ESAB HandyPlasma 35i User manual

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

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

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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