Page 1
A-01678
7/8"- 200 VOLT
AIR PLASMA CUTTING
POWER SUPPLY
Operating Manual
December 16, 1998
Manual No. 0-2700
Page 2
Page 3
WARNING
Read and understand this entire Operating Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
WARNING
While the information contained in this Operating Manual
represents our best judgement, Firepower® assumes no liability
for its use.
FP-78 Air Plasma Cutting Power Supply
Operating Manual Number 0-2700
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1998 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
omission in the FP-78 Air Plasma Cutting Power Supply Operating Manual, whether such error results from negligence, accident,
or any other cause.
Printed in the United States of America
December 16, 1998
Page 4
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMA TION................................................................................................... 1
1.01 Notes, Cautions and Warnings ....................................................................... 1
1.02 Important Safety Precautions......................................................................... 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et Av ertissement ................................................................... 3
1.05 Precautions De Securite Importantes............................................................. 3
1.06 Documents De Reference .............................................................................. 5
1.07 Declaration of Conformity............................................................................... 6
1.08 Statement of W arranty ................................................................................... 7
SECTION 2:
INTRODUCTION .................................................................................................................. 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description........................................................................................ 9
2.03 Specifications/Design Features...................................................................... 9
2.04 P ower Supply Options and Accessories........................................................10
SECTION 3:
INST ALLATION PROCEDURES ..........................................................................................11
3.01 Introduction ...................................................................................................11
3.02 Site Selection ...............................................................................................11
3.03 Unpacking.....................................................................................................11
3.04 Lifting Options...............................................................................................12
3.05 Input Po wer Connections...............................................................................1 2
3.06 Input Po wer Cable Connections.....................................................................1 3
3.07 Gas Connections ..........................................................................................13
3.08 Connecting T orch Leads................................................................................15
3.09 W ork Cable And Ground Connections............................................................1 6
SECTION 4:
OPERATION .......................................................................................................................17
4.01 Introduction ...................................................................................................17
4.02 Functional Overview......................................................................................1 7
4.03 Operating Controls ........................................................................................17
4.04 Sequence Of Operation.................................................................................19
4.05 Preparations for Operating.............................................................................20
4.06 Cut Quality....................................................................................................20
SECTION 5:
CUSTOMER/OPERAT OR SERVICE ...................................................................................23
5.01 Introduction ...................................................................................................23
5.02 General Maintenance ....................................................................................23
5.03 Common Operating Problems .......................................................................23
5.04 T roub leshooting Guide ...................................................................................24
5.05 Po wer Supply P arts Replacement .................................................................26
Page 5
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS .................................................................................................................... .29
6.01 Introduction ...................................................................................................29
6.02 Ordering Information .....................................................................................29
6.03 Complete System Replacement....................................................................3 0
6.04 Options and Accessories ..............................................................................30
APPENDIX I: INPUT WIRING REQ UIREMENTS........................................................................31
APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM).............................................32
APPENDIX III: SYSTEM SCHEMATIC.......................................................................................34
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Page 7
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A pr ocedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A pr ocedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
• 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 of metal being used, coatings
on the metal, and the different processes. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always r ead the Material Safety Data Sheets (MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information
regarding the kind and amount of fumes and gases
that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.03, Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-571 1 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
• W ear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
1 GENERAL INFORMATION
Page 8
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area wher e
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. T rapped hydr ogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Ar c 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
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as recommended in Subsection 1.03, item 4.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, W ashington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
Government Printing Office, W ashington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standar ds Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
9. NFPA Standard 70, NATIONAL ELECTRICAL
CODE, obtainable from the National Fire Pr otection
Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymar ch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
GENERAL INFORMATION 2
Page 9
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply
Association, 1900 Ar ch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable 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 utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
1.05 Precautions De Securite
Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de
sécurité et toutes les consignes avant d’utiliser le
matériel. Composez le + 603-298-5711 ou votre
distributeur local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
3 GENERAL INFORMATION
Page 10
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
P AS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
INCENDIE ET EXPLOSION
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur . Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
• Respectez le teint de lentille recommandé dans le
article 4, page 5.
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
GENERAL INFORMATION 4
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contr e les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
Page 11
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible aupr ès du Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (A WS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American Welding Society, 550 N.W . LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDA TIONS DE PRA TIQUES
SURES POUR LA PRÉPARATION À LA COUPE
ET AU SOUDAGE DE CONTENEURS ET TUY AUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
5 GENERAL INFORMATION
Page 12
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
W est Lebanon, New Hampshir e 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Dir ective 93/68/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical r equirements among them ar e:
* CSA (Canadian Standar ds Association) standar d C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-cir cuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) applicable to welding equipment and associated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used accor ding to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured pr oduct meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible repr esentative: David Ashworth
Vice Pr esident & Managing Director
Thermadyne Europe
Chorley England.
