Firepower FP-82 User Manual

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Plasma Cutting

Power Supply

Firepower FP-82

A-02990

Service Manual

December 4, 2002 Manual No. 0-2871

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply Firepower FP-82 Service Manual Number 0-2871

www.firepoweronline.com

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: December 4, 2002

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and Warnings..................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

1.06 Documents De Reference............................................................................ 1-5

1.07 Declaration of Conformity............................................................................. 1-7

1.08 Statement of W arranty.................................................................................. 1-8

SECTION 2:

INTRODUCTION .............................................................................................................. 2-1

2.01 Scope Of Manual ......................................................................................... 2-1

2.02 General Service Philosophy ......................................................................... 2-1

2.03 Service Responsibilities ............................................................................... 2-1

SECTION 3:

DESCRIPTION ................................................................................................................. 3-1

3.01 Scope........................................................................................................... 3-1

3.02 General Description ..................................................................................... 3-1

3.03 Specifications/Design Features.................................................................... 3-1

3.04 P ow er Supply Options and Accessories....................................................... 3-2

SECTION 4:

SERVICE TR OUBLESHOOTING DIAGNOSTICS ............................................................ 4-1

4.01 Introduction .................................................................................................. 4-1

4.02 P eriodic Inspection & Cleaning Procedures.................................................. 4-1

4.03 System Theory ............................................................................................. 4-1

4.04 Common Operating Problems...................................................................... 4-2

4.05 Troubleshooting Guide - General Information ............................................... 4-3

4.06 Circuit Fault Isolation .................................................................................... 4-4

4.07 Main Input and Internal Po wer Prob lems...................................................... 4-5

4.08 Pilot Arc Problems........................................................................................ 4-8

4.09 Main Arc Problems..................................................................................... 4-10

4.10 Test Procedures ......................................................................................... 4-10

SECTION 5:

REPAIRS & REPLACEMENT PROCEDURES.................................................................. 5-1

5.01 Scope........................................................................................................... 5-1

5.02 Anti-Static Handling Procedures................................................................... 5-1

5.03 Parts Replacement - General Inf ormation .................................................... 5-1

5.04 Major External Parts Replacement............................................................... 5-2

5.05 Front Panel Parts Replacement.................................................................... 5-3

5.06 Left Side Internal Component Parts Replacement........................................ 5-4

5.07 Rear Panel P arts Replacement .................................................................... 5-6

5.08 Right Side Internal Component Parts Replacement ..................................... 5-9

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

6.01 Introduction .................................................................................................. 6-1

6.02 Ordering Information .................................................................................... 6-1

6.03 Major External Replacement Parts............................................................... 6-2

6.04 Front Panel Replacement Parts.................................................................... 6-3

6.05 Left Side Internal Replacement Parts........................................................... 6-4

6.06 Rear Panel Replacement P arts .................................................................... 6-5

6.07 Right Side Internal Replacement Parts ........................................................ 6-6

6.08 Options and Accessories ............................................................................. 6-8

APPENDIX 1: INPUT WIRING REQ UIREMENTS ....................................................................A-1

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIA GRAM) ..........................................A-2

APPENDIX 3: LOGIC PC BO ARD LAYOUT .............................................................................A-3

APPENDIX 4: MAIN PO WER PC BOARD LAYOUT ................................................................. A-4

APPENDIX 5: MAIN PC BO ARD WIRING .................................................................................A-6

APPENDIX 6: CD PC BOARD LAYOUT ...................................................................................A-7

APPENDIX 7: LED/POT PC BOARD LA YOUT..........................................................................A-8

APPENDIX 8: IGBT CIRCUIT PC BO ARD LAYOUT ................................................................. A-9

APPENDIX 9: INPUT DIODE PC BO ARD LAYOUT................................................................A-10

APPENDIX 10: OUTPUT DIODE PC BO ARD LAYOUT ..........................................................A-11

APPENDIX 11: PO WER OUTPUT PCB WIRING DIAGRAM................................................... A-12

APPENDIX 12: 28VAC CIRCUIT DIAGRAM........................................................................... A-13

APPENDIX 13: MAINTENANCE SCHEDULE ........................................................................ A-14

APPENDIX 14: SYSTEM SCHEMATIC...................................................................................A-16

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEAL TH.

Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different pr ocesses. Y ou must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

Date: No v ember 15, 2001 1-1 GENERAL INFORMATION

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

• Provide a fire watch when working in an area where fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. T rapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• T o protect your hearing from loud noise, wear pr otective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

PLASMA ARC RA YS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly pr otected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12 400 - 800* 10 14

* These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEAL TH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Date: Nov ember 15, 2001

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFP A Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W1 17.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable fr om the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédur e en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA TOR Y PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.

Date: No v ember 15, 2001 1-3 GENERAL INFORMATION

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votr e distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différ ents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer . (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (V oir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper . Le gas hydrogène accumulé explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’éner gie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

GENERAL INFORMATION 1-4 Date: Nov ember 15, 2001

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons

RAYONS D’ARC DE PLASMA

ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur . Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculair e.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12 400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L ’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. V ous dú4ez vous pr otéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS A YANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymar ch Park, Quincy, MA 02269

Date: No v ember 15, 2001 1-5 GENERAL INFORMATION

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARA TION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-6 Date: Nov ember 15, 2001

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street

W est Lebanon, New Hampshire 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requir ements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative: Giorgio Bassi

Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy

Date: No v ember 15, 2001 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Firepower® (hereinafter “Firepower”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Firepower products as stated below , Firepower shall, upon notification thereof and substantiation that the pr oduct has been stored, installed, operated, and maintained in accordance with Firepower’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Firepower’s sole option, of any components or parts of the product determined by Firepowerto be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE.

LIMIT ATION OF LIABILITY: Firepower shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Firepower with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Firepower whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY FIREPOWER PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Firepower products shall be as follows: A maximum of four (4) years fr om date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the following further limitations on such three (3) year period.

POWER SUPPLIES PA R TS LABOR

MAIN POWER MAGNETICS ......................................................................................................3 YEARS ................... 1 YEAR

ORIGINAL MAIN POWER RECTIFIER ..................................................................................... 3 YEARS ................... 1 YEAR

CONTROL PC BOARD .................................................................................................................. 3 YEARS ................... 1 YEAR

ALL OTHER CIRCUITS AND COMPONENTS......................................................................... 1 YEAR ....................1 YEAR

INCLUDING, BUT NOT LIMITED TO, STARTING CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS, POWER SWITCHING SEMI-CONDUCTORS

CONSOLES, CONTROL EQUIPMENT, HEAT ............................................................................. 1 YEAR .................. 1 YEAR

EXCHANGES, AND ACCESSORY EQUIPMENT

TORCH AND LEADS ......................................................................................................................... 1 YEAR .................. 1 YEAR

REPAIR/REPLACEMENT PARTS.................................................................................................... 90 DAYS .................. NONE

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Firepower repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer ’s risk and expense. This warranty supersedes all previous Firepower warranties.

Effective November 15, 2001

GENERAL INFORMATION 1-8 Date: Nov ember 15, 2001

SECTION 2:

2.03 Service Responsibilities

INTRODUCTION

2.01 Scope Of Manual

This manual provides service instructions for the Firepower 82 Plasma Cutting Power Supply. Information in this manual is particularly applicable to the troubleshooting and repair of this power supply, and is intended for use by properly-trained service technicians familiar with this equipment.

For setup of this equipment, individual operating procedures, and basic troubleshooting, refer to the Operating Manual.

Read both the operating manual and the service manual thoroughly. A complete understanding of the capabilities and functions of this equipment will assure obtaining the performance for which it was designed.

2.02 General Service Philosophy

Several key points are essential to properly support the application and operation of this equipment.

The service technician should be familiar with the equipment and its capabilities and should be prepared to recommend arrangements of components which will provide the most efficient layout, utilizing the equipment to its best possible advantage.

Maintenance work should be accomplished in a timely manner. If problems are encountered, or the equipment does not function as specified, contact the Technical Services Department.

A. Application

The equipment should satisfy the customer ’s requirements as supplied and as described in Section 3 of this manual. Be sure to confirm that the equipment is capable of the application desired.

B. Modifications

No physical or electrical modifications other than selection of standard options and Accessories are to be made to this equipment.

C. Customer/Operator Responsibilities

It is the customer/operator's responsibility to maintain the equipment and peripheral accessories provided by Firepower in good operating order in accordance with the procedures outlined in the operating manual, and to protect the equipment from accidental or malicious damage.

D. Repair Restrictions

The electronics consists of Printed Circuit Board (PCB) Assemblies which must be carefully handled and must be replaced as units. No replacement of printed circuit solder-mounted components is allowed except as noted in this manual.

Printed Circuit Board Assemblies to be returned must be properly packaged in protective material and returned intact per normal procedures.

Manual 0-2871 2-1 INTRODUCTION

INTRODUCTION 2-2 Manual 0-2871

SECTION 3:

DESCRIPTION

4. Input Power*

• 208/230VAC (± 10%), Single Phase, 50/60 Hz *refer to Appendix 1 for input wiring r equir ements.

3.01 Scope

The purpose of this section is:

• T o familiarize the service technician with the capabilities and limitations of the equipment,

• T o provide an overall understanding which will allow the technician, in turn, to properly train customer operating personnel.

3.02 General Description

The power supply provides 60 amp maximum output and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch & leads, work cable with clamp, and input power cable.

3.03 Specifications/Design Features

1. Front Panel Controls

• Main Power ON/OFF Switch

• RUN/SET Switch

• Torch Leads

• Work Lead

• Output Current Control

2. Front Panel Indicators

• AC

• TEMP

• GAS

• DC

3. Rear Panel Features

• Primary Input Power Cable

• Gas Pressure Regulator/Filter Assembly

• Gas Inlet Port

5. Output Power

Continuously variable up to 60 amps maximum.

6. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher than shown in the chart.

Fi rePower F P - 82 P owe r S upply Duty Cycl e

Ambient

Tem

erature

Duty Cy cle

Current

DC Voltage

7. Pilot Circuitry

Capacitive Discharge (CD), Ignition DC Pilot

8. Weight

Power Supply w/Input Cable & Work Lead, Torch & Leads 83 lbs. (37.6 kg).

9. Overall Dimensions (w/handles)

• Length: 27.4 (696 mm)

• Width: 12.4 (315 mm)

• Height: 17.3 (439 mm)

10. Gas Regulator/Filter Assembly Specifications

• Operating Pressure: 70 psi (4.8 bar)

• Maximum input gas supply pressure: 125 psi (8.6 bar)

• Filter: Particulate Type Filter (to 20 microns)

104° F

(40° C)

50% 60% 100%

60 Amps 60 Amps 45 Amps

109V 109V 98V

104° F

(40° C)

104° F

(40° C)

Manual 0-2871 3-1 DESCRIPTION

3.04 Power Supply Options and Accessories

The following accessories are available for this power supply. Refer to Section 6, Parts Lists, for catalog numbers and ordering information.

A. Single Stage Air Line Filter Kit

A Single Stage In-Line Air Filter for use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 0.85 microns.

B. Two Stage Air Line Filter

A Two Stage In-Line Air Filter for use on compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 5.0 microns.

DESCRIPTION 3-2 Manual 0-2871

SECTION 4:

SERVICE

4.01 Introduction

This section provides service diagnostics for the Firepower FP-82 Power Supply, allowing the Technician to isolate any faulty subassemblies. Refer to Section 5, Repairs & Replacement Procedures, for parts replacement instructions.

Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other subassemblies of this unit. Evidence of unauthorized repairs will void the factory warranty.

NOTE

The troubleshooting contained in this manual is for the Power Supply only. Troubleshooting other parts of the system is covered in the manuals for those products.

4.02 Periodic Inspection & Cleaning Procedures

A. Logic PC Board Functions

The Logic PC Board controls the timing and sequencing of the system. It monitors the pressure and temperature, and controls the gas flow in Run and Set modes by turning on the plasma solenoid.

After the ON/OFF switch is closed on the front panel, the AC Indicator blinks for approximately eight seconds then it becomes steady and the Main Contactor closes.

