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Tp 72
Instruction Manual
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Fimer Tp 72 Instruction Manual

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INSTRUCTION MANUAL
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1 MANUFACTURER’S NAME, ADRESS AND COMPANY LOGO 2 MODEL 3 SERIAL NUMBER 4 BLOCK DIAGRAM 5 TYPE OF WELDING 6 SUITABLE FOR USE IN AN ENVIRONMENT WITH INCREASED HAZARD OF ELECTRIC SHOCK. 7 POWER SUPPLY 8 PROTECTION DEGREE 9 TYPE OF WELDING OUTPUT CURRENT 10 RATED NO-LOAD VOLTAGE
11 RATED INPUT VOLTAGE 12 MAXIMUM RATED INPUT CURRENT 13 MAXIMUM EFFECTIVE INPUT CURRENT 14 APPLICABLE STANDARDS 15 RANGE OF WELDING VOLTAGE­CURRENT 16 DUTY CYCLE 17 RATED WELDING CURRENT 18 CONVENTIONAL LOAD VOLTAGE
TECHNICAL DATA
Weigh: 14Kg Dimensions: 170x450x320 Static characteristic: Drooping Power supply protection: Slow Action 25A Fuses Int. 3ph – 25A C or K Type Input voltage: 400V ±10% Thermal Protection: Bimetallic thermostat The overheating tests were performed at 40°C. Thickness of cutting: 25 – 22 mm
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INSTRUCTION MANUAL
Fimer S.p.A. thanks you for selecting this unit: It will prove to be a useful, problem-free tool for many years to come if the instructions contained in this manual are followed scrupulously. This manual must be considered as an integral part of the unit and must accompany it when it change location or is resold. The user must assume responsibility for maintaining this manual intact and legible at all times. Fimer S.p.A. reserves the right to modify this manual at any time without notice. All rights of translation and total o partial reproduction by any means whatsoever (including scanner, photocopy, film and microfilm) are reserved and reproduction is prohibited without the express written consent of Fimer S.p.A.
WARNING.........................................................................................................................................................................................3
SAFETY RULES...............................................................................................................................................................................8
PRECAUTIONS................................................................................................................................................................................8
PRESSURE REGULATOR: ............................................................................................................................................................9
OVERVIEW ......................................................................................................................................................................................9
HOW TO START............................................................................................................................................................................10
LAY-OUT ........................................................................................................................................................................................10
PUTTING IN SERVICE AND USE ..............................................................................................................................................10
OPERATOR PANEL......................................................................................................................................................................12
REMOTE CONTROL CONNECTOR.........................................................................................................................................13
IGNITION........................................................................................................................................................................................13
ADJUSTMENTS .............................................................................................................................................................................14
SAFETY TORCH............................................................................................................................................................................14
CUTTING DRAWBACK ..............................................................................................................................................................14
PRACTICAL ADVICE...................................................................................................................................................................14
PRACTICAL ADVICE...................................................................................................................................................................15
SCHEMATIC DIAGRAM .............................................................................................................................................................16
SPARE PARTS................................................................................................................................................................................17
SAFETY RULES
INTRODUCTION:
We therefore recommend following strictly the instructions contained in this manual.
WARNING: Your safety is in your hands!
Follow carefully all the safety instructions. It is your duty to protect yourself and others from risks related to welding operations. The operator is responsible for his own safety and that of those who are in the work zone. Consequently must know and observe all the safety rules.
PRECAUTIONS A) Electric Shock
ELECTRIC SHOCK CAN KILL.
Plasma arc cutting equipment uses high open circuit voltage to initiate the plasma arc. Normal load voltage are higher them experienced with other types of welding equipments. Caution must be exercised when operating or servicing this equipment.
Input connections:
Connect the mains power cable to the wall outlet provided with electromagnetic switch or fuses. Frequently inspect the line cable for damage or cracking of the insulation, and replace immediately if it is damaged.
Grounding:
Input Side
The mains socket must be provided with and efficient ground connection. Make sure all connections are tight to avoid any overheating of the electrical junctions.
Output side:
The ground clamp must be firmly connect to the workpiece. The work plan must be connected to ground.
Personal protection:
Keep operator’s body and clothing dry. DO NOT stand in, sit on, lie on the workpiece when the generator is running. Avoid working in damp surroundings or on wet ground. Check that the output cables and the power cord do not show areas where the copper is even partially open, in which case replace it immediately. Disconnect power supply while working on the torch, on the generator or the cables. Never place the torch directly on the work table or on metal surfaces connected to the ground of the generator to avoid any risk of short circuit or accidental ignition of the arc.
