Page 1
Plasma Cutting
Power Supply
Model FP-80
A-02218
November 7, 2001
Operating Manual
Manual No. 0-2803
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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, the manufacturer assumes no
liability for its use.
FirePower FP-80 Plasma Cutting Power Supply
Operating Manual Number 0-2803
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 2000 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 this Manual, whether such error results from negligence, accident, or any other cause.
Printed in the United States of America
November 7, 2001
Page 4
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .................................................................................................. 1
1.01 Notes, Cautions and Warnings ...................................................................... 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et Avertissement ................................................................... 3
1.05 Precautions De Securite Importantes ............................................................ 3
1.06 Documents De Reference ............................................................................. 5
1.07 Declaration of Conformity .............................................................................. 7
1.08 Statement of W arranty................................................................................... 8
SECTION 2:
INTRODUCTION ................................................................................................................. 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description....................................................................................... 9
2.03 Specifications/Design Features ..................................................................... 9
2.04 Po wer 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.............................................................................................. 11
3.05 Input Po wer Connections............................................................................. 12
3.06 Input Voltage Selection ................................................................................ 13
3.07 Input Pow er Cable Connections................................................................... 13
3.08 Gas Connections......................................................................................... 14
3.09 Connecting Torch Leads .............................................................................. 1 6
3.10 W ork Cable And Ground Connections ......................................................... 16
SECTION 4:
OPERATION ...................................................................................................................... 19
4.01 Introduction.................................................................................................. 19
4.02 Functional Overview .................................................................................... 19
4.03 Operating Controls ...................................................................................... 19
4.04 Sequence Of Operation ............................................................................... 21
4.05 Preparations for Operating........................................................................... 22
SECTION 5:
CUSTOMER/OPERATOR SERVICE.................................................................................. 23
5.01 Introduction.................................................................................................. 23
5.02 General Maintenance .................................................................................. 23
5.03 Common Operating Problems ..................................................................... 23
5.04 Troubleshooting Guide ................................................................................. 24
5.05 Pow er Supply Parts Replacement ............................................................... 26
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TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS.....................................................................................................................29
6.01 Introduction.................................................................................................. 29
6.02 Ordering Information.................................................................................... 29
6.03 Complete Po wer Supply Replacement......................................................... 30
6.04 Basic Parts Replacement ............................................................................ 30
6.05 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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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 procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 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.
• 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 read 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.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer . (California Health
& Safety Code Sec. 25249.5 et seq.)
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.”
Date: 5/1/00 (Special) 1 GENERAL INFORMA TION
Page 8
• 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.
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.
• T o pr otect your hearing fr om 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 Arc Rays can injur e 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 suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
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
GENERAL INFORMATION 2 Date 5/1/00 (Special)
Page 9
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards 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. NFP A Standar d 70, NA TIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch 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
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 Arch Street, Philadelphia, PA 19103
14. American W elding Society Standard A WSF4.1, 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
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.
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
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.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques 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 votr e distributeur
local si vous avez des questions.
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 :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Date: 5/1/00 (Special) 3 GENERAL INFORMA TION
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.
Page 10
• 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 différ ents
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
• 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.
• 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.
• 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.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir
des éléments reconnu dans L’ état de la Californie,
qui peuvent causer des défauts de naissance et le
cancer . (La sécurité de santé en Californie et la code
sécurité Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
INCENDIE ET EXPLOSION
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.
• 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.
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
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.
GENERAL INFORMATION 4 Date 5/1/00 (Special)
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.
Page 11
• 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.
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
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 contre 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.