When the unit is at “idle” the AC indicator on the Front Panel should be ON. When the torch is activated, the gas begins to flow . When the preflow time is over, the INV ON signal is given, and the DC indicator at the Front Panel turns ON.

An open circuit voltage of approximately 230 to 300 vdc (depending on input power) is produced when the switching of the IGBTs in the Main PC Board is turned ON by an INV ON signal from the Logic PC Board. A circuit on the Logic PC Board monitors the output voltage. When the output voltage drops below 60 vdc, indicating a problem exists, the Logic PC Board sends a signal which turns OFF the INV ON Enable signal. This happens in less than 50 milliseconds.

WARNING

Disconnect primary power and bleed down the system before disassembling the torch, leads, or power supply.

To clean the unit, open the enclosure per procedure in section 5.05-A, Cover Removal, and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean. If necessary, solvents for cleaning electrical apparatus may be used.

Refer to Appendix 13 for maintenance schedule and procedures.

4.03 System Theory

The Firepower FP-82 System is designed for hand operation using the torch control bulkhead within the power supply as the interface.

When the torch is activated, gas will flow for approximately two seconds before DC is established (indicated on the front panel). During this time the CD Enable indicator will come on and sends a logic signal to the CD Board which fires the spark gap and initiates the pilot. The CD Enable indicator should go out immediately if the pilot starts immediately.

When the torch is close to the workpiece, the cutting arc "transfers" to the work.

The resulting current is sensed by the Current Sense circuit, resulting in the demand level changing from pilot current to whatever the main current control is set at, and then the main cutting arc is initiated. If the torch is removed from the workpiece while the tor ch switch is still pressed, the main arc extinguishes and the pilot arc automatically restarts.

Firepower FP-82 Logic Board Indicat ors

Indicator Meaning

D20 CD on D21 Inverter on D32 Torc h Switch On D37 Drag Circuit on

Manual 0-2871 4-1 SERVICE

B. CD (Capacitive Discharge) Board Functions

D. Direction of Cut

The CD Board functions are initiated by the CD Enable signal from the Logic PC Board. The CD arc starting circuit fires the spark gap producing the high voltage spark which starts the DC pilot arc. When the Logic Board senses a pilot arc, the signal shuts off the CD enable.

4.04 Common Operating Problems

WARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.

Frequently review the Important Safety Precautions in Section 1. Be sure the operator is equipped with proper gloves, clothing, and eye and ear protection. Make sure no part of the operator's body comes into contact with the workpiece while the torch is activated.

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

Handle torch leads with care and protect them fr om damage.

The plasma gas stream swirls as it leaves the torch. The purpose of the swirl is to maintain a smooth column of gas. The swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.

E. Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove and can often be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.

F. Common Cutting Faults

1. Insufficient Penetration

a. Cutting speed too fast

A. Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

B. Torch Standoff

Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff generally results in a more square cut.

C. Edge Starting

For edge starts, hold the torch perpendicular to the workpiece with the front of the torch tip at the edge of the workpiece, not touching, at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to “reach” for the edge of the metal. Establish the cutting arc as quickly as possible.

b. Torch tilted too much c. Metal too thick d. Worn torch parts e. Cutting curr ent too low f. Non-Genuine Firepower parts used

2. Main Arc Extinguishes

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high d. Work cable disconnected e. Worn torch parts f. Non-Genuine Firepower parts used

SERVICE 4-2 Manual 0-2871

3. Excessive Dross Formation

The troubleshooting guide has subsections as follows:

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current e. Non-Genuine Fir epower parts used

4. Short Torch Parts Life

a. Moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time d. Gas pressure too low e. Impr operly assembled tor ch f. Incorrect torch parts for the operation g. Non-Genuine Firepower parts used

4.05 Troubleshooting Guide General Information

Section 4.06 -Circuit Fault Isolation Section 4.07 -Main Input and Internal Power Prob-

lems Section 4.08 -Pilot Arc Problems Section 4.09 -Main Arc Problems Section 4.10 -Test Procedures

Subsection 4.10 includes specific test procedures and LED status identification tables. The subsection is referenced by the troubleshooting guide for the specific test to be performed.

B. How to Use the Troubleshooting Guide

The following information is a guide to help the Service Technician determine the most likely causes for various symptoms. This guide is set up in the following manner:

1. Perform operational check(s) on the equipment to isolate problem to possible circuit(s) per Subsection 4.06, Circuit Fault Isolation.

2. Determine symptom and isolate to defective assembly using the following format:

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

A. General Information

Basic troubleshooting and parts replacement procedur es are described in the Firepower FP-82 Operating Manual.

This Service Manual covers advanced troubleshooting, which requires power supply disassembly and live measurements. Advanced tr oubleshooting and repair of this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment.

If major complex subassemblies are faulty , the faulty subassembly must be returned for repair.

NOTE

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (T ext Type)

3. Locate your symptom in the appropriate Subsection.

4. Check the causes (easiest listed first) for the symptom.

5. Check the remedies listed for each cause.

6. Repair as needed being sure to verify that unit is fully operational after any repairs.

NOTES

Many signals are transferred between Printed Circuit Board Assemblies on Cables. If these cables become faulty they can then cause various problems. Do not forget about these cables when troubleshooting.

While troubleshooting visually inspect the internal components for signs of overheating, fractures and damage.

Follow all instructions as listed and complete each in the order presented.

Manual 0-2871 4-3 SERVICE

4.06 Circuit Fault Isolation

A. Controls and Indicators

3. Set the Power Supply controls as follows:

• ON/OFF switch to OFF (Down)

• RUN/SET switch to SET (Down)

• CURRENT control (A) to maximum

4 5 6

C. Main Input and Internal Power Tests

1. Connect main AC power to the unit.

2. Set the Power Supply ON/OFF switch to ON (up) and note the following:

• AC indicator blinks for eight seconds (approximately), then steady ON

• Relay K4 on Main PC Board energizes (clicks) while

AC indicator is blinking

• Relay K5 energizes pulling in W1 after AC light stops blinking.

A-03208

1. ON/OFF switch. This switch controls AC power to

unit. Up is ON, down is OFF.

2. RUN/SET switch. This switch controls gas to torch.

Up is RUN, for general torch operation. Down is SET , for setting gas pressure and purging lines.

3. Current control knob. This control regulates current

to torch. At output settings over 40 amps, cir cuitry in the power supply automatically reduces output current to 40 amps if the torch tip contacts the workpiece.

4. AC indicator. When lit, indicates operating

power is present in the unit.

5. TEMP indicator. Indicator comes on when inter-

nal sensors detect temperatures above normal limits.

6. GAS indicator. Indicates adequate supply pres-

sure is present in the unit.

7. DC indicator. Indicates DC power output cir-

cuit is active. (Torch must be activated).

B. Initial Setup Conditions

This section is to help isolate the defective circuit before troubleshooting, identify symptoms, and test the unit for proper operation. Follow the instructions as given to identify the possible symptom(s) and the defective circuit. After repairs are complete, run the following tests again to verify that the unit is fully operational.

• TEMP Indicator OFF

• GAS Indicator ON

• Gas flows

• Fans operate

• DC lndicator is OFF

3. Set the Power Supply RUN/SET switch to the RUN (up) position and note the following:

• GAS indicator goes OFF

• Gas flow stops

This completes the Main Input and Internal Power T ests. If the above are all correct then pr oceed to paragraph 'D'. If not, note the symptom and proceed to Subsection 4.07, Main Input and Internal Power Problems.

D. Pilot Arc Test

1. Activate the torch to establish a pilot arc and note the following:

• Gas flows

• GAS indicator turns ON

• Preflow delay (two seconds) then DC indicator turns ON

• Pilot arc established

This completes the Pilot Arc Test. If the above are all correct then proceed to paragraph 'E'. If the unit does not function properly, then note the symptom and proceed to Subsection 4.08, Pilot Arc Pr oblems.

1. Connect gas supply to rear of Power Supply .

2. Turn on gas supply and adjust Power Supply Gas Regulator to 70 psi (4.8 bar).

SERVICE 4-4 Manual 0-2871

E. Main Arc Test

A-03001

Lower screws

Upper screws

Ground wire

Lower screws

Upper screws

Make sure the work cable is firmly connected to the workpiece. Activate the torch to establish a pilot arc.

Bring the torch to within 1/8"-3/8" (3-10 mm) of the workpiece to establish the main cutting arc, and note the following:

• Main cutting arc starts

• Pilot Control Relay (PCR) opens

This completes the Main Arc Test. If the above are all correct then the equipment should be operating properly. If problems still persist then contact Technical Services.

If the torch does not function as noted then note the symptom and proceed to Subsection 4.09, Main Ar c Problems.

4.07 Main Input and Internal Power

Problems

A. Opening Power Supply Enclosure

The Power Supply cover must be removed for access to input power connections and test points.

WARNING

Disconnect primary power at the source before assembling or disassembling the Power Supply, torch parts, or torch and leads assemblies.

1. Remove the upper screws securing the cover to the main assembly.

2. Loosen, but do not remove, the lower screws.

NOTE

There is a ground wire attached from the cover to the main body of the unit.

3. Carefully lift the cover off the unit, and remove the nut securing the ground wire to the side panel.

4. Re-install the cover by reversing the above steps.

Cover Removal

Locate your symptom below:

A. Main power line fuses blow as soon as main

disconnect is closed

1. Input power cable installed incorrectly or defective power cord.

a. Refer to Subsection 5.07-E, Input Power Cable

Replacement procedures, and check that the input power cable is not defective or installed incorrectly. Section 4.10-D illustrates wiring connections.

B. Main power line fuses blow immediately after the

ON/OFF Switch is turned on.

1. Faulty Input Diode

a. Test Input Diode per Subsection 4.10-C; repair

as necessary.

C. Fan does not operate; AC indicator on front panel

of power supply is OFF

1. Front Panel ON/OFF switch in OFF position

a. Place switch to ON (up) position.

Manual 0-2871 4-5 SERVICE

2. Main power disconnect switch open

a. Close main power disconnect switch.

3. Main power line fuses blown

a. Replace main power line fuses.

4. Improper input power cable connections inside Power Supply

a. Refer to System Schematic and correct if

needed.

J23-1

J23-3

J24-3

J24-4

Main PC Board

J18-3

J18-4

J18-5

J18-6

5. Defective input power cable

a. Replace input power cable. Refer to Section

5.07-E.

6. Fuse blown inside Power Supply

a. Replace internal Fuse per Subsection 5.06-A.

7. Line voltage above 10% tolerance (over voltage protection)

a. Reduce line supply .

8. Faulty Auxiliary Transformer (refer to Appendix 12, 28 VAC Circuit Diagram)

Measure for 28 VAC on Main PC Board from J18-1 to J18-3.

a. If voltage is not present, replace the Main PC

Board.

J23-1

J23-3

J24-3

J24-4

J18-3

J18-4

J18-5

J18-6

A-03171

10. Faulty Main PC Board (refer to Appendix 4, Main PC Board Layout).

Measure for 12 vdc on Main PC Board from TP4 to TP6.

a. If voltage is not present, replace the Main PC

Board.

D. System will not pilot; AC indicator ON, TEMP

indicator ON

1. Air flow through unit is restricted

a. Provide adequate air flow (Refer to Operating

Manual, Subsection 3.02, Site Selection).

2. Exceeded Duty Cycle of Power Supply

a. De-activate torch and wait for fan to cool unit.

Refer to Section 3 for proper duty Cycle for this unit.

3. Faulty Fan(s)

Measure for 230 VAC (±) on the Main PC Board from J15-1 to J15-5, and from J15-2 to J15-6.

Main PC Board

• If voltage at J15-1 to J15-5 is correct, replace lower Fan (M1).

• If voltage at J15-2 to J15-6 is correct, replace upper Fan (M2).

A-03171

9. Faulty ON/OFF switch (refer to Appendix 12, 28 VAC Circuit Diagram).

Measure for 28 VAC on the Main PC Board between J18-5 to J18-6.

a. If voltage is not present replace the ON/OFF

Switch.

