ESAB Firepower 25i/35i/45i User manual

Category
Welding System
Type
User manual

This manual is also suitable for

HandyPlasma 35i,
HandyPlasma 45i,
Firepower25i/35i/45i,
CutSkill35/45
Service manual
0463 806 001  GB  20210617
Ordering no. Product Notes Serial no.
0559 160 135 HandyPlasma 35i Global
0559 160 145 HandyPlasma 45i Global
1445-1925 Firepower 25 North America
1445-1935 Firepower 35 North America
1445-1945 Firepower 45 North America
1-1601-30 CutSkill 35 Australia
1-1601-40 CutSkill 45 Australia
TABLE OF CONTENTS
0463 806 001 -3- © ESAB AB 2021
1 READ THIS FIRST...................................................................................................................... 4
1.1 Read this first .............................................................................................................. 4
2 BEFORE STARTING SERVICE.................................................................................................. 5
2.1 Before starting the service ......................................................................................... 5
3 INTRODUCTION ......................................................................................................................... 6
3.1 Introduction.................................................................................................................. 6
3.2 Overview ...................................................................................................................... 6
3.3 Rating plates ................................................................................................................ 8
3.4 Operation...................................................................................................................... 11
4 ERROR CODES.......................................................................................................................... 12
5 WIRING DIAGRAM ..................................................................................................................... 13
6 TECHNICAL DATA ..................................................................................................................... 16
6.1 HandyPlasma 35i/45i ................................................................................................... 16
6.2 Firepower 25i/35i/45i ................................................................................................... 16
6.3 CutSkill 35/45 ............................................................................................................... 18
7 TROUBLESHOOTING ................................................................................................................ 21
7.1 Pre power up checks .................................................................................................. 21
7.2 Power up checks ......................................................................................................... 24
8 REPLACEMENT INSTRUCTIONS ............................................................................................. 29
8.1 Replacing the Front Control panel............................................................................. 29
8.2 Replacing the Cover panel ......................................................................................... 30
8.3 Replacing the Handle .................................................................................................. 30
8.4 Replacing the Air filter ................................................................................................ 31
8.5 Replacing the Power switch ....................................................................................... 32
8.6 Replacing the Rear panel ........................................................................................... 33
8.7 Replacing the Fan........................................................................................................ 33
8.8 Gas valve removal ....................................................................................................... 34
9 IN-SERVICE INSPECTION AND TESTING................................................................................ 35
9.1 In-service inspection-overview .................................................................................. 35
9.2 General requirements ................................................................................................. 35
9.3 Periodic inspection and test ...................................................................................... 35
9.4 Cleaning instruction.................................................................................................... 35