• 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 Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRA TIQUES 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 W elding 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
Date: 5/1/00 (Special) 5 GENERAL INFORMA TION
Page 12
11. Br ochure GCA P-1, LA MANIPULA TION 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 W elding Supply Association),
1900 Arch Street, Philadelphia, PA 19103
14. Norme A WSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA
COUPE ET AU SOUDAGE DE CONTENEURS
ET TUYAUX 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
GENERAL INFORMATION 6 Date 5/1/00 (Special)
Page 13
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
W est Lebanon, New Hampshire 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 Directive 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 requir ements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated 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 representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: 5/1/00 (Special) 7 GENERAL INFORMA TION
Page 14
1.08 Statement of Warranty
LIMITED WARRANTY: Firepower® (hereinafter “Firepower”) warrants that its products will be free 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 , Firepower shall, upon notification thereof and substantiation that the pr oduct has been stored, 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
PAR TICULAR PURPOSE.
LIMIT ATION 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 Purchaser 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 WARRANTY BECOMES INVALID IF REPLACEMENT PARTS 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 thr ee (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-80, 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 ......................................................................................................................... 1 YEAR .................. 1 YEAR
REPAIR/REPLACEMENT P ARTS .................................................................................................... 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 responsibility of the customer. All returned goods shall be at the
customer ’s risk and expense. This warranty supersedes all previous Firepower warranties.
Effective May 5, 2000
GENERAL INFORMATION 8 Date 5/1/00 (Special)
Page 15
SECTION 2:
INTRODUCTION
NOTE
Refer to Section 2.04 for list of power supply options and accessories.
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the FirePower
FP-80 Plasma Cutting Power Supply. Service of this
equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at
the risk of voiding the W arranty.
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 , tor ch leads receptacle and a work
cable with clamp.
NOTE
The power supply can be ordered in various configurations with various options factory installed.
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, RUN/SET Switch and Output Current Control
2. Front Panel LED Indicators
AC, TEMP, GAS, DC
3. Rear Panel
Input power cable strain relief, 230VAC input power
cable with plug, gas connection and Gas Regulator/
Filter Assembly
4. Input Power
Factory Supplied for:
208/230 VAC (±10%), 50/60 Hz, Single-Phase
Customer Selectable for:
208/230 VAC (±10%), 50/60 Hz, Three-Phase
Power Supply
Torch and
Leads
A-02837
Work Cable
With Clamp
Figure 2-1 FirePower FP-80 Power Supply
The power supply is designed to work with the Model
PCH-102 Plasma T orches. The torch includes a spar e parts
kit which provides an assortment of replacement torch
parts.
380-415 V AC (±10%), 50/60 Hz, Single or Three-Phase
460 VAC (±10%), 50/60 Hz, Single or Three-Phase
575 VAC, 50/60 Hz, Three-Phase (see Note)
NOTE
Requires Optional 575V Transformer.
5. Output Power
Continuously variable from 15 to 60 Amps maximum
6. Duty Cycle
45% Duty Cycle @ 120V output with 60 Hz input
45% 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
Capacitive Discharge (CD), Pulsed DC
9. Weight
Manual 0-2803 9 INTRODUCTION
72 lbs (32.7 kg)
Page 16
10. Overall Dimensions
18.9" (480 mm) High x 10" (254 mm) Wide x 23.5" (597
mm) Long
Overall dimensions are with handle installed.
B. Gas Regulator/Filter Assembly
Specifications
The following specifications apply to the Gas Regulator/Filter Assembly only:
1. Maximum input gas pressure
125 psi (8.6 bar)
2. Filter
Coalescent type filter
2.04 Power Supply Options and
Accessories
The following accessories are available for this power
supply. Refer to Section 6, Parts Lists, for part numbers
and ordering information.
A. Two Stage Air Line Filter
An optional two stage air line filter is available. The
filter will remove moisture and contaminants fr om 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. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and
front-mounted swivel casters. Provides maximum
mobility for the power supply and can also serve as a
display cart. T op shelf is 12 " (305 mm) x 20 (508 mm).
Steel handle is 30" (762 mm) high.
C. 575V Transformer
This step-down transformer allows the power supply to operate with 575 V AC three-phase input power.
INTRODUCTION 10 Manual 0-2803
Page 17
SECTION 3:
INSTALLATION
vide 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
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.
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.