SERVICE 4-6 Manual 0-2871

J15

3. Faulty Wiring or Faulty Logic PC Board

Fuse

Check for 12 vdc at Main PC Board pin J24-3 to J24-4 from the Logic PC Board. Refer to Appendix 4, Main PC Board Layout.

Auxiliary

Transformer

Main PC Board

INPUT DIODE

A-03172

J15-1

J15-2 J15-5

J15-6

E. No gas flow; AC indicator ON; TEMP indicator

OFF; GAS and DC indicators OFF

1. RUN/SET switch in RUN (up) position

a. Switch to SET (down) position.

2. Gas supply not connected to unit

a. Connect to gas supply.

3. Gas supply not turned on

a. Turn gas supply on.

4. Faulty RUN/SET switch

a. Check continuity.

5. Faulty Gas Solenoid circuit

a. Test Gas Solenoid circuit per Subsection

4.10-E; repair as necessary.

F. Gas flows; AC indicator ON; GAS indicator OFF;

DC indicator OFF

1. Gas pressure too low

a. Refer to Torch Instruction Manual for operat-

ing pressures.

2. Faulty Pressure Switch

Measure for 12 vdc from wire #10 to wire #11 at the Gas Pressure Switch, located on the right side of the unit. Refer to Appendix 14/15, System Schematic.

a. If 12 vdc is present and pressure is above 50 psi

(3.4 bar), replace Gas Pressure Switch/Solenoid Assembly. Refer to Section 5.08-A.

b. If pressure is above 50 psi (3.4 bar) and 12 vdc

is not present, replace the Logic PC Board.

• If less than a volt, replace Logic PC Board.

J23-1

J23-3

J24-3

J24-4

Main PC Board

J18-3

J18-4

J18-5

J18-6

A-03171

G. Gas continues to flow with RUN/SET switch in

RUN position.

1. Damaged gas solenoid.

a. Turn the front panel ON/OFF switch to OFF.

• If gas continues to flow , debris from the air line is preventing the solenoid from closing. Clean or replace the solenoid.

2. Faulty RUN/SET switch.

a. Check continuity.

3. Faulty Logic PCB.

a. Measure for approximately 12 vdc between

P1-7 and TP-1 on the Logic PCB.

• If 12 vdc is present, replace Logic PCB.

• If less than 2 vdc, replace Main PCB.

H. Arc in torch without activating torch; Gas flows;

AC indicator ON; GAS and DC indicators ON

1. Faulty torch switch

a. Refer to appropriate Tor ch Instruction Manual

and check continuity.

2. Faulty torch leads

a. Refer to appropriate Tor ch Instruction Manual

and check continuity.

3. Faulty Power Output PC Board (Refer to Appendix 11, Power Output PC Board Diagram)

a. Disconnect J41 Connector from the Power Out-

put PC Board.

b. Unplug Logic PC Board.

Manual 0-2871 4-7 SERVICE

c. Measure across pins J41-1 and J41-3 on Power

Output PC Board.

• If less than 2K ohms, replace Power Output PC Board.

• If more than 2K ohms, replace Logic PC Board.

d. Check for damaged torch leads. If pilot wire

arcs to torch switch PIP lead it can damage PCB and the torch leads.

2. Faulty Output Power PC Board

a. With ON/OFF switch in the OFF position, dis-

connect J39 from the Output Power PCB. Activate the torch and check for continuity between J39-6 and J39-7 on Output Power PCB.

• If no continuity is found, check for continuity between J41-1 and J41-3. If continuity is found, replace the Power Output PCB.

• If no continuity, check the tor ch connection. If torch connection is okay , r eplace the torch.

J41-1

A-03173

J41-3

Power Output PC Board

Output Diode A

4.08 Pilot Arc Problems

W ARNING

The following tests must be performed with the power supply connected to primary input power. There are extremely danger ous voltage and power levels present inside this unit. Do not attempt to diagnose or repair without proper training in power electronics measurement and troubleshooting techniques.

J39-6

J39-7

Power Output PC Board

Output Diode B

A-03266

3. Faulty Logic PCB

a. With torch activated, check indicator D20 on

the Logic PCB. Replace Logic PCB if D20 is on.

B. Gas flows; small arc may be visible in torch; AC

indicator ON; TEMP indicator off; GAS indicator ON; DC indicator off or blinks on/off once.

1. Faulty torch

a. Disconnect and isolate the Pilot return wire

from the Power Supply. Activate the torch and observe the front panel DC LED.

Locate your symptom below:

A. No gas flow; AC indicator ON; TEMP indicator

on, replace the torch.

2. Faulty IGBT or Output Diode Module Assembly(s)

off; GAS and DC indicators OFF (Torch Switch,

• If the DC indicator comes on and remains

CNC Control Switch or Pendant Control switch must be pressed)

1. Faulty torch or leads

a. Check per Subsection 4.10-C; repair as needed.

3. Faulty Main PCB

a. Test per Subsection 4.10-F; repair as needed.

a. Test per Torch Instruction Manual.

SERVICE 4-8 Manual 0-2871

C. Gas flows; No arc in torch; No arc at spark gap on

CD PC Board; AC indicator ON; TEMP indicator off; GAS and DC indicators ON; CD enable indicator ON

D. No arc or intermittent arc in torch; Gas flows;

Spark at gap on CD PC Board; AC indicator ON; TEMP indicator off; GAS and DC indicators ON; and CD enable indicator ON

1. Faulty IGBT

a. Measure between the following points on the

IGBTs: (Refer to Appendix 4)

• IGBT A: E4 to E10 E10 to E20

•IGBT B: E23 to E27 E27 to E30

V oltage should be approximately 20 vdc befor e the start signal is active. If voltage measures approximately 440 vdc when the start signal is active, replace the respective IGBT(s).

2. Faulty CD PC Board. (Refer to Appendix 6, CD Board Layout)

a. Measure for approximately 12 vdc at J28-1 to

TP-6 (on Main PC Board) when the torch is activated. Measure for less than 2 vdc at J28-2 to TP6 (on Main PC Board).

• Check for approximately 250 V AC between pin J28-5 and J28-8 on CD PC Board.

• If voltages are not present, check all wiring and connections. If wiring is connected properly and is not shorted, replace the main transformer.

b. Check for OCV at E61 to E64 on Power Output

PC Board.

• If voltage is present, and the other measure-

ments above are correct, replace CD Boar d.

1. Gas pressure set incorrectly (too high)

a. Refer to appropriate Tor ch Instruction Manual.

2. Oil/moisture in air lines

a. Purge system. If problem corrected, add filters

in line with air source.

3. Incorrect torch parts

a. Refer to appropriate Tor ch Instruction Manual.

4. Faulty leads

a. Check continuity per appropriate T or ch Instruc-

tion Manual.

5. Faulty torch

a. Check continuity per T orch Instruction Manual.

6. Faulty connection of wire #58 or 62 to Main PC Board

a. Check wiring connection. Refer to the appro-

priate System Schematic in the Appendix.

7. Faulty Main PC Board

a. Check for approximately 12 vdc at TP2 to TP1.

If less than 2 vdc, replace the Main PC Board.

8. Faulty Logic PCB or Faulty PCR Relay

a. Visually check that the pilot control relay (PCR)

is closed. If not, check for approximately 12 vdc across the coil.

• If approximately 12 vdc is present, replace the relay.

• If there is no 12 vdc across the coil, replace the logic board.

b. Install a jumper between wires 58 and 62 on

PCR relay and retry piloting. If torch pilots with jumper installed, replace PCR Relay.

J28-1

J28-2

CD PCB

A-03175

Manual 0-2871 4-9 SERVICE

4.09 Main Arc Problems

4.10 Test Procedures

Locate your symptom below:

A. Main cutting arc will not initiate

1. Work cable not connected.

a. Connect work cable.

2. Holding too high of a standoff.

a. Refer to Torch Instruction Manual for recom-

mended standoff heights.

3. Workpiece is painted or rusty.

a. Clean workpiece.

4. Faulty Main PC Board or Logic Board.

a. Measure for ±0 vdc at TP2 to TP1 on the Logic

Board when attempting to transfer. Refer to Appendix 3.

• If TP2 goes to 0 vdc replace Logic Board.

• If not, replace Main PC Board.

5. Faulty Main Input Contactor.

a. Check per Subsection 4.10-D.

B. When operating the amperage drops off after the

main cutting arc initiates.

1. Torch tip contacts work.

The test procedures in this subsection are referenced in the troubleshooting section.

A. Safety Precautions

1. Significant DC Voltage exists after removal of input power . Allow two minutes for discharge time. Voltage measured on input capacitors must be zero before performing service on the power supply.

2. Do Not touch electrical components with any part of the human body when power is applied.

3. Keep away from any moving parts.

4. Hot surfaces can cause severe burns. Allow equipment to cool before servicing.

5. Electrostatic discharge can damage printed circuit board assemblies. T ransport printed cir cuit boards in proper antistatic shielded packages. Use proper grounding techniques with wrist strap before handling printed circuit boards.

6. Misaligned plugs can cause printed circuit board damage. Be sure plugs are properly aligned and completely seated.

7. Excessive pressure can damage printed cir cuit boards. Use only minimal pressure and gentle movement when disconnecting or connecting printed circuit board plugs.

Lift the torch tip off the work. At output settings over 40 amps, circuitry in the power supply automatically reduces output current to 40 amps if the torch tip contacts the workpiece.

2. Faulty Pilot (PCR) Relay a. With power off, measure for continuity between

wires #58 and #62. Refer to the System Schematic in the Appendix. If continuity is found, replace PCR.

B. Diode Testing Basics

WARNING

Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.

T esting of diode modules r equires a digital volt/ohmmeter that has a diode test scale. Remember that even if the diode module checks good, it may still be bad. If in doubt, replace the diode module.

1. Locate the diode module to be tested.

2. Remove cables from mounting studs on diodes to isolate the module.

3. Set digital volt/ohmmeter to diode test scale.

4. Using the Figures for each test, check each diode in the module. Each diode must be checked in forward bias (plus to negative) and reverse bias (negative to plus) direction.

SERVICE 4-10 Manual 0-2871

5. Connect the volt/ohmmeter positive lead to the anode (+) of the diode and the negative lead to the cathode (-) of the diode for forward bias testing (refer to following figure). A properly functioning diode will conduct in the forward bias direction and indicate between 0.3 to 0.9 volts.

A-00307

0.75

C. Diode Module Board Tests

WARNING

Disconnect primary power at the source before taking any resistance checks.

1. Input Diode Module Board Circuit Test

a. Remove AC power. Refer to Appendix 5-A or 5-B,

Main Power Wiring diagram.

Forward Bias

Diode Conducting

Diode T est Symbol

Anode

Cathode

COM

Testing Diode Forward Bias

6. Reverse the meter leads across the diode for reverse bias testing (refer to following figure). A properly functioning diode will block in the reverse bias direction and depending on the meter function will indicate an open or “OL”.

7. If a diode checks bad, replace the diode module.

8. Reconnect all cables.

b. Check Input Diode for shorted input diode. With

an ohmmeter set on the diode range make the following checks from Main PC Board to Input Diode:

Input Diode PCB

Meter (+) M eter (-) Indicat i on

E7 E1 Open E1 E7 Diode Drop

E15 E1 Diode Drop

E1 E15 Open

E15 E7 Diode Drop *

E7 E15 Open

* Indicat i on c an be t wi c e

other indications.

c. The meter should indicate a diode drop in one di-

rection and an open in the other direction for each check. Replace the Input Diode Module Board if the readings do not match the chart.

d. If Input Diode Module Boar d is shorted, make the

following checks with an ohmmeter at the Main Contactor (W1):

A-00306

Met e r (+) Met er (-) Indication

L1 T1 Open

L2 T2 Open L3 T3 Open

Reverse Bias

Diode Not Conducting

Cathode

Anode

COM

If any test has resistance, then replace the Main Contactor.

Testing Diode Reverse Bias

Manual 0-2871 4-11 SERVICE

2. Output Diode Module Board Circuit Test

a. Use an ohmmeter set on the diode function and

make the following measurements on the Output Diode Module Boards to Power Output PC Board.

