FIREPOWER 45i Portable Plasma Cutter Instruction Manual

1. Introduction and Overview

This manual provides essential information for the safe and effective operation, setup, and maintenance of your FirePower 45i Portable Plasma Cutter. The FP-45i is a light and portable plasma cutting system designed for various metal cutting applications, utilizing a 208/230V 50/60Hz power supply. It features a user-friendly 2.8-inch color LCD panel for easy adjustments and incorporates a torch trigger lock for enhanced safety.

The system automatically displays and regulates set pressure, ensuring consistent performance. A complete line of long-life consumables is available for this unit, ensuring readiness for work. The ergonomically designed torch is included with the system.

Figure 1.1: FirePower 45i Plasma Cutter with included torch, ground clamp, and accessories.

2. Safety Information

Always prioritize safety when operating the plasma cutter. Failure to follow safety precautions can result in serious injury or death.

• Electrical Shock: Ensure the unit is properly grounded. Do not operate in wet conditions. Always wear dry welding gloves.
• Fumes and Gases: Work in a well-ventilated area. Fumes and gases can be hazardous to health.
• Arc Rays: Plasma arc rays can injure eyes and burn skin. Always wear appropriate welding helmet with proper shade, and protective clothing.
• Fire and Explosion: Sparks and hot metal can cause fire. Keep flammable materials away from the work area. Have a fire extinguisher readily available.
• Hot Parts: Torch and workpieces become hot. Allow them to cool before handling or wear appropriate heat-resistant gloves.
• Compressed Air: Ensure air supply connections are secure and within specified pressure limits.

3. Package Contents

Verify that all items are present and undamaged upon unpacking. If any items are missing or damaged, contact your vendor immediately.

• FirePower 45i Plasma Cutter Unit
• Plasma Torch with lead
• Ground Clamp with lead
• Power Cord
• Consumables (starter set)
• Instruction Manual (this document)

4. Setup

Follow these steps to set up your FirePower 45i Plasma Cutter:

1. Placement: Place the plasma cutter on a stable, level surface, ensuring adequate ventilation around the unit.
2. Power Connection: Connect the power cord to a suitable 208/230 VAC, 50/60Hz power outlet. Ensure the circuit can handle the required amperage.
3. Air Supply Connection: Connect your compressed air supply to the air inlet on the rear of the unit. The internal regulator will automatically adjust to the optimal pressure, typically around 70 PSI for cutting operations.
4. Torch Connection: Securely connect the plasma torch lead to the front panel connection point.
5. Ground Clamp Connection: Attach the ground clamp lead to the designated terminal on the front panel. Ensure the ground clamp is securely attached to the workpiece or work table to establish a good electrical connection.
6. Consumables: Install the appropriate consumables (electrode, nozzle, shield cup) into the torch head according to the torch manufacturer's instructions.

Figure 4.1: Rear panel of the FirePower 45i, highlighting the power input and air filter/regulator.

Figure 4.2: Front angle view of the FirePower 45i, showing the torch and ground clamp connection points.

5. Operating Instructions

Once the unit is set up, you can begin cutting operations.

1. Power On: Turn on the main power switch located on the rear of the unit. The 2.8-inch color LCD panel will illuminate.
2. Parameter Adjustment: Use the single control knob on the front panel to navigate through the menu and adjust cutting parameters such as amperage. The unit automatically manages air pressure.
3. 2T/4T Function:
   • 2T (Two-Touch): Press and hold the torch trigger to initiate the arc. Release the trigger to stop the arc. This mode is suitable for short cuts.
   • 4T (Four-Touch): Press and release the torch trigger to initiate the arc. The arc will continue until the trigger is pressed and released again. This mode is ideal for longer cuts, reducing hand fatigue.
   Select the desired 2T/4T mode via the LCD panel.
4. Cutting Process:
   • Ensure proper eye and body protection is worn.
   • Position the torch nozzle close to the workpiece.
   • Activate the torch trigger (2T or 4T mode).
   • Move the torch steadily along the desired cut line. Maintain a consistent standoff distance for optimal cut quality.
   • The FirePower 45i is capable of cutting Steel, Stainless Steel, Brass, and Aluminum, with a maximum cut thickness of 1 inch.
5. Torch Trigger Lock: Utilize the torch trigger lock for greater safety when the unit is not in active use or during transport.

Figure 5.1: The 2.8-inch color LCD panel and control knob for adjusting settings.

6. Maintenance

Regular maintenance ensures the longevity and optimal performance of your plasma cutter.

• Consumables: Inspect torch consumables (nozzle, electrode, shield cup) regularly for wear. Replace them when signs of degradation are visible to maintain cut quality and extend torch life.
• Air Filter: Periodically check and clean or replace the air filter on the rear of the unit to ensure a clean and dry air supply, which is crucial for plasma cutting performance.
• General Cleaning: Keep the unit clean and free from dust and metal particles. Use compressed air to blow out internal components if necessary, ensuring the unit is unplugged.
• Cable Inspection: Regularly inspect all cables (power, torch, ground) for cuts, abrasions, or damage. Replace damaged cables immediately.

7. Troubleshooting

This section addresses common issues you might encounter. For more complex problems, contact technical support.

8. Specifications

9. Warranty and Support

For warranty information and technical support regarding your FirePower 45i Portable Plasma Cutter, please contact the vendor directly. Refer to your purchase documentation for specific contact details or visit the official FirePower website.

Customer Service: Please refer to the contact information provided at the point of purchase or on the manufacturer's official website.