3.04 Lifting Options
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
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 . Pro-
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
This unit is equipped with one handle mounted onto the
top of the enclosure for hand carrying purposes.
WARNING
F ALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
• Lift unit with the handle on top of the enclosure.
• Only persons 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.
Manual 0-2803 11 INST ALLATION PROCEDURES
Page 18
• Unit has a handle mounted on top of the enclosure
for hand lifting only. Be sure unit is lifted and transported safely and securely.
WARNING
Mounting Screws
Handle
HANDLE is not for mechanical lifting.
3.05 Input Power Connections
The Power Supply accepts input voltages from 208 to
460VAC, 50/60 Hz, single-phase or three-phase power.
A. Input Voltage Selection
The Power Supply is factory-wired for 230VAC singlephase input power . For any other input voltage the Power
Supply must be changed using the procedure in Section
3.06, Input Voltage Selection.
B. Electrical Connections
The power source must conform to local and national electric codes. Recommended circuit protection and wiring
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.
WARNING
Leads Wrap
A-02220
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.
Cover
Disconnect primary power at the source before assembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.
1. Remove the two screws securing the Handle and the
Leads Wrap to the top of the Cover.
INST ALLATION PROCEDURES 12 Manual 0-2803
Cover Screws
(5 Places On Each Side)
A-02221
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.
Page 19
3.06 Input Voltage Selection
NOTE
For power supplies to use 575 VAC input power,
the unit must be setup for 460V three-phase operation and the 575V T ransformer Accessory must
be installed.
NOTE
Units are shipped with an input power cable and
plug for 230 VAC, single-phase, operation.
1. Route the primary power cable through the strain relief fitting in the rear panel of the Power Supply and
tighten stain relief screws.
The Power Supply has three voltage settings;
208/230VAC, 380-415VAC, or 460VAC. Power Supplies
are factory-wired for 230VAC single-phase input power.
Input voltage selection is accomplished by switching a
wire harness connector inside the Power Supply. Also, a
jumper wire must be properly installed depending on the
input used.
WARNING
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
Move the Voltage Selection Plug to the desired Voltage
Selection Connection for 208/230V , 380-415V, or 460V operation per the label attached to the panel.
Voltage Selection
460 V olts
380-415 V olts
208/230 V olts
Connectors
A-02222
AC Input Power
Cable Strain Relief
A-00912
AC Input
Power Cable
Figure 3-4 AC Input Power Cable Strain Relief
2. Connect the input cable inside the Power Supply for
the type of operation per the following:
Three-Phase Operation
Three-phase operation requires a 3-conductor cable
with ground.
a. Locate the ground stud and remove the top nut
and washer.
b. Install a lug terminal on the ground wire.
c. Place the ground wire onto the ground stud
and secure with the nut and washer.
Voltage Selection
Plug
Voltage Selection
Figure 3-3 Input Voltage Selection
3.07 Input Power Cable Connections
The primary power cable must be supplied (see Note) by
the end user and installed to the Power Supply assembly .
Recommended cable sizes are specified in Appendix I.
Manual 0-2803 13 INST ALLATION PROCEDURES
Label
d. Insert the other three wires into the L1, L2, and
L3 terminals on the contactor . For three-phase
operation, the jumper wire between L2 and L2
(storage) must be left in this storage connec-
tion.
e. Tighten all set scr ews.
NOTE
The jumper wire from L1 to L4 must not be removed.
Page 20
Input Contactor
L3
L2
e. Place the ground wire onto the ground stud
and secure with the nut and washer.
L1
f. Insert the other two wires into the L1 and L2
terminals on the contactor .
g. Tighten all set scr ews.
Input Contactor
L2
L1
A-00913
AC Input
Power Cable
GND
Unused Jumper
L2 to L2 (Storage)
Figure 3-5 Primary Power Cable Connections -
Three-Phase Operation
Single-Phase Operation
Single-phase operation requires a 2-conductor cable
with ground.
a. Locate the single-phase jumper wire connected
between the two L2 terminal lugs on the input
contactor.
b. Move one end of the jumper wire from termi-
nal lug L2 to L3 at the contactor.