D. Main Input Power Test

W ARNING

Output Diode A Output Diode B

Met er + Meter - M et er + M et er -

E37 E58 E36 E57 Diode Drop * E58 E37 E57 E36 Open E37 E47 E36 E49 Diode Drop E47 E37 E49 E36 Open E58 E47 E57 E49 Open E47 E58 E49 E57 Diode Drop

* Indicat i on c an be t wi c e ot her i ndications .

Indication

b. The meter should indicate a diode drop in one di-

rection and an open in the other direction for each check. Replace the Output Diode Module Board(s) if the readings do not match the chart.

3. IGBT Module Board Circuit Test

a. Use an ohmmeter set on the diode function and

make the following measurements on the IGBT Module Board(s) to the Main PC Board.

IGBT PCB A IGBT PCB B

Met er + M eter - Meter + Meter -

E10 E4 E27 E 23 Diode Drop

E4 E10 E23 E27 Open E10 E20 E27 E30 Open E20 E10 E 30 E27 Diode Drop

E4 E20 E23 E30 Open E20 E4 E30 E 23 Diode Drop *

* Indicat i on c an be t wi c e ot her i ndications .

Indication

b. The meter should indicate a diode drop in one di-

rection and an open in the other direction for each check. Replace IGBT Module Board(s) if readings are not the same as the chart.

The following tests must be performed with the power supply connected to primary input power. There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair without proper training in power electronics measurement and tr oubleshooting techniques.

Reconnect power and observe proper start-up procedure. AC LED Indicator on the Front Panel should be ON. If indicator is OFF there is no voltage to the Power Supply or an overvoltage condition exists.

1. If AC LED Indicator on Front Panel is OFF, check for proper AC input voltage between input cables on the Main Contactor. Input voltage should be 187-253VAC between contactor points L1 and L2. If not, check for proper voltage at the main power source.

#78

T1 T2 T3 T4

L1 L2 L3 L4

#12

#13

Input Side

A-03212

Main Input Contactor

2. Check for 28 VAC at J23-1 to J23-3 on the Main PC Board.

a. If greater than 30 V AC, input line power is too

high.

b. If there is no AC power, check the fuse. If the

fuse is ok, the auxiliary transformer is faulty. Replace the Main PC Board.

SERVICE 4-12 Manual 0-2871

E. Gas Solenoid Circuit Test

Make the following voltage checks and replace the faulty part as required.

1. Place the RUN/SET Switch to the SET position.

2. Measure for 28 V AC across Solenoid wir es #8 and #9. Refer to System Schematic in Appendix Section.

• If 28 V AC is present, replace Solenoid/Pressur e

Switch Assembly .

W ARNING

The following tests must be performed with the power supply connected to primary input power. There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair without proper training in power electronics measurement and tr oubleshooting techniques.

• If 28 VAC is not present, check for 70 psi (4.8

bar) at the pressure regulator.

3. Check for less than 2 vdc at P1-14 to TP1 on Logic Board.

• If less than 2 vdc, replace Main PC Board.

• If more than 2 vdc, replace Logic PC Board.

F. Output Power Tests

1. No DC Output

Activate the torch.

• If INV ON indicator D21 on Logic PC Board does

not turn ON, then replace the Logic PCB.

• If the INV ON indicator D21 blinks ON then OFF

immediately, perform the following test:

a. Disconnect J28 from the CD PC Board to dis-

able the CD signal.

WARNING

Connector J28 on the CD PC Board must be disconnected to prevent electrical damage to measuring equipment when testing the open circuit voltage (OCV).

b. Activate the torch. Logic PC Board Inverter

ON Indicator , D21, turns ON.

c. Activate the torch.

• After 2 seconds D21 on the Logic PCB should turn ON. If D21 does not turn ON, replace Logic PCB.

d. Measure open circuit voltage between E61(+) to

E43 (-) at the Output Power PC Board. Voltage should be greater than 200 V. If voltage is less than 10 V, refer to the output diode test measurements or IGBT module test measurements or shorted torch measurements.

4. Gate Drive & DC Sensing

a. After checking all previous steps in Subsection

4.10-G, jumper TP1 to TP7 on the Logic PCB. Re-

fer to Appendix 3.

b. When the unit is turned on, the DC light

should remain ON.

c. Activate the torch. After two seconds INV ON

Indicator on the Logic PCB should come on and remain on.

• If INV ON indicator does not remain on, replace Logic PCB.

• If INV ON indicator remains on, then check for approximately 6 vdc between TP-1 to TP-4 and between TP-1 to TP-8 on the Logic PCB. Refer to Appendix 3.

• If no voltage, replace Logic PC Board.

c. Measure open circuit voltage between E61(+)

to E43(-) on the Power Output PC Board. Voltage should be 200-300 Volts. If voltage is less than 10 V, each IGBT Module and Output Diode Module should be tested individually.

Manual 0-2871 4-13 SERVICE

• If voltage is correct, measure for approxi-

mately 6 vdc between points as in the following chart:

IGB T A IGB T B

E11 J2A E11 J2B E19 J10A E19 J10B

• If voltage is 0, replace Main PCB.

• If voltage is correct, proceed to the following step.

d. With jumper between TP1 to TP7 still in place, ac-

tivate the torch and measure for 250 vdc to 300 vdc between E61 (+) and E43 (-) on the Power Output PCB. Refer to Appendix 11.

• If voltage is 0 vdc, replace IGBT Module.

e. W ith jumper between TP-1 and TP-7 still in place,

activate the torch and measure for approximately 250-300 vdc between J39-1 and J39-2.

• If voltage is 0 vdc, replace Output Power PCB.

• If voltage is correct, replace Logic PCB.

This completes the test procedures.

SERVICE 4-14 Manual 0-2871

SECTION 5:

REPAIRS & REPLACEMENT

PROCEDURES

5.01 Scope

This section describes parts replacement procedures which may be performed on the Firepower FP-82 Power Supply.

Under no circumstances are field repairs to be attempted on Printed Circuits or other subassemblies of this unit. Evidence of unauthorized repairs may void the factory warranty.

5.02 Anti-Static Handling Procedures

B. Procedure

1. Open the wrist strap and unwrap the first two folds of the band. W rap the adhesive side firmly around your wrist.

2. Unroll the rest of the band and peel the liner from the copper foil at the opposite end.

3. Attach the copper foil to a convenient and exposed electrical ground.

4. Connect the equipment primary cable ground to the same electrical ground as the wrist strap.

5. Open the equipment enclosure and remove the failed PC board.

6. Carefully open the ESD protective bag and r emove the replacement PC Board.

7. Install the replacement PC Boar d in the equipment and make all necessary connections.

A. General

Caution: PC Boards can be irreparably damaged by improper handling due to electrostatic discharge (ESD).

Replacement PC Boards are shipped in a protective enclosure to prevent damage from electrostatic discharge (ESD) during shipping. A gr ound strap is included with each replacement board to prevent static damage during installation.

WARNINGS

Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or removing the replacement PC board from its protective enclosure.

Disconnect primary power to the system before disassembling the torch, torch leads, or power supply enclosure.

Where these instructions include specific torquing instructions, failure to torque properly will cause component damage.

8. Place the failed PC Board in the ESD protective bag and seal for return shipping.

9. Replace the power supply cover.

10. Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equipment.

5.03 Parts Replacement - General Information

The parts replacement procedures described in this manual, except for filter replacement, require that the Power Supply be disassembled. The part to be replaced will determine to what extent the Power Supply must be disassembled.

Before removing any connection mark each wire with the connection designation. When reassembling make sure the wires go to the proper terminals.

Note the routing of wires and make sure the wires are put back in the same place when re-assembling the unit.

Each subsection is referenced to Section 6 for parts lists and overall detailed drawings.

Do not operate the equipment or test equipment under power while wearing the grounding wrist strap.

Disconnect primary power from the source before opening or disassembling the power supply.

Before disassembling any part of the Power Supply first read the procedure for the part to be replaced, then proceed with the disassembly.

Manual 0-2871 5-1 REPAIRS & REPLACEMENT PROCEDURES

W ARNING

5.04 Major External Parts Replacement

B. Tube Handle Replacement

1. Remove the cover per subsection 5.04-A.

Refer to Section 6.03 for Major External Replacement Parts and overall detailed drawing.

WARNING

Disconnect primary power from the source before opening or disassembling the power supply.

A. Cover Replacement

1. Remove the upper screws securing the cover to the unit. Loosen the lower screws securing the cover to the base.

Upper screws

Lower screws

2. Remove the Fan Assembly Panel per section

5.08-C.

3. Remove the four bolts and star washers securing the frame to the base of the unit.

4. Move the input power cable, torch leads and work cable inside the handle. Lift the base of the unit away from the T ube Handle. Leave the rear panel fastened to the base assembly.

5. W ith a rubber mallet, separate the two handle ends as shown below.

6. Install the replacement Tube Handle by r eversing steps 1-4.

7. Replace the Fan Shroud per section 5.08-C.

8. Re-install the Power Supply cover.

Lower screws

Ground wire

A-03001

2. Carefully lift the cover up and away from the unit for access to the ground wire connection on the inside of the cover.

3. Remove the nut and washer from the ground stud on the inside of the cover .

4. Install the replacement cover by reversing the above steps.

A-02847

REPAIRS & REPLACEMENT PROCEDURES 5-2 Manual 0-2871

5.05 Front Panel Parts Replacement

A-02775

Wire #25

Wire #26

Top clip

C. RUN/SET Switch Replacement

Refer to Section 6.04 for Front Panel Replacement Parts and overall detailed drawing.

WARNING

Disconnect primary power from the source before opening or disassembling the power supply.

A. Current Control Knob Replacement

1. Turn the Current control knob fully clockwise and note the location of the pointer on the knob.

2. Loosen the screw securing the Curr ent Knob to the potentiometer shaft and remove the Current Knob.

3. Place the replacement Current Knob on the potentiometer shaft with the location of the pointer the same as noted in step 1.

4. Tighten the screw to secure the knob to the potentiometer shaft.

B. ON/OFF Switch Replacement

1. Remove the cover per subsection 5.04-A.

2. Disconnect the two wires on the rear of the RUN/ SET Switch. Note the location of each wire, as shown:

3. Squeeze together the clips on the top and bottom of the RUN/SET Switch, then remove the switch through the Front Panel.

4. Install the replacement RUN/SET Switch by reversing the above steps.

D. POT/LED PC Board Replacement

1. Remove the cover per subsection 5.04-A.

2. Disconnect the four wires on the rear of the ON/ OFF Switch. Note the location of each wire, as shown below:

Top clip

Wire #21

Wire #24

Wire #22

Wire #23

A-02774

3. Squeeze together the clips on the top and bottom of the ON/OFF Switch. Remove the Switch through the Front Panel.

4. Install the replacement ON/OFF Switch by r eversing the above steps.

Follow the antistatic procedures provided in subsection

5.02.

1. Remove the cover per subsection 5.04-A.

2. Remove Current Knob per subsection 5.05-A.

3. Disconnect J Connector fr om POT/LED PC Board.

4. Remove PC Board from standoffs.

5. Install the replacement POT/LED PC Board by reversing the above steps.

E. Work Cable Replacement

1. Remove the cover per subsection 5.04-A.

2. Disconnect the Work Cable from the WORK terminal on the Power Output PC Board, located on the right side of the unit.

3. Squeeze the top and bottom of the Work Cable Strain Relief and remove from the Front Panel.

4. Remove Work Cable from the unit.

5. Install the replacement Work Cable as follows: a. Ensure that the replacement Work Cable passes

through the grommet in the Fan Shroud.

b. Secure the Cable to the Work terminal on the

Power Output PC Board and secure the strain relief.

Manual 0-2871 5-3 REPAIRS & REPLACEMENT PROCEDURES

5.06 Left Side Internal Component Parts Replacement

Refer to subsection 6.05 for Left Side Internal Component Replacement Parts and overall detailed drawing.

WARNING

Disconnect primary power from the source before opening or disassembling the power supply.

