Diagnosing and Fixing a Nova Series machine that was powered by 220v instead of 110v AC

Preface: This article covers how to tell if your machine was plugged into 220v (or experienced a power surge) and which components typically fail

Signs and Symptoms:

      Two most obvious symptoms are that the machine will power up (lights on, controller on) but the Laser Head will not jog around and the bed will not raise of lower. This is symptomatic that the 36V power supply has failed. The second symptom for the 36V power supply failure is that there may be smoke and sparks at the initial startup and then a pool of Capacitor Fluid in the control panel below the 36V power supply.

      If you got lucky and did not turn on the 2nd switch marked LASER on the side of the machine, then the main contactor and LPSU will likely be safe. If the switch was on, then the main contactor coil likely fried and the LPSU is likely fried too. Check for burnt electrical smells near by.

How to Check for Incoming Power Voltage:

Use a multimeter to check at the outlet. You should have ~120v Line to Neutral and ~120V Line to Ground. Any reading over 135V and you should not plug in the machine and contact support@thunderlaserusa.com for more information.

How to Check for Failed Components:

36V Power Supply

Green Light will be off and possibly a pool of Capacitor Oil below the power supply

Main Contactor

May not pull in and may chatter when trying to pull in even after restoring 120v power to the machine.

LPSU

Dead, no lights, fan or screen. Depending on your model, the LPSU will look different and the location will vary. Nova 24's do not have a screen, so only will be able to see if there are LEDS or the internal fan on. If you attempt to do the red button test after restoring 120v power to the machine, it will likely not fire.

Replacements Parts:

Be sure to confirm your parts match the part that you are replacing before swapping.

36V Driver Power Supply

Main Contactor

Laser Power Supplies

Warranty Considerations:

      Technically, anything that the 220v power touches directly is no longer under warranty if the component is not rated for 220v. LPSU, Main Contactor, Chiller, 36V Driver power supply. If you source replacements from the Thunder Laser USA Ecom site, then the parts would carry the warranty from that purchase.

Reference Articles:

How To Use A Multimeter

Nova Series LPSU Replacement

Main Contactor Function Check & Removal

NOVA series How To replace the 36VDC Driver Power Supply

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