Plasma Cutting
Power Supply
FirePower FP-82
A-02990
Operating Manual
January 28, 2003 Manual No. 0-2870
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
Operating Manual Number 0-2870
www.firepoweronline.com
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
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: January 28, 2003
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 Description ..................................................................................... 2-1
2.03 Specifications/Design Features.................................................................... 2-1
2.04 Options and Accessories ............................................................................. 2-2
SECTION 3:
INST ALLATION PROCEDURES ....................................................................................... 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Selection ............................................................................................... 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Lifting Options .............................................................................................. 3-1
3.05 Primary Input Power Connections ................................................................ 3-2
3.06 Gas Connections ......................................................................................... 3-2
3.07 Torch Connections ....................................................................................... 3-4
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction .................................................................................................. 4-1
4.02 Product Features.......................................................................................... 4-1
4.03 Preparations For Operating.......................................................................... 4-2
4.04 Sequence of Operation ................................................................................ 4-3
TABLE OF CONTENTS (continued)
SECTION 5:
CUSTOMER/OPERATOR SERVICE................................................................................. 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 General Maintenance ................................................................................... 5-1
5.03 Common Faults............................................................................................ 5-2
5.04 Basic T roubleshooting Guide........................................................................ 5-3
5.05 P ow er Supply Basic P arts Replacement ...................................................... 5-5
SECTION 6:
PARTS LISTS.................................................................................................................... 6-1
6.01 Introduction .................................................................................................. 6-1
6.02 Ordering Information .................................................................................... 6-1
6.03 P ower Supply Replacement ......................................................................... 6-2
6.04 Replacement Parts....................................................................................... 6-2
6.05 Options and Accessories ............................................................................. 6-2
APPENDIX 1: INPUT WIRING REQ UIREMENTS ....................................................................A-1
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIA GRAM) .........................................A-2
APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................ A-3
APPENDIX 4: SYSTEM SCHEMATIC.......................................................................................A-4
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:
p
INTRODUCTION
2.01 Scope of Manual
3. 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.
This manual contains descriptions, operating instructions
and basic maintenance procedures for the FirePower 82
Plasma Cutting Power Supply only. Servicing of this
equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at
the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
NOTE
Refer to the Torch Manual for torch and cutting
information.
2.02 General Description
The power supply provides 60 amp maximum output and
includes all control circuitry, electrical and gas inputs and
outputs, pilot circuitry, primary input power cable, and
work cable & clamp.
Section 2.04 lists power supply options and accessories.
Fi rePower F P - 82 P owe r S upply Duty Cycl e
Ambient
erature
Tem
Duty Cy cle
Current
DC Voltage
4. Pilot Circuitry
Capacitive Discharge (CD), Ignition DC Pilot
5. Weight
83 lbs (37.6 kg)
W eight includes Power Supply w/Input Cable, W ork
Lead, and Torch & Leads.
6. Overall Dimensions (incl. handles)
• Length: 27.5 inches (696 mm)
• Width: 12.4 inches (315 mm)
• Height: 17.3 inches (439 mm)
7. Gas Regulator/Filter Assembly Specifications
104° F
(40° C)
50% 60% 100%
60 Amps 60 Amps 45 Amps
109V 109V 98V
104° F
(40° C)
104° F
(40° C)
2.03 Specifications/Design Features
A. Power Supply Technical Specifications
These specifications apply to the Power Supply only:
1. Input Power (See Note)
Available for the following input power:
• 208/230VAC (±10%), Single-Phase, 50/60 Hz
NOTE
Refer to Appendix 1 for input wiring requirements.
Units include an input cable and plug.
2. Output Power
Continuously variable from 15 to 60 amps.
The following specifications apply to the Gas Regulator/
Filter Assembly only:
• Operating Pressure (Output): 70 psi (4.8 bar)
• Maximum input gas pressure: 125 psi (8.6 bar)
• Filter: Coalescent type filter
Manual 0-2870 2-1 INTRODUCTION
2.04 Options and Accessories
The following options and 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
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
For use on compressed air shop systems. Filters moisture and particulate matter from the air stream to at
least 5.0 microns.
INTRODUCTION 2-2 Manual 0-2870
SECTION 3:
3.03 Unpacking
INSTALLATION
3.01 Introduction
This Section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for those
units.
Depending on how the system was ordered, some Power
Supply Options may already be installed.