GENERAL INFORMATION 6
Page 13
1.08 Statement of Warranty
LIMITED W ARRANTY : Firepower® (her einafter “Firepower”) warrants that its products will be fr ee of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the Firepower products
as stated below , Fir epower shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated,
and maintained in accordance with Firepower’s specifications, instructions, recommendations and recognized standard industry
practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement,
at Firepower’s sole option, of any components or parts of the product determined by Firepower to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Firepower shall not under any circumstances be liable for special or consequential damages,
such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter
“Purchaser”) for service interruption. The remedies of the Pur chaser set forth herein are exclusive and the liability of Firepower
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the
manufacture, sale, delivery, resale, or use of any goods covered by or furnished by 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 liability is based.
THIS W ARRANTY BECOMES INVALID IF REPLACEMENT P AR TS OR ACCESSORIES ARE USED WHICH MAY IMPAIR
THE SAFETY OR PERFORMANCE OF ANY FIREPOWER PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Firepower products shall be as follows: A maximum of three (3) years from date of sale to an
authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with the
following further limitations on such two (2) year period.
PARTS
FP-78, POWER SUPPLIES All OTHERS LABOR
MAIN POWER MAGNETICS ............................................................................................ 2 YEARS ................ 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ........................................................................... 2 YEARS ................ 1 YEAR
CONTROL PC BOARD ....................................................................................................... 2 YEARS ................ 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ............................................................... 1 YEAR ................. 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT................................................................... 1 YEAR ................ 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS ............................................................................................................. 180 DAYS ............. 180 DAYS
REPAIR/REPLACEMENT PARTS ......................................................................................... 90 DAYS ................. NONE
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Firepower repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the r esponsibility of the customer. All returned goods
shall be at the customer ’s risk and expense. This warranty supersedes all previous Firepower warranties.
Effective May 15, 1998
7 GENERAL INFORMATION
Page 14
GENERAL INFORMATION 8
Page 15
SECTION 2:
INTRODUCTION
or 50 ft (15.2 m) lengths with fittings for simple installation. The torch includes a spare parts kit which provides
an assortment of replacement torch parts.
NOTE
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the FP-78 Air
Plasma Cutting Power Supply. Service of this equipment is restricted to Firepower® trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this
manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
2.02 General Description
The power supply provides 60 amp maximum output
and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle
and a work cable with clamp.
NOTE
The power supply can be ordered in various configurations with various options factory installed.
Refer to Section 2.04 for list of power supply options and accessories.
2.03 Specifications/Design Features
A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
ON/OFF Switch and Output Current Control
2. Front Panel LED Indicators
AC, TEMP
3. Rear Panel
Input power cable with strain relief, gas connection,
Gas Regulator Assembly, optional Filter Assembly
4. Input Power
Available for the following input power:
208/230 VAC (±8%), 50/60 Hz, Single
5. Output Power
A-01679
Power Supply
Torch and
Work Cable
With Clamp
Leads
Figure 2-1 FP-78 Power Supply
The power supply is designed to work with the Model
FP78-1 Hand Plasma Torches.
Torches will provide a maximum 7/8 inch (22.2 mm)
cut capacity. Hand torches are available in 70° and 90°
configurations. Torch leads are available in 20 ft (6.1 m),
Continuously variable from 15 to 60 Amps maximum
6. Duty Cycle
40% Duty Cycle @ 120V output with 60 Hz input
40% Duty Cycle @ 120V output with 50 Hz input
7. Cut Capacity
7/8 inch (22.2 mm); 1 1/4 inch (31.8 mm) severance
8. Pilot Circuitry
High Frequency (HF), Pulsed DC
9. Weight
72 lbs (32.7 kg)
10. Overall Dimensions (with handle installed)
18.9" (480 mm) High x 10" (330 mm) Wide x 23.5"
(597 mm) Long
Manual 0-2700 9 INTRODUCTION
Page 16
B. Gas Regulator Assembly Specifications
The following specifications apply to the Gas Regulator Assembly only:
1. Gas regulator maximum gauge pressure
160 psi (11 bar or 11.03 kPa)
2. Maximum input gas pressure
125 psi (8.6 bar or 861 kPa)
2.04 P ower Suppl y Options and
Accessories
NOTE
Refer to Section 6, Parts Lists, for part numbers
and ordering information.
The following are accessories that are available for this
power supply:
A. Two Stage Air Line Filter
An optional two stage air line filter is available. The
filter will remove moisture and contaminants from
the air stream when using compressed air. The filter
is capable of filtering to at least 5 microns. The filter
assembly is pre-assembled at the factory and need
only be attached to the power supply.
B. Smart Cart
Steel cart on easy rolling 10" pneumatic tires to provide maximum mobility for the power supply.
Handle is 3/4" tubing with hooks for storage of torch
leads. A tie down strap is also included.
INTRODUCTION 10 Manual 0-2700
Page 17
SECTION 3:
INSTALLATION
Provide sufficient clearance in front of the unit to allow
access to the front panel controls (minimum 6 inches or
0.15 m).
PROCEDURES
3.01 Introduction
NOTE
Depending on how the system was ordered, some
Power Supply Options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended
that all sub-sections be read for general information.
This section describes installation of the power supply
and connecting the torch.
These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for
those units.