A. Fuse Replacement

1. Remove the cover per subsection 5.04-A.

2. Locate the Fuse near the top edge of the Main Power PC Board and remove the Fuse from the fuse holder .

3. Install replacement fuse.

4. Reinstall the cover.

B. Main Input Contactor Replacement

1. Remove the cover per subsection 5.04-A.

2. Label all wires connected to the Input Contactor.

3. Disconnect wires to the Input Contactor from the input cable.

4. Disconnect all other wires connected to the Input Contactor.

5. Remove the two nuts and washers securing the Input Contactor to the base of the power supply.

6. Position the replacement Input Contactor with the row of connectors labeled L towar d the rear of the Power Supply. Fasten in place with the hardware removed previously.

7. Complete the wiring connections as shown below.

NOTE

It is important that wires are installed correctly , as shown, to prevent damage to the unit.

#78

T1 T2 T3 T4

L1 L2 L3 L4

#12

#13

Input Contactor

C. Logic PC Board Replacement

Follow the antistatic procedures in subsection 5.02. The Logic PC Board connects to the Main PC Board through an extender board perpendicular to both boards.

1. Remove the cover per subsection 5.04-A.

2. Refer to Section 6.05, Left Side Internal Replacement Parts. Remove the bolts in each corner of the Logic PC Board.

3. Detach the Logic PC Board and the extender boar d from the Main Power PC Board. Detach the extender board from the Logic Board.

4. Install the replacement Logic PC Board by reversing the above steps. The pins on the right edge of the Logic PC Board must fully engage the sockets on the edge of the extender board. The extender board must fully engage sockets on the Main Power PC Board.

Input Side

A-03212

8. Reinstall cover.

REPAIRS & REPLACEMENT PROCEDURES 5-4 Manual 0-2871

D. IGBT Circuit PC Board or Input Diode PC

Board Replacement

Follow the antistatic procedures in subsection 5.02. The Power Supply includes two IGBT Circuit PC Boards.

NOTE

Follow the electrostatic discharge instructions provided with the replacement component to prevent damage to the component.

9. Install replacement components as follows:

For input diodes: A new style input diode assembly replaces the old style input diode assembly.

Old Style Assembly

Round Thermal

Pad

Thermal pads, heatsinks, and the large flat surface on the back of diodes and IGBT s must be kept clean. Diodes and IGBTs must not be bent or allowed to pick up any foreign material. A very clean installation between the module and the heatsink or chassis is essential for proper operation.

1. Remove cover per subsection 5.04-A.

2. Turn the Power Supply onto its side.

3. Locate the IGBT Circuit PC Boards or Input Diode mounted within the Main Power PC Board. Refer to Appendix pages for location and position.

4. For IGBTs, remove the small jumpers between the IGBT and the Main PC Board. T ransfer these jumpers to the replacement IGBT. Label, then remove all other wire connections to the Board(s) being replaced. Note the routing of wires. Ensure that the wires are put back in the same place when installing the replacement module.

5. Remove screw(s) securing PC Boar d(s) to the heatsink and remove board(s) fr om the Power Supply .

6. For input diodes only: If there is a solid metal disk attached to the heat-

sink, remove it by twisting it and pulling it away from the heatsink. Discard the disk.

7. Use isopropyl alcohol to clean and a clean rag to clean the heatsink or chassis area behind the component being replaced. Clean the large flat surface on the back of the replacement component. Do not scratch or abrade the surface.

8. The thermal pad(s), provided with the replacement part, is a thin metal pad. Remove any loose protective paper coverings from the pad(s).

NOTE

Protective coverings must be removed from the thermal pads. Installing thermal pads with protective coverings in place will cause equipment damage or failure.

Diode

Screw

Rectangular Thermal Pad

Washer

Solid Disk

New Style Assembly

Thermal Pad

Diode

Assembly

A-03446

a. Apply the rectangular thermal pad to the cen-

ter chassis with a small piece of light-duty tape. T ape must cover no mor e than 1/8” (3 mm) of the edge of the thermal pad. Use the screw holes in the chassis as a guide to position the pad. Align the pad to match the position of the rectangular flat surface on the back of the input diode.

b. Secure the diode and rectangular pad to the

chassis with the replacement screws and washers. Ensure that the rectangular pad is aligned with the rectangular flat surface on the back of the diode.

For IGBTs:

a. Remove the small jumpers from the component

being replaced and transfer them to the replacement component.

b. Secure replacement board(s) with the screw re-

moved previously. Ensure that the washer is under the head of the screw.

10. To rque screw to 17 in-lb. (1.9 Nm).

NOTE

Failure to torque properly will cause component damage.

Manual 0-2871 5-5 REPAIRS & REPLACEMENT PROCEDURES

11. Connect wires per the following applicable chart(s).

Firepower 82 Input Diode Connections

Input Diode To Main P CB

E18 E3 E13 E2

E5 E1

E14, E 16 E15

E6, E8 E7

6. Remove the Logic Board standoffs.

7. Carefully remove the original PC Board from the

unit.

8. Install the replacement PC Board by reversing the steps above. It may be easier to install the PC Board if the Power Supply is turned on its right side first. Refer to the charts in subsection 5.06-D for input diode and IGBT wiring connection points.

5.07 Rear Panel Par ts Replacement

Firepower 82 IGBT Connect i ons

IGBT A IGBT B

IGBT A

Connector

J3 J25 J3 J31 J7 J30 J7 J26

E9, E11 E10 E9, E11 E27 E19, E 21 E20 E 19, E21 E 30 E12, E 17 E 4 E 12, E17 E 23

To Main PCB

Connector

IGBT B

Connector

To Main PCB

Connector

12. Stand the unit upright; reinstall the cover.

E. Main Power PC Board Replacement

Follow the antistatic procedures in subsection 5.02.

1. Remove cover per subsection 5.04-A.

2. Remove the Logic PC Board per subsection 5.06-C.

3. Label and disconnect all wire and cable connections to the Main PC Board. Refer to the Main PC Board Wiring Diagrams in the Appendix Pages if necessary. Straighten the connections to the smaller PC Boards to be perpendicular to the Main PC Board.

4. Remove the two long Transformer screws securing the Transformer to the Center Chassis.

Refer to subsection 6.02 for parts list and overall detailed drawing.

WARNING

Disconnect primary power from the source before opening or disassembling the power supply.

A. Filter/Regulator Assembly Replacement

WARNING

Disconnect the gas supply at the source and bleed down the system before attempting this procedure.

1. Disconnect the gas input hose from the Filter/ Regulator Assembly on the Rear Panel of the unit.

2. Remove the four bolts securing the Regulator Mounting Bracket to the Rear Panel.

3. Disconnect the black gas tube from the Filter/ Regulator Assembly Adapter Fitting. Hold a wrench or similar tool against the locking ring on the Fitting and pull on the tube to release it.

5. Remove the other screws securing the PC Board to the Center Chassis.

4. Remove the nut securing the Filter/Regulator Assembly to the Regulator Mounting Bracket. Remove the Filter-Regulator Assembly from the Mounting Bracket.

5. Transfer the pressure gauge fr om the original Filter/ Regulator Assembly to the replacement assembly.

Screw locations

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch.

A-03165

REPAIRS & REPLACEMENT PROCEDURES 5-6 Manual 0-2871

6. Install the replacement Filter/Regulator Assembly by reversing the steps above. When connecting the gas tube to the Adapter Fitting, simply insert the hose into the fitting until fully seated. It will automatically lock.

B. Standard Filter Element Replacement

C. Optional Single-Stage Filter Element

Replacement

The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry.

WARNING

Disconnect the gas supply at the source and bleed down the system before attempting this procedure.

1. Remove power from the power supply; turn off the gas supply and bleed down the system.

2. Unscrew the bowl on the bottom of the Regulator/Filter Assembly. The filter element will be visible and still attached to the main body of the Regulator/Filter Assembly .

3. Grasp the filter element and unscrew it from the Regulator/Filter body. The filter element will come off with a spool and some additional pieces.

4. Note the correct assembly of the filter/spool then remove the filter from the spool. Either clean or replace the filter element.

5. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the Regulator body by compressing the spring on the spool. Tighten firmly by hand.

WARNING

Disconnect the gas supply at the source and bleed down the system before attempting this procedure.

1. Remove power from power supply. Turn off gas supply and bleed down the system.

2. Disconnect gas supply hose.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Assembled Filter

6. Reinstall the bowl.

7. Turn on the air supply.

Cover

Barbed

Fitting

A-02476

3. Turn the Cover counter-clockwise and remove it from the Filter Housing. The Filter Element is lo-

Regulator/Filter

Assembly

cated inside the Housing.

4. Remove the Filter Element from the Housing and set Element aside to dry.

Baffle Ring

Filter Element

Spring

Spool

5. Wipe inside of housing clean, then insert the replacement Filter Element open side first, as shown.

6. Replace Housing on Cover.

7. Reattach gas supply hose.

NOTE

If unit leaks between housing and cover, inspect the O-Ring for cuts or other damage.

Bowl

A-02995

Manual 0-2871 5-7 REPAIRS & REPLACEMENT PROCEDURES

D. Optional Two-Stage Filter Element

Replacement

NOTE

The T wo-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable.

1. Remove power from power supply .

WARNING

Always turn off the air supply and bleed the system before disassembling the Filter Assembly as injury could result.

E. Input Power Cable Replacement

1. Remove the cover per subsection 5.04-A.

2. Locate and label the input power cable connections and disconnect the cable.

3. Unthread the retaining nut on the Input Cable Strain Relief on the inside of the Rear Panel and remove the Input Power Cable from the unit.

4. Install the replacement Input Power Cable by reversing the above steps. The Input Power Cable ground wire requir es a ring terminal.

F. Rear Panel Replacement

WARNING

2. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

First & Second Stage Cartridges (as marked)

A-02942

3. Slide out the old Filter Elements.

4. Slide the replacement Filter Elements into the Filter Assembly, with the original orientation.

Disconnect primary input power and the gas supply at the source and bleed down the system before performing this procedure.

1. Remove the cover per subsection 5.04-A.

2. Remove the primary input power cable per section 5.07-C.

3. Remove the Regulator/Filter Assembly per section 5.07-A.

4. Remove two bolts at the bottom corners of the Rear Panel.

5. Remove one nut on a stud on the inside of the Rear Panel, at the rear edge of the center chassis.

6. Replace the Rear Panel by reversing the above steps.

7. If not already done, attach the data tag(s), pr ovided with the replacement Rear Panel. Position these as on the original Rear Panel.

5. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).

6. Slowly apply air pressure to the assembly, checking for leaks.

REPAIRS & REPLACEMENT PROCEDURES 5-8 Manual 0-2871

5.08 Right Side Internal Component Parts Replacement

Refer to Section 6.07 Right Side Internal Component Parts List and overall detailed drawing.

WARNING

6. Install the replacement Pressure Switch/Solenoid Assembly by reversing steps 2-5. Once installed, the Solenoid Assembly should fit securely on the Heatsink Shroud. It should not be moveable.

7. Re-install the power supply cover.

B. CD PC Board Assembly Replacement

Follow the antistatic procedures in subsection 5.02.

Disconnect primary power from the source before opening or disassembling the power supply.

A. Pressure Switch/Solenoid Assembly

Replacement

The Pressure Switch and Solenoid V alve ar e one Assembly . Disconnect primary input power and bleed down the system.

1. Remove the cover per subsection 5.04-A.

2. Disconnect the following wires: a. Wires #10 and #11 from the Pressure Switch

Assembly.

b. Wir es #8 and #9 from the Solenoid Assembly.

3. Push the clip on the front of the Heatsink Shroud to the left to release the Solenoid Assembly. Dislodge the Solenoid from underneath the clip on the top of the Heatsink Shroud.

1. Remove the cover per subsection 5.04-A.

2. Label, then disconnect the wiring connections to the CD PC Board Assembly.

3. Remove the bolt securing the PC Board to the standoffs.

4. Slide the PC Board upward to release it from its bottom supports.

5. Install the replacement CD PC Board Assembly by reversing the above steps.

C. Fan Replacement (M1, M2)

1. Remove the cover per subsection 5.04-A.

2. Label, then carefully remove the wiring connectors from the terminals on the Fans.

3. Disconnect the Work Cable from terminal E61 on the Power Output Board.

4. Remove one bolt from the Fr ont Panel of the Power Supply, near the Control Panel. Pull the Front Panel slightly away from the Power Supply.