If option(s) have been factory installed some of the instructions may not apply . It is r ecommended that all subsections be read for general information.
The complete installation consists of:
1. Site selection
2. Unpacking
3. Connections to Power Supply
a. Input power
b. Gas
c. Torch Leads
d. W ork cable
4. Grounding
5. Operator training
3.02 Site Selection
The product is packaged and protected to prevent damage during shipping.
1. Unpack each item and remove any packing material.
2. Locate the packing list(s) and use the list(s) to identify and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with the installation.
3.04 Lifting Options
This unit is equipped with a handle designed for hand
lifting only. Be sure unit is lifted and transported safely
and securely.
• Only persons of adequate physical strength should
lift the unit.
• Lift unit by the handle, using two hands.
• Use hand cart or similar device of adequate capacity to move unit.
• Place and secure unit on a proper skid before transporting with a fork lift or other vehicle.
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
Select a clean, dry location with good ventilation and adequate working space around all components.
Review Important Safety Precautions (Section 1) to be sure
that the selected location meets all safety requirements.
The power supply is fan cooled by air flow through the
side panel to the front and rear panels. Air flow must not
be obstructed. Provide at least 2 feet (61 cm) in the rear
and at least 6 inches (152 mm) on each side for clearance.
Provide a minimum of 6 inches (or 152 mm) clearance in
front of the unit to allow access to the front panel controls.
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
Manual 0-2870 3-1 INSTALLA TION
F ALLING EQUIPMENT can cause serious personal injury and equipment damage.
HANDLE is not for mechanical lifting.
3.05 Primary Input Power
1
Regulator/Filter
Connections
Check your power source for correct voltage before connecting the unit. This power supply includes a factoryinstalled input power cable and plug suitable for 208/
230V (± 10%) single-phase input power.
1. Check your power source for correct voltage before
plugging in the unit.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
CAUTION
The primary power source and power cable must
conform to local electrical code and the recommended circuit protection and wiring requir ements
(refer to table in Appendix 1).
3.06 Gas Connections
A. Gas Requirements
WARNING
B. Checking Air Quality
T o test the quality of air , place the RUN/SET switch to SET
(down) position, place a welding filter lens in front of the torch
and turn on the gas. Any oil or moisture in the air will be visible
on the lens. Do not initiate an arc!
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
C. Connecting Gas Supply to Unit
The gas supply is connected to the Regulator/Filter Assembly located on the rear of the unit. The connection is
the same for compressed air or high pressure gas cylinders. If an optional air line filter is to be installed, refer to
procedures in subsection 3.06-D.
Connect the gas supply as follows:
1. Use customer-supplied fittings to connect the gas line
to the Regulator/Filter . Typical fittings are shown as
an example. Install the fittings and tighten.
This unit is not to be used with oxygen (O2).
Gases: Single Gas - Plasma/Secondary
Compressed Air Only
Pressure: 70 psi (4.8 bar)
CAUTION
Maximum pressure at inlet must not exceed 125
psi (8.6 bar)
Flow: Cutting - 400 scfh (190 lpm)
Gouging - 400 scfh (190 lpm)
scfh = standard cubic feet per hour.
Inlet Port
Bowl
/4 NPT to 1/4"
(6mm) Fitting
Hose Clamp
Art # A-02999
Gas Supply
Hose
Assembly
Gas Connection to Regulator/Filter Assembly
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.
INSTALLATION 3-2 Manual 0-2870
D. Installing Optional Air Filter Kits
2. Optional Two-Stage Air Filter Kit
Additional filtering is recommended when using air from
a compressor to insure that moisture and debris fr om the
supply hose does not enter the torch. Although the Regulator/Filter Assembly has its own filter, the optional filter kits are recommended for improved filtering.
1. Optional Single-Stage Air Filter Kit
This optional in-line air filter for use on compressed
air shop systems is highly effective at removing moisture and particulate matter from the air stream to at
least 0.85 microns.
Regulator/Filter
Assembly
Bowl
1/4 NPT Hose Fitting
Hose Clamp
1/4" (6 mm) Gas Supply Hose
Inlet Port
A-03000
Optional Single-Stage Filter Installation
NOTE
This optional two-stage air line filter is also for use
on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns.
Connect the gas supply as follows:
a. Attach the T wo Stage Filter bracket to the back
of the power supply.
