Hypertherm Powermax105 Service Manual - Manual (Page 245)

Power SuPPly ComPonent rePlaCement
powermax
105 Service Manual 9-47
Replace the PFC Igbt module
Complete the instructions below while referring to the applicable figure:
• 200-600 V CSA heat sink components on page 9-50
• 230-400 V CE, 380 V CCC/230-400 V CE heat sink components on page 9-51
1. Remove the four mounting screws from the PFC IGBT module.
2. Remove the PFC IGBT module from the heat sink.
3. Clean the area where the PFC IGBT module was mounted, using isopropyl alcohol to remove the old thermal
grease from the heat sink.
4. Apply a thin coat (3 mils, approximately the thickness of a sheet of paper) of thermal grease evenly to the PFC IGBT
module mounting surface.
5. Orient the PFC IGBT module correctly and mount it to the heat sink by gently tightening the four supplied screws.
6. Alternately step torque the four mounting screws to the proper torque value as shown in the applicable figure.
7. Connect the supplied cables to the PFC IGBT module terminals. Attach the black wire from one cable to the "G2"
terminal and the red wire to the "E2" terminal. Attach the black wire from the remaining cable to the "E1" terminal
and the red wire to the "G1" terminal.
6. Orient the inverter IGBT module correctly and mount it to the heat sink by gently tightening the four supplied
screws, using the longer screw to capture the ring terminal of the thermal sensor between the screw head and the
upper left mounting hole of the inverter IGBT module.
7. Alternately step torque the four mounting screws to the proper torque value as shown in the applicable figure.
8. Connect the supplied cables to the inverter IGBT module terminals. Attach the black wire from one cable to the "6"
terminal and the red wire to the "7" terminal. Attach the black wire from the remaining cable to the "5" terminal and
the red wire to the "4" terminal.