The complete installation consists of:
1. Site selection
2. Unpacking
3. Connections to Power Supply
a. Input power
b. Gas
c. Work cable
d. Torch Leads
4. Grounding
5. Operator training
3.02 Site Selection
Select a clean, dry location with good ventilation and
adequate working space around all components.
NOTE
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
3.03 Unpacking
NOTE
Equipment that was ordered as a system is packaged in one shipping carton. All options and the
Torch are factory installed.
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
A. Power Supply
Included with each power supply is Work Cable and
Clamp; Pressure Regulator Assembly and connection
hardware; Primary Input Power Cable; Operating
Manual.
B. Torch and Leads
Included with each Torch is Torch and Leads with Torch
Handle Assembly, Shield Cup, Tip, Electrode, Gas Distributor and all connectors installed; Torch Spare Parts
Kit; Instruction Manual.
C. Options and Accessories
Options and Accessories are packaged separately if not
installed at the factory.
D. Unpacking Procedure
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system installation.
Review Important Safety Precautions (page 1) to
be sure that the selected location meets all safety
requirements.
The power supply is fan cooled by air flow through the
front panel to the rear panel. Air flow must not be obstructed. Provide at least 2 feet (0.61 m) in the rear and
at least 6 inches (0.15 m) on each side for clearance .
Manual 0-2700 11 INSTALLATION PROCEDURES
Page 18
3.04 Lifting Options
WARNING
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-en-
ergized supply line before moving unit.
This unit is equipped with one handle mounted onto
the top of the enclosure for hand carrying purposes.
WARNING
FALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
• Lift unit with the handle on top of the enclosure.
• Persons only of adequate physical strength should
lift the unit.
• Use hand cart or similar device of adequate capacity.
• If using a fork lift vehicle, place and secure unit on
a proper skid before transporting.
• Unit has a handle mounted on top of the enclosure
for hand lifting only. Be sure unit is lifted and
transported safely and securely.
Disconnect primary power at the source before assembling or disassembling the Power Supply, tor ch
parts, or torch and leads assemblies.
1. Remove the four screws securing the Handle and the
Leads Wrap to the top of the Cover.
Mounting Screws
Handle
Mounting Screws
Leads Wrap
A-01693
WARNING
HANDLE is not for mechanical lifting.
3.05 Input Po wer Connections
A. Input Voltag e Selection
The Power Supply accepts input voltages from 208V to
230VAC, 50 or 60 Hz, single-phase.
B. Electrical Connections
The power source must conform to local and national
electric codes. Recommended circuit protection and wir ing requirements are shown in Appendix I.
C. Opening Power Supply Enclosure
The Cover of the Power Supply must be removed to gain
access to the input power connections inside the unit.
Figure 3-1 Handle and Leads Wrap Removal
2. Using a phillips head screw driver remove the ten
screws which secure the Cover to the frame assembly.
INSTALLATION PROCEDURES 12 Manual 0-2700
Page 19
Cover
3.07 Gas Connections
A. Gas Requirements
WARNING
This unit not to be used with oxygen (O2).
Cover Screws
(5 Places On Each Side)
A-01680
Figure 3-2 Cover Removal
3. Carefully pull the Cover up and away from the unit
to gain access to the inside of the unit.
3.06 Input P ower Cable Connections
WARNING
Gases: Compressed Air or Nitrogen (N2) Only
Pressure: 60 psi (4.1 bar or 410 kPa)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar or 861 kPa)
Flow: Cutting and Gouging - 300 scfh (141.5 lpm)
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
B. Gas Connection
The gas supply is connected to the rear of the Power
Supply. The connection is the same for compressed air
or high pressure gas cylinders.
Disconnect primary power at the source before assembling or disassembling the power supply, tor ch
parts, or torch and leads assemblies.
The air supply must be free of oil, moisture, and
The primary input power cable (6ft.(1/8m) is supplied with a NEMA 6-50 plug. Connect the plug to a
customer supplied 230 V AC, single-phase mating connector.
NOTE
Refer to Appendix I for recommended fuse sizes
for the voltage application.
Manual 0-2700 13 INSTALLATION PROCEDURES
other contaminants. Excessive oil and moisture
may cause double-arcing, rapid tip wear, or even
complete torch failure. Contaminants may cause
poor cutting performance and rapid electrode wear .
Filtering is required when using air from a compressor to insure that moisture and debris from
the supply hose does not enter the torch. It is recommended to order the Optional Two Stage Air
Line Filter for air filtering.
1. Locate the 1/4 NPT to #4 (6mm) hose barb fitting
shipped inside the Torch Spare Parts Kit.
CAUTION
NOTE
Page 20
NOTE
A barb fitting is provided for connection of the
gas supply hose to the rear of the Power Supply.
The fitting is placed in the Spare Parts Kit for
shipment.
2. Depending on the options installed at the factory, install the supplied barb fitting into the gas connector
fitting input or the IN port of the Optional Two Stage
Air Filter Assembly at the rear panel.
3. Tighten the barb fitting.
Filter IN Port
Gas Connector
Fitting
1/4 NPT to
#4 (6 mm) Hose
Fitting
4. Place an adjustable hose clamp, 1/4" (6.35mm) to 5/
8" (15.88mm)) over the gas supply hose.