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.
b. Connect the two stage filter outlet hose to the
inlet port of the Regulator/Filter Assembly.
c. Use customer-supplied fittings to connect the
gas line to the Filter . T ypical fittings are shown
as an example. Install the fittings and tighten.
Regulator/Filter
Assembly
Hose
Clamp
Regulator Inlet Port
2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
Two Stage
Filter
Assembly
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. Connect the
1/4" (6 mm) Gas
Supply Hose)
1/4 NPT
Hose Fitting
A-03004
gas supply as follows:
a. Attach the Single-Stage Filter Hose to the
Optional Two-Stage Filter Installation
Regulator/Filter Assembly inlet port as
shown.
b. Attach the Single-Stage Filter Assembly to the
filter hose.
c. Use customer-supplied fittings to connect the
gas line to the Filter . T ypical fittings are shown
as an example. Install the fittings and tighten.
Manual 0-2870 3-3 INSTALLA TION
E. Using High Pressure Gas Cylinders
Refer to the following when using high pressure gas cylinders as the gas supply:
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.
Torch Leads
Assembly
Strain Relief
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high
pressure gas regulators.
2. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign material. Momentarily open each cylinder valve to
blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high-pressure regulator capable of outlet
pressures up to 100 psi (6.9 bar) maximum and
flows of up to 400 scfh ( 190 lpm).
4. Use a customer-supplied fitting to connect the gas
line to the cylinder . Install the fitting and tighten.
5. Secure the gas supply hose in place with a (customer supplied) adjustable hose clamp.
NOTE
Supply hose must be at least 1/4 inch (6 mm) I.D.
3.07 Torch Connections
NOTE
Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.
Negative /
Plasma Lead
A-03529
Pilot Lead
Strain Relief
Nut
Retaining Nut Removal
3. Feed the torch lead ends and the Strain Relief into
the hole in the front of the unit.
4. Secure the Strain Relief with the retaining nut removed earlier .
5. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.
Note: Actual Bulkhead
configuration may
differ from that shown.
Negative/Plasma
Lead Connection
Adapter
Control Circuit
Connectors
Adapter
Connector
The T orch Leads must be pr operly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the T or ch
Bulkhead Panel for the desired application.
WARNING
Negative/Plasma
Torch Lead
Assembly
Pilot Lead Stud
Pilot Lead
Lead
A-03542
Disconnect primary power at the source before disassembling the torch or torch leads.
1. Remove the Cover of the Power Supply for access to the T orch Bulkhead Panel. See Section 5.05.
2. Remove the retaining nut from the Strain Relief.
Torch Lead Connections To Bulkhead
6. Connect the Control (PIP) Circuit Connectors to
the mating connectors on the Power Supply
Adapter.
7. Remove the top nut and washer from the Pilot
Stud.
INSTALLA TION 3-4 Man ual 0-2870
8. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in Step 7.
9. Tighten the Strain Relief onto the Torch Leads.
10. Check the torch for proper parts assembly.
CAUTION
The torch parts must correspond with the type of
operation. Refer to the appropriate torch manual
for proper parts selection.
11. Re-install the Power Supply Cover on the Power
Supply.
Manual 0-2870 3-5 INSTALLA TION
INSTALLA TION 3-6 Man ual 0-2870
SECTION 4:
OPERATION
4.01 Introduction
This section describes the power supply operating controls and procedures, identifies the front and rear components, and describes the operating procedures.
5. Torch Bulkhead Panel
The torch bulkhead panel is under the power supply
cover.
• Pilot Lead Stud
Connects the pilot control wire on the torch to the
unit.
• Control Cable Connector
Connects the torch switch to the unit.
4.02 Product Features
A. Front and Side Panel Features
1. Control Panel
All operator controls, except gas pressure adjustment,
are on this panel.
4
1
3
A-02992
• Gas/Power Lead Connection
Connects the torch gas/negative lead to the unit.
B. Control Panel Features
A
40
3
20
60
2
1
A-03208
4
5
6
7
2
Operating Controls
1. ON/OFF Power Switch
2. Torch Leads Input
Hole in the front panel to feed the torch leads through
to the internal bulkhead connections.
3. Work Cable and Clamp
20 ft (6.1 m) work cable with clamp, factory installed.