NOTE
The jumper wire from L1 to L4 must not be removed.
Input Contactor
L3
L2
A-00915
GND
AC Input
Power Cable
Figure 3-7 Primary Power Cable Connections -
Single-Phase Operation
CAUTION
The primary power source, power cable, and plug
all must conform to local electric code and the recommended circuit protection and wiring requirements (refer to Appendix I).
3.08 Gas Connections
A. Gas Requirements
A-00914
Figure 3-6 Single Phase Jumper Wire Installation
c. Locate the ground stud and remove the top nut
and washer .
d. Install a lug terminal on the ground wire.
INST ALLATION PROCEDURES 14 Manual 0-2803
Single Phase
Jumper Wire
(L2 to L3)
WARNING
This unit not to be used with oxygen (O2).
Gases: Compressed Air or Nitr ogen (N2) Only
Pressure: 60 psi (4.1 bar)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
Flow: Cutting and Gouging - 300 scfh (141.5 lpm)
Page 21
B. Gas Connection
The gas supply is connected to the rear of the Power Supply.
CAUTION
The 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 .
NOTE
Filtering is required when using air from a compressor to insure that moisture and debris fr om 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.
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.
A-00917
1/4 NPT to
#4 (6mm) Hose
Fitting
Hose Clamp
#4 (6mm) Gas
Supply Hose
Two Stage Filter
Assembly
Figure 3-9 Gas Connection To Optional Two Stage
Filter Assembly
5. Refer to the following when using high pressure gas
cylinders as the gas supply:
CAUTION
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 T wo Stage
Air Filter Assembly at the rear panel.
3. Tighten the barb fitting.
4. Place an adjustable hose clamp over the gas supply
hose.
1/4 NPT to #4 (6mm)
Regulator/Filter
Assembly
Hose Fitting
Hose Clamp
A-00916
#4 (6mm) Gas
Supply Hose
Figure 3-8 Gas Connection To Standard Air Filter
Assembly
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 pr essures
up to 100 psi (6.9 bar) 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.
7. Secure the gas supply hose in place with the adjustable hose clamp.
NOTE
Supply hose must be at least #4 hose (1/4 in or 6
mm I.D.).
Manual 0-2803 15 INST ALLATION PROCEDURES
Page 22
3.09 Connecting Torch Leads
WARNING
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
Adapter
(Supplied With
Power Supply)
Control (PIP) Circuit
Connectors
Adapter
Connector
Pilot Lead Stud
The T orch Leads must be pr operly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the T or ch
Bulkhead Panel for the desired application.
NOTE
Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.
CAUTION
This system is designed for use with the PCH-102
torch only. Do not connect any other torch to this
power supply.
1. Remove the Cover of the power supply to gain access
to the torch bulkhead panel.
2. Remove the securing nut from the strain relief supplied on the end of the Torch Leads.
Torch Leads
Assembly
Strain Relief
Negative/Plasma Lead
Connection
Pilot Lead
Negative/Plasma
Lead
Torch Lead
Assembly
A-02825
Figure 3-11 Torch Lead Connections
6. Connect the PIP Cables to the mating connectors on
the Adapter supplied on the Power Supply.
7. Remove the top nut and washer from the Pilot Stud.
8. Place the lug on the Pilot Control Wire onto the stud
and secure with the nut and washer removed in the
above Step.
9. Tighten the Strain Relief onto the Torch Leads.
10. Check the torch for proper parts assembly.
11. Re-install the Power Supply Cover on the Power Supply.
3.10 Work Cable And Ground
Connections
Retaining Nut
Figure 3-10 Torch Strain Relief Nut
3. Feed the torch lead ends and the Strain Relief into the
hole in the unit.
4. Secure the Strain Relief with the retaining nut removed
earlier.
5. Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply.
