Hypertherm Powermax65 Service Manual Rev.1 - Manual (Page 206)

Component ReplaCement
6-24
powermax
65/85 Service Manual
Install the new power board (200 – 600V CSA)
1. Position the left edge of the power board on a slight angle toward the front end panel, so the previously removed
wire connectors will reach their intended locations.
2. If a CNC interface is installed on the power supply, plug the respective wire connectors into the J21 and J32 power
board connectors.
3. Plug the respective wire connectors into the J1, J2, J3, J4, J5, J12, and J20 power board connectors.
4. Slide the power board into the mounting position while routing the gate drive wires through the two openings in the
board.
Note: Make certain all power board connection wires (10 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 (red) to J28 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 (black) 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 J28, 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 six snubber resistor screws using a #2 Phillips screwdriver to tighten to 15 in-lbs (17.3 kg cm).
11. 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).
12. Connect the top snubber resistor wire to J13 using a #2 Phillips screwdriver to tighten the screw to 20 in-lbs
(23.0 kg cm).
13. Install the two input bridge screws, securing the remaining snubber resistor wire with the upper input bridge screw.
Tighten both screws to 20 in-lbs (23.0 kg cm).
14. Connect the work lead at J26 using a #3 Phillips screwdriver to tighten the screws to 30 in-lbs (34.6 kg cm).