4. Roll Handle/Torch Leads Wrap
The torch leads and work cable wrap around the
handle for easy storage.
Manual 0-2870 4-1 OPERATION
ON (up) position supplies AC power to activate all
system control circuits. OFF (down) position deactivates control circuits.
2. RUN/SET Switch
RUN (up) position is used for general torch operation. Torch switch must be held. SET (down) position used for setting gas pressure and purging lines.
3. Current Control (A)
Adjustment to set the desired output current up to 40
amps (for drag cutting) or up to 60 amps (for standoff
cutting). Minimum output is approximately 15 amps.
At output settings over 40 amps, control circuitry in
the power supply automatically reduces output current to 40 amps if the torch tip contacts the workpiece.
4. AC Power Indicator
3
Primary input power cable with plug.
Green indicator will blink ON-OFF for approximately eight
seconds and then stay ON after the ON/OFF power switch
is set to ON. Indicates operating power is present in the
unit.
5.
TEMP Indicator
Normally OFF . Y ellow indicator will come ON when the
internal temperature sensors detect temperatures above
normal limits. The unit should be allowed to cool before
continuing operation.
GAS Indicator
6.
Green indicator will come ON when the input gas pressure
is set to
when the pressure falls below 35 psi (2.4 bar).
7. DC Indicator
Green indicator will come ON while the torch switch is
pressed. Indicates DC output circuit is active.
35 psi (2.4 bar) or higher . Indicator will be OFF
C. Rear Panel Features
1. Gas Input Port
Input connection for compressed air input.
3. Gas Pressure Regulator/Filter Assembly
Pressure regulator to adjust the input gas pressure to the
Power Supply . The pressure r egulator has its own built-in
filter .
For improved filtering, other filtering packages are
available as options.
4.03 Preparations For Operating
This procedure should be followed at the beginning of each
shift:
W ARNING
Disconnect primary power at the source before
assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate
front end torch parts. The torch parts must corr espond
with the type of operation (cutting or gouging). Refer to the torch manual for proper parts selection.
B. Check Primary Input Power Source
W ARNING
This unit is not to be used with oxygen (O2).
1. Check the power source for proper input voltage.
Make sure the input power source meets the power
requirements for the unit per subsection 2.03-A,
Specifications/Design Features.
2. Connect the input power cable (or close the main
disconnect switch) to supply power to the system.
C. Gas Selection
Select desired single gas supply . Make sur e gas source
1
meets requirements (refer to subsection 3.06, Gas Re-
quirements). Check connections and turn gas supply
on.
2
2. Primary Input Power Cable
OPERATION 4-2 Manual 0-2870
A-02996
D. Work Cable Connection
4.04 Sequence of Operation
Check for a solid work cable connection to the workpiece.
Make a solid work cable
connection to the workpiece or cutting table
A-00925
E. Torch Connection
Check that the torch is properly connected.
F. Power On
The following is a typical sequence of operation for this
power supply. Refer to Appendix 2 for block diagram.
1. Close main power source disconnect switch.
a. AC power is available at the Power Supply.
2. Place RUN/SET switch to RUN (up) position.
3. Place the ON/OFF power switch to ON (up) posi-
tion.
a. AC Power Indicator
for eight seconds then stays ON; Fans turn on.
NOTE
Gas comes on if Torch is activated (although unit
will not pilot until switch is released and re-closed
after the light stops blinking).
4. Place RUN/SET switch to SET (down) position.
a. Gas flows to set pressure. Gas Pressure Regu-
lator/Filter Assembly should be set to 70 psi
(4.8 bar).
b. GAS indicator turns ON.
blinks ON and OFF
Place the power supply ON/OFF switch to the ON
(up) position.
G. Select Current Output Level (A)
Set the desired current output level between 20-60
amps for cutting or gouging.
H. Set Operating Pressure
Place the RUN/SET switch to the SET (down) position. Gas will flow . Adjust gas pr essur e control to 70
psi (4.8 bar).
I. Prepare to Cut
Return the RUN/SET switch to RUN (up) position.
Gas will not flow until the Torch Trigger is pr essed.
The system is now ready for operation. Press torch
switch on the handle. There is a 2 second pre-flow
before the arc starts.
NOTE
GAS Indicator will not come ON if the gas pressure is set below 35 psi (2.4 bar) at the Gas Pressure Regulator/Filter Assembly.
