Firepower FP-82 User Manual

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
[phone]

Copyright 2002 by
Thermal Dynamics Corporation

All rights reserved.

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:

p

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

A

40

3

20

60

1

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:

7

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

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

2

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