5. Remove one nut from a stud at the bottom of the Fan Shroud.

6. Lift the Fan Shroud and pull it out of the Power Supply.

7. Remove two bolts per Fan. Set the Fan(s) aside.

Dislodge Solenoid Assembly

Push Clip

to the left to

release Solenoid

Assembly

4. Release the hose from the Adapter Fitting on the input side of the Solenoid Assembly. Hold a wrench or similar tool against the locking ring on the Fitting, then pull on the hose to release it.

5. Release the hose from the Adapter Fitting on the output side of the Pressure Switch.

Manual 0-2871 5-9 REPAIRS & REPLACEMENT PROCEDURES

A-02854

8. Install the replacement Fan Assembly as follows: a. Fasten Fan(s) in position with the wiring con-

nectors at the bottom of the Fan(s).

NOTE

Only two screws are needed to attach the Fan to the Fan Shroud. They can be installed in any two holes provided they are opposite each other. For grounding purposes, one of those screws must be installed with a star washer.

b. Place the Fan Shroud in position in the Power

Supply.

1) The inner edge of the Panel has tabs that engage slots in the center chassis. Ensure that these tabs fully engage in the chassis.

2) Press the Panel downward. Press the bottom flange fully against the bottom panel of the Power Supply.

3) Ensure that the hole in the bottom flange of the Fan Shroud engages the mounting stud.

5. Use isopropyl alcohol to clean the heatsink and the large flat surface on the back of the replacement component(s). Do not scratch or abrade the surfaces.

6. The thermal pad(s), provided with the replacement part, is a thin metal pad. Remove any loose protective paper coverings from the pad(s).

NOTE

c. Replace nut on the bottom mounting stud. d. Ensure that top flange of the Fan Shroud is

fully against the top forward edge of the Heatsink Shroud.

e. Press the front panel of the Power Supply

against the Fan Shroud, and fasten in place with the bolt removed previously.

f. Secure the nut on the stud at the bottom of the

Fan Shroud.

9. Re-connect the wires to the Fan Assemblies.

10. Pass the Work Cable through the hole in the bottom of the Fan Shroud. Ensure that the grommet is in place in the hole.

11. Connect the Work Cable to terminal E61 on the Power Output PC Board. Secure the Work Cable Strain Relief.

12. Re-install the Power Supply Cover.

D. Output Diode PC Board Replacement

Follow the antistatic procedures in subsection 5.02.

NOTE

Follow the electrostatic discharge instructions provided with the replacement component to prevent damage to the component.

Thermal pads and the large flat surface on the back of diodes and IGBTs must be kept clean. Diodes and IGBTs must not be bent or allowed to pick up any foreign material. A very clean installation between the module and the heatsink or chassis is essential for proper operation.

Protective coverings must be removed from the thermal pads. Installing thermal pads with protective coverings in place will cause equipment damage or failure.

7. Apply a round thermal pad to the heatsink with a small piece of light-duty tape. Tape must cover no more than 1/8” (3 mm) of the edge of the thermal pad. Use the screw hole in the heatsink as a guide to position the pad.

8. Secure replacement board as follows: a. Position the hardware at the bottom of a recess

in the face of the diode. Ensure that the washer is under the head of the screw(s).

b. Torque hardware to 17 in-lb. (1.9 Nm).

NOTE

Failure to torque properly will cause component damage.

9. Connect wires as follows:

Output Diode A Output Diode B

From Output

Diode A

E34, E 39 E37 E34, E 39 E36 E48, E 50 E47 E48, E 50 E45 E56, E 60 E58 E56, E 60 E57 E53, E 54 E52 E53, E 54 E49

To Output

Power PCB

From Output

Diode B

To Output

Power PCB

1. Remove cover per subsection 5.04-A.

2. Locate the Output Diode PCB(s) located within the Output Power PC Board on the Heatsink Shroud.

3. Carefully remove all wire connections to the Output Diode Board(s).

4. Remove screw(s) securing Output Diode PC Board(s) to the Heatsink and remove board(s) fr om the Power Supply.

REPAIRS & REPLACEMENT PROCEDURES 5-10 Manual 0-2871

E. Output Power PC Board Replacement

F. Pilot Control Relay Replacement

Follow the antistatic procedures in subsection 5.02.

NOTE

Follow the electrostatic discharge instructions provided with the replacement component to prevent damage to the component.

1. Remove cover per subsection 5.04-A.

2. Locate the Power Output PC Board, mounted to the Heatsink Shroud.

3. Carefully remove all wire connections to the Output Diodes.

4. Straighten the Output Diode wires to be perpendicular to the Output Power PC Board.

5. Label, then disconnect all other wire connections to the Output Power PC Board. Refer to Appendix pages for wiring connection layout.

6. Remove the bolts at the top left and bottom right corners of the Output Power PC Board.

1. Remove the Power Supply cover per section

5.04-A.

2. Push the clip on the front of the Heatsink Shroud to the left to release the Solenoid Assembly. Dislodge the Solenoid from underneath the clip on the top of the Heatsink Shroud.

3. Label, then disconnect the wires connected to the Relay.

4. Remove the two standoff nuts which fasten the Relay to the center chassis.

5. Pull the Relay and its dust cover away from the center chassis and out of the Power Supply.

6. Position the replacement Relay in the dust cover, and position both on the studs fastened to the center chassis.

7. Put an internal star washer on each stud.

8. Fasten the Relay in position with the standof f nuts.

CAUTION

Screw Locations

A-03166

7. Lift the Output Power PC Board off its supports, and set aside.

8. Install the replacement Output Power PC Board by reversing the above steps.

Be careful that the tool does not get wedged between the standoff nut and the plastic area around the standoff nut. Damage may occur if the tool is pried against this area.

Star Washers

Dust Cover

Relay

A-03177

Standoff Nuts

9. Reconnect the wires removed in Step 3.

10. Return the Pressure Switch/Solenoid Assembly to its position on the top of the Heatsink Shroud. Slide the right edge of its base into the slot, and secure the assembly in place with the clip.

11. Re-install the Power Supply Cover.

Manual 0-2871 5-11 REP AIRS & REPLA CEMENT PR OCEDURES

G. CD T ransformer Replacement

H. Heatsink Shroud Assembly Removal

1. Locate the CD PC Board Assembly . Label and disconnect wires E1 and E2. Refer to Appendix 6.

2. Disconnect the transformer wire connected to the inside of the Power Supply bulkhead.

3. Disconnect the transformer wires connected to E64 on the Power Output PC Board. Refer to Appendix 11.

4. Remove the two long screws securing the Ferrite U-Cores and CD Coil of the CD T ransformer Assembly to the Heatsink Shroud. Set the Ferrite U- Cores aside.

5. Install the replacement CD T ransformer as follows:

WARNINGS

The Ferrite U-Cores are very brittle and can be damaged easily if not handled properly.

DO NOT allow the CD T ransformer wires to touch anything metal.

a. Place the CD T ransformer Assembly in the cor-

rect orientation and install it on the Heatsink Shroud using the two long bolts.

b. Attach the transformer wire connected to the

inside of the Power Supply bulkhead. Make

sure the wires are not touching anything metal. c. Connect wires to E1 & E2 on the CD PC Board. d. Connect the transformer wires to E64 on the

Power Output PC Board. Refer to the follow-

ing illustration:

The Heatsink Shroud Assembly must be disengaged for access to either the Main Transformer or the Output Inductor. Follow these steps for access to either component.

1. Remove the Power Supply cover per subsection

5.04-A.

2. Release the tab on the Fan Shroud that secures the Bulkhead in position. Pull the Bulkhead upward to release the Bulkhead tabs from the slots on the Center Chassis.

3. Release the tab on the vertical face of the Heatsink Shroud securing the Solenoid/Pressure Switch Assembly in position.

4. Remove the gas hose from the Regulator Fitting on the back panel of the Power Supply by pressing on the locking ring on the elbow fitting, while pulling on the hose.

5. Remove the Power Supply Back Panel per subsection 5.07-D.

6. Remove the grommets from the two holes on the right (rear) edge of the Heatsink Shroud.

7. Remove the Fan Assembly per subsection 5.08C.

8. Label and disconnect the wires fr om the CD T ransformer to the CD PC Board.

9. Remove the hardware securing the Pilot Control Relay in place. Pull the Relay and its dust cover off the center chassis. Set the dust cover aside.

10. Label and disconnect wires No. 45, 49, 47, and 52 from the Power Output PC Board.

11. Disconnect the wires from the Output Inductor to terminal E43 on the Power Output PC Board.

12. Disconnect the ground wire connected to the center chassis between the Pilot Control Relay and the

Wires to E1 & E2

CD PC Board.

13. Remove nuts on two studs at the top corners of the Heatsink Shroud, and nuts on two studs on the bottom flange of the Heatsink Shroud.

14. Remove the Heatsink Shroud as follows: a. Use the open left end of the Heatsink Shroud

and the Pressure Switch/Solenoid opening as

Keep wire away from all metal parts.

handles.

b. Pull the Heatsink Shroud away from the cen-

A-03193

To Power Output PC

Board

ter chassis, and then up. It may be necessary to pry the top and bottom flanges of the Heatsink Shroud slightly to release them from their mounting studs. Movement will be limited by the wiring harness.

REPAIRS & REPLACEMENT PROCEDURES 5-12 Manual 0-2871

c. Ensure that the top edge of the Shroud does

not hit the bottom edge of the CD PC Board. Stand the Heatsink Shroud Assembly against the Power Supply.

I. Main Transf ormer Replacement

1. Disengage the Heatsink Shroud per Paragraph H.

2. Disconnect wires #27 and 32, connected to terminals E27 and E32 on the Main Power PC Board. Pull these wires through the hole in the center chassis.

J. Output Inductor Assembly Replacement

1. Disengage the Heatsink Shroud per paragraph H.

2. Disconnect the wires to the thermal switch on the Output Inductor .

3. Remove hex nuts at the left forward and right rear corners of the Inductor base.

4. Remove the Inductor as follows: a. Note the position of the wires leading from the

Inductor.

3. Remove the Main Transformer as follows: a. Lift the Main Transformer slightly and swing

the left edge away from the center chassis. Pull the right edge of the Transformer away from the center chassis.

b. Lift the Transformer out of the Power Supply

through the opening at the rear of the Power Supply.

4. Position the replacement Main T ransformer behind the Heatsink Shroud Assembly. Position its wires at the right edge (as you face it) of the transformer .

5. Install the replacement transformer as follows: a. Pass the tabs on the right edge of the base of

the transformer into slots in the center chassis of the Power Supply.

b. Swing the transformer against the chassis, and

pass the tabs on the left edge of the base into slots in the chassis. Press the transformer downward to lock it into position.

c. Check for proper installation; the transformer

should remain securely in place.

b. Lift out the Inductor through the opening at

the rear of the Power Supply. It may be necessary to lift the Main T ransformer slightly to create room for the Inductor to pass through the rear opening.

5. Install the replacement Inductor. a. Put the replacement Inductor in place, with the

wires oriented the same way as the original Inductor.

b. Secure the Inductor in place with hex nuts at

opposite corners of the Inductor base.

6. Reconnect the wires to the thermal switch on the Output Inductor .

7. Replace the Heatsink Shroud per paragraph K.

K. Heatsink Shroud Assembly Replacement

1. Pass transformer wires #45 and 49 through the upper hole in the right (rear) edge of the Heatsink Shroud. Pass transformer wires #47 and 52 through the lower hole.

2. Route wires as follows:

6.. Pass wires #27 and 32 through the hole in the center of the main chassis. Connect wire #27 to terminal E27 and wire #32 to terminal E32 on the Main Power PC Board.

7. Replace the Heatsink Shroud Assembly per subsection K.

Manual 0-2871 5-13 REP AIRS & REPLA CEMENT PR OCEDURES

a. Pass the red wires from the output inductor

through the upper hole in the right (rear) edge of the Heatsink Shroud.

b. Pass the black wires from the output inductor

through the lower hole in the right (rear) edge of the Heatsink Shroud. Refer to Appendix 1 1, Power Output Board Layout.

c. Pass the wires from the temperature switch on

the Output Inductor through the upper hole in the Shroud.