5. Place RUN/SET switch to RUN (up) position.
a. Gas flow stops; GAS Indicator turns OFF.
6. Protect eyes and activate torch.
a. Gas pre-flow starts (appr oximately 2 seconds);
GAS Indicator turns ON.
7. After gas pre-flow:
a. DC indicator turns ON.
8. Pilot arc is established.
9. Move T orch within transfer distance of workpiece.
a. Main arc transfers; Pilot arc OFF .
Manual 0-2870 4-3 OPERATION
10. Complete cutting operation.
NOTES
If the torch is lifted from the workpiece while the
torch is activated, the main arc will stop and the
pilot arc will automatically restart.
At output settings over 40 amps, control circuitry
in the power supply automatically reduces output
current to 40 amps if the torch tip contacts the
workpiece.
11. Release the torch switch.
a. Main arc stops; Pilot arc stops.
If torch is activated during post-flow, the pilot
arc will immediately restart. If tor ch is within
1/4 inch (6.4 mm) transfer distance to
workpiece, the main arc will transfer.
12. Gas will flow for 10 seconds (post-flow).
a. Gas flow stops; GAS indicator turns OFF.
13. Place the ON/OFF power switch to OFF (down)
position.
a. AC Power indicator turns OFF; Fans turn OFF .
14. Place the main power disconnect to OFF (open).
a. Main AC power is removed from the system.
For information on cutting techniques, cutting problems,
cutting speeds, cut quality , etc., r efer to the torch manual
supplied with the torch.
OPERA TION 4-4 Man ual 0-2870
SECTION 5:
CUSTOMER/OPERATOR
SERVICE
5.01 Introduction
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.
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted other than by properly trained
personnel.
5.02 General Maintenance
A. Maintenance Schedule
W ARNING
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 3 for maintenance schedule and procedures.
Regulator/Filter
Assembly
Baffle
Ring
Filter
Element
Spring
Spool
Bowl
A-02995
Regulator/Filter Element Replacement
6. Reinstall the bowl.
7. T urn on the air supply.
B. Regulator/Filter Element Replacement
The Regulator/Filter Assembly is on the rear panel. For
better system performance, the Regulator/Filter Assembly
filter element should be checked per the Maintenance
Schedule, and either cleaned or replaced. Refer to Section
6, Parts List, for replacement filter element catalog number .
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 .
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 and either clean it
or replace it.
C. Optional Single-Stage Filter Element
Replacement
These instructions apply to power supplies where the optional Single-Stage Filter has been installed.
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. Refer to Section
6, Parts List, for replacement filter element catalog number .
1. Remove power from power supply .
2. Shut off air supply and bleed down system before
disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Cover counter-clockwise and remove it
from the Filter Housing. The Filter Element is located inside the Housing.
Manual 0-2870 5- 1 CUSTOMER/OPERATOR SER VICE
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move
freely.
4. Note the location and orientation of the old Filter
Elements.
5. Slide out the old Filter Elements.
O-ring
Cover
Barbed
Fitting
Assembled Filter
A-02476
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and
set Element aside to dry .
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE
If unit leaks between housing and cover , inspect the
"O" Ring for cuts or other damage.
D. Optional Two-Stage Filter Element
Replacement
First & Second
Stage
Cartridges
(as marked)
A-02942
Optional Two-Stage Filter Replacement
6. Slide the replacement Filter Elements into the Filter
Assembly, with the same orientation as noted in
Step 4 above.
7. Hand tighten the two bolts evenly , then torque each
bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).
8. Slowly apply air pressure to the assembly, checking for leaks.
These instructions apply to any power supply where the
optional T wo-Stage Filter has been installed.
The Two-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. Refer to Section 6, Parts List, for replacement filter
5.03 Common Faults
1. Insufficient Penetration
a. Cutting speed too fast
b. T or ch tilted too much
element catalog number .
c. Metal too thick
1. Remove power from power supply .
d. Worn torch parts
2. Shut off air supply and bleed down system before
changing Filter Elements.
e. Cutting current too low
f. Non-Genuine FirePower parts used
W ARNING
Always turn off the air supply and bleed the system
before disassembling the Filter Assembly as injury
could result.
