Nova Series LPSU Replacement

Nova Series LPSU Replacement

Preface: This article will cover Laser Power Supply replacement on Thunder Laser Nova series machines.


At some point you will have to replace your high-voltage laser power supply. We employ the highest quality components but even they have a finite lifespan. 


This is a pretty quick and painless procedure if you have a clear picture of what needs to take place and in what order. 


If you run into any trouble email support@thunderlaserusa.com and we will get you squared away.


Always power off and unplug the main power to the equipment before working on it. Take before pictures, make alignment/indexing marks, etc... at adjoining parts, etc... so you get everything back the same way.


Here is how the LPSU gets its main input voltage (110VAC@60Hz): Nova Series v8 AC Power Overview and Diagnostics


The LPSU outputs somewhere around 30,000 VDC and can store a charge so always heed the big red wires and connectors. They are specially insulated but could still pose a hazard. The HV output does utilize a fly back transformer.


Always refer to the Nova Series Users Manual


Take some clear pictures of everything before you begin so you can refer to them later if necessary.


There are 2 green Euroblocks (terminals) that come installed from the manufacturer can be removed from the New LPSU and set aside (can use if your existing LPSU has damaged Euroblocks).




1. There is a 3 pin connector that delivers 110VAC to the LPSU from the Laser Power Switch on the side of the machine. Remove the 3 pin connection from the LPSU. 



2. There is a 6 pin low-voltage DC connector that may or may not have a circuit board inline. Remove the 6 pin connector (or board) from the LPSU. 



3. There is a high-voltage connector that allows the separation of the LPSU pigtail from the tube pigtail. Unscrew the barrel connector in the middle and gently pull apart. Release the pigtail going to the LPSU from all cable management, fixtures, entanglements, etc... 



4. There are 4 small screws with flat washers securing the LPSU to the frame. These can fall even with a good magnetic screwdriver that has just been magnetized so tape a piece of paper under the area, or make some other provisions, to collect anything that drops (or at least so it doesn't fall into a terminal strip and short it down). You can now remove the LPSU from the machine.



5. Check the wiring harness screw terminations on the green Euroblock connectors and verify that they are properly seated, snug, etc... and exhibit no signs of heat, arcing, fraying, etc...

Now you can install the new LPSU and reconnect the Euroblocks.



Be sure to mark the bad power supply and be prepared to return to Thunder Laser upon request if it was a warranty replacement.



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