INST ALLATION PROCEDURES 16 Manual 0-2803
A-02836
A. Electromagnetic Interference (EMI)
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 procedures 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 create a solid earth gr ound, drive a 1/2 in (12 mm)
diameter copper rod into the earth so that the rod contacts moist soil over most of its length. The required
depth will vary depending on location (see NOTE).
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.
Page 23
NOTE
A properly installed ground rod will have a resistance of one ohm or less.
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 mm
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.
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 pr operly
connected. The work cable must have a solid connection to the workpiece or cutting table. The connection must be free from dirt, gr ease, oil and paint.
2
)
A-02227
Work Cable
And Clamp
Make a solid work cable
connection to the workpiece or cutting table
Figure 3-12 Power Supply Work Cable Connection
Manual 0-2803 17 INST ALLATION PROCEDURES
Page 24
INST ALLATION PROCEDURES 18 Manual 0-2803
Page 25
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-80 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 and RUN/
SET switches; CURRENT control; LED indicators for
AC Power , TEMP, GAS, and DC.
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
1
8
CURRENT
35
15
A
ON
60
8
AC
TEMP
GAS
DC
RUN
4
5
6
7
4
5
1
A-02228
3
Figure 4-1 Front Panel Controls
2
2
OFF
SET
A-02229
3
Figure 4-2 Operating Controls
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. RUN/SET Switch
RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.
Manual 0-2803 19 OPERA TION
Page 26
4. AC Power Indicator
3. Pilot Lead Stud
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..
5. TEMP Indicator
Normally OFF. Yellow LED indicator will come ON
when the internal temperature sensors detect temperatures above normal limits. The unit should be allowed
to cool before continuing operation.
6. GAS Indicator
Green LED indicator will come ON when the input
gas pressure is set to 45 psi (3.1 bar) or higher . Indicator will be OFF when the pressure falls below 45 psi
(3.1 bar).
7. DC Indicator
Green LED indicator will come ON while the torch
switch is pressed.
8. CURRENT Control Knob Guards
T wo guards used to prevent damage to the CURRENT
Control Knob.
Stud used to connect the Torch Leads Pilot Lead to
the Power Supply.
D. Rear Panel
1. Gas Input
Input connection for nitrogen (N2) or air input.
WARNING
This unit not to be used with oxygen (O2).
1
3
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. Negative/Plasma Lead Connection
Connects the torch negative/plasma lead to the unit.
3
2
1
A-02230
Figure 4-3 Torch Panel Bulkhead Area
2. Control Cable Connector
Used to interface the Adapter (supplied with Power
Supply) to the Torch Leads Control Cable.
2
A-02231
Figure 4-4 Rear Panel With Standard Air Filter
Installed
2. Primary Input Power Cable Strain Relief
NOTE
Input power cable for 230 VAC, single-phase, operation is factory supplied on unit.
Primary input power cable strain relief for the primary power cable (see Note) capable of handling the
input voltage designed for this unit.
3. Gas Pressure Regulator/Filter Assembly
Pressure regulator to adjust the input gas pr essur e to
the Power Supply . An air line filter is supplied as part
of the Pressure Regulator.
OPERATION 20 Manual 0-2803
Page 27
NOTE
GAS indicator will not come ON if the gas pres-
1
sure is set below 45 psi (3.1 bar) at the Regulator/
Filter Assembly.
5. Place RUN/SET switch to RUN mode.
a. Gas flow stops.
b. GAS indicator turns OFF.
3
4
2
A-02232
Figure 4-5 Rear Panel With Optional Two Stage Air
Filter Installed
4. 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
6. Protect eyes and press or activate torch switch
a. Gas pre-flows starts.
b. GAS indicator turns ON.
7. After gas pre-flow (appr oximately 2 seconds)
a. Power supply enabled.
b. DC indicator turns ON.
c. Pilot relay closes.
8. Pilot arc is established
9. Move T orch within transfer distance of workpiece.
a. Main arc transfer.
b. Pilot arc OFF.
10. 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.
11. Release or deactivate the torch switch.
The following is a typical sequence of operation for this
a. Main arc stops.
cutting system. Refer to Appendix II for a block diagram.