3. Re-install the Heatsink Shroud as follows: a. Lift the Heatsink Shroud (Assembly) into po-

sition. Studs on the Power Supply base pass through holes in the bottom flange of the Shroud.

b. Swing the top edge of the Shroud Assembly

into place. Studs on the Center Chassis of the Power Supply pass through holes in the top flanges of the Shroud.

c. Ensure that the rubber feet on the Main T rans-

former engage holes in the Shroud.

d. Put hex nuts on the studs. Tighten the nuts on

the right (rear) top and bottom studs. Leave the nuts on the left (forward) studs loose temporarily.

4. Put the Fan Assembly in place per subsection

5.08-C. Reconnect the work cable to terminal E61 on the Power Output PC Board.

5. T ighten the nuts securing the left edge of the Heatsink Shroud Assembly. The stud and nut on the bottom left edge fasten a wire stay to the Power Supply.

6. Replace the grommets around the wire harnesses passing through the right (rearward) edge of the Heatsink Shroud.

7. Reconnect the wires to the CD PC Board.

8. Put the Torch Contr ol Bulkhead Panel in position. Notches on its inner edge engage slots in the center chassis. A tab on the Heatsink Shroud secures the Bulkhead in place.

9. Reconnect the ground wire to the center chassis, between the CD PC Board and the Pilot Control Relay.

10. Replace the Pressure Switch/Solenoid Assembly. This assembly fits into a slot in the top horizontal surface of the Heatsink Shroud. A notched pin holds the assembly in place.

11. Connect the gas hose between the Regulator/Filter Assembly and the Gas Pressure Switch/Solenoid Assembly .

12. Connect wiring to the Output Power PC Board. Refer to the Appendix pages for wiring layout.

13. Replace the Power Supply rear panel per subsection 5.07-D.

This concludes the replacement procedur es.

REPAIRS & REPLACEMENT PROCEDURES 5-14 Manual 0-2871

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts lists provide a breakdown of all replaceable components. The parts lists are arranged as follows:

Section 6.03 Major External Replacement Parts Section 6.04 Front Panel Replacement Parts Section 6.05 Left Side Internal Replacement Parts Section 6.06 Rear Panel Replacement Parts Section 6.07 Right Side Internal Replacement Parts Section 6.08 Options and Accessories

NOTE

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the power supply. Address all inquiries to your authorized distributor .

Manual 0-2871 6-1 P A RTS LISTS

6.03 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-8598-FP 2 1 Rear Panel (Provide data tag information when ordering) 9-8595-FP 3 1 Tube, roll handle 9-8573

Hardware:

A 12 Screw, 10-32 x 1/5" PPH, swageform See Note 1

B 4 Washer, 1/4 External Star See Note 1 C 4 Screw, 1/4-20 x 3/4 Hex head See Note 1

D 1 10-32 kepnut w/ star washer See Note 1

B, C

NOTES

A-03374

1. Hardware may be purchased locally.

2. Illustration may vary slightly from unit.

PARTS LISTS 6-2 Manual 0-2871

6.04 Front Panel Replacement Parts

Item# Qty Description Ref Catalog #

1 1 Knob, Fluted, Skirted, 0.250 I.D. 9-8527 2 1 On/Off Rocker Switch, DPST SW1 8-3258 3 1 Run/Set Switch, Rocker , SPST, Center Off SW2 9-1042 4 1 Assembly, Pot/LED PCB 9-8004 5 1 Cable, Work, #6 AWG with Clamp, 20 Ft (6.1 m) 9-8528

A-03008

NOTE

Illustration may vary slightly from unit.

Manual 0-2871 6-3 P A RTS LISTS

6.05 Left Side Internal Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Fuse F1 9-8588 2 Main Input Contactor W1 9-8587 3 1 Connector PCB 9-8576 4 1 PCB Assembly, Logic 9-8597 5 1 PCB Assembly Kit, IGBT Circuit 9-8578

Round Thermal Pad

6 1 PCB Assembly Kit, Input Diode 9-8579

Rectangular Thermal Pad Solid Disk Round Thermal Pad

7 1 PCB Assembly , Main Power 9-8594

A-03375

NOTE

Illustration may vary slightly from unit.

PARTS LISTS 6-4 Manual 0-2871

6.06 Rear Panel Replacement Par ts

Item # Qty Description Ref Catalog #

1 1 Assembly, Filter/Regulator 9-7514 2 1 Regulator/Filter Replacement Element 9-4414 3 1 Regulator Mounting Bracket 9-7589 4 1 Input Power Cable with plug 9-8596 5 1 Mounting Nut 9-8504 6 1 Pressure Gauge 9-1045

A-03005

NOTE

Illustration may vary slightly from unit.

Manual 0-2871 6-5 P A RTS LISTS

6.07 Right Side Internal Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Assembly, Pressure Switch/Solenoid Sol1, PS1 9-8563 2 1 Assembly, CD PC Board 9-8552 3 1 Coil, CD Transformer T10 9-8582 4 1 Pilot Relay PCR 9-8574 5 1 Fan, 220V, 115 CFM M1, M2 9-7687 6 1 Assembly, Main Transformer T5 9-8589 7 1 Assembly, Output Inductor L1 9-8591 8 1 PCB Assembly , Output Power 9-8577 9 1 PCB Assembly Kit, Output Diode 9-8580

Round Thermal Pad

PARTS LISTS 6-6 Manual 0-2871

A-03189

Work Cable

Heatsink

Heatsink Shroud

Fan Shroud

Bulkhead

PCR Cover

NOTE

Illustration may vary slightly from unit.

Manual 0-2871 6-7 P A RTS LISTS

6.08 Options and Accessories

Qty Description Catalog #

1 Single-Stage Filter Kit (Includes Filter And Hose) 7-7507 1 Replacement Filter Body 9-7740 1 Replacement Filter Element 9-7741 1 Replacement Filter Hose (Not Shown) 9-7742

1 Two-Stage Air Line Filter Kit (Includes Hose & Mounting Screws) 7-7500 1 Bracket, Filter Mounting (Not Shown) 9-7535 1 T wo-Stage Air Filter Assembly 9-7527 1 Replacement First Stage Cartridge 9-1021 1 Replacement Second Stage Cartridge 9-1022

Housing

Filter

Element

Spring

O-ring

Cover

Barbed

Fitting

Assembled Filter

A-02476

Single-Stage Filter Kit Two-Stage Air Filter Kit

First & Second Stage Cartridges (as marked)

A-02942

PARTS LISTS 6-8 Manual 0-2871

APPENDIX 1: INPUT WIRING REQUIREMENTS

Firepower 82 Input Wi ring Re qui rements

Input Power Inpu t Curre nt Input Suggested Sizes (See N ote s )

Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)

(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph

208 50/60 11.8 57 60 6 6 230 50/60 11.8 52 60 6 6

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. Cable size is de-rated based on the Duty Cycle of the equipment. The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations

refer to local or national codes. Cable conductor temperature used is 167° F (75° C). An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be

used to minimize damage to Plasma Cutting, Welding or power distribution equipment. NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

Manual 0-2871 A-1 APPENDIX

APPENDIX 2: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch.

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8

seconds then steady on.

Fans on.

Power circuit ready.

gas flows to set pressure.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed)

post-flow, pilot arc will immediately restart.

(1/4 in/6.4mm) of workpiece, main arc

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (10 seconds)

NOTE - If torch is activated during

If torch is within transfer distance

will transfer.

After post-flow:

GAS indicator off.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

A-02778

APPENDIX A-2 Manual 0-2871

APPENDIX 3: LOGIC PC BOARD LAYOUT

D20

D21

TP3

TP12

TP2

TP1

TP9

D32

D37

TP4

TP8

TP5

TP6

Logic Board Signals

P1-1 +12 vdc from Main PCB P1-2 +12 vdc from Main PCB P1-3 DC Common P1-4 DC Common P1-5 W1 ON Signal P1-6 Tip Sense P1-7 RUN/SET signal logic low for SET P1-8 Pressure good signal (Logic low) P1-9 OVERTEMP signal (Logic low) P1-10 Inrush done signal from Main PCB P1-11 CD Enable signal from Main PCB P1-12 CD Enable signal from Main PCB P1-13 Open P1-14 Gas ON signal to Main PCB P1-15 Logic low CSR signal P1-16 Logic low PILOT ON signal P1-17 Logic low DC OK signal P1-18 Logic low OVERTEMP signal P1-19 Logic low AC OK signal P1-20 Return for torch switch P1-21 Logic low = torch switch signal P1-22 +12 vdc P1-23 to curr ent control pot P1-24 Current contr ol P1-25 Current control return P1-26 Gate drive B return

TP7

TP10

P1-27 Gate drive B signal P1-28 Gate drive A return P1-29 Gate drive A signal P1-30 (-) out signal P1-31 Current sense P1-32 Current sense P1-33 Current sense return P1-34 Current sense return P1-35 DC Common P1-36 DC Common

TP-1 Common TP-2 CSR (Logic low) TP-3 Converter enable TP-4 Gate Drive B TP-5 Demand Signal TP-6 Output voltage sense TP-7 DC ok (Logic low) TP-8 Gate Drive A TP-9 Fault (Logic low) TP-10 T ip sense

Indicators: D20 CD ON D21 INV ON D32 SW ON D37 DRAG ON

A-03156

Manual 0-2871 A-3 APPENDIX

APPENDIX 4: MAIN POWER PC BOARD LAYOUT

E22

E15

J25 E10 J30

J11

J15

Fuse

LT1

J17 TP4

INPUT DIODE

J16

TP6

J23

J24

J32

J29

J33

J18

J43

J27

E32

J26

E27

E30

J31

E20

IGBT A

Main Power PC Board Signals

J11-1 L1 Input J11-2 Not Used J11-3 Not Used J11-4 L3 Input

J15-1 Fan (M1) J15-2 Fan (M1) J15-3 Not Used J15-4 Not Used J15-5 Fan (M2) J15-6 Fan (M2)

J16-1 Not Used J16-2 Not Used

E33 E4

E23

IGBT B

J18-1 PCR J18-2 PCR J18-3 28VAC B J18-4 28V AC A J18-5 On-Off Switch J18-6 On-Off Switch J18-7 Run-Set Switch J18-8 Run-Set Switch

A-03149

J17-1 Not Used J17-2 Not Used

APPENDIX A-4 Manual 0-2871

J23-1 Not Used J23-1 Not Used J23-3 Not Used

J24-1 Gas Solenoid J24-2 Gas Solenoid J24-3 Pressure Switch J24-4 Pressure Switch J24-5 Main Contactor J24-6 Main Contactor J24-7 Not Used J24-8 Not Used

J25-1 Gate Drive J25-2 Gate Drive

J26-1 Gate Drive J26-2 Gate Drive

J27-1 Pot High J27-2 Pot Wiper J27-3 Pot Low J27-4 +12vdc J27-5 AC J27-6 Gas J27-7 Over Temp J27-8 DC

J29-1 IGBT Heatsink Temp J29-2 IGBT Heatsink Temp J29-3 Jumper J29-4 Jumper

J30-1 Gate Drive J30-2 Gate Drive

J31-1 Gate Drive J31-2 Gate Drive

J32-1 Inductor Temp Switch J32-2 Inductor Temp Switch

J43-1 +12vdc J43-2 +12vdc J43-3 DC Com J43-4 DC Com J43-5 MC1 On J43-6 Tip Sense J43-7 Run/Set J43-8 Press Good J43-9 Over Temp J43-10 Inrush Done J43-11 CD Enable J43-12 CD Enable J43-13 (Open?) J43-14 Gas On J43-15 CSR J43-16 Pilot On J43-17 DC Ok J43-18 OV Temp J43-19 AC Ok J43-20 Torch Switch Return J43-21 Torch Switch J43-22 +12vdc J43-23 Pot High J43-24 Pot Wiper J43-25 Pot Low J43-26 Gate Drive B Return J43-27 Gate Drive B J43-28 Gate Drive A Return J43-29 Gate Drive A J43-30 - Out J43-31 Current Sense J43-32 Current Sense J43-33 Current Sense Return J43-34 Current Sense Return J43-35 DC Com J43-36 DC Com

