Page 1
D
2
T
W
S
Manual 0-2555
82 Benning Street, West Lebanon, NH 03784 USA
(603) 298-5711 • www.thermal-dynamics.com
General Information
NOTE
The installation of this replacement kit should only
be performed by a qualified electronic technician.
This Kit replaces the Driver PC Board, Shunt Amp PC Board,
Switching T ransistor/IGBT Assembly, and IGBT wire harness in the Merlin Series Power Supplies. The kit includes
an IGBT Suppressor PC Board.
W ARNING
If any of the parts listed above have failed, all must
be replaced at the same time with parts provided in
this kit. Failure to replace all parts together may
lead to parts failure.
Merlin Power Driver PC
Board Replacement Kit
Catalog # 7-3360
Installation Instructions
The kit also includes:
• Installation Instructions
• Static Dissipative Bag
• Grounding W rist Strap
• Static Handling Instructions
Installation Procedure
W ARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
A. Opening Enclosure
Kit Contents
Rear of Front Panel
river PC Board
IGBT Suppressor
PC Board
IGBT
hermal Pad
hunt Amp PC Board
ire Harness
1. Turn OFF main input power to the Power Supply both at the
Power Supply ON/OFF switch and at the main power disconnect.
2. W ait at least two minutes to allow the input capacitors
to discharge.
3. Remove the top and side panels of the Power Supply.
T o remove the top panel of the Power Supply r equires
the removal of several screws. Carefully remove all the
screws before attempting to remove the panels.
August 19, 2005 1 Manual 0-2555
Art # A-0608
Page 2
B. Driver PC Board Assembly Installation
rd
R
U
rd
ls
Style With 3 T erminals
Art # A-06055
C. IGBT (Q1) Installation
1. Locate the old Driver PC Board Assembly on the inside
left side, behind the front panel, as viewed from the
front of the unit.
ear of Front Panel
A-01083
Driver PC Boa
Driver PC Board Location
2. Note and label the two wiring connectors that connect
to the Driver PC Board.
3. Disconnect the two wiring connectors from the Driver
PC Board.
4. Press in the securing tab knob on the PC Board Guide
to release the PC Board from the PC Board Guides.
There is a securing tab on both the upper and lower PC
Board Guides.
1. Locate the old Switching Transistor/IGBT Assembly
on the inside center-left, between the four large blue
capacitors, as viewed from the front of the unit.
Transistor/Coil
Switching T r ansistor
Q1
Large Blue
Capacitors
Bracket
A-01085
2. There are two differ ent types of Switching T ransistor/
IGBT. The types can be identified by the top of the
transistor casing. This kit replaces both types.
Style With 2 T ermina
pper PC Board Guide
5. Carefully pull the PC Board from the guides and remove from the unit.
6. Install the replacement Driver PC Board Assembly reversing the above steps.
Securing T ab
Lower PC Boa
Securing T ab
PC Board Guide Securing Tab
Driver PC
Board
Guide
A-01084
Switching Transistor/IGBT Styles
3. Remove the two screws securing the wires to the Switching Transistor/IGBT Assembly terminals. Remove
and discard the wire harness.
4. Remove the screw that secures the Capacitor Mounting Bracket to the Switching T ransistor/IGBT Assembly.
5. Remove the screw that secures the Transistor/Coil
Bracket to the Switching T ransistor/IGBT Assembly.
6. Remove the screw and washer securing the PTC Resistor Assembly to the Main Heatsink. Move the PTC
Resistor Assembly out of the way to prevent it from
becoming damaged.
August 19, 2005 2 Manual 0-2555
Page 3
or
A
6. Connect Harness.
D. Shunt Amp PCB Replacement
PTC Resist
Assembly
Q1
rt # A-01089
Main Heatsink
PTC Resistor Assembly Location
7. Remove the four screws securing the Switching T ransistor/IGBT module to the Main Heatsink. Be careful
not to damage the surface of the heatsink.
8. Pry between the Main Heatsink and the faulty Switching T ransistor/IGBT Assembly until it slides easily.
9. Remove the faulty Switching T ransistor/IGBT Assembly from the unit by sliding it towards the center of the
Main Heatsink.
10. If the transistor thermal pad was not removed with the
transistor, r emove it now .
1. Locate the Shunt Amp PCB, mounted to the Shunt on the
main heatsink.
2. Use the grounding wrist strap provided separately in
this kit. Follow all static handing instructions on the
separate instruction sheet.
3. Open two locking tabs securing the ribbon cable connector to the Shunt Amp PCB. Carefully remove the
cable connector from the Shunt Amp PCB.
4. Loosen, but do not remove, the bolt securing the Shunt
to the main heatsink, to allow access to screws securing the Shunt Amp PCB to the Shunt.
Rear of Power Supply
Shunt
Main Heatsink
Shunt
Amp PCB
Ribbon
Cable
11. Use isoproply alcohol to clean the residue of the old transistor thermal pad from the transistor mounting area.
12. Install the replacement Thermal pad, the IGBT Assembly , IGBT Suppr essor PC Board, and the replacement
wire harness included in this kit in the sequence
shown. Note the torque requirements. Connect the
other end of the harness to the terminal from which the
previous harness was disconnected, on the driver PC
board.
5. Install IGBT
Suppressor
PC Board.
Torque hardware
to 14 in-lbs.
(1.6 N-m).
4. Torque IGBT
hardware (only)
to 26 in-lbs.
(2.9 N-m).
3. Remove
copper tape.
1
3
1
Art # A-03839
Shunt Amp PCB Disconnection
2
2. Install IGBT.
1. Install Thermal Pad.
IGBT Installation Sequence
Art # A-06083
August 19, 2005 3 Manual 0-2555
Page 4
5. Loosen, but do not remove, the screws securing the
R
Shunt Amp PCB to the Shunt.
6. Refer to the illustration. Remove the Shunt Amp PCB
from the power supply . Lift the end of the PCB closer to
the rear of the Power Supply, and slide the PCB rearward to release it fr om the forward screw.
ear of Power Supply
3
8. Position the replacement Shunt Amp PCB on the Shunt.
Secure with the hardware loosened pr eviously . T ighten
securely . Do not overtighten.
9. Fasten the Shunt to the main heatsink by tightening
the bolt loosened previously . T ighten securely. Do not
overtighten.
10. Align the ribbon cable connector with the receptacle
on the Shunt Amp PCB. Press the connector fully into
the receptacle. Close the two locking tabs on the receptacle. Check for a secure connection.
11. Reinstall the power supply outer panels.
2
1
Art # A-03850
Shunt Amp PCB Removal
7. If necessary , carefully clean the PCB mounting surfaces
on the shunt. Wipe the surfaces clean with a lint-fr ee
rag.
CAUTION
Do not use conductive material such as steel
wool to clean the mounting surfaces.
This completes the installation of the Replacement Kit.
NOTE
Every effort has been made to provide complete
and accurate information in this manual. However , the publisher does not assume and hereby
disclaims any liability to any party for any loss
or damage caused by errors or omissions in
this Manual, whether such errors result from
negligence, accident, or any other cause.
August 19, 2005 4 Manual 0-2555
Loading...