9.5 After repair, inspection and test ................................................................................ 36
9.6 Visual inspection ......................................................................................................... 36
9.7 Electrical test ............................................................................................................... 37
9.8 Functional test ............................................................................................................. 37
9.9 Test report .................................................................................................................... 38
10 SPARE PARTS AND ACCESSORIES ....................................................................................... 40
10.1 SPARE PARTS AND ACCESSORIES ......................................................................... 40
1  READ THIS FIRST
0463 806 001 -4- © ESAB AB 2021
1 READ THIS FIRST
1.1 Read this first
Maintenance and repair work must be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for help in
connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit boards are
divided into numbered blocks, which are described individually in more detail in the description of
operation. Component names in the wiring diagram are listed in the component description.
Use the spare parts list as a guide to where the components are located in the equipment. The spare
parts list is published as a separate document, see the "SPARE PARTS AND ACCESSORIES"
chapter in this manual.
This manual contains details of design changes that have been made up to and including 05 2021.
The manual is valid for:
HandyPlasma 35i
HandyPlasma 45i
Firepower 25
Firepower 35
Firepower 45
CutSkill 35
CutSkill 45
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and function, of
the specific set-up, lies with the integrator.
The HandyPlasma 35i/45i, Firepower 25/35/45 and CutSkill 35/45 are designed and tested in
accordance with the standards stated in the instruction manual. On completion of service or repair
work, it is the responsibility of the person(s) performing the work to ensure that the product still
complies with the requirements of the involved standards.
2  BEFORE STARTING SERVICE
0463 806 001 -5- © ESAB AB 2021
2 BEFORE STARTING SERVICE
2.1 Before starting the service
NOTE!
Follow the instructions in chapter "IN-SERVICE INSPECTION AND TESTING" when
performing service work on the equipment!
ESAB can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001 (Europe)
The kit makes it easier to protect sensitive
components from electrostatic discharge.
Contents:
A conductive mat (size 610×610mm /
24×24in.)
A 1.5m (3.28ft) long ground cable with a
crocodile clip
An adjustable wrist strap and cable with a
built-in protective resistor
Recommended equipment:
Oscilloscope (50 MHz -100 MHz, 1- 2 GSa/s)
3  INTRODUCTION
0463 806 001 -6- © ESAB AB 2021
3 INTRODUCTION
3.1 Introduction
The HandyPlasma35i/45i, Firepower25/35/45 and CutSkill35/45 provide excellent cutting
performance when used with the correct consumables and plasma cutting procedures. It is very simple
to use with the included coloured LCD and adjustments can be done with a single knob.
3.2 Overview
1 Main switch 5 Display PCB
2 Input EMI inductor 6 Torch connector
3 Pressure regulator 7 PFC inductor
4 Pressure sensor 8 Air solenoid
3  INTRODUCTION
0463 806 001 -7- © ESAB AB 2021
1 Input rectifier 6 Output rectifiers
2 Inrush relay 7 PFC diodes
3 Main transformer 8 PFC IGBTs
4 Output inductor 9 Bulk capacitors
5 Pilot IGBT
3  INTRODUCTION
0463 806 001 -8- © ESAB AB 2021
3.3 Rating plates
HandyPlasma 35i
3  INTRODUCTION
0463 806 001 -9- © ESAB AB 2021
HandyPlasma 45i
3  INTRODUCTION
0463 806 001 - 10 - © ESAB AB 2021
Firepower 25i Firepower 35i
Firepower 45i
3  INTRODUCTION
0463 806 001 - 11 - © ESAB AB 2021
CutSkill 35 CutSkill 45
3.4 Operation
For operation instructions, see HandyPlasma35i and HandyPlasma45i Instruction manual, document
number 0-5584.
Refer Firepower 25/35/45 instruction manual, document number 0-5563.
Refer CutSkill 35/45 instruction manual, document number 0-5528.
4  ERROR CODES
0463 806 001 - 12 - © ESAB AB 2021
4 ERROR CODES
For Error Code description, see HandyPlasma 35i and HandyPlasma 45i Instruction manual, 0-5584.
Refer Firepower 25/35/45 instruction manual, document number 0-5563.
Refer CutSkill 35/45 instruction manual, document number 0-5528.
5  WIRING DIAGRAM
0463 806 001 - 13 - © ESAB AB 2021
5 WIRING DIAGRAM
HandyPlasma
5  WIRING DIAGRAM
0463 806 001 - 14 - © ESAB AB 2021
FirePower
5  WIRING DIAGRAM
0463 806 001 - 15 - © ESAB AB 2021
CutSkill
6  TECHNICAL DATA
0463 806 001 - 16 - © ESAB AB 2021
6 TECHNICAL DATA
