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Firepower FirePower FP-82, Operating Manual

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APPENDIX

A-4

Manual 0-2870

APPENDIX 4:  SYSTEM SCHEMATIC

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

3

GATE DRIVE A

(22)

SOL1

J32

19

32

(38)

33

28

2

AC

PILOT ON

27

20

3

K1

34

TIP SENSE

P1

4

22

MAIN CONTACTOR

4

18

35

30

23

14

(37)

AC

21

17

7

(23)

230V

K5

29

3

3

P32

3

19

INRUSH DONE

+12VDC

26

29

4

CURRENT
CONTROL

24

460V

MC1ON

(40)

6

4

1

35

OVERTEMP

+12V

POT LOW

8

11

OVTEMP

K2

LOGIC BOARD

34

24

3

J14

26

GATE
DRIVE

FILTERING

30

22

1

(5)

10

10

CURRENT SENSE

8

7

1

4

(36)

(19)

1

30

OVERTEMP

600V, 6/10A, KTK

24

GATE DRIVE A RTN

7

25

30

6

31

18

1

4

18

CURRENT SENSE RTN

(39)

J18

(3)

J29

11

1

(35)

2

6

13

CURRENT SENSE

17

+12VDC

(42)

1

11

17

6

CSR

230V

14

35

21

3

2

4

1

34

DC OK

(41)

P18

(20)

(26)

20

8

5

P29

1

6

CD ENABLE

IGBT PCB ASSEMBLY  19X1756

7

GAS ON

15
16

POT WIPER

3

GAS

POT HIGH

1

29

36

1

2

1

TO BIAS SUPPLY

28

(7)

GATE
DRIVE

36

32

+12VDC

6

6

3

33

AC OK

4

13

DC

22

32

GAS

1

CD ENABLE

J13

5

W1

24

33

DC

5

1

7

MAIN BOARD ASSEMBLY 19X1777

GATE
DRIVE

P24

17

PILOT ON

11

2

4

4

TORCH SW

28

15

ON/OFF SW

CHASSIS
  GND

J43

19

J27

5

8

5

P11

FAN1

14

8

16

15

5

(25)

1

1

PRESS GOOD

23

22

9

(24)

RUN/SET SW

20

GATE DRIVE B

35

LED PCB
19X1604

27

J11

2

2

32

5

12

M2

7

4

8

W1

A

33

GATE DRIVE B RTN

GAS SOLENOID

1

13

(12)

34

3

28VAC B

31

2

28VAC B

S

3

27

D21

9

6

8

8

8

7

K4

21

2

12

20

(8)

25

D32

27

12

5

J12

26

16

P15

(6)

36

TEMP

FAN2

15

PRESS GOOD

W1

(9)

5

31

IGBT PCB ASSEMBLY  19X1756

(1)

21

PILOT RELAY

GATE

DRIVE

J24

7

2

25

29

14

6

B

4

23

POT WIPER

7

P27

5

(13)

5

3

28

(21)

D37

36

10

4

31

6

1

W1

16

19

10

R

J15

9

2

(4)

26

-OUT

6

2

PRESSURE SW

RUN/SET

(2)

2

2

2

25

M1

9

18

POT HIGH

12

J23

23

13

28VAC A

K1

400V

POT LOW

2

CURRENT SENSE RTN

CURRENT ADJUST
  20  -  60

D20

INV ON

DRAG ON

CD ON

SW ON

(6)

(7)

1

7

3
4
5

2

8

6

1

7

3
4
5

2

8

6

K1

INPUT DIODE

ASSEMBLY 19X1755

PCR

INRUSH

0.9A

EXTENDER BOARD

ASSEMBLY 19X1775

TEST CONNECTOR

28VAC A

K5

K4

CONTACTOR ON RELAY

SOLENOID ON RELAY

SW1

SW2

TS1

F2

PS1

(11)

(10)

IGBT HEATSINK

TEMP

TS2

INDUCTOR TEMP

ASSEMBLY 19X1784

K2

FAN

NTC

DC COM
DC COM

DC COM

DC COM

TORCH SW RTN

208/230V
SINGLE PHASE 
INPUT

COPPER
STRAP

(78)

W1

L1

L2

L3

L4

R30

FOR 230V
ONLY

ZERO

(33)

CW

+12VDC

+18V

+18VDC

+18VDC

+18V

E30

E13

 
 

E22

 

 

E3

 

 

E12B

E16

 

 

E17B

E6

E17A

E33

 

 

E19A

E21A

 
 

E5

 

 

24

12

23

13

14

25

27

2

4

5

6

7

1

28

E1

E23

E8

F1

FUSE

 

 

 

 

24

12

23

13

14

25

27

2

4

5

6

7

1

28

E4

E12A

RESETABLE

 

 

E15

E20

T1

 

6

1

3

5

7

9

10

12

E14

E2

E19B

t

E7

 

 

E18

 

 

LT1

1

2

E21B

A-03221

Summary of Contents for FirePower FP-82

Page 1: ...Operating Manual Plasma Cutting Power Supply FirePower FP 82 January 28 2003 Manual No 0 2870 A 02990...