CUSTOMER/OPERA T OR SERVICE 5- 2 Manual 0-2870
2. Main Arc Extinguishes
B. How to Use This Guide
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
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine FirePower parts used
4. Short T orch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
The following information is a guide to help the Customer/
Operator determine the most likely causes for various
symptoms. Follow all instructions as listed and complete
each section in the order presented.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (T ext T ype)
1. Cause (Italic Type)
a. Check/Remedy (T ext T ype)
Locate your symptom, check the causes (easiest listed
first), then remedies. Repair as needed being sure to
verify that unit is fully operational after any repairs.
C. Common Symptoms
A. AC Power indicator OFF
1. Switch at customer's main power panel in OFF position.
a. Close main power panel switch.
2. Customer's main power line fuse(s) blown
d. Gas pressure too low
e. Improperly assembled torch
f. Non-Genuine FirePower parts used
5.04 Basic Troubleshooting Guide
W ARNING
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. Basic Tr oubleshooting: Overview
This guide covers a basic level of troubleshooting that re-
quires limited disassembly and measurements. It is helpful for solving many of the common problems that can
arise with this system.
If major complex subassemblies are faulty, the unit must
be returned to an authorized service center for repair .
Follow all instructions as listed and complete each section in the order presented.
a. Check main power panel fuse(s) and replace as
required.
3. Actual input voltage does not correspond to voltage of
unit
a. Verify that the input line voltage is corr ect. Re-
fer to Appendix 1, Input W iring Requirements.
4. Unit internal fuse blown or loose
a. If blown, double check input voltage and replace
fuse per subsection 5.05-B. If fuse blows again,
return unit to an authorized service center .
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
B. AC Power indicator ON; TEMP indicator
ON
1. Air flow obstructed
a. Check for obstructed air flow around the unit
and correct condition.
2. Fan(s) blocked
a. Check and correct condition.
For major troubleshooting and parts replacement procedures refer to Power Supply Service Manual 0-2871.
Manual 0-2870 5- 3 CUSTOMER/OPERATOR SERVICE
3. Unit is overheated
E. Low cutting output
a. Allow unit to cool down for at least 5 minutes.
Make sure the unit has not been operated beyond Duty Cycle limit. Refer to Section 2.03.
4. Input line voltage is below 75% of rated level
a. Check and connect to proper input power line.
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
C. T orch will not pilot when torch switch is activated
1. RUN/SET switch in SET (down) position
a. Move switch to RUN (up) position.
2. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
fer to Instruction Manual supplied with torch).
3. Gas pressure too high or too low
a. Set pressure to 70 psi (4.8 bar).
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
1. Incorrect setting of CURRENT (A) control
a. Check and adjust to proper setting.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
F . Limited output with no control
1. Poor input or output connections
a. Check all input and output connections.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
G. Erratic or improper cutting output
1. Poor input or output connections
a. Check all input and output connections.
2. Poor ground or work connection is poor.
a. Check connection.
H. Arc shuts off during operation; Arc will not re-start
when torch switch is activated.
D. No cutting output; T orch activated; AC Power
indicator
1. Work cable not connected to workpiece
a. Connect work clamp to workpiece. Connection
area must be clear of oil, grease, rust, etc.
2. T orch not properly connected to power supply
a. Check that torch leads are properly attached to
power supply .
3. Shield cup not properly installed on torch
a. Check that shield cup is fully seated against torch
head. Refer to the torch manual for details.
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
5. Faulty T orch
a. Return for repair or have qualified technician
repair per T or ch Manual.
ON; Gas flows; Fans operate
1. Unit is overheated (TEMP indicator ON)
a. Allow unit to cool down for at least 5 minutes.
Make sure the unit has not been operated beyond Duty Cycle limit. Refer to Section 2 for
duty cycle specifications.
2. Fan blades blocked (TEMP indicator ON)
a. Check and clear blades.
3. Air flow obstructed (TEMP indicator ON)
a. Check for obstructed air flow around the unit
and correct condition.
4. Gas pressure too low (GAS indicator OFF when torch
switch is activated)
a. Check source for at 70 psi (4.8 bar); adjust as
needed.
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
CUSTOMER/OPERA T OR SERVICE 5- 4 Manual 0-2870
I. No gas flow; AC POWER indicator ON; Fan
A-03001
Lower
screws
Upper screws
Ground wire
Lower
screws
Upper
screws
operates
1. Gas not connected or pressure too low
5.05 Power Supply Basic Parts Replacement
a. Check source for at least 70 psi (4.8 bar).
