Install the power PCB

Refer to this image as you do the steps in this procedure.

Figure 1. Component connections on the power PCB
The image shows the interior of the plasma power supply with callouts.
1 Power switch connections (J1 and J2 for 1-phase; J1, J2, and J4 for 3-phase) 8 Power transformer primary – red
2 Dual red nozzle wires from torch receptacle (J15) 9 Power Factor Correction (PFC) inductor – red (J5)
3 White electrode wire from torch socket (J18) 10 PFC inductor – black (J4 for 1-phase; J26 for 3-phase)
4 Power transformer secondary – black (J14) 11 Output inductor – yellow (J13)
5 Power transformer secondary – red (J12) 12 Work lead wire (J23)
6 Power transformer primary – black (J6) 13 PFC inductor
7 Power switch connections (J1 and J2 for 1-phase; J1, J2, and J4 for 3-phase) 14 Power transformer
  1. Make sure that you have the correct power Printed Circuit Board (PCB) for your system.
    • The replacement kit number for a 200 V – 240 V CSA/CE/CCC system is 528140.
    • The replacement kit number for a 400 V CE/CCC system is 528141.
    • The replacement kit number for a 480 V CSA system is 528142.
  2. Use isopropyl alcohol to remove the old thermal grease from the heatsink.
  3. Evenly apply a 0.0762 mm (0.003 inch) layer of thermal grease, about the thickness of a sheet of paper, on the Insulated-gate Bipolar Transistor (IGBT)s and on the rectifier.
    Note:

    There are 3 IGBT components and 1 rectifier component for 1-phase models. There are 2 IGBT components and 1 rectifier component for 3-phase models.

  4. 1-phase models: Plug the 2-wire connector from the power switch assembly into J10 on the power PCB.
    Note:

    The J10 connection is for the trip coil on the power switch. There is no trip coil on 3-phase models.

    Figure 2. J10 connector on the 1-phase power PCB
  5. Move the wires away from where you will install the power PCB.
  6. Put the power PCB into position inside the plasma power supply.
    Note:

    Make sure that the white polarity dot on each capacitor aligns with the viewing hole on the power PCB.

    The image shows the power board with the dots aligned.
  7. Reconnect the screws and wires.
    Note:

    Loosely tighten all the screws with your fingers before fully tightening any of them.

  8. Slowly tighten to 2.3 N∙m (20 lbf·in) the IGBT screws and the rectifier screw in the sequence shown here.
    Figure 3. 1-phase power PCB sequence for tightening the screws
    Figure 4. 3-phase power PCB sequence for tightening the screws
  9. Tighten the 4 snubber resistor screws and the 4 machine screws to 1.7 N∙m (15 lbf·in).

    Start with the top left and bottom right machine screws.

  10. Tighten the 4 capacitor screws to 2.3 N∙m (20 lbf·in).
  11. Tighten the 3 self-tapping standoff screws.
  12. Tighten the screw-secured wires to 2.3 N∙m (20 lbf·in).
  13. Make the following connections to the power PCB.
    Component Connector on power PCB Connector type
    Solenoid valve assembly J8 8-pin
    Fan J7 4-pin
    RS-485 serial interface J11 5-pin
    Machine interface port J21 4-pin
    Voltage divider PCB J17 2-pin
    Torch receptacle J19 10-pin
    Display PCB J3 Ribbon cable
    Figure 5. More component connections on the power PCB
    The image shows the plasma power board with connection callouts.
  14. Complete the following procedures:
    1. Install the component barrier.
    2. Install the plasma power supply cover and handle.
    3. Reconnect the gas supply.
    4. Reconnect the power cord.