B) Explosion
Newer cut on or near pressurized vessels. Never cut in rooms containing explosive gases and/or vapours or dangerous materials.
Cylinders:
Handle and use pressure cylinders in accordance with the regulations in force. Never connect directly the pressurized cylinder to the gas hose; ever use a pressure regulator. Never use leaking or damaged cylinder. Never use a cylinder that is not upright and secured in place. Never move or transport a cylinder without the protective valve cover in place. Do not use cylinders whose content has not been clearly identified. Never allow electrical contact such as cutting arc with cylinder.
Never tamper with the valves of the cylinder Never attempt to unlock a blocked valve using tools as hammers, wrenches, etc Never delete or alter the name, number or other markings on the cylinders. That is illegal and dangerous. Do not lift cylinders from the valve or the cap, or using chains, slings or magnets.
PRESSURE REGULATOR:
Keep pressure regulators in good condition. Damaged regulators they cause damage or serious accidents, they must be repaired only by qualified personnel Do not use regulators for gases other than those for which they were manufactured. Never use a damaged regulator. Never lubricate a regulator with oil or grease.
Hose:
Gas hose used for plasma cutting systems adheres to the following colour coding:
Green or Blue: Oxygen Black: Inert gas or air NEVER USE OXYGEN FOR PLASMA CUTTING.
Immediately replace the hoses that are damaged by cuts or burns. Do not bend the hoses to avoid bottlenecks that reduce the pressure. Periodically examine the hose for any leaks, wear or faulty connections.
OVERVIEW
THE PACKAGE CONTAINS:
No. 1 Generator TP. No. 1 Instruction booklet. No. 1 Heart cable. N°1 Torch.
INTRODUCTION
The TP cutting generators are designed for cutting all metals: aluminium, stainless steel, iron, etc..
The TP generator is composed of: A) Current generator.
B) Cutting torch C) ground cable with clamp
The essential parts of the TP generators are:
− Electronic control card.
− Power Electronic control card.
The use of inverter systems allows for a compact generator, to cut on restricted areas, and achieve high quality. The high frequency used by the inverter (35 kHz) allows you to control the arc in the most suitable for the cutting. Changes in the input line voltage or in the load do not produce change in the cutting current. Particular design attention was paid to design a cutting machine that guarantees good performance, longevity and low maintenance; to achieve this FIMER adopted solid-state electronics, both for the power electronic, both for the control. It is well known for the absolute reliability of these components, after the first operating period, during which any construction defects could cause breakage (the "infant mortality"). FIMER use highly selected oversized components and performs a test bench for every unit built. FIMER has prepared this manual to provide the user with both instructions for use, is the description of the principles
of operation for the TP plasma cutting generators.
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HOW TO START
This part of the manual is important for the proper use of the plasma cutting generator.
This manual not contain special instructions for maintenance since these generators are maintenance­free. The only precautions to be taken are those of any electrical machine with metal frame. Let us hope to avoid shock, dripping, excessive heat, and any other abnormal situations.
In case of transport and/or in storage, the temperature must be between: - 25°C to + 55°C. - . As for any unplanned maintenance is necessary to follow the appropriate service manual, if you have the technical
knowledge of the equipment, or contact the nearest service point or directly to the parent. Repairs performed by unauthorized service, involve the immediate decay of the warranty.
PRECAUTIONS BEFORE PERFORMING ANY CONNECTION OR SWITCH-ON THE UNIT CAREFULLY READ THE INSTRUCTION
MANUAL!
Following the instructions you can avoid improper installation of the unit, that could result in an irreparable failure. Damage due to improper use of the generator to make void the warranty This units are designed for professional use and reserved exclusively for trained and qualified personnel. The generators can work in environments where conditions of use are particularly heavy and a temperature between
-20 to + 40°C with humidity
Max 50% up to + 40°C. Max 90% up to + 20°C.
LAY-OUT
1. Do not place the generator against the wall or in positions which still restrict the flow of air through the air-intake grills (avoid cover the generator with rags, paper, nylon, etc.)
2. Make sure that the air sucked in the unit is at temperatures below 40oC and the working environment is not particularly polluted, or is not in the presence of: a) moist air with the presence of dust mixed with acids or salts; b) air with a strong presence of ferrous metal powders.
3. Verify that the value of the mains voltage is suitable for this type of generator.
4. Make sure that the available power of the mains is adequate to the power required for operation of the machine. If in doubt consult the technical data.
5. The degree of protection from the outside of these generators is IP 23 (CEI EN 60529): the cover protects the unit from items with a diameter greater than 12 mm and against vertically falling drops of water. So avoid:
− Submerge generators in liquids of any kind,
− Put them on muddy or wet surfaces,
− Insert any objects through the air-intake grills.
