screw hole), remove the 3 screws that attach the IGBTs and the screw that

attaches the input bridge diode to the heat sink. There are holes in the power board to provide access to them.

Figure 1 – Removing the screws from the handle

Powermax45/45 XP Field Service Bulletin 807990 3

Powermax45/45 XP Snubber Resistor Replacement Kit

9. Remove the screw at J1 that secures the white wire and the screw at J2 that secures the black wire from the

ON/OFF switch to the power board.

10. Stand up the unit again. Tuck out of the way all the wires that you detached.

11. Pull the board straight out from the power supply and set aside.

Proceed to page 7 for further instructions.

Figure 2 – Newer 200–240 V CSA and 230 V CE power board

TP 19

TP 18

TP 17

192 VDC 192 VDC

Heat sink assembly

screw

Ribbon cable (J7)

J10, J12

J13

J14

J16

J17

J19

J22

Heat sink

assembly screw

J3, J4, J5

Retaining screw IGBT attachment

screws (3)

ON/OFF

switch wires

Retaining screw

Heat sink assembly

screw

Newer boards have a

slot here

J18

Heat sink assembly

screw

Input bridge diode

screw

J2 J1

J15

J20

Retaining

screw

Work lead

connector (J21)

Snubber resistor screws (4)

Pressure relief

vents Capacitor

screws (4)

4Powermax45/45 XP Field Service Bulletin 807990

Powermax45/45 XP Snubber Resistor Replacement Kit

Figure 3 – Older 200–240 V CSA and 230 V CE power board

TP 19

TP 18

TP 17

192 VDC 192 VDC

Heat sink assembly

screw

Ribbon cable (J7)

J10, J12

J13

J14

J16

J17

J19

J22

Heat sink

assembly screw

J3, J4, J5

Retaining screw IGBT attachment

screws (3)

ON/OFF

switch wires

Retaining screw

Heat sink assembly

screw

J18

Heat sink assembly

screw

Input bridge diode

screws (2)

J2 J1

J15

J20

Retaining

screw

Work lead

connector (J21)

Snubber resistor screws (4)

Pressure

relief vents Capacitor

screws (4)

Powermax45/45 XP Field Service Bulletin 807990 5

Powermax45/45 XP Snubber Resistor Replacement Kit

Remove the power board (400 V CE and 480 V CSA)

The following procedure applies to 400 V CE and 480 V CSA power boards. Please refer to Figure 4 on page 5 and

Figure 5 on page 6 when performing this procedure.

1. Detach the ribbon cable from J8 on the heat sink side of the power board.

2. Remove the connectors at J10, J12, and J22 on the heat sink side of the power board.

3. Remove the connectors at J4, J5, and J6 on the heat sink side of the power board.

4. Remove the wires for the transformers and inductors at J13, J14, J15, J16, J17, J18, J19, and J20.

5. Remove the work lead ring terminal from J21 and the 4 capacitor screws.

6. Remove the 3 retaining screws, the 4 snubber resistor screws, and the 4 heat sink assembly screws.

Figure 4 – Newer 400 V CE and 480 V CSA power board

TP17

+-+-

TP18

TP16

~280 VDC

Heat sink assembly

screw

Ribbon cable (J8)

J10, J12

J13

J14

J15

J16

J18

J22

Heat sink

assembly screw

J4, J5, J6

Retaining screw IGBT attachment

screws (2)

ON/OFF

switch wires

Retaining screw

Heat sink assembly

screw

Newer boards have a

slot here

J17

Heat sink assembly

screw

Input bridge diode

screw

J3 J2 J1

J19

J20

Retaining

screw

Work lead

connector (J21) Snubber resistor screws (4)

Pressure relief

vents Capacitor

screws (4)

Ferrite

(CE units only)

6Powermax45/45 XP Field Service Bulletin 807990

Powermax45/45 XP Snubber Resistor Replacement Kit

Figure 5 – Older 400 V CE power board

7. If you have an older 400 V CE power board that has 2 input bridge diodes (and without the small slot below the

heat sink assembly screw hole), remove the 2 screws that attach the IGBTs and the 2 screws that attach the input

bridge diodes to the heat sink. There are holes in the power board to provide access to them.

If you have a newer 400 V CE or 480 V CSA power board that has a single input bridge diode (and has a small slot

below the heat sink assembly screw hole), remove the 2 screws that attach the IGBTs and the screw that attaches

the input bridge diode to the heat sink. There are holes in the power board to provide access to them.

8. Remove the screws at J1, J2, and J3 that secure the 3 white wires from the bottom of the ON/OFF switch to the

power board.

9. Stand up the unit again. Tuck out of the way all the wires that you detached.

10. Pull the board straight out from the power supply and set aside.

Continue with the procedure on the next page.

TP17

+-+-

TP18

TP16

~280 VDC

Heat sink assembly

screw

Ribbon cable (J8)

J10, J12

J13

J14

J15

J16

J18

J22

Heat sink

assembly screw

J4, J5, J6

Retaining screw IGBT attachment

screws (2)

ON/OFF

switch wires

Retaining screw

Heat sink assembly

screw

J17

Heat sink assembly

screw

Input bridge diode

screw

J3 J2 J1

J19

J20

Retaining

screw

Work lead

connector (J21) Snubber resistor screws (4)

Pressure relief

vents Capacitor

screws (4)

Ferrite

Powermax45/45 XP Field Service Bulletin 807990 7

Powermax45/45 XP Snubber Resistor Replacement Kit

Replace the snubber resistors

Refer to Figure 6 on page 8 when performing the following procedure.

1. Remove both snubber resistors from the heat sink. Each resistor has 2 mounting screws. Discard both of the

snubber resistors.

2. Clean the area on the heat sink where the snubber resistors were mounted. Use isopropyl alcohol to remove the old

thermal grease.

3. Evenly apply a thin coat of thermal grease (3 mm, approximately the thickness of a sheet of paper) to the new

snubber resistor mounting surface. Use the thermal grease included in the kit (128836).

4. Attach the 2 new snubber resistors (109670) to the heat sink using the mounting screws supplied in the kit

(075526). Orient each resistor properly, as shown in Figure 6. Tighten all screws to 23.0 kg cm (20 inch-pounds).

5. Clean the heat sink with isopropyl alcohol. Gently scrub away any excess grease, being careful not to scratch the

heat sink. Wipe it with a clean cloth.

If your power supply is a 200–240 V CSA or a 230 V CE model, proceed to page 9 for further instructions.

If your power supply is a 400 V CE or a 480 V CSA model, proceed to page 10 for further instructions.

8Powermax45/45 XP Field Service Bulletin 807990

Powermax45/45 XP Snubber Resistor Replacement Kit

Figure 6 – Powermax45 snubber resistors

Snubber resistor – 10Ω

(Kit 428065)

Mounting screws*

* Torque all snubber resistor mounting screws to 23.0 kg cm (20 inch-pounds).

Heat sink

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