2. Gas supply pressure too high
a. Maximum 125 psi (8.6 bar) inlet pressure
3. Shield Cup not properly installed.
a. Check to see that Control Circuit (PIP) pins are
installed. Refer to the torch manual for details.
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
J. Torch cuts but not adequately
1. Current set too low
a. Increase current setting.
2. T orch is being moved too fast across workpiece
a. Reduce cutting speed (refer to Torch Instr uction
Manual supplied with torch).
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface
while purging and observe oil or moisture
buildup (do not activate torch).
W ARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
This section describes procedures for basic parts replacement. For more detailed parts replacement procedures,
refer to the Power Supply Service Manual.
A. Cover Removal
1. Remove the upper screws which secure the cover
to the main assembly .
NOTE
There is a ground wire connection to the inside of
the unit. There is no need to disconnect the ground
wire, unless there is a need for more room to work.
4. Tor ch tip being dragged on work.
a. Lift torch tip off work. At output settings over 40
amps, control circuitry in the power supply automatically reduces output current to 40 amps if
the torch tip contacts the workpiece.
Cover Removal
Manual 0-2870 5- 5 CUSTOMER/OPERATOR SERVICE
2. Loosen, but do not remove, the lower screws, then
carefully pull the Cover up and away from the unit
to gain access to the inside of the unit.
3. T o reinstall the cover , complete the following:
a. Reconnect the ground wire, if necessary.
b. Place the cover onto the frame so that it rests on
the lower screws.
c. Reinstall and tighten the upper screws.
d. Tighten lower screws.
B. Fuse Replacement
1. Remove the unit cover per paragraph "A" above.
2. Locate the internal fuse on the left side of the center
chassis.
3. Replace the fuse. Refer to Section 6, Parts Lists, for
replacement fuse catalog number .
4. Reinstall the cover by reversing the steps in paragraph "A" above.
Fuse Location
A-03002
Internal Fuse Location
This completes the parts replacement procedures.
CUSTOMER/OPERA T OR SERVICE 5- 6 Manual 0-2870
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all r eplaceable components. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Replacement Parts
Section 6.05 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 0-2870 6-1 P A RTS LISTS
6.03 Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, gas pressur e regulator/
filter , and operating manual.
Qty Description Catalog #
1 Firepower FP-82 Power Supply, 208/230VAC, Single-Phase, 1445-0002
with input power cable and plug
6.04 Replacement Parts
Qty Description Catalog #
1 Fuse 9-8588
1 Regulator/Filter Assembly Replacement Element 9-4414
6.05 Options and Accessories
Qty Description Catalog #
1 Single-Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two-Stage 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 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Cover
Barbed
Fitting
Assembled Filter
A-02476
First & Second
Stage
Cartridges
(as marked)
A-02942
Optional Single-Stage Filter Kit Optional Two-Stage Filter Kit
PARTS LISTS 6-2 Manual 0-2870
APPENDIX 1: INPUT WIRING REQUIREMENTS
FireP ower FP -82 Input Wiring Re quireme nts
Input Power Input Current Input Suggested Sizes (See Note 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 50 6 6
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on Na tional 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 0-2870 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 moved within
transfer distance of workpiece.
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.
RESULT
Main arc transfer.
Pilot arc off.
ACTION
Open external
disconnect.
RESULT
No power to system.
A-02778
APPENDIX A-2 Manual 0-2870
APPENDIX 3: 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 .