NOTE
1. Close main power source disconnect.
If torch is activated during post-flow , pilot arc will
a. AC power is available at the Power Supply.
2. Place RUN/SET switch to RUN mode.
3. 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
immediately restart.
If torch is within 3/8 in (9.53mm) transfer distance
of workpiece, main arc will transfer.
12. Gas will flow for 15 seconds (post-flow).
a. Gas solenoid closes
for eight seconds then stays ON.
b. Gas flow stops.
b. Fans turn on.
c. GAS indicator turns OFF.
4. Place RUN/SET switch to SET mode.
13. Place the ON/OFF power switch on the front panel
a. Gas solenoid opens and gas flows to set pres-
of the unit to OFF
sure.
b. GAS indicator turns ON.
Manual 0-2803 21 OPERA TION
Page 28
a. AC Power indicator turns OFF.
b. Fans turn OFF.
14. Place the main power disconnect to open.
a. Main AC power is removed from the system.
4.05 Preparations for Operating
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 fr ont
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 T orch 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 2.03-A-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 sour ce
meets pressure and flow requirements (refer to Section
3.08, Gas Connections). Check connection and turn gas
supply on.
D. Work Cable Connection
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. Torch Connection
Check that the torch is properly connected.
F. Purge the System (Gas Pre-Flow)
Move the ON/OFF switch to ON position. To start the
pre-flow move the RUN/SET switch to SET position for
a minimum of 20 seconds. The pre-flow gas purge will
remove any moisture that may have accumulated in the
torch and leads while the system was shut down. The
torch cannot be activated during pre-flow.
G. 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
H. Set Operating Pressure
Move the RUN/SET switch to SET position. Adjust the
gas pressure to 60 psi (4.1 bar).
I. RUN/SET Switch
Set the RUN/SET switch to RUN position.
The system is now ready for operation.
OPERATION 22 Manual 0-2803
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 properly
T rained personnel.
For major troubleshooting and parts replacement procedures refer to FirePower FP-80 Power Supply Service
Manual 0-2804.
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.
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
CAUTION
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.
T o clean the unit, open the enclosure (refer to Section 5.05A, 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.
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.
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
Manual 0-2803 23 SERVICE
Page 30
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 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.
d. Work cable disconnected
e. Worn torch parts
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 r equired 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
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 repairing 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.
For major troubleshooting and parts replacement procedures refer to FirePower FP-80 Power Supply Service
Manual 0-2804.
b. Torch standoff too high from workpiece
c. Cutting current too high
SERVICE 24 Manual 0-2803
Page 31
C. How to use this Guide
3. Unit is overheated
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)
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.
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. Allow unit to cool down for about 5 minutes.
Make sure the unit has not been operated beyond duty cycle limit.
4. Low input line voltage
a. Check and connect to proper input power line
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 required.
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 activated
1. RUN/SET switch in SET position
a. Move switch to RUN position
2. Torch switch activated during 2 second pre-flow
a. Release switch and wait at least 2 seconds be-
fore activating switch again
3. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
fer to Instruction Manual supplied with torch).
4. Gas pressure too high or too low
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
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.
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
a. Set pressure to 60 psi (4.1 bar).
5. 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. 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. Limited or low cutting output
1. Incorrect setting of CURRENT control
a. Check and adjusted to proper setting.
Manual 0-2803 25 SERVICE
Page 32
2. Tip contacting workpiece
a. Drag cutting circuit limits current output, keep
tip off workpiece.
5.05 Power Supply Parts
Replacement
3. Poor input or output connections
a. Check all input and output connections.
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
F. 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.
G. 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.
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
Leads Wrap
H. AC POWER indicator ON; Fans operate; No gas
flow
1. Gas not connected or pressure too low
a. Check source for at least 60 psi (4.1 bar).
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
I. 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-02220
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 0-2803
Page 33
Cover Screws
(5 Places On Each Side)
Cover
A-02221
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. T o reinstall the Cover reverse the above pr ocedure.