1/4 NPT to
#4 (6 mm) Hose
Fitting
Hose Clamp
#4 (6 mm) Gas
Supply Hose
Gas Connector
Fitting
Hose Clamp
#4 (6 mm) Gas
Supply Hose
Two Stage Filter
Assembly
A-01682
Figure 3-8 Gas Connection To Optional Two Stage
Filter Assembly
5. Refer to the following when using high pressure gas
cylinders as the gas supply:
CAUTION
Figure 3-7 Gas Connection To Regulator/Filter
Assembly
INSTALLATION PROCEDURES 14 Manual 0-2700
A-01681
Pressure should be set at 100 psi (6.9 bar or 690
kPa) at the high pressure gas cylinder regulator.
a. Refer to the manufacturer ’s specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
b. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign material. Momentarily open each cylinder valve to
blow out any dust which may be present.
c. The cylinder must be equipped with an adjustable
high-pressure regulator capable of outlet pressures up to 100 psi (6.9 bar or 690 kPa) maximum
and flows of up to 300 scfh (141.5 lpm).
6. Slide the gas supply hose over the barb fitting installed in Step 2.
Page 21
7. Secure the gas supply hose inplace with the adjustable hose clamp.
CAUTION
NOTE
Supply hose must be at least #4 hose (1/4 in or 6
mm I.D.).
3.08 Connecting Torch Leads
WARNING
Disconnect primary power at the source before assembling or disassembling the power supply, tor ch
parts, or torch and leads assemblies.
The Torch Leads are factory installed to the Power Supply. The information in this Section is only used if the
Torch Leads need to be replaced. The Torch Leads must
be properly installed to the Power Supply for proper operation. Make all torch connections to the Torch Bulkhead Panel and Pilot PC Board per the following:
NOTE
Equipment ordered as a system will have the Torch
factory connected to the Power Supply.
This system is designed for use with the FP781torch only. Do not connect any other torch to
this power supply.
3. Connect the torch gas/power lead fitting onto the
Gas/Power Lead Connection.
Pilot Lead
Torch Leads
Control Cable
Lead
Bulkhead
Gas/Power Lead
Connection
A-01684
1. Remove the Cover of the power supply to gain access
to the torch bulkhead panel and Pilot/Output PC
Board.
2. Feed the end of the torch leads through the hole in the
front panel in the following order:
• Control Cable with Connector
• Pilot Cable with Lug
• Gas/Power lead
Torch Leads
Boot
Torch Leads
Figure 3-10 Lead Connection and Routing
4. Feed the Control Cable and Pilot Cable through the
hole in the bulkhead.
5. Connect the Torch Control and Pilot Cables to the
Pilot/Output PC Board as follows:
a. Twist the Pilot Cable around the black wire
located between E8 and E23 (see NOTE).
NOTE
The Pilot Cable must be twisted around the black
wire between E8 and E23 to ensure proper operation of the torch pilot.
b. Connect the end of the Pilot Cable to E27 con-
nector lug.
c. Connect the end of the Control Cable to the
mating connector at J12.
A-01683
Figure 3-9 Routing Torch Leads
Manual 0-2700 15 INSTALLATION PROCEDURES
Page 22
J12
Pilot/Output
PC Board
Control
Cable
E27
4. Keep torch leads clean. Dirt and metal particles bleed
off energy, which causes difficult starting and increased chance of RF interference.
5. Make sure work cable and ground cables are properly connected.
Black Wire From
E8 to E23
Pilot Cable
A-01685
Figure 3-11 Control and Pilot Cable Connections
5. Re-install the Power Supply Cover on the Power Supply.
3.09 W ork Cab le And Ground
Connections
A. Electromagnetic Interference (EMI)
High frequency pilot arc initiation generates a certain
amount of electromagnetic interference (EMI), commonly
called RF noise. This RF may interfere with other electronic equipment such as CNC controllers, etc. To minimize RF interference, follow these grounding procedur es
when installing mechanized systems:
B. Creating an Earth Ground
1. Install a ground wire (not included) between the system and a solid earth ground (also called star ground).
T o cr eate a solid earth ground, drive a 1/2 in (12 mm)
diameter copper rod approximately 6 - 8 ft (1.8 - 2.4
m) into the earth so that the rod contacts moist soil
over most of its length. The required depth will vary
depending on location. Locate the rod as close as
possible to the power supply. The work table should
be connected to the same earth ground as the power
supply.
A-01686
Work Cable
And Clamp
Make a solid work cable
connection to the workpiece or cutting table
Figure 3-12 Power Supply Work Cable Connection
2. Connect the control device (CNC) to a separate earth
ground similar to the ground rod described above.
The ground cable should be at least 12 gauge (4 mm2)
wire.
3. To minimize RF interference, position torch leads as
far as possible (at least 1 ft or 0.3 m) from any CNC
components, drive motors, control cables, or primary
power lines.
INSTALLATION PROCEDURES 16 Manual 0-2700
Page 23
SECTION 4:
OPERATION
2. Torch Leads Input
Torch leads boot and hole in the front panel to allow
feeding the torch leads through to an internal bulkhead for connecting the torch leads.