6.1 HandyPlasma 35i/45i
HandyPlasma 35i HandyPlasma 45i
Equipment development technology Inverter
Idle state power consumption 35 W
Network voltage and frequency 220–240 V, 1~ 50/60 Hz
Current range 20–35 A (DC) 20–45 A (DC)
Permissible load
35 % duty cycle 35 A / 94 V 45 A / 98 V
60 % duty cycle 28 A / 91.2 V 35 A / 94 V
100% duty cycle 22 A / 88.8 V 30 A / 92 V
Power factor at maximum current 0.99
Efficiency 84%, 35 A / 94 V 84%, 45 A / 98 V
Open-circuit voltage 315 V
Apparent power at maximum current 9 kVA 10 kVA
Rated power consumption at maximum current 6.4 kW 7.2 kW
Recommended circuit breaker or fuses at
maximum output 11 A 15.4 A
Recommended air input requirements 6-8 bar (87–116 PSI)
Recommended air flow 110 LPM
Operating temperature 0 to +40°C
Dimensions l × w × h 176 × 415 × 324 mm
Weight 13.5 kg
Enclosure class IP21S
Application class
6.2 Firepower 25i/35i/45i
Firepower 25i
Description 25 A, Clean cut 10 mm plasma
cutter
Cutting capacity Genuine: 8 mm
Severance: 10 mm
Rated input voltage 115 V
Frequency 50/60 Hz
Effective input current, I1eff 16.9 A
Input cable
20 A plug and 12 AWG lead;
2.5 m long
6  TECHNICAL DATA
0463 806 001 - 17 - © ESAB AB 2021
Firepower 25i
Current adjust range 20-25 A
Rated output current
25% 25 A / 90 V
60% 23 A / 89.2 V
100% 20 A / 88 V
Rated output at 100% duty cycle 20 A
Fan noise, measured at 1 m from rear panel of machine 40–60 dB
Insulation class H
Enclosure class IP21S
Weight 12.6 kg
Power factor ≥0.97
Rated duty cycle (%) 25%
Firepower 35i
Description 35 A, Clean cut 10 mm plasma
cutter
Cutting capacity Genuine: 12 mm
Severance: 16 mm
Rated input voltage 230 V
Frequency 50/60 Hz
Effective input current, I1eff 10.1 A
Input cable
NEMA 50 A plug and 12 AWG
lead; 2.5 m long
Current adjust range 20-35 A
Rated output current
35% 35 A / 94 V
60% 28 A / 91.2 V
100% 22 A / 88.8 V
Rated output at 100% duty cycle 22 A
Fan noise, measured at 1 m from rear panel of machine 40–60 dB
Insulation class H
Enclosure class IP21S
Weight 12.6 kg
Dimensions l × w × h 445 × 176 × 324 mm
Power factor ≥0.97
Rated duty cycle (%) 35%
6  TECHNICAL DATA
0463 806 001 - 18 - © ESAB AB 2021
Firepower 45i
Description 45 A, Clean cut 16 mm plasma
cutter
Cutting capacity Genuine: 16 mm
Severance: 24 mm
Rated input voltage 230 V
Frequency 50/60 Hz
Effective input current, I1eff 14.1 A
Input cable
NEMA 50 A plug and 12 AWG
lead (equal 3.3mm2; 2.5m
long
Current adjust range 20-25 A
Rated output current
35% 45 A / 98 V
60% 35 A / 94 V
100% 30 A / 92 V
Rated output at 100% duty cycle 30 A
Fan noise, measured at 1 m from rear panel of machine 40–60 dB
Insulation class H
Enclosure class IP21S
Weight 12.6 kg
Dimensions l × w × h 445 × 176 × 324 mm
Power factor ≥0.97
Rated duty cycle (%) 35%
6.3 CutSkill 35/45
CutSkill 35
Description 35 A, Clean cut 12 mm plasma
cutter
Cutting capacity Genuine: 12 mm
Severance: 16 mm
Rated input voltage 240 V
Frequency 50/60 Hz
Effective input current, I1eff 10 A
6  TECHNICAL DATA
0463 806 001 - 19 - © ESAB AB 2021
CutSkill 35
Input cable
10 A plug and 10 A lead (min.
1.5mm2heavy Duty); 3 m
long;
(10 A 3 pin insulated type.
Australian pin configuration.
Complies with AS/NZ3112)
(10 A, 1.5mm2heavy duty
cable type. Complies with
AS/NZ3191)
Current adjust range 20-35 A
Rated output current
35% 35 A / 94 V
Fan noise, measured at 1 m from rear panel of machine 40–45 dB
Insulation class H
Enclosure class IP21S
Weight 11 kg
Dimensions l × w × h 445 × 176 × 324 mm
Power factor ≥0.97
Rated duty cycle (%) 50%
CutSkill 45
Description 45 A, Clean cut 16 mm plasma
cutter
Cutting capacity Genuine: 16 mm
Severance: 24 mm
Rated input voltage 240 V
Frequency 50/60 Hz
Effective input current, I1eff 10 A
Input cable
15 A plug and 10 A lead (min.
1.5mm2heavy Duty); 3 m
long;
(15 A 3 pin insulated type.
Australian pin configuration.
Complies with AS/NZ3112)
(15 A, 1.5mm2heavy duty
cable type. Complies with
AS/NZ3191)
Current adjust range 20-45 A
Rated output current
35% 45 A / 98 V
Fan noise, measured at 1 m from rear panel of machine 40–45 dB
Insulation class H
Enclosure class IP21S
6  TECHNICAL DATA
0463 806 001 - 20 - © ESAB AB 2021
CutSkill 45
Weight 11 kg
Dimensions l × w × h 445 × 176 × 324 mm
Power factor ≥0.97
Rated duty cycle (%) 35%
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a
certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid
objects or water.
Equipment marked IP21S is intended for indoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased electrical
hazard.
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ESAB Firepower 25i/35i/45i User manual

Category
Welding System
Type
User manual
This manual is also suitable for

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