Hypertherm Powermax 65, Service Manual

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Component ReplaCement
powermax
65/85 Service Manual 6-19
Replace the power board (380/400V CE)
Refer to the figure on the next page when performing the following procedure.
Remove the old power board (380/400V CE)
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 the right-hand edge of the power board forward, while pushing the gate drive wires through the opening in the
board, until the components on the back side of the board clear the rear panel.
Note: Silkscreen printing above the opening in the board denotes the color and order of the gate drive wires.
The printing is “BLK” (black), “RED” (red), “BLK” (black), “RED” (red) from left to right.
17. Slide the board to the right until the wire connectors on the left edge of the board are accessible, approximately
2inches (5.1 cm).
18. Unplug the wire connectors from the J15 and J20 power board connectors.
19. If a CNC interface is installed on the power supply, unplug the wire connectors from the J21 and J33 power board
connectors.
20. Remove the power board from the power supply and set aside.