4.01 Introduction
This section provides a description of the Power Supply
operating controls and procedures. Identification of the
Front and Rear Panel components is followed by operating procedures.
4.02 Functional Overview
The Firepower FP-78 provides a degree of operating flexibility and the use of simple controls.
4.03 Operating Controls
This subsection provides specific functional descriptions
of the Power Supply operating controls and indicators.
A. Front Panel
1. Control Panel
All operator controls, except gas pressure adjustment,
are located on this panel. Power ON/OFF; CURRENT control; LED indicators for AC Power and
TEMP.
3. Work Cable and Clamp
Work cable with clamp (factory installed).
4. Handle
Handle used to lift and transport the power supply.
5. Leads Wrap
Bracket connected to the Cover of the unit for use in
storing the torch, torch leads and work cable when
not in use. The torch leads and work cable wrap
around the bracket for easy storage.
B. Control Panel
3
CURRENT
35
1
A
ON
60
OUTPUT CURRENT
Drag Cutting
Standoff Cutting
& Gouging
15
2
AC
TEMP
15-35A
15-60A
4
4
5
A-01687
3
Figure 4-1 Front Panel Controls
OFF
1
2
Figure 4-2 Operating Controls
A-01688
1. Current Control
Adjustment to set the desired output current between
15-60 amps. For drag cutting applications set the control between 15 - 35 amps.
2. ON/OFF Power Switch
ON position supplies AC power to activate all system control circuits. OFF position deactivates control circuits.
3. AC Power Indicator
Green LED indicator will blink ON then OFF for approximately eight seconds and then stay ON after
the ON/OFF power switch is set to ON. Indicates
operating power is present in the unit..
Manual 0-2700 17 OPERATION
Page 24
4. TEMP Indicator
Normally OFF. Yellow LED indicator will come ON
when the internal temperature senors detect temperatures above normal limits. The unit should be allowed to cool before continuing operation.
C. Torch Panel Bulkhead
The torch panel bulkhead area is located behind the Front
Panel and requires removal of the Power Supply Cover
for access.
1. Gas/Power Lead Connection
Connects the torch gas/negative lead to the unit.
1
4
1
3
2
2
A-01689
Figure 4-3 Torch Panel Bulkhead Area
2. Control and Pilot Cable Hole
Hole used to allow the Control and Pilot Cables to
be fed into the power supply for internal connections
to the Pilot/Output PC Board.
D. Rear Panel
1. Gas Input Fitting
Input connection for nitrogen (N2) or air input.
A-01690
Figure 4-4 Rear Panel
2. Primary Input Power Cable and Strain Relief
NOTE
Input power cable is supplied on units.
Primary input power cable and strain relief for the
six foot (1.8 m) primary power cable capable of handling the input voltage designed for this unit.
3. Gas Pressure Adjustment
Adjustment knob on internal pressure regulator to
adjust the input gas pressure to the Power Supply.
Pull knob out and turn clockwise to increase pressure to desired level.
4. Pressure Gauge
Displays input gas pressure to the torch.
WARNING
This unit not to be used with oxygen (O2).
OPERATION 18 Manual 0-2700
Page 25
NOTE
Power Supply will not come ON if the gas pressure is set below 45 psi (3.1 bar or 310 kPa) at the
Regulator Assembly.
3. Protect eyes and press or activate torch switch
a. Gas pre-flows starts.
4
b. GAS indicator turns ON.
4. After gas pre-flow (approximately 2 seconds)
3
1
a. Power supply enabled.
b. Pilot relay closes.
5
5. Pilot arc is established
6. Move T or ch within transfer distance of workpiece.
a. Main arc transfer.
2
A-01691
Figure 4-5 Rear Panel With Optional Two Stage
Filter Installed
5. Optional Two Stage Air Line Filter
The optional filter will remove moisture and contaminants from the air stream when using compressed
air. The filter is capable of filtering to at least 5 microns.
4.04 Sequence Of Operation
The following is a typical sequence of operation for this
cutting system. Refer to Appendix II for a block diagram.
1. Close main power source disconnect.
a. AC power is available at the Power Supply.
2. Place the ON/OFF power switch on the front panel
of the Power Supply to ON.
a. AC Power indicator LED blinks ON and OFF
for eight seconds then stays ON.
b. Pilot arc OFF.
7. Complete cutting operation
NOTE
If the torch is lifted from the workpiece, while still
having torch swicth activated, the main arc will
stop and the pilot arc will automatically restart.
8. Release or deactivate the torch switch.
a. Main arc stops.
b. Pilot arc stops (power supply enable signal
removed).
NOTE
If torch is activated during post-flow , pilot arc will
immediately restart.
If torch is within 3/8 in (9.53mm) transfer distance of workpiece, main arc will transfer.
9. Gas will flow for 15 seconds (post-flow).
a. Gas solenoid closes
b. Gas flow stops.
10. Place the ON/OFF power switch on the front
panel of the unit to OFF
a. AC Power indicator turns OFF.
b. Fans turn OFF.