Page 2: ......

Page 3: ...n 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 Wa...

Page 4: ...ranty 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 INSTALLATION PROCEDURES 3...

Page 5: ...5 05 Power Supply Basic Parts Replacement 5 5 SECTION 6 PARTS LISTS 6 1 6 01 Introduction 6 1 6 02 Ordering Information 6 1 6 03 Power Supply Replacement 6 2 6 04 Replacement Parts 6 2 6 05 Options a...

Page 6: ......

Page 7: ...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...

Page 8: ...ns in this manual PLASMAARC RAYS PlasmaArc 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 eye...

Page 9: ...able 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 utilis s pour mettre e...

Page 10: ...er ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres pe...

Page 11: ...ue les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suiva...

Page 12: ...S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA...

Page 13: ...tion standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 E...

Page 14: ...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 liabili...

Page 15: ...n 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 H...

Page 16: ...ts for cata log 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 8...

Page 17: ...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 con trols CAUT...

Page 18: ...weldingfilterlensinfrontofthetorch andturnonthegas Anyoilormoistureintheairwillbevisible onthelens Donotinitiateanarc CAUTION Air supply must be free of oil moisture and other contaminants Excessive o...

Page 19: ...tor 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 Typical fittings are shown a...

Page 20: ...nnected to the Power Supply The Torch Leads must be properly installed to the Power Supply for proper operation If the torch leads were not factory installed make all torch connections to the Torch Bu...

Page 21: ...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 t...

Page 22: ...INSTALLATION 3 6 Manual 0 2870...

Page 23: ...upply 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 Gas Power Lead Connection Connects the torch gas nega...

Page 24: ...latortoadjusttheinputgaspressuretothe PowerSupply Thepressureregulatorhasitsownbuilt in filter Forimprovedfiltering otherfilteringpackagesare availableasoptions 4 03 Preparations For Operating Thispro...

Page 25: ...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...

Page 26: ...stops Pilot arc stops If torch is activated during post flow the pilot arc will immediately restart If torch is within 1 4 inch 6 4 mm transfer distance to workpiece the main arc will transfer 12 Gas...

Page 27: ...he filter element will be visible and still attached to the main body of the Regula tor Filter 3 Grasp the filter element and unscrew it from the Regulator Filter body The filter element will come off...

Page 28: ...List for replacement filter element catalog number 1 Remove power from power supply 2 Shut off air supply and bleed down system before changing Filter Elements WARNING Always turn off the air supply a...

Page 29: ...order presented For major troubleshooting and parts replacement proce dures refer to Power Supply Service Manual 0 2871 B How to Use This Guide ThefollowinginformationisaguidetohelptheCustomer Operat...

Page 30: ...4 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual 5 Faulty Torch a Return for repair or have qualified technician repair per Torch Manual E Low cu...

Page 31: ...inch 3 mm from clean surface while purging and observe oil or moisture buildup do not activate torch 4 Torch tip being dragged on work a Lift torch tip off work At output settings over 40 amps contro...

Page 32: ...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 intern...

Page 33: ...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 p...

Page 34: ...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 Fil...

Page 35: ...ing 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...

Page 36: ...h is within transfer distance 1 4 in 6 4mm of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to s...

Page 37: ...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 f...

Page 38: ...RUN SET SW 20 GATE DRIVE B 35 LED PCB 19X1604 27 J11 2 2 32 5 12 M2 7 4 8 W1 A 33 GATE DRIVE B RTN GAS SOLENOID 1 13 12 34 3 28VAC B 31 2 28VAC B S 3 27 D21 9 6 8 8 8 7 K4 21 2 12 20 8 25 D32 27 12 5...

Page 39: ...OLENOID SWITCH ON OFF SWITCH RUN SET C1 F3 F2 C1 D1 T5 B7 TS1 TS2 E1 F1 GCW W1 MAIN CONTACTOR F3 A2 TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CURRENT SENSE L1 PCR T10 CD L1 E3 OUTPUT INDUCTO...

Page 40: ......

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