Manual 0-2870 A-3 APPENDIX
APPENDIX 4: SYSTEM SCHEMATIC
A
B
C
D
E
F
208/230V
SINGLE PHASE
INPUT
M2
FAN2
M1
FAN1
PILOT RELAY
PCR
28VAC B
28VAC A
ON/OFF SW
SW1
R
RUN/SET SW
SW2
CW
CURRENT
CONTROL
LED PCB
19X1604
CURRENT ADJUST
20 - 60
IGBT HEATSINK
INDUCTOR TEMP
1
W1
L1
W1
L2
(2)
W1
L3
(3)
W1
L4
230V
J15
P15
(6)
6
6
(6)
5
5
(7)
2
2
(7)
1
1
J18
P18
(19)
1
1
(20)
2
2
(21)
3
3
(22)
4
4
(23)
5
5
(24)
6
6
(25)
7
7
(26)
8
8
S
P27
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
J27
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
J29
P29
1
1
2
2
3
3
4
4
J32
P32
1
1
2
2
AC
TEMP
NTC
TS1
TEMP
GAS
DC
J14
1
2
3
4
5
6
7
8
t
TS2
COPPER
STRAP
CHASSIS
GND
(4)
(5)
(1)
(78)
(33)
P11
1
4
K2
POT HIGH
POT WIPER
POT LOW
+12V
AC
GAS
OVERTEMP
DC
2
E1
E2
E3
E33
E22
J11
1
4
+18V
FILTERING
600V, 6/10A, KTK
PILOT ON
1
2
J23
TEST CONNECTOR
K4
(8)
SOL1
A
GAS SOLENOID
R30
ZERO
FOR 230V
ONLY
3
FUSE
J24
P24
B
F1
0.9A
E13
E18
F2
(9)
INPUT DIODE
ASSEMBLY 19X1755
1 2
LT1
RESETABLE
2
1
3
4
4
3
1
2
(11)(10)
PRESSURE SW
460V
400V
230V
6
5
3
1
5
5
6
6
(12)
PS1
3
T1
K5
7
7
K1
7
9
10
12
PRESS GOOD
8
8
(13)
W1
MAIN CONTACTOR
E6
E8
E14
E16
INRUSH
K1
28VAC A
TO BIAS SUPPLY
28VAC B
4
E7
E5
E15
K1
+12VDC
+18V
FAN
K2
+18VDC
SOLENOID ON RELAY
+18VDC
CONTACTOR ON RELAY
MAIN BOARD ASSEMBLY 19X1777
CD ON
INV ON
DRAG ON
SW ON
LOGIC BOARD
ASSEMBLY 19X1784
D20
D21
D37
D32
E4
E20
E23
E30
K4
K5
P1
J13
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
27
28
28
29
29
30
30
31
31
32
32
33
33
34
34
35
35
36
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
5
GATE
12231314
DRIVE
28
27
GATE
DRIVE
1
24567
GATE
12231314
DRIVE
28
27
GATE
DRIVE
1
24567
J43
J12
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
1010
11
11
12
12
13
13
14
14
15
CSR
15
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
27
28
28
29
29
30
30
31
31
32
32
33
33
34
34
35
35
36
36
A-03221
1
2
3
4
5
APPENDIX A-4 Manual 0-2870
E11A
E11B
6
P25J25
1
J3A
1
2
E9A
J7A
1
2
J3B
1
2
E9B
J7B
1
2
212
P3A
1
2
E32
MAIN
T5
P7A
E10
1
2
P3B
1
2
P7B
1
2
1
J30 P30
212
1
J31 P31
212
E27
P26J26
1
212
TIP SENSE
TORCH SW
TORCH SW RTN
CD ENABLE
DC COM
+12VDC
-OUT
PRI
PRI
P33
J33
CSR
(70)
1
1
(71)
2
2
(72)
3
3
(73)
4
4
(74)
5
5
(75)
6
6
(76)
7
7
(77)
8
8
SEC
SEC
7
OUTPUT DIODE
ASSEMBLY
19X1757
E50B
E45
E48B
E49
E53B
E54B
OUTPUT DIODE
ASSEMBLY
19X1757
E50A
E47
E48A
E52
E53A
E54A
P39
J39
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
8
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
9
E32
E62
E35
E43
E64
E63
J40
1
2
3
4
5
6
7
8
E61
J41
3
2
1
OUTPUT INDUCTOR
PILOT
THRU SCREW TERMINAL
CHASSIS GND
CD ASSEMBLY
19X1751
P40
(14)
1
(15)
2
3
4
(17)
5
6
7
(18)
8
P41
(30)
3
2
(31)
1
L1
E(62)
E(35)
J28
2
E(58)
J42
3
4
13
10
A
B
PCR
T10
CD
581
T
O
R
C
H
WORK
C
D
(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
6
7
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
AA
Last Modified:
Tuesday, August 21, 2001
GCW 08/21/01
15:05:29
8
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
9
PCB No:
Assy No:
Date:
Drawn: References
Size
SupersedesScale
Tuesday, May 15, 2001
GCW
11
DWG No:
42X1096
C
10
Sheet
A-03221
E
F
of
Manual 0-2870 A-5 APPENDIX
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