Hypertherm Powermax45 XP Reference manual

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)
[e-mail] (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
[e-mail] (Main Office Email)
TechSupportAPA[email protected]
()
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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
W
-
+-
+
TP 18
R
TP 17
B
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
J6
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
W
-
+-
+
TP 18
R
TP 17
B
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)
J6
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
W
+-+-
TP18
B
TP16
R
~280 VDC
~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
W
+-+-
TP18
B
TP16
R
~280 VDC
~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