IGBT Tester
Field Service Bulletin
804810 – Revision 2 – April, 2005
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel 603-643-5352 Fax
www.hypertherm.com
IGBT TESTER
Contents of package
Kit 128883
Part Number
Description
128884
804810
IGBT Tester
Field Service Bulletin
Qty
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1
Controls and indicators
Circuit Diagram
Pass LED (Green)
Fail LED (Red)
Low Battery LED (Red)
Test for
Shorted IGBT
Test for
Open IGBT
Rocker Switch
Collector (Red)
Gate (Yellow)
128884
Emitter (Black)
Prepare IGBTs for test
The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply
theory. In addition to being technically qualified, technicians must perform all testing with safety in mind. See
Section 1 in the manual for your power supply for more safety precautions before proceeding.
WARNING
ELECTRIC SHOCK CAN KILL
• Use extreme caution when working near live electrical circuits. Dangerous voltages exist
inside the power supply that can cause serious injury or death.
• Turn off the power and remove the input plug from its receptacle before removing the
cover from the power supply.
• See warnings in the manual of the unit under test before proceeding.
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IGBT TESTER
Connect leads
Connect the colored leads to the IGBT as shown below.
Before the IGBT can be tested it must be electrically isolated from all circuits. If the IGBT is installed in a power
supply the power board and any lead connections must be removed before testing. Failure to do so may result in
false readings and/or damage to the IGBT tester.
CAUTION: Failure to ensure that IGBT is isolated may result in
false readings and/or damage to the IGBT Tester.
The IGBTs in Hypertherm power supplies may have one or two devices contained within the same housing. The
illustration below depicts two common configurations of an IGBT. Each connection on the IGBT will be labeled with
an abbreviation. They may be labeled as C, E, G or 1, 2, 3 with a schematic depicting numbers and pin functions.
Single Device IGBT
Two Device IGBT
Device 1
Device 2
Gate (G)
Gate 2 (G2)
Gate 1 (G1)
Collector 1 (C1)
Emitter (E)
Emitter 2 (E2)
Collector (C)
Collector 2 (C2)
Emitter 1 (E1)
Note: Each device should be tested seperately.
Indicator LEDs and device tests
Red fail LED
When illuminated during test this indicates that the IGBT failed the test, for either an open IGBT when
switch is pressed to the right or a shorted IGBT when switch is pressed to the left.
Green pass LED
When illuminated during test this indicates that the IGBT passed the test, for either an open IGBT when
switch is pressed to the right or a shorted IGBT when switch is pressed to the left.
Red low battery LED
When illuminated during test this indicates that the remaining voltage in the battery is insufficient to
power the test circuitry. Replace battery immediately.
NOTE: The IGBT Tester requires a minimum of 8V to properly power its circuitry.
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Field Service Bulletin
IGBT TESTER
Perform IGBT device test
Press and hold the switch in the desired direction to perform test.
Switch
Position
Fail
LED
Pass
Battery
This May Mean
Corrective Action
Left
X
–
–
IGBT is shorted
Replace IGBT
Left
–
X
–
IGBT passed short test
None
Left
–
–
X
Battery below 8V
Replace battery
Left
–
–
–
Dead battery
Replace battery
Right
X
–
–
IGBT is open
Replace IGBT
Right
–
X
–
IGBT passed open test
None
Right
–
–
X
Battery below 8V
Replace battery
Right
–
–
–
Dead battery
Replace battery
Note: The IGBT is considered to be good only if it passes both the open and short device tests.
Troubleshooting
1. Visually inspect leads and IGBT Tester for damage.
2. Verify that the battery voltage is greater than 8V.
3. Perform a self test on the IGBT Tester as shown below. If the results do not match the table replace the
lead connections.
Connect leads
Short Test
Open Test
None
Red to Black
Pass
Fail
Fail
Pass
Technical questions
If you are unable to fix the problem by following this basic troubleshooting guide or if you need further assistance
call Hypertherm Technical Service at (800) 643-9878.
Warranty
Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm
is notified of a defect within a period of six (6) months from its date of delivery to you. This warranty shall not apply
to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole
option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall
be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to
Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all
costs, insurance and freight prepaid. Hypertherm shall not be liable for any repairs, replacement, or adjustments of
Products covered by this warranty, except those made pursuant to this paragraph or with Hypertherm’s prior written
consent. The warranty above is exclusive and is in lieu of all other warranties, express, implied, statutory,
or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all
implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or
against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by
Hypertherm of its warranty. Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs
are not authorized to give any additional warranty protection to you or make any representation to you purporting to
be binding upon Hypertherm.
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© Copyright 2005 Hypertherm, Inc.
All Rights Reserved
Hypertherm and Powermax are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries.
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