11. Place the main power disconnect to open.
a. Main AC power is removed from the system.
b. Fans turn on.
Manual 0-2700 19 OPERATION
Page 26
4.05 Preparations for Operating
D. Work Cable Connection
Follow this set-up procedure each time the system is operated:
WARNING
Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate front end torch parts. The torch parts (shield cup,
tip and electrode) must correspond with the type of
operation (cutting or gouging). Refer to the Instruction Manual supplied with the Torch Assembly for
proper parts selection.
B. Check primary power source as follows:
1. Check the power source for proper input voltage.
Make sure the input power source meets the
power requirements for the unit per Section 2.03A-4, Specifications/Design Features.
2. Connect the input power cable (or close the main
disconnect switch) to supply power to the system.
C. Gas Selection
Select desired gas (air or nitrogen). Make sure gas
source meets pressure and flow requirements (refer
to Section 3.08, Gas Connections). Check connection
and turn gas supply on.
Check for a solid and clean work cable connection to
the workpiece. The area must be free from paint and
rust.
Make a solid work cable
connection to the workpiece or cutting table
A-00925
Figure 4-6 Work Cable Connection To Workpiece
E. To rch Connection
Check that the torch is properly connected.
F. Select Output Current
Select the desired current output level for the operation.
• 15 to 60 amps for standoff cutting and gouging
• 15 to 35 amps for drag cutting
G. Set Operating Pressure
OPERATION 20 Manual 0-2700
Adjust the gas pressure to 60 psi (4.1 bar or 410 kPa).
The system is now ready for operation.
4.06 Cut Quality
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may
be major factors when the surface will be welded after
cutting. Dross-free cutting is important when finish cut
quality is desired to avoid a secondary cleaning operation.
The following cut quality characteristics are illustrated
in Figure 4-7 below:
Cut Surface
The condition (smooth or rough) of the face of the cut.
Page 27
Bevel Angle
The angle between the surface of the cut edge and a plane
perpendicular to the surface of the plate. A perfectly
perpendicular cut would result in a 0° bevel angle.
Top-Edge Rounding
Type of M aterial
Gas
Air
Nitrogen Good G ood G ood
Carbon
Steel
G ood -
Excellent
S tainless
Steel
G ood -
Excellent
Aluminum
G ood -
Excellent
Rounding on the top edge of a cut due to wearing from
the initial contact of the plasma arc on the workpiece.
Dross Build-up and Top Spatter
Dross is molten material which is not blown out of the
cut area and re-solidifies on the plate. Top spatter is
dross which accumulates on the top surface of the workpiece. Excessive dross may require secondary clean-up
operations after cutting.
Kerf Width
The width of material removed during the cut.
Nitride Build-up
Nitride deposits which may remain on the surface of
the cut when nitrogen is present in the plasma gas stream.
Nitride buildups may create difficulties if the material
is welded after the cutting process.
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Description of Cut Characteristics
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross,
smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily removed), medium-smooth cut surface, slight top
edge rounding.
Fair - Excessive bevel (over 10°), wide kerf (over 2-1/2 x
tip orifice diameter), medium to heavy dross,
rough cut surface, top edge rounding.
NOTES
Cut quality depends heavily on set-up and parameters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and operator ability.
Top Edge
Rounding
Dross
Build-Up
Cut Surface
A-00007
Drag Lines
Figure 4-7 Cut Quality Characteristics
Cut quality will vary on different types of and material
thicknesses.
The following table shows the cut quality that can be
expected from this equipment for materials with a thickness from gage to 7/8 inch (22.2 mm):
Manual 0-2700 21 OPERATION
Page 28
OPERATION 22 Manual 0-2700
Page 29
SECTION 5:
CUSTOMER/OPERATOR
SERVICE
5.03 Common Operating Problems
WARNINGS
5.01 Introduction
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than Firepower
Trained personnel.
For parts and service, call your local dealer or call toll
free 1-877-288-4822.
5.02 General Maintenance
WARNING
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
The only routine maintenance required for the power
supply is a thorough cleaning and inspection, with the
frequency depending on the usage and the operating environment.
CAUTION
Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.
Frequently review the Important Safety Precautions (page 1). Be sure the operator is equipped
with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body
comes into contact with the workpiece while the
torch is activated.
CAUTION
Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as
glass, plastic and metal.
NOTE
Handle torch leads with care and protect them fr om
damage.
A. Piloting
Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the
tip rather than to a workpiece. Whenever possible, avoid
excessive pilot arc time to improve parts life.
Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause metal
particles to interfere with sensitive electrical components and cause damage to the unit.
To clean the unit, open the enclosure (refer to Section
5.05-A, Opening Enclosure) and use a vacuum cleaner
to remove any accumulated dirt and dust. The unit
should also be wiped clean. If necessary, solvents that
are recommended for cleaning electrical apparatus may
be used.
B. Torch Standoff
Improper standoff (the distance between the torch tip
and workpiece) can adversely affect tip life as well as
shield cup life. Standoff may also significantly affect the
bevel angle. Reducing standoff will generally result in a
more square cut.