6. Never use the generator without its cover.
This is very dangerous for both the machine and the operator
PUTTING IN SERVICE AND USE
The installation of the unit must be made by qualified personnel. All connections must be made in accordance with existing rules and in full compliance of safety laws.
Place the unit in a room with adequate ventilation, taking care not to block the entry and exit of air from the cooling fins.
Torch Connection
The torch connection is very easy, because use a quick connector including gas, signals, torch button and power to the torch. Regarding the mass to be connected to the workpiece, the front panel is provided with a fast connector where it will be connected the clamp.
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Cutting gas connection Check if the pressure and air flow rates are in accordance with to the values required by the torch
The plasma cutter uses a jet of compressed air both for the blowing of the arc and for cooling the torch The air circuit includes a pressure regulator, adjusted to 3.5 bar. In any case the air supply must provide a minimum flow of 150 l/min. When the cutting arc is triggered, a second solenoid valve is opened allowing the flow of the primary air flow. This valve allows the passage of air only when properly controlled by electronic logic, during the pre-flow, post-flow, cutting or when directly activated by button "AIR TEST".
Mains connection
Before making the connection of the unit to the network, verify that the supply voltage is 400 VAC ± 10%.
ATTENTION, if the voltage exceeds 440Vac, the generator stops. Voltages over 460 VAC can seriously damage the generator.
PROTECTIONS
The generators have different internal protection:
− Protection against maximum voltage of the mains.
− Protection against minimum voltage of the mains.
− Thermal Protection:
− Inverter overcurrent protection
− Electromagnetic circuit breaker
a) Maximum value of input voltage:
The generators are protected against mains voltage irregularities. Avoid exceeding the threshold MIN and MAX allowed.
b) Thermal Protection:
The generators are designed for use at a temperature between -20 °C to +40 °C. If the temperature were to rise beyond the preset limits or the duty-cycle was exceeded, special internal temperature sensors stop the operation (resulting in the LED lighting). When operating conditions are restored, the generator resume the operation.
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OPERATOR PANEL
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COMMANDS AND LEDS
1 - Cutting current adjustment knob 2 - "AIR COOLING" Test Button
When pressed, the air flows from the torch, so to verify that the cooling system works correctly.
3 - Led "remote mode"
Lights when the converter is set by the remote potentiometer
4 - Led "local mode"
Lights when the converter is set by the potentiometer 1.
5- “Generator ON”: Green Led
Lights when the mains is connected and the rear switch-button is ON and therefore the generator is ready to work.
6- “Alarm": Yellow Led
Lights whenever an overheating occurs on the power stages or a mains under-over voltage appears.
7- “Low Gas”: Yellow Led
Turns on whenever the working pressure of the air is insufficient.
8- “Arc Pilo”: Red Led
Lights when you press the torch button before the cutting operation.
9- “Arc Cut”: Red Led
Comes on every time we proceed to cut
10- “Air-Flow” Green Led
Lights when you test the compressed air flow
11 - DINSE Connector: ground of the system.
Be connected to the metal piece to be cut
12- Cutting Torch Connector 13 - Compressed air pressure adjustment knob 14 - ON-OFF switch: turns ON or OFF the converter 15 - Connector for remote control of the cutting current
REMOTE CONTROL CONNECTOR
The functions corresponding to the connector pins are:
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PIN 1-6 normally open contact, (120 VAC, 1 A max), closes when the arc is transferred to the piece.
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PIN 3: output current adjustment:.
The generator is prepared for a 0-10 VDC signal to adjust the output current, where:
input signal: 0VDC output current: 0A
input signal: 10VDC  output current:: 110A
Through a jumper JP2 on the card control, can vary the adjustment range in the field (0 - 5 VDC) where:
input signal: 0VDC output current: 0A input signal: 5VDC output current:: 110A
WARNING: To make this change you need to contact a service center or directly FIMER
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Pin 2 voltage output +15 V /-20mA (output)
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PIN 5-9 ground.
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PIN 7 start (INPUT), when closed on 8, activates the generator.
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PIN 8: 0V reference for PIN 2 / 3 / 7.
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PIN 4: closed with the PIN 2 enables the external adjustment of output current.
N.B.: To use the generator in combination with an automatic machinery (eg pantograph), You need to use a
torch in which there is this contact.
IGNITION
WARNING! If the torch is inserted into the connector, the generator is inoperative. The circuit is blocked if the pressure is adjusted below 3.5 bar. Always turn off the generator for any action on the torch.