B. Fuse Replacement
1. Remove the Cover per paragraph "A" above.
2. Locate the internal fuse above the Input Power PC
Board on the left side of the unit.
Internal Fuse
0.8 Amps, 600V
A-00919
Figure 5-3 Internal Fuse Location
3. Replace the fuse (0.8 amp, 600V).
4. Reinstall the Cover per paragraph "A" above.
Manual 0-2803 27 SERVICE
Page 34
SERVICE 28 Manual 0-2803
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 Basic Replacement Parts
Section 6.05 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 product must be returned for service, contact your
authorized distributor . Materials returned 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. Addr ess all inquiries to your authorized distributor .
Manual 0-2803 29 P A RTS LISTS
Page 36
6.03 Complete Power Supply Replacement
Power supply includes: Work cable, pressure regulator/filter, air hose and fittings, and operating manual.
Description Qty Catalog #
FirePower FP-80 Power Supply
208/230VAC, Single-Phase With Input Power Cable & Plug 1 1445-0002
6.04 Basic Parts Replacement
Qty Description Catalog #
1 230V Single-Phase Input Power Cable 9-8599
1 Fuse, 0.8A 600V 9-7526
1 Knob, Current Control 9-4146
6.05 Options and Accessories
Qty Description Catalog #
1 Two Stage Air Filter Kit 7-7500
Replacement Elements
1 First Stage 9-1021
1 Second Stage 9-1022
1 575V Transformer 9-7500
1 Multi-Purpose Cart 7-8888
P AR TS LISTS 30 Manual 0-2803
Page 37
APPENDIX I: INPUT WIRING REQUIREMENTS
Input Power Input Current Su g g e sted Sizes (See N o te s)
Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph
(V olts) (Hz) (kVA ) (kV A) (Am ps) (A mp s) 1-P h 3-P h 1-P h 3-P h 1-P h 3-P h
208 50/60 14.6 11.6 60.5 32.3 80 40 8 10 8 10
230 50/60 14.8 11.9 55.6 29.9 70 35 8 12 8 12
240 50/60 14.9 12 53.7 29 70 35 8 12 8 12
380 50/60 15.9 13.4 36.3 20.4 45 30 12 14 12 14
415 50/60 16.4 13.8 34.1 19.2 45 25 12 14 12 14
460 50/60 16.9 14.2 31.7 17.9 40 25 12 14 12 14
Fu se ( A mp s) Wire (AWG) Wire (C an ad a)
575
Line Voltages w ith Suggested C ir c uit Protection and Wire Siz es
B ased on National Elec tric Code and Cana dian Elec tric al C ode
Requir es Transformer M odule
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 0-2803 31 APPENDIX
Page 38
APPENDIX II: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION
Close external
disconnect switch.
RESULT
Power to system.
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
ON/OFF switch
to ON.
RESULT
AC indicator blinks for 8
seconds then steady on.
Fans on.
Power circuit ready.
gas flows to set pressure.
PILOT ARC
ACTION
RUN/SET switch
to SET.
RESULT
Gas solenoid open,
GAS indicator on.
ACTION
RUN/SET
switch to RUN.
RESULT
Gas flow stops.
GAS indicator off.
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
(Power supply enable signal removed.)
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of
Gas solenoid closes, gas flow stops.
Main arc stops.
Gas flows (15 seconds)
NOTE - If torch is activated during
workpiece, main arc will transfer.
After post-flow:
GAS indicator off.
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-000926
APPENDIX 32 Manual 0-2803
Page 39
Manual 0-2803 33 APPENDIX
Page 40
APPENDIX III: SYSTEM SCHEMATIC
A-02234
APPENDIX 34 Manual 0-2803
Page 41
Manual 0-2803 35 APPENDIX
B EC 8055 HAS
C EC 8087 HAS
ECO 39F6
AE
ECO 3AF2
HAS
11/23
12/18
09/15
2001
98
98
A-02234
Page 42
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