C. Edge Starting
For edge starts, hold the torch perpendicular to the workpiece with the front of the tip at the edge of the workpiece at the point where the cut is to start. When starting
at the edge of the plate, do not pause at the edge and
force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible.
D. Direction of Cut
In the torches, the plasma gas stream swirls as it leaves
the torch to maintain a smooth column of gas. This swirl
effect results in one side of a cut being more square than
the other. Viewed along the direction of travel, the right
side of the cut is more square than the left (Refer to Figure 5-1). To make a square-edged cut along an inside
Manual 0-2700 23 SERVICE
Page 30
diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an
outside diameter cut, the torch should travel in a clockwise direction.
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
Left Side
Cut Angle
Right Side
Cut Angle
A-00512
Figure 5-1 Side Characteristics Of Cut
E. Dross
Generally when dross is present on carbon steel, it is
referred to as either "high speed or slow speed dross".
"High speed dross" usually forms a narrow bead along
the bottom of the cut edge and is very difficult to remove. "Slow speed dross" will be in larger quantities
but does not adhere tightly to the cut edge and can be
easily removed.
When cutting a troublesome steel, it is suggested that
the torch travel speed be reduced to produce "slow speed
dross". Any required cleanup can then be done by scrapping, not grinding.
Dross present on top of the plate (top spatter), is normally caused by a slow torch travel speed or too high of
a torch standoff distance.
F. Common Cutting Faults
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
c. Worn torch parts
d. Improper cutting current
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
5.04 Troubleshooting Guide
A. General
T roubleshooting and r epairing this unit is a process which
should be undertaken only by those familiar with high
voltage high power electronic equipment.
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training
in power electronics measurement and troubleshooting techniques.
B. Basic Troubleshooting
This manual covers a basic level of troubleshooting that
requires limited dissasembly and measurements. It is
helpful for solving many of the common problems that
can arise with this system.
If major complex subassemblies are faulty, the unit must
be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
C. How to use this Guide
The following information is a guide to help the Customer/Operator determine the most likely causes for
various symptoms.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (Text Type)
SERVICE 24 Manual 0-2700
Page 31
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
Locate your symptom, check the causes (easiest listed
first) then remedies. Repair as needed being sure to
verify that unit is fully operational after any repairs.
5. Input voltage of 460 VAC applied to 208/230/240 VAC
or 380/415 VAC Models
a. Check input line voltage and correct as re-
quired.
6. Faulty components in unit
A. AC Power indicator OFF
1. Switch at customer's main power panel in OFF position.
a. Close main power panel switch
2. Input power not properly connected to customer's main
power panel
a. Check that input power is present and unit is
properly connected (refer to Section 3.05, Input Power Connections)
3. Actual input voltage does not correspond to voltage
phase selection inside unit
a. Check actual line voltage phase vs. voltage
phase selection (inside of unit)
4. Customer's main power line fuse(s) blown
a. Check main power panel fuse(s) and replace
as required.
5. Unit internal fuse blown or loose
a. If blown, double check input voltage vs. volt-
age selection (inside of unit) and replace fuse
per Section 5.05-B. If fuse blows again, return
unit to an authorized service center.
6. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
C. Torch will not pilot when torch switch is acti-
vated
1. Torch switch activated during 2 second pre-flow
a. Release switch and wait at least 2 seconds be-
fore activating switch again
2. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
fer to Instruction Manual supplied with torch).
3. Gas pressure too high or too low
a. Set pressure to 60 psi (4.1 bar or 410 kPa).
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
D. AC Power indicator ON; Fans operating; No
cutting output
1. Torch not properly connected to power supply
a. Check that torch leads are properly attached to
power supply
2. Shield cup not properly installed on torch
a. Return for repair or have qualified technician
repair per Service Manual.
B. AC Power indicator ON; TEMP indicator ON
1. Airflow obstructed
a. Check for obstructed air flow and correct con-
dition.
2. Fan blocked
a. Check and correct condition
3. Unit is overheated
a. Allow unit to cool down for about 5 minutes.
Make sure the unit has not been operated be-
a. Check that shield cup is fully seated against
torch head (do not overtighten if screwed on)
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
E. Low cutting output with no control
1. Incorrect setting of CURRENT control
a. Check and adjusted to proper setting.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
yond duty cycle limit.
F. Limited output with no control
4. Input line voltage is below 75% of rated level
1. Poor input or output connections
a. Check and connect to proper input power line
a. Check all input and output connections.
Manual 0-2700 25 SERVICE
Page 32
2. Incorrect setting of CURRENT control
a. Check and adjusted to proper setting.
3. Faulty components in unit
5.05 P o wer Suppl y Parts
Replacement
a. Return for repair or have qualified technician
repair per Service Manual.
G. Erractic or improper cutting output
1. Poor input or output connections
a. Check all input and output connections.
2. Incorrect type and size cable on input or output
a. Use proper type and size cables.
H. AC Power indicator ON; Cutting output avail-
able; Fans not operating,
1. Fan blades blocked
a. Check and clear blades.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
I. AC POWER indicator ON; Fans operate; No gas
flow
1. Gas not connected or pressure too low
WARNING
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
A. Cover Removal
1. Remove the four screws securing the Handle and
the Leads Wrap to the top of the Cover.