TP-4 +12 vdc TP-6 Common

J33-1 - Out J33-2 DC Com J33-3 Tip Sense J33-4 +12vdc J33-5 CSR J33-6 Tor ch Switch J33-7 Tor ch Switch Return J33-8 CD Enable

Manual 0-2871 A-5 APPENDIX

APPENDIX 5: MAIN PC BOARD WIRING

Copper Strap

To Main Input Contactor

To Fans

To Press Sw/ Solenoid/ Contactor

Fuse

Input Diode

To Inductor Temp Switch

Secondary

Transformer

To HeatSink T emp Switch

To Power Output Board

To PCR/On-Off Switch/ Run-Set Switch

To Pot/LED PCB

To Logic PCB

via Extender

To Main

Transformer

Heatsink

Temp Switch

IGBT B

To Main Input

{

Contactor

A-03187

#33

IGBT A

#78

{

To Main Input Contactor

APPENDIX A-6 Manual 0-2871

APPENDIX 6: CD PC BOARD LAYOUT

CD PC Board Signals

J28-1 +12 vdc J28-2 CD Enable J28-3 Not Used J28-4 Not Used J28-5 E47 J28-6 Not Used J28-7 Not Used J28-8 E45

J28

A-03086

Manual 0-2871 A-7 APPENDIX

APPENDIX 7: LED/POT PC BOARD LAYOUT

J14

A-01206

Pot/LED PC Board Signals

J14-1 +10 vdc from Logic PC Board (J27-1) Pot High J14-2 Current Controlto Logic PC Board (J27-2) Pot Wiper J14-3 Return for Current Control from Logic PC Board (J27-3) Pot Low J14-4 12vdc (J27-4) J14-5 Logic Low Signal for AC OK Indicator from Logic PC Board (J27-5) J14-6 Logic Low Signal for GAS Indicator from Logic PC Board (J27-6) J14-7 Logic Low Signal for TEMP Indicator from Logic PC Board (J27-7) J14-8 Logic Low Signal for DC Indicator from Logic PC Board (J27-8)

D4 Front Panel AC Indicator D5 Front Panel TEMP Indicator D6 Front Panel DC Indicator D7 Front Panel GAS Indicator

APPENDIX A-8 Manual 0-2871

APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT

TP1A

E11

IGBT A

E21 E19

E12

E17

TP2A

TP1B

E11

IGBT B

E21

E12

E19

TP2B

E17

A-03154

Manual 0-2871 A-9 APPENDIX

APPENDIX 9: INPUT DIODE PC BOARD LAYOUT

E13

E18

E14

NOTE:

Refer to Appendix 5 for wiring connections.

E16

A-03155

APPENDIX A-10 Manual 0-2871

APPENDIX 10: OUTPUT DIODE PC BOARD LAYOUT

Output Diode A

E34

E39

E60

E56

Output Diode B

E48

E50

E54

E53

A-03152

NOTE:

Refer to Appendix 11 for wiring connections.

Manual 0-2871 A-11 APPENDIX

APPENDIX 11: POWER OUTPUT PCB WIRING DIAGRAM

Output

Diode A

T o Torch Switch

J41

E37

To Bulkhead

E35 E62

To PCR

E47

E52

To Main Power PC Board

TP1

J39

To CD PCB J40

E36

E32

To Output Inductor

Output

Diode B

E45

#45

E49

#49

E57

#47

To CD Coil

E64

E43

To Output Inductor

Power Output PC Board Signals

J39-1 - Out J39-2 DC Com J39-3 Tip Sense J39-4 +12vdc J39-5 CSR J39-6 Torch Switch J39-7 Torch Switch Return J39-8 DC Enable

J40-1 +12vdc J40-2 CD Enable J40-3 Not Used J40-4 Not Used J40-5 E47 J40-6 Not Used J40-7 Not Used J40-8 E45

E58

Work Cable

J41-1 Torch Switch J41-2 Not Used J41-3 Torch Switch

E61

#52

A-03153

APPENDIX A-12 Manual 0-2871

APPENDIX 12: 28VAC CIRCUIT DIAGRAM

Line V oltage

J24

SOL

1 2 5 6

Auxiliary

Transformer

Fuse

primary

J81

J11

J18

secondary

3 4 5 6

Voltage Protection

J23

+12vdc

ON/OFF Switch

Main Power PC Board

A-03071

Manual 0-2871 A-13 APPENDIX

APPENDIX 13: MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Check plasma and secondary supply and pressure/flow.

4. Purge plasma gas line to remove any moisture build-up.

5. Inspect input power cable for damage or exposed wires, replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

APPENDIX A-14 Manual 0-2871

Manual 0-2871 A-15 APPENDIX

APPENDIX 14: SYSTEM SCHEMATIC

208/230V SINGLE PHASE INPUT

FAN2

FAN1

PILOT RELAY

PCR

28VAC B 28VAC A

ON/OFF SW

SW1

RUN/SET SW

SW2

CURRENT CONTROL

LED PCB 19X1604

CURRENT ADJUST 20 - 60

IGBT HEATSINK

INDUCTOR TEMP

NTC

TEMP

TS1

TEMP

(2)

(3)

230V

J15

P15

(6)

(7)

J18

P18

(19)

(20)

(21)

(22)

(23)

(24)

(25)

(26)

P27

(35) (36) (37) (38) (39) (40) (41) (42)

J27

J29

P29

2 3

J32

P32

J14

1 2 3 4 5 6 7 8

GAS

TS2

COPPER STRAP

CHASSIS GND

(4)

(5)

(1)

(78)

(33)

P11

E33

E22

J11

POT HIGH POT WIPER POT LOW +12V AC GAS OVERTEMP DC

+18V

FILTERING

600V, 6/10A, KTK

PILOT ON

J23

TEST CONNECTOR

(8)

SOL1

GAS SOLENOID

R30 ZERO

FOR 230V ONLY

FUSE

J24

P24

0.9A

E13

E18

(9)

LT1

PRESSURE SW

INPUT DIODE

ASSEMBLY 19X1755

1 2

460V

400V

230V

RESETABLE

(12)

(11)(10)

PS1

PRESS GOOD

MAIN CONTACTOR

(13)

9 10

E14

E16

INRUSH

28VAC A

TO BIAS SUPPLY

28VAC B

E15

+12VDC

+18V

FAN

+18VDC

SOLENOID ON RELAY

CONTACTOR ON RELAY

MAIN BOARD ASSEMBLY 19X1777

CD ON

INV ON

DRAG ON

SW ON

LOGIC BOARD

ASSEMBLY 19X1784

D20

D21

D37

D32

E20

E23

E30

J13

1 2

6 7

7 8

8 9

9 10

10 11

11 12

13 14

14 15

16 17

20 21

23 24

25 26

27 28

29 30

30 31

31 32

32 33

35 36

IGBT PCB ASSEMBLY 19X1756

E12A

E17A

24 25

E19A

E21A

IGBT PCB ASSEMBLY 19X1756

E12B

E17B

24 25

E19B

E21B

+12VDC

+12VDC DC COM DC COM

MC1ON

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

INRUSH DONE

CD ENABLE CD ENABLE

GAS ON

PILOT ON

DC OK

OVTEMP

AC OK

TORCH SW RTN

TORCH SW

+12VDC

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

CURRENT SENSE

CURRENT SENSE CURRENT SENSE RTN CURRENT SENSE RTN

EXTENDER BOARD

ASSEMBLY 19X1775

DC COM DC COM

-OUT

GATE

12231314

DRIVE

GATE DRIVE

24567

GATE

12231314

DRIVE

GATE DRIVE

24567

J43

J12

3 4

4 5

7 8

1010 11

11 12

12 13

13 14

CSR

15 16

16 17

17 18

19 20

21 22

22 23

23 24

24 25

27 28

28 29

29 30

30 31

31 32

35 36

A-03221

APPENDIX A-16 Manual 0-2871

E11A

E11B

P25J25 1

212

P3A

J3A

E9A

J7A

J3B

E9B

J7B

E32

P7A

E10

P3B

P7B

J30 P30

212

J31 P31

212

E27

P26J26

212

TIP SENSE

TORCH SW

TORCH SW RTN

CD ENABLE

-OUT

DC COM

+12VDC

CSR

MAIN

PRI

P33

J33

(70)

(71)

(72)

(73)

(74)

(75)

(76)

(77)

SEC

OUTPUT DIODE ASSEMBLY 19X1757

E50B

E45

E48B

E49

E53B E54B

OUTPUT DIODE ASSEMBLY 19X1757

E50A

E47

E48A

E52

E53A E54A

P39

J39

1 2

4 5

6 7

E34B

POWER OUTPUT BOARD ASSEMBLY 19X1754

E39B

E56B E60B

E34A E39A

E56A E60A

E36

E57

E37

E58

+12VDC

CD ENABLE

E47

E45

CURRENT SENSE

DC COM

E32

E62

E35

E43

E64

E63

J40

1 2 3 4 5 6 7 8

E61

J41

OUTPUT INDUCTOR

PILOT

THRU SCREW TERMINAL

CHASSIS GND

CD ASSEMBLY 19X1751

P40

(14)

(15)

2 3 4

(17)

5 6 7

(18)

P41

(30)

(31)

E(62)

E(35)

J28

E(58)

J42

PCR

T10

581

T O

R C H

WORK

(30)

TORCH SWITCH

(31)

COMP DESCRIPTION LOCATION

F1 F2 L1 M1 M2 PCR PS1 PRESSURE SWITCH SOL1 GAS SOLENOID SW1 SW2 T5 T10 CD TRANSFORMER C10 TS1 TS2 W1

FUSE, 6/10A 600V , KTK FUSE, 0.9A, RESETABLE OUTPUT INDUCTOR A10 FAN, 4.5" 220VAC FAN, 4.5" 220VAC PILOT RELAY

SWITCH, ON/OFF SWITCH, RUN/SET MAIN TRANSFORMER

TEMP. SENSOR, IGBT HEATSINK TEMP. SENSOR, INDUCTOR MAIN CONTACTOR F3,A2

DateByRevisionsRev

RELEASE ECO 3A16

Last Modified:

Tuesday, August 21, 2001

GCW 08/21/01

15:05:29

B2 E3

C1 B1 C1 F3 F2 C1 D1 B7

E1 F1

THERMAL DYNAMICS INDUSTRIAL PARK No. 2 WEST LEBANON, NH 03784

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF) Chk: App:

TITLE:

CM75 208/230V SINGLE PHASE 50/60 Hz

SCHEMATIC,

603-298-5711

PCB No: Assy No:

SupersedesScale

Date:

Tuesday, May 15, 2001

Drawn: References

GCW

Sheet

DWG No:

Size

42X1096

A-03221

Manual 0-2871 A-17 APPENDIX

Firepower FP-82 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.03 Service Responsibilities

2.01 Scope Of Manual

2.02 General Service Philosophy

3.01 Scope

3.02 General Description

3.03 Specifications/Design Features

3.04 Power Supply Options and Accessories

4.01 Introduction

4.02 Periodic Inspection & Cleaning Procedures

4.03 System Theory

4.04 Common Operating Problems

4.06 Circuit Fault Isolation

4.08 Pilot Arc Problems

4.10 Test Procedures

5.01 Scope

5.02 Anti-Static Handling Procedures

5.03 Parts Replacement - General Information

5.04 Major External Parts Replacement

5.06 Left Side Internal Component Parts Replacement

5.07 Rear Panel Par ts Replacement

5.08 Right Side Internal Component Parts Replacement

6.01 Introduction

6.02 Ordering Information

6.03 Major External Replacement Parts

6.04 Front Panel Replacement Parts

6.05 Left Side Internal Replacement Parts

6.06 Rear Panel Replacement Par ts

6.07 Right Side Internal Replacement Parts

6.08 Options and Accessories

APPENDIX 1: INPUT WIRING REQUIREMENTS

APPENDIX 3: LOGIC PC BOARD LAYOUT

APPENDIX 4: MAIN POWER PC BOARD LAYOUT

APPENDIX 5: MAIN PC BOARD WIRING

APPENDIX 14: SYSTEM SCHEMATIC