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ADJUSTMENTS
The concept that underlies the operation of these generators is to provide a constant current equal to the set value, regardless of the length of the arc. After making the connections of the torch, and turned on the generator, check that the air is circulating in the circuit, acting on the button AIR TEST Next, set the value of current using the keys. Table 1 shows the approximate current values to be set depending on the thickness to be cut. To begin to cut, press the button on the torch. On completion of the operation button is released resulting in extinguishing the arc. The air will continue to flow for about 60 seconds, (post-flow) required for the complete cooling of the torch.
SAFETY TORCH
ATTENTION voltage exceeding 113V CLASS M TORCH.
The torch fitted with the generator, is provided with a safety circuit that prevents the user to come into contact with live parts; in fact by loosening the insulated terminal block, torch button is disabled.
CUTTING DRAWBACK
1) Insufficient penetration
The causes of this problem can be:
- Too fast Always make sure that the arch cuts completely the piece and the arc never should be tilted in the sense of progress, above 10-15°.
- The electrode must be replaced when it has a deep crater about 2 mm.
- The nozzle should be replaced when it has the central hole ruined or very extended compared to new.
- Too thick piece
- Heart clamp not in good electrical contact with the workpiece.
2) Cutting arc goes off
The causes of this problem can be:
- Feed rate too low.
- Cutting current too high in relation to the thickness of the workpiece, adjust to the thickness.
PRACTICAL ADVICE
- If the air contains moisture and/or oil is good to use a dryer filter to prevent excessive oxidation, consumption and damaging of parts of the torch.
- Impurities in the air cause the oxidation of the electrode and nozzle, and may make more difficult the striking of the pilot arc. If this condition occurs clean the terminal electrode and the inside of the nozzle-end with sandpaper
- Ensure that the new electrode and the nozzle are about to be mounted are well cleaned and degreased.
To avoid damaging the torch always use genuine parts FIMER. THE OPERATIONS REQUIRING ACCESS INSIDE THE MACHINE MUST BE EXECUTED AFTER DISCONNECT THE
POWER PLUG FROM THE OUTLET! TECHNICAL DATA
The inverter is a special oscillating circuit that, supplied by an input continuous voltage, provides an output AC voltage having the frequency required. Increasing the frequency, achieves multiple benefits:
- Use of power transformers, small and light;
- High Bandwidth of the output cutting current, resulting in a current always appropriate to the process;
- Eliminate the annoying hum of common electromechanical equipment.
TABLE 1
MATERIAL
THICKNESS
MATERIAL
(mm)
VALUE
CURRENT
(A)
NOTES
1 22
2 30
CONTACT CUTTING
IRON
3 38
5 50
10 60
15 70
CUTTING WITH SPACER
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PRACTICAL ADVICE
- If the air contains moisture and/or oil is good to use a dryer filter to prevent excessive oxidation, consumption and damaging of parts of the torch.
- Impurities in the air cause the oxidation of the electrode and nozzle, and may make more difficult the striking of the pilot arc. If this condition occurs clean the terminal electrode and the inside of the nozzle-end with sandpaper
- Ensure that the new electrode and the nozzle are about to be mounted are well cleaned and degreased.
To avoid damaging the torch always use genuine parts FIMER. THE OPERATIONS REQUIRING ACCESS INSIDE THE MACHINE MUST BE EXECUTED AFTER DISCONNECT THE
POWER PLUG FROM THE OUTLET! TECHNICAL DATA
The inverter is a special oscillating circuit that, supplied by an input continuous voltage, provides an output AC voltage having the frequency required. Increasing the frequency, achieves multiple benefits:
- Use of power transformers, small and light;
- High Bandwidth of the output cutting current, resulting in a current always appropriate to the process;
- Eliminate the annoying hum of common electromechanical equipment.
TABLE 1
MATERIAL
THICKNESS
MATERIAL
(mm)
VALUE
CURRENT
(A)
NOTES
1 22
2 30
CONTACT CUTTING
IRON
3 38
5 50
10 60
15 70
CUTTING WITH SPACER
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SCHEMATIC DIAGRAM
SPARE PARTS
DESCRIPTION
1 Inductor 2 Pilot Arc Card 3 Handle 5 Air reducer 6 Keyboard 7 Torch Connector 8 HP Solenoid 9 Filter Card 10 Resistor: 15 Ohm 50 W 11 Fan 12 Ground Connector 13 LP Solenoid
13/1 Reduction for LP
14 High frequency card 15 Resistor: 33 Ohm 100 W 16 Toroidal transformer 17 Power Supply Card 18 Inverter Card 19 Regulator Card 20 Mains Switch 21 HF transformer 22 Power transformer 23 Cable-holder
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