Mounting Screws
Handle
Mounting Screws
Leads Wrap
a. Check source for at least 60 psi (4.1 bar or 410
kPa).
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
J. Torch cuts but not adequately
1. Current set too low
a. Increase current setting.
2. Torch is being moved too fast across workpiece
a. Reduce cutting speed (refer to Instruction
Manual supplied with torch.
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface
while purging and observe oil or moisture
buildup (do not activate torch)
A-01693
Figure 3-1 Handle and Leads Wrap Removal
2. Using a phillips head screw driver remove the ten
screws which secure the Cover to the frame assembly.
SERVICE 26 Manual 0-2700
Page 33
Cover Screws
(5 Places On Each Side)
Cover
A-01680
Figure 5-2 Cover Removal
3. Carefully pull the Cover up and away from the
unit to gain access to the inside of the unit.
4. To reinstall the Cover reverse the above procedure.
B. Fuse Replacement
1. Remove the Cover per paragraph "A" above.
2. Locate the internal fuse above the input power
contactor on the left side of the unit.
3. Replace the fuse (0.8 amp, 600V).
Internal Fuse
0.8 Amps, 600V
A-01692
Figure 5-3 Internal Fuse Location
4. Reinstall the Cover per paragraph "A" above.
Manual 0-2700 27 SERVICE
Page 34
SERVICE 28 Manual 0-2700
Page 35
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all r eplaceable components. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Options and Accessories
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a Firepower product must be returned for service, contact your Firepower distributor . Materials returned to Fir epower without proper authorization will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. For parts and service, call your
local dealer or call toll free 1-877-288-4822.
Manual 0-2700 29 PARTS LISTS
Page 36
6.03 Complete System Replacement
System includes: Input Power Cable & Plug, Work cable, pressure regulator/air filter, air hose and fittings, torch &
leads, torch manual and operating manual.
Description Qty Catalog #
FP-78 Plasma Cutting System
208/230VAC, Single Phase 1 1445-0002
6.04 Options and Accessories
Qty Description Catalog #
1 Torch Lead 70 deg, 20' 1445-0003
2 O-Ring 1445-0004
5 Electrode, Air/N2 1445-0007
1 Gas Distributor, Cutting 1445-0008
1 Gas Distributor , Gouging 1445-0009
5 Tip, Cutting, 70 Amp, Air/N2 1445-0014
5 Tip, Cutting, 35 Amp, Drag 1445-0019
5 Tip, Gouging 1445-0022
1 Coil Spring 1445-0023
1 Shield Cup 1445-0024
1 Shield Cup, Crown 1445-0029
PARTS LISTS 30 Manual 0-2700
Page 37
APPENDIX I: INPUT WIRING REQUIREMENTS
g
Input Power Input Current Suggested Sizes (See N ote s )
Volta
eFreq. 1-Ph 1-Ph
(Volts) (Hz) (kVA) (Amps ) Fuse (Amps ) Wire (AWG) W i re (Cana d a)
208 50/60 14.6 41.7 50 6 6
230 50/60 14.8 38.4 40 8 8
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on Na tional Electric Code and Canadian Electrical Code
NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
Cable conductor temperature used is 167° F (75° C).
An energy limiting 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 like UL Class H, or "one-time" fuses like UL Class K5.
Flexible cable must have an outside diameter of 0.69 inches (17.5 mm) or greater.
Manual 0-2700 31 APPENDIX
Page 38
APPENDIX II: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION
Protect eyes and
activate torch
RESULT
Gas flows (2 seconds).
After gas pre-flow:
DC indicator on.
Pilot relay closes.
Pilot arc established
ACTION
Close external
disconnect switch.
RESULT
Power to system.
ACTION
ON/OFF switch to ON.
RESULT
AC indicator blinks for 8 seconds then steady on.
Gas solenoid open, gas flows to set pressure.
Gas flow stops after pre-flow (purge).
Fans on.
Power circuit ready.
PILOT ARC
ACTION
Torch moved away
from work (while
still activated).
RESULT
Main arc stops.
Pilot arc automatically
restarts.
ACTION
Torch deactivated (by torch switch
release or by remote device).
RESULT
Main arc stops. Pilot stops.
(Power supply enable signal removed.)
Gas flows (15 seconds)
NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of
workpiece, main arc will transfer.
After post-flow:
Gas solenoid closes, gas flow stops.
APPENDIX 32 Manual 0-2700
ACTION
ON/OFF switch
to OFF
RESULT
All indicators off.
Power supply fans off.
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
Main arc transfer.
Pilot arc off.
ACTION
Open external
disconnect.
RESULT
No power to system.
A-01654
Page 39
Manual 0-2700 33 APPENDIX
Page 40
APPENDIX III: SYSTEM SCHEMATIC
A-01707
APPENDIX 34 Manual 0-2700
Page 41
Manual 0-2700 35 APPENDIX
D EC 8055 HAS
11/23
98
A-01707
Page 42
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