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 1 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. Field Service Bulletin 1 0 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. 2 1 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. Field Service Bulletin 3 2 © Copyright 2005 Hypertherm, Inc. 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